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DEP 34.19.20.11-Gen.
January 2010
This document is restricted. Neither the whole nor any part of this document may be disclosed to any third party without the prior written consent of Shell Global
Solutions International B.V., The Netherlands. The copyright of this document is vested in this company. All rights reserved. Neither the whole nor any part of this
document may be reproduced, stored in any retrieval system or transmitted in any form or by any means (electronic, mechanical, reprographic, recording or otherwise)
without the prior written consent of the copyright owner.
DEP 34.19.20.11-Gen.
January 2010
Page 2
PREFACE
DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of:
Shell Global Solutions International B.V. (Shell GSI)
and/or
Shell International Exploration and Production B.V. (SIEP)
and/or
other Shell Service Companies.
They are based on the experience acquired during their involvement with the design, construction, operation and
maintenance of processing units and facilities, and they are supplemented with the experience of Shell Operating Units.
Where appropriate they are based on, or reference is made to, international, regional, national and industry standards.
The objective is to set the recommended standard for good design and engineering practice applied by Shell companies
operating an oil refinery, gas handling installation, chemical plant, oil and gas production facility, or any other such
facility, and thereby to achieve maximum technical and economic benefit from standardization.
The information set forth in these publications is provided to Shell companies for their consideration and decision to
implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at
each locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the
information set forth in DEPs to their own environment and requirements.
When Contractors or Manufacturers/Suppliers use DEPs they shall be solely responsible for the quality of work and the
attainment of the required design and engineering standards. In particular, for those requirements not specifically
covered, the Principal will expect them to follow those design and engineering practices which will achieve the same
level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting
from his own responsibility, consult the Principal or its technical advisor.
The right to use DEPs is granted by Shell GSI, in most cases under Service Agreements primarily with Shell companies
and other companies receiving technical advice and services from Shell GSI or another Shell Service Company.
Consequently, three categories of users of DEPs can be distinguished:
1)
Operating Units having a Service Agreement with Shell GSI or other Shell Service Company. The use of DEPs
by these Operating Units is subject in all respects to the terms and conditions of the relevant Service
Agreement.
2)
Other parties who are authorized to use DEPs subject to appropriate contractual arrangements (whether as part
of a Service Agreement or otherwise).
3)
Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI
disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or
person whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination
of DEPs or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell
Service Company. The benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Service
Company, or companies affiliated to these companies, that may issue DEPs or require the use of DEPs.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall
not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and
the DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be
returned after use, including any copies which shall only be made by users with the express prior written consent of
Shell GSI. The copyright of DEPs vests in Shell GSI. Users shall arrange for DEPs to be held in safe custody and Shell
GSI may at any time require information satisfactory to them in order to ascertain how users implement this
requirement.
All administrative queries should be directed to the DEP Administrator in Shell GSI.
DEP 34.19.20.11-Gen.
January 2010
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TABLE OF CONTENTS
1.
1.1
1.2
1.3
1.4
1.5
1.6
1.7
INTRODUCTION ........................................................................................................4
SCOPE........................................................................................................................4
DISTRIBUTION, APPLICABILITY AND REGULATORY CONSIDERATIONS ..........4
DEFINITIONS .............................................................................................................4
CROSS-REFERENCES .............................................................................................5
SUMMARY OF CHANGES SINCE PREVIOUS EDITION .........................................6
COMMENTS ON THIS DEP .......................................................................................8
PROJECT DOCUMENTATION REQURIEMENTS ....................................................8
2.
2.1
2.2
2.3
OBJECTIVES OF FIREPROOFING...........................................................................9
GENERAL ...................................................................................................................9
FIRE SEVERITY .........................................................................................................9
FIRE RESISTANCE DURATION ................................................................................9
3.
3.1
3.2
3.3
3.4
3.5
3.6
4.
4.1
4.2
4.3
5.
