NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES H.09

EMERGENCY SHOWER AND EYEWASH FACILITIES

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

 GENERAL ENGINEERING SPECIFICATION GES H.09
EMERGENCY SHOWER AND EYEWASH FACILITIES Page 2 of 16
Rev 0 1999

INDEX

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 4

1.1 Introduction 4
1.2 Other NOC Specifications 4

2.0 DEFINITIONS 4

2.1 Contractual 4

3.0 DESIGN 5

3.1 Codes and Standards 5

3.2 Water Supply 5
3.3 Equipment Design 6
3.4 Drainage 6
3.5 Enclosures 6
3.6 Identification 7
3.7 Alarms 7
3.8 Supports 7

4.0 MATERIALS 7

4.1 General 7
4.2 Showerhead and Eyewash 7
4.3 Pipe and Fittings 7
4.4 Valves 7
4.5 Flanges 8
4.6 Gaskets 8
4.7 Bolts and Nuts 8

5.0 FABRICATION AND ASSEMBLY 8

5.1 Procedures 8
5.2 Cleaning of Piping 8

6.0 INSTALLATION 8

7.0 INSPECTION 9

7.1 Procedures 9
7.2 Scope 9
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SEC TITLE PAGE

8.0 TESTING 9

8.1 Statutory Tests 9

8.2 Test Procedures 9
8.3 Site Acceptance Test Requirements 10
8.4 Test Certificates 10
8.5 Test Equipment 10

9.0 DOCUMENTATION 10

9.1 Introduction 10
9.2 Schedules and Reports 11
9.3 Data and Calculations 11
9.4 Drawings 12
9.5 Final Records, Documents and Manuals 12

10.0 PRIOR TO SHIPMENT 13

10.1 Painting and Coatings 13

10.2 Spares 13
10.3 Packing and Storage 13
10.4 Shipping 14
10.5 Warranty 14

11.0 FIGURES SUB-INDEX 14

Figures 15
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1.0 SCOPE OF SPECIFICATION

1.1 Introduction

1.1.1 This specification defines the minimum requirements for design, fabrication, inspection and testing for
safety showers and eyewash facilities.

1.1.2 This specification applies to emergency shower and eyewash equipment for refineries, onshore oil and gas
installations and processing facilities including items purchased either directly or as a part of a package.

1.1.3 The Vendor/Contractor shall comply fully with the provision laid down in this specification. Any
exception must be authorised in writing by the Owner.

1.1.4 In the event of any conflict between this specification and the Data Sheets, or with any of the applicable
codes and standards, the Vendor/Contractor shall inform the Owner in writing and receive written
clarification before proceeding with the work.

1.1.5 Emergency shower eyewash and facilities shall be located wherever an accidental spillage or discharge of
chemicals would most likely cause damage to the eyes or body of an operator during the course of his duty.
Examples of this are, an area or unit where an acid or caustic solution is used, or a chemical dosing
package where chemicals are manually loaded into a vessel.

1.1.6 This General Engineering Specification will form part of the Purchase Order/Contract, together with any
Data Sheets, drawings or other attachments.

1.2 Other NOC Specifications

The following NOC General Engineering Specifications are an integral part of this specification and any
exceptions shall be approved in advance by the Owner:

GES P.10 Erection and Testing of Steel Piping

GES X.01 Surface Preparation and Painting Application

GES X.02 Colour Coding of Equipment and Piping

GES X.03 External Protective Coatings

2.0 DEFINITIONS

2.1 Contractual

The commercial terms used in this specification are defined as follows:

Owner

The oil or gas company, an associate or subsidiary, who is the end user of the equipment and facilities.

Vendor

The company supplying the equipment and material.

Contractor

The main contractor for a defined piece of work.

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Sub-Contractor

A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.

Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements of this
specification and the Purchase Order/Contract.

Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority,
who verifies that the equipment and facilities have been designed, constructed, inspected and tested in
accordance with the requirements of this specification and the Purchase Order/Contract.

3.0 DESIGN

3.1 Codes and Standards

The design shall comply with this specification and the following Codes and Standards:

3.1.1 American National Standards Institute (ANSI)

ANSI Z358.1 Emergency Eyewash and Shower Equipment

ANSI B.16.5 Steel Pipe Flanges

ANSI B.316.11 Forged Steel Fittings

ANSI B.16.21 Non-Metallic Flat Gaskets

ANSI B.31.3 Petroleum Refinery Piping

3.1.2 Manufacturer's Standards Society (MSS)

MSS Sp-25 Standard Marking Systems for Valves Fittings, Flanges and Unions

3.1.3 American Society for Testing Materials (ASTM)

ASTM B61 Specification for Bronze Valves

3.1.4 Unless specified otherwise in the Purchase Order/Contract, the current editions of the Codes and Standards
at the time of the order should be used.

