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Abu Dhabi Oil Refining Company

DEMINERALIZED WATER SYSTEM

DGS-MA-005 Rev-0 Mar 2008

DGS-MA-005 Rev.0

DEMINERALIZED WATER SYSTEM

Amendment History

No

Date

Amendment

Description

Proposed

Approved

Incorporated

DGS History

Mar 2008

Demineralized Water System Description

Previous Projects

KRB/DDC

ETSDM / EPDM

No

Date

Source

Reviewed

Approved

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Abu Dhabi Oil Refining Company

DEMINERALIZED WATER SYSTEM

DGS-MA-005 Rev-0 Mar 2008

Table of Contents

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0 23.0 24.0

GENERAL............................................................................................................................ 3 CODES AND STANDARDS ................................................................................................. 3 REFERENCE DOCUMENTS............................................................................................... 4 DOCUMENT PRECEDENCE............................................................................................... 5 SPECIFICATION DEVIATION/CONCESSION CONTROL .................................................. 6 QUALITY ASSURANCE/QUALITY CONTROL .................................................................... 6 DOCUMENTATION.............................................................................................................. 6 SUBCONTRACTORS/SUBVENDORS................................................................................ 7 HANDLING .......................................................................................................................... 7 SCOPE OF SUPPLY............................................................................................................ 7 OPERATION AND EQUIPMENT DESCRIPTION ................................................................ 8 MECHANICAL DESIGN ..................................................................................................... 10 INSTRUMENTATION AND CONTROL .............................................................................. 12 ELECTRICAL EQUIPMENT............................................................................................... 13 STRUCTURAL................................................................................................................... 13 WELDING .......................................................................................................................... 13 PAINTING AND INSULATION ............................................................................................ 13 INSPECTION AND TESTING ............................................................................................ 14 IDENTIFICATION AND TAGGING ..................................................................................... 14 SPARE PARTS................................................................................................................... 15 SPECIAL TOOLS PROVIDED BY VENDOR...................................................................... 15 GUARANTEE..................................................................................................................... 15 CERTIFICATION................................................................................................................ 16 INFORMATION REQUIRED FROM VENDOR WITH BID .................................................. 16

List of Authorized Signatures/ Initials


DGS Discipline Committee Member, ADRD DGS Discipline Committee Member, RRD : : None A. Balasubramanyan (AB) K. R. Bhushan (KBR) Quazi Abdul Matin (QAM) Mohd AL Yabhouni (MAY)

DGS Discipline Committee Member Leader, E&PD : Engineering & Technical Services Manager, E&PD : Engineering & Projects Division Manager, E&PD :

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Abu Dhabi Oil Refining Company

DEMINERALIZED WATER SYSTEM

DGS-MA-005 Rev-0 Mar 2008

1.0 1.1

GENERAL INTRODUCTION This specification describes the minimum requirements for the design, fabrication, assembly, inspection, testing and handling of Packaged Demineralized Water System complete with all associated auxiliaries and instrumentation, as specified herein and the attachment thereof.

1.2

PURPOSE The Demineralized Water System is required to deliver demineralized water to meet the boiler feedwater requirements of the General Utility Plant and Refinery expansions plus the boiler feedwater requirements of the existing Refinery. Refer to the scope of supply section for additional information.

1.3

DEFINITIONS For the purpose of this Specification, the following definitions shall apply. COMPANY The Abu Dhabi National Oil Company (ADNOC). 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 project requirements. A CONCESSION REQUEST is subject to COMPANYADNOC/PMT approval. CONTRACTOR The party which carries out all or part of the design, engineering, procurement, construction, commissioning or management of this Project. MANUFACTURER/VENDOR The party which manufactures and/or supplies equipment, technical documents/drawings and services to perform the duties specified by COMPANY/CONTRACTOR. PROJECT The Ruwais Refinery Expansion Project (EUM Plan). SHALL Indicates a mandatory requirement. SUBCONTRACTOR/SUBVENDOR The party(s) which carry(s) out all or part of the design, procurement, installation and testing of the System(s) as specified by the CONTRACTOR/VENDOR.