REFERENCES .........................................................................................................19
APPENDICES
APPENDIX 1
APPENDIX 2
APPENDIX 3
TYPICAL
DETAILS
OF
CONCRETE
FIREPROOFING
OF
STRUCTURAL MEMBERS .............................................................................24
APPENDIX 4
APPENDIX 5
PIPERACK DETAILS.......................................................................................26
APPENDIX 6
APPENDIX 7
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January 2010
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1.
INTRODUCTION
1.1
SCOPE
This DEP specifies requirements and gives recommendations for the design and
application/installation of passive fire protection (PFP or fireproofing) of steel. The extent of
fireproofing and PFP requirements SHALL [PS] be established on the basis of the
requirements of DEP 80.47.10.30-Gen. and a fire safety assessment executed for the
particular plant or unit.
The zones where PFP are required are called Fire Protection Zones (FPZ). The extent of
the fireproofing around equipment and structures SHALL [PS] be indicated on layout and
construction drawings.
This DEP applies to steel supporting structures (and in some cases piping and equipment)
in process areas and processing plants as well as to storage facilities, jetties and pipe
bridges (including those outside the battery limits) in oil/gas/petrochemical installations.
This DEP is intended to ensure that the degree of fireproofing applied is effective and
practical in terms of maintainability and reduction of risks. As there is a wide variation in the
design of structures, the intent of this DEP SHALL [PS] be considered at all times when
prescribing the fireproofing of structures not specifically mentioned in (3).
This DEP is not applicable to jet fires.
This is a revision of the DEP of the same number dated December 1999; see (1.5)
regarding the changes.
1.2
1.3
National and/or local regulations for fire protection are generally intended for structures erected in
populated areas and may therefore be inappropriate for oil, gas and chemical plants, where the fire
loadings and risks are different.
DEFINITIONS
The Contractor is the party which carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the contractor.
The Manufacturer/Supplier is the party which manufactures or supplies equipment and
services to perform the duties specified by the Contractor.
The Principal is the party which initiates the project and ultimately pays for its design and
construction. The Principal will generally specify the technical requirements. The Principal
may also include an agent or consultant to act for, and on behalf of, the Principal.
The lower-case word shall indicates a requirement.
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January 2010
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The capitalised term SHALL [PS] indicates a process safety requirement.
The word should indicates a recommendation.
1.4
CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced section
number is shown in brackets. Other documents referenced by this DEP are listed in (5).
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January 2010
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1.5
New section
Change
Process safety requirements have been indicated by the use of the
capitalised term "SHALL [PS]".
General
2.2
---------
Removed old section Fire Proofing Zone (FPZ). Added a new section
Fire Severity.
2.3
---------
2.4
---------
3.1
----------
Reworded section.
3.1.1
----------
Deleted subheading.
3.2
----------
Reworded section
3.2.1
----------
Deleted subheading
3.3
----------
Reworded section.
---------
3.4
---------
3.5
Added new section - Process Unit Pipe Racks and Pipe Support
Columns
---------
3.6
4.1
-------------
---------
4.1.1
---------
4.1.2
4.2
4.2
4.2.1
4.2.1
-----------
4.2.1.1
4.2.2
4.2.2
4.2.3
4.3
---------
4.2.3
---------
4.2.4
4.2.4
4.2.5
continued
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Old section
New section
Change
4.3
---------
---------
4.3.1
---------
4.3.2
---------
4.3.3
---------
4.3.4
---------
4.3.5
Added: Inspection
4.4
---------
Deleted Section
4.5
---------
Deleted Section
---------
Deleted Section
ACI 216.1/TMS-0216
ACI 318
ACI 506.2
ACI 506.3
ASTM A185
ASTM C33
ASTM C150
ASTM E119
UL 1709
API Publ 2218
Added to European Standards and Industry Practices:
FIB Bulletin No. 34
EN 197-1
EN 197-4
EN 1992
Removed:
DEP 00.00.05.05-Gen.from Shell Standards
DEP 00.00.06.06-Gen. from Shell Standards
BS 8110 from British Standards
Appendix 1
Appendix 3
Appendix 2
Appendix 4
---------
Appendix 1
---------
Appendix 2
---------
Appendix 5
---------
Appendix 6
---------
Appendix 7
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1.6
1.7
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2.