3.2 Water Supply

3.2.1 The water supply system to the combination emergency shower and eyewash shall be directly supplied
from a potable water system.

3.2.2 The water system shall be capable of supplying a minimum of 25 U.S gallons per minute (95 litres per
minute) at the shower head and 3.0 U.S gallons per minute (11.4 litres per minute) at the eyewash, at a
minimum operating pressure of 30 psig (200 KPag).
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3.2.3 The supply of potable water shall be uninterrupted.

3.2.4 All block valves in the system shall be locked open.

3.2.5 When the potable water supply is below ground, the interface with the above ground supply to the shower
and eyewash shall be a flanged joint terminating 12 inches (300 mm) above grade.

3.3 Equipment Design

3.3.1 Equipment shall be the combination eyewash and shower type, and shall be consistent with the standard
make and model already being used in existing installations.

The following requirements shall be adhered to:

(a) the shower shall be activated by a pull rod to a stay-open 1½ inch full flow ball valve;

(b) the minimum supply line size and Vendor/Contractor supplied piping shall be 1½ inch nominal
pipe size;

(c) the eyewash shall have a stainless steel bowl and shall be both hand and foot operated;

(d) hand drench hoses shall be provided only if specified by the Owner.

3.3.2 Figure 11.1 shows a typical arrangement of an emergency shower and eyewash with the required optimum
elevations of the shower head and eyebath. The required foot control (not shown) is to be added by the
Vendor/Contractor in accordance with his standard design or existing facilities on site. NOTE: With this
typical arrangement, the section of piping located between the facewash supply and the facewash drainage
line is fitted with either an orifice plate or a locked closed valve, dependant on pressure control
requirements.

3.4 Drainage

3.4.1 An outdoor emergency shower and eyewash facility shall be located on concrete paving (at least one metre
x one metre square) which shall be sloped to a central drain that will carry away the water effluent during
operation.

3.4.2 The emergency shower and eyewash assembly shall be self-draining.

3.5 Enclosures

3.5.1 The Owner may require the emergency shower and eyewash facility to be housed in a roofed enclosure.

3.5.2 The enclosure if specified, shall be of fireproof construction. For a typical enclosure design see Figure
11.2.

3.5.3 The enclosure shall be mounted on a concrete slab finished 6 inches (150 mm) above paving or grade, and
shall have a floor drain discharging to a sewer.

3.5.4 The shower enclosure shall be finished with white and light green striped paintwork.

3.6 Identification

The emergency shower and eyewash facility shall be clearly identified on site by a notice and a blue light
shall be installed over the facility whether it is located in a housing or in the open.

3.7 Alarms
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A flow switch shall be installed in the supply line which will activate an alarm in a manned control house
and at the shower facility. The local alarm shall consist of a flashing red light and an audible alarm which
is distinguishable from the plant fire or evacuation alarms.

3.8 Supports

All piping supplied as part of the emergency shower and eyewash facility shall be properly supported,
restrained and guided to protect the system against the effects of pressure surge when the shower and
eyewash facility is first activated.

4.0 MATERIALS

4.1 General

4.1.1 The Owner shall specify whether the emergency shower and eyewash facility is to be a Vendor/Contractor
supplied package, or alternatively the Vendor/Contractor is to design, fabricate and erect the facility with
the showerhead and eyewash fountain supplied as separate special material items.

4.1.2 If the facility is to be supplied as a package, the Vendor/Contractor may offer alternate materials to those
given below, subject to the Owner's approval. Plastic pipe shall not be used in areas subject to any fire risk,
acid attack or solvent attack.

4.1.3 All materials of construction shall be corrosion resistant to prevent rust and scaling.

4.2 Showerhead and Eyewash

The shower head and eyewash shall be fabricated from stainless steel.

Both the shower head and facewash shall be designed for easy disassembly to facilitate regular cleaning
and maintenance.

4.3 Pipe and Fittings

Pipe shall be Schedule 80 seamless, galvanized carbon steel to ASTM A106 Grade B.

Fittings including unions shall be forged steel 3000 lb rating threaded galvanized carbon steel to ASTM
A105 GR.B.

Pipe nipples shall be schedule 160 threaded ends galvanized carbon steel.

4.4 Valves

Shut-off valves shall be class 150 API threaded, bronze material.

The shower actuating valve shall be a 1½ inch full flow ball valve, 150 lb RF flanged in stainless steel.
This valve shall be supplied complete with a pull rod or chain.

4.5 Flanges

Flanges shall be galvanized, threaded, 150 lb ANSI RF forged carbon steel to ASTM A105.