2.0

CODES AND STANDARDS It shall be the VENDORS responsibility to be, or to become, knowledgeable of the requirements of the referenced Codes and Standards. The following Codes, Standards and References shall, to the extent specified herein, form a part of this specification. When an edition date is not indicated for a document, the latest edition in force at the time of VENDORS commitmentproposal submittal shall apply. American Society of Civil Engineers (ASCE) ASCE 07-1993 Minimum Design Loads for Buildings and Other Structures

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Abu Dhabi Oil Refining Company

DEMINERALIZED WATER SYSTEM American Society of Mechanical Engineers (ASME) ASME -B1.20.1 ASME -B16.5 ASME -B31.3 Pipe Threads, General Purpose Pipe Flanges and Flanged Fittings Chemical Plant and Petroleum Refinery Piping

DGS-MA-005 Rev-0 Mar 2008

Boiler and Pressure Vessel Code: Section VIII, DIV. 1 Pressure Vessels

American Society for Testing and Materials (ASTM) American Welding Society (AWS) AWS-A2.4 AWS-A3.0 AWS-D1.1 Standard Symbols for Welding, Brazing and Nondestructive Examination Terms and Definitions Structural Welding Code - Steel

API (American Petroleum Institute) API 650 Welded Steel Tank for Oil Storage

European Committee for Standardization (EN) EN 10204 Types of Inspection Documents - Metallic Products

Instrument Society of America (ISA) ISA-S5.1 UBC Instrumentation Symbols and Identification Uniform Building Code

International Organization for Standardization (ISO) ISO 9001 ISO 9003 ISO 9004 3.0 Quality Systems - Model for Quality Assurance in Design, Development, Production, Installation and Servicing. Quality Systems - Model for Quality Assurance in Final Inspection and Test. Quality Management and Quality System Elements - Guidelines.

REFERENCE DOCUMENTS The following reference documents form a part of this specification. When a revision date is not indicated for a document, the latest revision in force at the time of VENDORS proposal submittal shall apply. Project Specifications: DGS-CU-002 Structural Engineering Design Criteria
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Abu Dhabi Oil Refining Company

DEMINERALIZED WATER SYSTEM

DGS-MA-005 Rev-0 Mar 2008

DGS-EU-002 DGS-IU-007 DGS-MD-001 DGS-MD-002 DGS-MD-007 DGS-MD-008 DGS-MG-002 DGS-MG-003 DGS-MM-001 DGS-MN-001 DGS-MU-001 DGS-MU-002 DGS-MU-003 DGS-MU-009 DGS-MU-012 DGS-MU-013 DGS-MU-014 DGS-MW-001 DGS-MW-002 DGS-MX-001 DGS-MS-002 DGS-MX-004 4.0

Specification for Electrical Items on Packaged Equipment Instrumentation Furnished with Package Units Vessel Design Basis Pressure Vessels - General Requirements for Manufacturing Data Report for Pressure Vessels Ladders and Platforms - Pressure vessels Reciprocating Positive Displacement Pumps and Metering Pumps Centrifugal Pumps for General Services Electric Motors Cage-Induction and Synchronous Insulation General Equipment Requirements Preservation and Export Packing Spare Parts Equipment Noise Control Requirements for MANUFACTURERS Data Report for Nonpressure Vessel Equipment Criticality Rating System Minimum Shop Inspection and Certification Requirement Welding, NDE and Prevention of Brittle Fracture of Pressure Vessels, and Heat Exchangers Welding, NDE and prevention of Brittle Fracture of Piping Painting Galvanizing Internal Linings

DOCUMENT PRECEDENCE The VENDOR shall notify the CONTRACTOR of any apparent conflict between this specification, the related data sheets, the Codes and Standards and any other specifica-

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DEMINERALIZED WATER SYSTEM

DGS-MA-005 Rev-0 Mar 2008

tions noted herein. Resolution and/or interpretation shall be obtained from the CONTRACTOR in writing before proceeding with the design/manufacture. In case of conflict, the order of precedence shall be: 5.0 Equipment Data Sheet(s) Equipment Narrative Specification (this specification) Project Specifications and Standards Industry Codes and Standards

SPECIFICATION DEVIATION/CONCESSION CONTROL Any technical deviations to this specification and its attachments 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 approval are subject to rejection.