OBJECTIVES OF FIREPROOFING
2.1
GENERAL
Fireproofing is a measure intended to improve the fire resistance of structures that support
pressure vessels, piping and other equipment located in fire hazardous areas. Protection is
provided by the application of concrete or other approved insulating materials to structural
steel supports.
Fireproofing offers protection against the adverse thermal effects of fire for a defined period
and defined degree of exposure. It should not be considered as a replacement for active
fire fighting or lead to relaxation of normal design requirements (spacing and layout
considerations) and precautions in operation and maintenance.
2.2
FIRE SEVERITY
Unless otherwise specified the severity of the fire shall be based on hydrocarbon pool fires.
For hydrocarbon pool fire exposures, the fire temperature profile will be based on UL 1709.
The hydrocarbon fire test as defined in UL 1709 is applicable to all fireproofing systems
applied on steel supports and structures. This fire is more severe than the cellulose type of
fire which is usually referred to in building regulations. During the test a protected steel
column is exposed to a particular heat flux that produces a temperature of 1093 C
(2000 F). The test is terminated (failure point) when the average temperature of the steel
substrate reaches 538 C (1000 F).
2.3
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3.
3.1
3.2
3.3
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3.4
3.5
3.6
BUILDINGS
All enclosed buildings shall as a minimum follow the requirements of the local fire
regulations and building code. The fireproofing standards, methods and materials specified
in this DEP are applicable to buildings or enclosed structures containing process
equipment. Where industrial structures containing process equipments are not completely
covered in the local building code requirements and local fire regulations, this DEP
SHALL [PS] supplement the local requirements.
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4.
4.1
GENERAL
4.1.1
Basic Materials
The following should be considered when selecting fireproofing materials and an applicator:
For new structures, reinforced concrete support columns and beams are preferable to
fireproofed steel because it is economical, robust, and it has been proven to be
effective.
When there are significant economic incentives or physical limitations, then proprietary
materials may be used instead of concrete. The experience of the applicator shall be
assessed. The importance of surface preparation and correct application of proprietary
materials cannot be overstressed.
If surface preparation requires blasting this may rule out the application of the material in
an operating plant.
Flammable solvents used in the mixing of some proprietary materials shall be rigidly
controlled.
The capacity of the structure to handle the weight of the fireproofing SHALL [PS] be
assessed.
Climatic conditions during installation may rule against the selection of certain materials.
The standard fireproofing material is normal weight concrete because of:
Durability
Availability
Good pool fire protection
Inherent torch fire protection
No or minimum ongoing maintenance when applied correctly.
Proprietary fireproofing systems (4.3) may be used if approved by the Principal.
Mixed systems of approved proprietary fireproofing and normal weight concrete fireproofing
are acceptable.
The type of fireproofing material and its construction method shall be specified by the
Contractor and approved by the Principal.
Where proprietary materials are proposed Contractor SHALL [PS] provide the Principal with
calculations or other documentation demonstrating that the design will provide the specified
fire protection for approval.
The Principal shall specifically authorize the use of hollow box fireproofing designs where it
is envisioned that maintenance activities or personnel access requirements will not damage
the fireproofed member. Otherwise this design shall not be used.
4.1.2
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3. Joint shall be protected with a continuously welded galvanized steel shield
(recommended in design Class III plants subject to severe freeze/thaw cycles). Shield
shall be a minimum of 3 mm (1/8 in) thick and shall have a drip lip.
4. For moisture ingress protection for fireproofing for structural steel, see (Appendix 4).
The corrosion protection shall be compatible with the fireproofing to be applied and
shall be in accordance with DEP 30.48.00.31-Gen.