4.6 Gaskets

Gaskets shall be 1/16 inch thick, 150 lb RF, non-metallic to ANSI B16.21.
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When there are dissimilar materials at mating flanges where corrosion could occur, or at an interface
between below ground and above ground piping, insulating sets shall be provided.

4.7 Bolts and Nuts

Bolt sets shall be alloy steel stud bolts complete with heavy hexagonal nuts in accordance with ASTM
A193 GR B7 and ASTM A194 GR 2H.

5.0 FABRICATION AND ASSEMBLY

5.1 Procedures

5.1.1 Piping for emergency shower and eyewash facilities shall be assembled with threaded joints. All threaded
connections shall be made using jointing compounds or sealing tapes suitable for the service conditions.

5.1.2 Threaded joints shall not be seal welded.

5.1.3 Pipe unions shall be used to fit-up the piping system. The piping assembly shall be straight and true with
the correct horizontal and vertical alignment.

5.2 Cleaning of Piping

Upon completion of fabrication and assembly, all piping shall be thoroughly flushed and cleaned with fresh
water. Pipework shall be dried with dry compressed air after washing.

6.0 INSTALLATION

The final locations of the shower and eyewash facility shall be approved by the Owner, but the following
minimum guidelines shall be utilised:

(a) the shower and eyewash facility shall be located at grade in an accessible location that is easily
reached by an accessway or an escape route;

(b) the location shall not be more than 50 feet (15 m) from the source of contamination, and requires
no more than 10 seconds to reach;

(c) there shall be a straight and unobstructed path from the source of contamination to the facility;

(d) the shower and eyewash facility shall be located in an area that is free of the contaminant;

(e) stairs and ladders shall not be used to reach the facility.

7.0 INSPECTION

7.1 Procedures

The inspection requirements are covered by the document "General Conditions of Purchase" which forms
part of the Purchase Order/Contract. Additional requirements are given below.

The Vendor/Contractor shall allow the Inspector free access to all areas of manufacture, fabrication,
assembly and testing.
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The Vendor/Contractor always has the responsibility to provide adequate quality control and inspection of
equipment and materials. Any inspection by the Owner or his Inspector shall not relieve the
Vendor/Contractor of these responsibilities or those under his guarantees.

The Inspector shall ensure that any shortcomings in the Vendor/Contractor's documentation or data are
rectified before any equipment is accepted for shipment.

7.2 Scope

Prior to testing, the following checks shall be carried out:

(a) all screwed and flanged joints shall be visually examined and checked for tightness;

(b) the assembly shall conform to the engineering flow diagrams;

(c) all pipe supports and guides have been correctly installed;

(d) the correct gaskets have been fitted in the flanged joints and all flange bolts have been installed
and tightened;

(e) all valves have been correctly installed.

8.0 TESTING

8.1 Statutory Tests

Pressure testing shall be carried out in accordance with ANSI B31.3.

Where the emergency shower and eyewash facility is a Vendor/Contractor supplied package, shop
hydrostatic testing shall be carried out in accordance with ANSI B31.3.

8.2 Test Procedures

8.2.1 Site hydrostatic testing shall be carried out for both Vendor/Contractor supplied and Vendor/Contractor
built assemblies. Hydrotest shall proceed only after satisfactory completion of all inspection as detailed in
section 7.0 above, is carried out.

8.2.2 Site pressure testing shall be carried out in the presence of the Owner and/or the Inspection Authority.
Hydrostatic test procedures shall be carried out in accordance with GES P.10 Section 8.0.

8.2.3 The Vendor/Contractor shall submit his test procedures in writing to the Owner for approval prior to the
start of the testing programme.

8.3 Site Acceptance Test Requirements

8.3.1 Test Schedules

The Vendor/Contractor shall submit a schedule of Site Acceptance Tests that are to be undertaken to ensure
that the equipment is satisfactory.

The test schedules shall be approved by the Owner. There shall be a separate set of acceptance tests for
each unit supplied.

8.3.2 Initial Acceptance Tests

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The initial acceptance tests shall be performed by the Vendor/Contractor when all relevant equipment has
been installed.

8.3.3 Final Acceptance Tests

Fourteen days after the system have been put into service, or fourteen days after the initial acceptance tests,
whichever is the earliest, the Final Acceptance Tests shall be effected by the Vendor/Contractor, and be
witnessed by the Inspector.

8.4 Test Certificates

8.4.1 Test Certificates

Final acceptance of the system will be given following satisfactory Final Acceptance Tests.

All copies of test certificates shall be furnished with final drawings as called for in the documentation
section. The Final Acceptance Tests shall be witnessed by the Inspector who shall retain one copy of the
certified tests.

8.5 Test Equipment

8.5.1 Supply

The Vendor/Contractor shall supply a set of test equipment if it is required.