6.0

QUALITY ASSURANCE/QUALITY CONTROL VENDORS proposed quality system shall fully satisfy all the elements of ISO 9001, Quality Systems - Model for Quality Assurance in Design, Development, Production, Installation and Servicing, ISO 9003, Quality Systems -Model for Quality Assurance in final Inspection and Test, and ISO 9004, Quality Management and Quality System Elements - Guidelines. 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 with the CONTRACTORS 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. The Criticality Rating (CR) System outlined in Project Specification DGS-MU-013 shall be used to develop the design checking levels and minimum requirements for shop inspection, testing and material certification given in Project Specification DGS-MU-014.

7.0

DOCUMENTATION VENDOR shall submit the type and quantity of drawings and documentation for CONTRACTORS authorization or information as listed in the Drawing and Data submittal form. Mutual agreement on scheduled submittal of drawings and engineering data shall be an integral part of any formal Purchase Order. Comments made by Contractor on drawing submittal shall not relieve VENDOR or SUBVENDORS of any responsibility in meeting the requirements of the specifications. Such comments shall not be construed as permission to deviate from requirements of the Purchase Order unless specific and mutual agreement is reached and confirmed in writing. Each drawing shall be provided with a title block in the bottom right-hand corner incorporating the following information: Official trade name of the company. Vendors drawing number.
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DEMINERALIZED WATER SYSTEM

DGS-MA-005 Rev-0 Mar 2008

Drawing title giving the description of contents whereby the drawing can be identified. A symbol or letter indicating the latest issue or revision. PO number and item tag numbers.

Revisions to drawing shall be identified with symbols adjacent to the alterations, a brief description in tabular form of each revision shall be given, and if applicable, the authority and date of the revision shall be listed. The term "Latest Revision" shall not be used. VENDOR shall submit Manufacturers Data Book in accordance with Specification DGSMD-007 for pressure vessels and/or specification DGS-MU-012 for all other equipment. 8.0 SUBCONTRACTORS/SUBVENDORS All SUBCONTRACTORS/SUBVENDORS shall be preapproved by the CONTRACTOR/COMPANY. The VENDOR shall assume unit responsibility and overall guarantee for the equipment package and associated equipment. The VENDOR shall transmit all relevant purchase order documents including specifications to his SUBVENDORS and SUBCONTRACTORS. It is the VENDOR'S responsibility to enforce all Purchase Order and Specification requirements on his SUBVENDORS and SUBCONTRACTORS. The VENDOR shall submit all relevant SUBVENDOR and SUBCONTRACTOR drawings and engineering data to the CONTRACTOR. The VENDOR shall obtain and transmit all SUBVENDOR and SUBCONTRACTOR warranties to the CONTRACTOR/COMPANY, in addition to the system warranty. 9.0 HANDLING Preparation for shipment shall be in accordance with the VENDOR'S standards and as noted herein. VENDOR shall be solely responsible for the adequacy of the preparation for shipment provisions with respect to materials and application, and to provide equipment at the destination in ex-works condition when handled by commercial carriers. Adequate protection shall be provided to prevent mechanical damage and atmospheric corrosion in transit and at the job site. Preparation for shipment and packing will be subject to inspection and rejection by COMPANY'S/CONTRACTOR'S inspectors. All costs occasioned by such rejection shall be to the account of the VENDOR. After inspection and test, equipment shall be completely free of water and dry before start of preparation for shipment. All equipment and material shall be preserved and export packed in accordance with specification DGS-MU-002. 10.0 10.1 SCOPE OF SUPPLY This specification describes the minimum requirements for the design and supply of Demineralized Water System. All equipment, instruments and controls within the battery limits of the Demineralized Water System shall be included in VENDORS scope of supply. As a minimum the following equipment shall be supplied by the VENDOR.
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DEMINERALIZED WATER SYSTEM Quantity 3 3 3 3 3 3 3 Description Cartridge Filter Cation Exchanger Anion Exchanger Mixed Bed Polisher Cation Resin Trap Anion Resin Trap Mixed Bed Polisher Resin Trap Regeneration Unit Caustic Storage Tank Acid Storage Tank Acid Fume Scrubber Acid Dosing Pump (Regeneration) Caustic Dosing Pump (Regeneration) Acid Dosing Pump (Neutralization) Caustic Dosing Pump (Neutralization) Anion Regeneration Water Heater Mixed Bed Regeneration Water Heater Mixed Bed Blower (One Spare) Caustic Dilution Water Pump Demineralized Water System PLC