5. Moisture ingress protection for fireproofing for non-galvanized steel equipment
supports (e.g., vessel skirts, and vessel support legs) shall be steel drip angles
regardless of plant class or freeze/thaw potential (3.2).
6. Penetrations through fireproofing, such as clips, attachments, etc., shall be sealed
with a polysulfide or other approved material, typically these need replacement every
5 to 10 years and need to be maintained.
7. Fireproofing should be applied monolithically where practical. The designer shall
consider appropriate fireproofing block-outs for assembly and for expected
attachments. Where welding of fixtures to the surfaces after the application of the
fireproofing is required, the materials and procedures used shall be approved by the
Principal.
4.2
CONCRETE FIREPROOFING
4.2.1
4.2.1.1
Environmental Controls
A topcoat is normally not required for concrete fireproofing surfaces, but it can be beneficial
depending on the environment.
1.
2.
The top of fireproofing shall be protected by cover plates continuously welded to the
steel structure in order to prevent ingress of rainwater between the members and the
fireproofing as shown in (Appendix 3) and (Appendix 4). In mild or non-corrosive
conditions mastic sealants may be used in lieu of cover plates with the approval of
the Principal. Steel Columns shall be protected by a 2 mill (minimum) thick Glass
Reinforced Epoxy (GRE) (also known as Fiber Reinforced Plastic (FRP) fabric
adhered to concrete and steel surfaces as shown in (Appendix 4). The GRE material
selection shall be in accordance with DEP 30.10.02.13-Gen. and it shall be approved
by the Principal.
DEP 34.19.20.11-Gen.
January 2010
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4.2.2
4.2.3
4.2.3.1
Quality Control
The preparation for, and the placing of, fireproofing material shall be supervised and
inspected during application by trained and experienced personnel. Particular attention
shall be paid to the following:
1. The condition of the steel surfaces to be fireproofed;
2. The quality and placing of mesh reinforcement;
3. The quality and application of the fireproofing material;
4. The joints between steel work and fireproofing where exposed to the weather;
5. Weatherproofing, where required.
NOTE :
1. Protection against heavy rain, frost and other extreme weather conditions shall be provided
during the application of fireproofing.
2.
In extremely dry and hot conditions, appropriated measures shall be taken to keep fire
proofing moist until set. Measures such as screening the work area from radian sunlight and
wrapping the finished work may be required, depending on the severity of the ambient
conditions.
The following documents shall be approved by Principal prior to the start of any application
of fireproofing:
1. Inspection and Test plan (ITP)
2. Quality control procedures, including Quality Control Records (QCRs)
3. Erection plan, including method statements covering application methods, temporary
facilities to be installed for application and Health Safety Environment (HSE) aspects
4. Materials and workmanship specifications.
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The applicator shall establish an inspection system to perform inspections and tests
required to assure compliance with the requirements. Completed QCRs shall be handed
over to the Principal before acceptance of the work
4.2.3.2
4.2.3.3
4.2.3.4
4.2.3.5
Surface Preparation
1.
Loose dirt, oil and grease present on the surface shall be removed to ensure
good adhesion of the fireproofing to the primed or galvanized steel.
2.
Mesh Reinforcement
1.
Mesh reinforcement shall be wrapped around the steel section and retained firmly
by clips. Welded clips shall be pre-fabricated, attached to steel and galvanized
per steel supplier. Field stud welding requires approval of the principal. Overlaps
shall be at least 50 mm (2 in) and shall be wired at approximately 150 mm (6 in)
intervals.
2.
The minimum cover applied on any wire mesh installed SHALL [PS] be 25 mm
(1 in)
3.
The longitudinal overlap shall be in the web face, and all overlaps shall be
staggered so that no more than three layers of mesh are present at any one point.
4.
If spacers are required between the mesh and the steel surface (to keep the
mesh in position during application of the fireproofing material) concrete spacer
blocks may be considered as a cheaper alternative for studs welded to the
steelwork.