DGS-MA-005 Rev-0 Mar 2008

1 1 1 3 3 2 2 1 1 2 2 1 10.2

It is the vendor's responsibility to ensure that the design and supply of the equipment are in accordance with the applicable specifications, codes and design conditions referred to in this requisition. Any item required to complete and facilitate the installation shall be included in the scope of supply. OPERATION AND EQUIPMENT DESCRIPTION DEMINERALIZER TRAIN The Demineralized Water System shall be designed based on the process design basis furnished to the VENDOR separately. VENDOR shall add to the net demand additional capacity for demineralized water required during regeneration. The Demineralized Water System shall be supplied complete with regeneration system and all necessary interconnecting piping, valves, controls and instrumentation. Each demineralizer train shall consist of one cation exchanger and one anion exchanger, followed by a mixed bed polishing unit. A set of three cartridge filters shall be supplied upstream of the demineralizer trains. Filter effluent shall be combined (common header) to be able to feed either of the three demineralizer trains. Similarly, the two-bed (cationanion) effluent to be combined to be able to feed either of the three mixed bed polishers. VENDOR design shall permit simultaneous operation of any two demineralizer trains each operating at 50% of the plant design capacity. In addition the unit shall be capable to operate between 20% and 100% of its design capacity. The cation and anion exchangers design shall be based on high efficiency packed bed concept. VENDOR may propose alternate cost-effective schemes for CONTRACTORS

10.3 11.0 11.1

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DEMINERALIZED WATER SYSTEM

DGS-MA-005 Rev-0 Mar 2008

consideration. Regeneration (end of the service cycle) of a train shall be initiated based on first occurrence of any one of the following: a. b. c. d. High sodium content in the effluent water of the cation exchanger High conductivity or high silica measured in the effluent of the anion exchanger Preset volume of product water has been reached (minimum 12 hours operation) High differential pressure across any ion exchange column

Regeneration (end of the service cycle) of the mixed bed polisher shall be initiated based on first occurrence of any one of the following: 11.2 High silica in the effluent High conductivity in the effluent Preset volume or time has been reached High differential pressure across the resin bed

REGENERATION AND NEUTRALIZATION SYSTEMS The regeneration system shall include all necessary piping, valves, instrumentation and accessories required for preparation and injection of chemicals at the required concentration and quantity. Also sampling points shall be provided for manual sampling of the diluted chemicals. Chemical dosages shall be selected to ensure minimum possible total chemical consumption per unit volume of demineralized water produced. VENDOR is allowed to make the necessary adjustments in the chemical dosages to produce theoretically neutral waste upon completion of each regeneration cycle. VENDOR shall submit chemical consumption data for CONTRACTORS evaluation. VENDOR shall also submit volume of wastewaters that will be generated during each regeneration. This data shall be submitted separately for the two-bed and the mixed bed units. Acid Storage Tank shall be minimum 30 m3 in size and the caustic storage tank shall be minimum of 20 m3 in size. VENDOR shall submit proposed storage tanks size and configuration. Three acid regeneration dosing pumps (one for cation, one for mixed bed and one common spare) and two acid neutralization dosing pumps shall be provided all prepiped, prewired and skid mounted. Three caustic regeneration dosing pumps (one for anion, one for mixed bed and one common spare) and two caustic neutralization dosing pumps shall be provided all prepiped, prewired and skid mounted. Two dilution water feed pumps shall be supplied, one in service and other one spare. VENDOR shall supply the caustic dilution water heater(s) if required to introduce warm caustic during regeneration of anion resins. Two mixed bed resin mix blowers shall be supplied, one in service and the other one spare. The neutralization basin will be by CONTRACTOR. Neutralization process will be carried out automatically. Regenerant wastewater will be mixed (circulated) using the neutralization pumps and necessary amount of acid or caustic will be added to reach ac-