5.
6.
Proportioning
1.
2.
3.
4.
Shotcrete
1.
Installation of shotcrete shall conform to ACI 506.2, this DEP and applicable local
design code and standard.
2.
3.
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January 2010
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4.2.4
4.2.4.1
Cast-in-Place Concrete
1. Testing shall conform to ACI 318 or applicable local design code and standard.
2. One set of test cylinders / cubes shall be made for every 40 m3 (50 cu. yds.) of
concrete (i.e. daily testing is not required). The Principal shall select the mixes to be
tested.
3. Slump shall be measured for every batch on every mix.
4.2.4.2
Shotcrete
1. Evaluation shall conform to ACI 506.4 or applicable local design code and standard
2. Test panels shall be 450 mm (18 in) long sections taken from shotcrete installed on
the smallest structural member.
3. If shotcrete is to be installed on vessel skirts only, test panels shall be
450 mm x 450 mm (18 in x 18 in) squares.
4. One panel shall be tested (in addition to the qualification work) for each nozzleman,
for each 40 m3 (50 cu. yds.) of shotcrete placed (i.e. daily testing is not required).
4.2.5
Brickwork Fireproofing
Common types of brickwork are sometimes used for fireproofing column and vessel skirts
(See Standard Drawing S 20.002). However, for large and/or high skirts, proprietary
systems or concrete (site applied by means of the guniting method) may offer a less
expensive alternative if labour rates are high, provided a qualified Contractor is available.
4.3
4.3.1
General
Proprietary fireproofing systems offer weight saving compared with normal weight concrete
fireproofing. This aspect is important in the case of modular construction and/or installation
of fully dressed assemblies with fireproofed skirts. Proprietary systems may also be more
economical for the fireproofing of large/high column and vessel skirts if labour costs for the
alternative concrete or brickwork are high. However, the material cost for proprietary
fireproofing systems is typically substantially higher than with concrete.
Proprietary fireproofing systems may be recommended by the Contractor if they meet the
following requirements:
1.
The proprietary fireproofing design SHALL [PS] be UL 1709 listed for structural
steel fireproofing applications or equivalent local code.
2.
3.
For equipment / pipe fireproofing, the proprietary fireproofing design SHALL [PS]
have fire test certification (e.g., Lloyd's Register, NORSOK, etc.). The Contractor
shall specify and ascertain that for this specific application the following additional
requirements apply:
a. Define the end point metal temperature for the fire exposed piping/equipment.
The maximum metal temperature corresponding to end of the specified fire
duration shall be specified. This temperature shall be is less than the 538 C
(1000 F) end point temperature used for structural steel.
b. Assess how external inspections of the pipe/equipment will be conducted (i.e.
will the material interfere with non-destructive metal thickness measurements
or will inspection ports be required?)
c.
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January 2010
Page 17
NOTE:
If thermal insulation is required for process reasons, this shall be installed over
the proprietary fireproofing (Installing insulation under fireproofing introduces
the risk of corrosion).
4.
The system has a proven track record, demonstrating durability under normal
climatic conditions of at least 15 years without major problems or excessive
maintenance. When applied in special climates such as sub-tropical, tropical, subarctic, arctic etc., the system concerned shall have demonstrated suitability for at
least 10 years without problems or excessive maintenance.
5.
A weatherproof topcoat is normally required for most proprietary systems, and may
only be omitted with approval of Principal. This weatherproof topcoat must typically
be maintained if the performance is to be guaranteed. Any expected maintenance
costs shall be included in the life cycle costs when comparing alternatives.
6.
7.
The system shall not cause corrosion of the steel work when exposed to the
expected ambient conditions (e.g. freeze/thaw or moisture).
8.
The toxicity of off-gasses and excessive production of smoke from the fire exposed
proprietary fireproofing shall be assessed for applications where fireproofed
equipment or structures are located indoors.