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ceptable pH level. VENDOR shall supply necessary controls for automatic operation of neutralization process and to be able to monitor its status from CONTRACTOR furnished DCS. Operating capacity of the neutralization basin shall be a minimum of 200% of the maximum expected regeneration waste volume per regeneration of one train and the mixed bed. Mixing, neutralization and disposal of the neutralized waste shall complete well within available time between regeneration cycles. Bidder shall recommend basin size in accordance with the above criteria and may also propose alternate sizing based on bidders other sizing criteria that offers savings in installed and operating costs while providing the necessary operating flexibility. 12.0 12.1 MECHANICAL DESIGN VESSELS Pressure vessels shall be designed, fabricated, inspected and tested in accordance with ASME Code Section VIII, stamped. Pressure vessel design and fabrication shall also meet the requirements of specifications DGS-MD-001 and DGS-MD-002. TheSelected design pressure shall be in accordance with specification DGS-MD-001 and be at least 10% higher than the feed pump shutoff head. Acid and Caustic Storage tanks shall be designed per API 650. Materials of construction shall be as follows: Plate Forgings Castings A-516 Gr. 60 (*) A-105B Normalized (**) A-216 WCB

Carbon content of carbon and carbon-manganese steels shall not exceed 0.23%, except for forgings and castings, where this may be relaxed to 0.25%. For pressure containing components, the carbon equivalent (CE) shall not exceed 0.43, as given by:

CE = %C =

%Mn %Cr + %Mo + %V %Cu + %Ni + + 6 5 15

Each vessel shall be furnished with the following nozzles as a minimum: a. b. c. d. e. Inlet, outlet, vent/relief and drain Resin sampling, fill and removal Regenerant inlet and outlet, as necessary Manhole, 24" diameter, flanged and davited. Sight glasses (90mm x 330mm), two on each cation and anion and four on each mixed bed polishers

Ladder and platform shall be provided for access to the top manway of each vessel in accordance with specification DGS-MD-008. Desiccant breather shall be provided on the acid storage tank. 12.2 VESSEL/TANK LINING All ion exchange vessels and the acid/caustic storage tanks shall be internally lined with 5 mm thick vulcanized natural rubber. Lining shall be steam cured to required hardness
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(80-90 shore, scale D) and shall be spark tested at 12000 volts minimum. Cartridge filters shall be internally coated with epoxy as per the requirements of specification DGSMX-004. VENDOR shall submit lining application and testing procedures for COMPANY/ CONTRACTORs review and approval prior to commencement of the work. 12.3 PIPING AND VALVES All piping shall meet the requirements of ASME B31.3. Piping, flanges and valves shall conform to ANSI Standards. All water service and dilute regenerant piping, fittings and valves within the demineralizer and the neutralization systems shall be PPL lined carbon steel or 304L stainless steel. Tank vents and other non-pressure type vent and drain piping may be glass reinforced vinylester (GRV). Acid piping material shall be selected based on final selection of type of acid to be used for regeneration and neutralization. VENDOR shall propose regenerant piping material based on the following guide lines: Concentrated sulfuric acid piping shall be PPL lined carbon steel and/or Alloy 20. Concentrated caustic piping shall be carbon steel. Carbon steel caustic piping shall be postweld heat treated in accordance with specification DGS-MW-002. Wall thickness shall be sch.80 for up to 1.5 lines and sch.40 for 2 and larger. VENDOR shall propose sch.40 316L stainless steel piping for concentrated caustic as an alternate. For hydrochloric acid regenerated units, the piping in contact with concentrated and dilute acid, the material shall be PPL lined carbon steel and/or Hastelloy-C.

VENDOR proposal shall spell out additional details of piping material and type of fittings proposed. Cast iron fittings in the lined piping system are not acceptable. Threaded fittings are not acceptable except for the instrument hook-up connections. Pipe size shall be based on liquid velocity of less than 2.5 m/s during normal operation. Switching valves 6 and smaller shall be Saunders patent diaphragm type or equal with spring loaded diaphragm type pneumatic actuators. Butterfly valves with elastomer lining (seats) are acceptable for size 8 and larger. Butterfly valves shall have piston type spring loaded actuators. Use of diaphragm type switching valves shall be maximized. VENDOR must give full consideration to using 6 or smaller valves where ever design permits in order to be able to use the diaphragm valves. Concentrated chemical lines shall be supplied with double block and bleed valving. Switching valves shall be furnished with limit switches for indication of valve positions at DCS provided by others. Piping around the equipment shall be so arranged to allow ready access to all components during normal operation and maintenance. Valve operators and electrical boxes on the skid shall be located within the skid boundary to avoid damage to the equipment and to avoid hazardous conditions for the operating personnel. Assembled piping system shall be adequately supported to prevent damage during shipment, installation and normal operation and maintenance. Piping supports shall be
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neatly located and shall in no way present hazardous obstruction for operating personnel. A resin trap must be installed at the outlet of each ion exchanger to prevent passage of resin particles into the downstream units. Each resin trap shall be designed to withstand the maximum system pressure, must retain all particles larger than 50 mesh and shall be constructed of 316L stainless steel body and the screen material. 12.4 VESSEL INTERNALS Vessel internals shall be 316L stainless steel construction except for hydrochloric acid regenerated units shall have Hastelloy-C internals. Vessel internals shall be designed to accomplish even distribution of all flows across the cross section of the bed. Header-laterals type distributors are preferred. Other proven designs will be considered. Any correction in the internals design that may become necessary to meet system performance guarantee shall be the responsibility of the VENDOR. Supports for the internals shall be designed to maintain complete rigidity during service and the regeneration cycles. Loss of resin due to damage of the internals and/or the resin trap will become the responsibility of the VENDOR. 12.5 PUMPS Centrifugal pumps shall be supplied in accordance with specification DGS-MG-003. Chemical dosing metering pumps shall be supplied in accordance with specification DGS-MG-002. Pumps shall be furnished as completely piped up skid mounted assemblies including necessary local instrumentation, junction boxes for signals to the off-skid controls. Suction strainer, block valves and discharge check valve shall be provided on each pump. Calibration pot shall be provided for the regenerant pumps. Each pump shall be furnished with discharge pressure gauge. Chemical pump gauges shall be supplied with diaphragm seals. Pulsation dampeners and external relief valve shall be provided on discharge of the chemical pumps. All rotating equipment shall meet noise level limitation per specification DGS-MU-009. 13.0 13.1 13.2 INSTRUMENTATION AND CONTROL All instrumentation and control shall comply with specifications DGS-IU-007. The demineralized water system PLC shall be provided by Vendor and installed in the SIS. Instrumentation and control panels shall be suitable for location in a classified area. Zone 2, Gas Group IIC, Temperature Classification T3. Although normal monitoring of the system will be from SIS and DCS it is required that VENDOR supply necessary local instrumentation for monitoring of pressures, temperatures, flows, conductivity and chemical concentration during start-up, occasional local monitoring and the troubleshooting periods. Pressure vessels shall be supplied with suitable safety relief valve per applicable ASME code requirements. Each pump shall be furnished with discharge pressure gauge. Chemical pump gauges shall be supplied with diaphragm seals. Pulsation dampeners and external relief valve shall be provided on discharge of the chemical pumps.
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Acid and caustic storage tanks shall be provided with level gauge and level transmitter. 13.3 Process Control The system shall be designed for three modes of operation, as follows: a. Automatic mode shall permit normal service cycle with automatic shutdown and switchover. Automatic shutdown shall be initiated when set limits for throughput, service time, effluent quality and differential pressure across each vessel is reached. Also, regeneration of the exhausted column is initiated automatically during this mode. In the supervised manual mode (Semiautomatic) of operation, initiation and termination of each step within the regeneration/backwash sequence shall be manual by pressing step advance buttons/keys at CRT or panel. Override manual mode shall permit for the operator to override the PLC via override switches for all automatic valves and pumps.