9.
4.3.3
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January 2010
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4.3.4
Intumescent coatings, which expand and form an insulating, layer when the
temperature increases.
4.3.5
1.
2.
Surfaces on which material will be installed shall be clean, dry and free of oil and
other contaminants immediately prior to material installation.
3.
4.
5.
Suitable precautions shall be taken to terminate the fireproofing surface evenly and
without overspray above the termination line.
6.
7.
The entire thickness of the material shall be installed in one continuous operation
unless prohibited by manufacturer's instructions.
8.
9.
Damage to the material shall be repaired after construction activities in the area
are finished.
Inspection
A non-destructive testing device or method shall be used to determine the required
thickness gauge.
1.
2.
3.
Application work shall be subject to inspection and approval by the Principal and material
manufacturer.
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Page 19
5.
REFERENCES
In this DEP, reference is made to the following publications:
NOTES:
1. Unless specifically designated by date, the latest edition of each publication shall be used,
together with any amendments/supplements/revisions thereto.
2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell
Wide Web) at http://sww.shell.com/standards/.
SHELL STANDARDS
Non-metallic materials Selection and application
DEP 30.10.02.13-Gen.
DEP 30.46.00.31-Gen.
DEP 30.48.00.31-Gen.
DEP 33.64.10.10-Gen.
DEP 80.47.10.30-Gen.
S 20.002
Report GS 06.50615
AMERICAN STANDARDS
Code Requirements for Determining Fire Resistance of
Concrete and Masonry Construction Assemblies
ACI 216.1/TMS-0216
ACI 318
ACI 506.2
ACI 506.3
ACI 506.4
Issued by:
American Concrete Institute (ACI)
P.O. Box 9094
Farmington Hills, MI 48333
USA
ASTM A 185
ASTM C 33
ASTM C 150
ASTM E 119
Issued by:
American Society for Testing and Materials (ASTM)
ASTM International;
100 Barr Harbor Drive
P.O. Box C700
West Conshohocken, PA 19428
USA
UL 1709
DEP 34.19.20.11-Gen.
January 2010
Page 20
Issued by:
API Publishing Services
1220 L Street, N.W.
Washington, D.C. 20005
USA
Issued by:
Fdration Internationale du Bton (FIB)
Case Postale 88
CH 1015 Lausanne
Switzerland
Cement
Part 1: Composition, specifications and conformity
criteria for common cements
EN 197-1
EN 197-4
Concrete
Part 1: Specification, performance, production and
conformity
EN 206-1
EN 1992
Issued by:
CEN Secrtariat Central
Rue de Stassart 36
B-1050 Brussels
Belgium
INTERNATIONAL STANDARDS
Tests for electric cables under fire conditions - Circuit
integrity - Part 21: Procedures and requirements - Cables of
rated voltage up to and including 0.6/1.0 kV
Issued by:
Central Office of the IEC
3, Rue de Varemb
CH 1211 Geneva 20
Switzerland
Copies can also be obtained from national standards organizations.
IEC 60331-21
DEP 34.19.20.11-Gen.
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APPENDIX 1
1.0
1.1
DEFINITION PHASE
The Project Specification shall be developed by the Contractor and include:
The above documentation shall be based on the DEP's and Model Technical Specifications
contained in the Shell Standards Website to be provided by the Principal.
Reference shall also be made in the Project Specification to Standard Inspection and Test
Plans (ITP) and Quality Control Records (QCR) contained in the Shell Standard Website for
use in the Execution Phase of the Project.
1.2
EXECUTION PHASE
The following SHALL [PS] be produced based on the Project Specification:
1.3
OPERATIONAL PHASE
During the Operational Phase the following shall be used
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Figure 1:
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APPENDIX 2
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APPENDIX 3
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APPENDIX 4
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APPENDIX 5
PIPERACK DETAILS
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APPENDIX 6
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APPENDIX 7