b.

c. 14.0

ELECTRICAL EQUIPMENT All electrical components shall be suitable for installation in a classified area, Zone 2, Gas Group II, Temperature Class T3. All electrical equipment shall comply with specification DGS-EU-002. All electric motors shall comply with specification DGS-MM-001.

15.0

STRUCTURAL System structural design, where applicable, shall be in accordance with specification DGS-CU-002. Skids shall be fabricated of structural steel. Structural steel shall be ASTM A-36 or better. All skid joints shall be continuously seal welded. No skip welding or crevices are permitted. There shall be no projections of equipment outside of the outer edge of the skids. All equipment shall be mounted on the skid. A sufficient number of adequately sized lifting attachments for proper handling of the skids during shipment shall be provided.

16.0

WELDING Welding of pressure vessels shall be per specification DGS-MW-001. Welding of piping shall be per specification DGS-MW-002. All structural welding shall conform to the requirements of AWS D1.1 Welding symbology and terms and definitions shall be in accordance with AWS-A2.4 and AWS-A3.0 respectively.

17.0

PAINTING AND INSULATION Except as otherwise stated below surface preparation and painting shall be in accordance with specification DGS-MX-001. Structural steel shall be galvanized and painted or painted only in accordance with specifications DGS-MS-002.

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CONTRACTOR shall insulate steam line within the VENDOR package if the heat exchanger for caustic dilution water is furnished by the VENDOR. Insulation shall be per specification DGS-MN-001. 18.0 18.1 INSPECTION AND TESTING INSPECTION As a minimum, the system shall be visually inspected at the VENDOR'S shop to verify the following: Compliance to specified material of construction for all equipment, piping, valves, instrumentation and vessel internals. Quality of welding, surface finish and painting meet project specifications and codes and standards. Vessel internals to check proper installation of the distributors and their supports. Internals shall also be checked to make sure no damage to the vessel lining or the distributor screening material has taken place during installation. Limit switches are firmly secured in place and no damage to the switches has taken place during installation or testing of the switches. General quality of equipment and piping assembly meet high quality workmanship. Selection and installation of instrumentation meet project specifications and standards, and are adequately protected in preparation for shipment per specification DGS-MU-002. Quantity and type of all ion exchange material (resins) are as specified and that the material is in sealed drums. 18.2 TESTING All pressure vessels shall be hydrostatically tested in accordance with ASME Code Section VIII. All piped assemblies shall be pressure tested for leaks in accordance with ASME B31.3. A suitable filter shall be provided in the hydrotest water fill line to remove sand, rust, and other particles in the test water. The Vendor shall submit filter requirements, as part of the hydrotest procedure, to the COMPANY for approval. All instruments shall be precalibrated. Automatic switching valves shall be stroked and the limit switches shall be set at correct positions. Functional test and continuity test of the wiring shall be performed for all control valves, instruments and controls prior to shipment. All design interlocks and sequencing of the automatic valves shall be verified through VENDOR supplied simulating testing equipment. Records for the equipment tested at the SUBVENDOR facility shall be submitted to the CONTRACTOR. 19.0 19.1 IDENTIFICATION AND TAGGING NAMEPLATES A corrosion resistant metal nameplate shall be permanently attached to the equipment (not base plate) and contain the following information using specified units:

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DEMINERALIZED WATER SYSTEM PO Number Equipment Item Number MANUFACTURER/VENDORS Name Serial Number Rated Capacity Size and Type Year Built

DGS-MA-005 Rev-0 Mar 2008

This instruction is not intended to supersede or supplement the requirements of the governing codes and standards. 19.2 MARKING Connections furnished on the purchased equipment shall be impression stamped or permanently tagged to agree with MANUFACTURER/VENDORS connection table or general arrangement drawing. 19.3 TAGGING Instruments and control valves tagging shall be in accordance with specification DGSEU-007. All items shipped loose shall be identified with its PO Number and Item Number. Tags shall be corrosion resistant metal (not aluminum) and impression stamped with the following information: PO No PO Item No Equipment Item No

Tags shall be attached to each component with stainless steel wire. Equipment shipped in fully enclosed containers also shall include the above information marked on the outside of the container. Markings on containers shall include equipment description. 20.0 SPARE PARTS The MANUFACTURER/VENDOR shall provide spare parts requirements in accordance with specification DGS-MU-003. 21.0 SPECIAL TOOLS PROVIDED BY VENDOR VENDOR shall furnish all special tools required for installation , commissioning, disassembly and reassembly of the equipment. VENDOR shall provide with his proposal a list of special tools included in his offer. For multi-unit installations, VENDOR shall provide one set of special tools for each pair of units. Special tools required for use during normal operation shall be suitable for the specified area classification. All special tools shall be packaged in metal containers 22.0 GUARANTEE Materials and workmanship shall be guaranteed in accordance with the terms and conditions of purchase. System performance shall be guaranteed in accordance with the requirements covered in the system design basis document. As a minimum, it shall be guaranteed to meet the
Takreer DGS-MA-005-Rev-0 Mar-2008 Printed 16-Oct-08 11:33:32
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Abu Dhabi Oil Refining Company

DEMINERALIZED WATER SYSTEM

DGS-MA-005 Rev-0 Mar 2008

specified effluent water quality at the design rate producing specified net throughput and limiting the chemicals consumption to that agreed upon at the time of purchase agreement. VENDOR shall provide necessary technical assistance at the jobsite during the system performance testing. VENDOR representation will be required until the system proves out to be performing with consistency for minimum of five complete cycles in the automatic mode. 23.0 CERTIFICATION VENDOR shall furnish Material Certificates in accordance with the requirements of EN 10204 (formerly DIN 50049). The type of certificate required A, B or C is determined by the inspection class assigned to the type of equipment or material. Component parts of a piece of equipment may require different types of certificates. For certification requirements, refer to Project Specification DGS-MU-014. The vendor's test engineer(s) shall certify that the various equipment and piping assemblies have been hydrotested, the instruments are calibrated and that functionality of the control system has been checked out prior to shipment. CONTRACTOR shall be notified in advance when the required tests are carried out by the VENDOR. 24.0 INFORMATION REQUIRED FROM VENDOR WITH BID P&ID and a full equipment list including instrumentation required and also equipment specifications. Equipment specifications and type of proposed resins including manufacturer. Type, quantity and quality of chemicals required for resin regeneration and neutralization of the wastewater. Pressure drops across all units during normal operation and during the regeneration/back-wash cycle. Regeneration efficiency and waste volume per exchanger and the total waste volume. Regeneration/backwashing procedures including pressure, flows, duration, chemicals required and nature of waste produced and recommendations for neutralizing. Maximum turndown ratio while meeting the required effluent water quality. Dimensions and weights (shipping and operating) of each individual piece of equipment and the complete package. List of utilities required. List of interface connections including size, flow rate and pressure at each interface point. Estimated (recommended) dimensions of the neutralization basin. Estimated instrument air, power and steam consumptions.

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