8.5.2 Test Accessories

All necessary test accessories shall be provided.

Note:

All instrument and apparatus used in the performance of the tests shall have been calibrated to an agreed
standard at a laboratory of National standing within the period of 15 months of the test date. The cost of
carrying out such calibrations shall be borne by the Vendor/Contractor in all cases.

9.0 DOCUMENTATION

9.1 Introduction

9.1.1 This section covers the documentation required for the design, fabrication, inspection and testing for the
emergency shower and eyewash facilities if purchased as a Vendor/Contractor supplied package.

9.1.2 The detailed list of documents that are required will be attached to the Purchase Order/Contract.

9.2 Schedules and Reports

9.2.1 The Vendor/Contractor shall supply a schedule showing the documents for review and approval, proposed
Sub-Vendors/Sub-Contractors and material procurement and a production/fabrication programme.

9.2.2 The Vendor/Contractor shall submit his Quality Control Plan at the start of the contract.

9.2.3 Full documentation of all activities shall be made, and it is the Vendor/Contractor's responsibility to collate
all documentation and certification and to generate and issue data books in accordance with the Purchase
Order/Contract requirements.
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9.2.4 As a minimum, these data books shall include the following where applicable:

(a) quality plans;

(b) design calculations, with particular emphasis on how water pressures are to be controlled at safe
but adequate levels;

(c) materials;

(d) applicable operating procedures;

(e) pressure test procedures;

(f) pressure test reports;

(g) inspection reports;

(h) concession documents;

(i) release notes;

(j) certificate of conformity;

(k) dimensional test certificates.

9.2.5 All appropriate documentation and certification necessary to complete the contract data shall be collated,
checked and authorised by the Inspector prior to despatch.

9.3 Data and Calculations

9.3.1 The Vendor/Contractor shall provide a clear description of how he intends to ensure that water pressures
are controlled to safe but adequate levels.

9.3.2 The Vendor/Contractor shall supply with his tender completed Data Sheets containing all the relevant
information necessary for appraisal of the design by the Owner.

9.3.3 Project specific instructions will be issued to the Vendor/Contractor with the Purchase Order/Contract,
which describes the data and calculations to be submitted, and the methods of submission.

9.3.4 The Vendor/Contractor shall be responsible for obtaining approvals from the Inspection Authority.

9.3.5 All calculations shall be carried out in clear and logical manner. Where conditions involve the use of
formulae or methods not specified in the Design Code, the source of these formulae or methods shall be
clearly referenced.

9.3.6 Computer calculations will only be acceptable if all input is shown, together with calculated values of
intermediate terms and factors and options chosen, as well as final calculated dimensions, stresses or other
values and the computer program has been validated to the satisfaction of the Owner.

9.3.7 Calculations and drawings that are interdependent, i.e. foundation loading and equipment footprint, shall be
presented for appraisal together.

9.4 Drawings
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9.4.1 The drawings listed with the Purchase Order/Contract shall be sent by the Vendor/Contractor to the Owner
and/or the Inspection Authority for review and approval.

9.4.2 The components and process to produce the ordered equipment shall be shown in sufficient detail to be
fully appraised e.g. outline drawings, components list and schematic.

9.4.3 General arrangement drawings shall be to scale and show the relative location and main dimensions of all
components including elevations.

9.4.4 Detail drawings which may be included on the general arrangement shall include thickness and dimensions
of all components.

9.4.5 As-built drawings may be the general arrangement drawings marked-up with the actual as-built dimensions.

9.5 Final Records, Documents and Manuals

9.5.1 Two copies of the Data Dossier shall be supplied, and shall be a record of the manufacturing process.
Where stated in the Purchase Order/Contract, besides the documents itemised in Section 9.2.4, it shall
contain the following:

- general arrangement drawings and bill of material;

- the quality control plan;
- material certificates;
- positive material identification certificates;
- NDT procedures and records;
- hazardous areas certificates;
- performance test procedures and test certificate;
- non-conformity records;
- approvals by the Independent Inspection Authority;
- certificate of conformity;
- Owner's release certificate.

9.5.2 Six sets of the Installation, Operations and Maintenance Manual (IOM) shall be specifically compiled for
the equipment supplied. A compendium of manufacturer's data for a range of like products is not
acceptable. The IOM shall contain the following:

- a description of the equipment;

- the master document list and certified copies of key drawings;
- packing, shipping and site preservation instructions;
- step by step installation instructions;
- step by step pre-commissioning procedures;
- step by step commissioning procedures;
- step by step procedures for dismantling and re-assembly;
- routine preventive maintenance schedule and major repair procedures;
- list of special tools;
- spare parts ordering information.

The IOMs shall be presented in A4 format, and be securely bound in heavy duty 4-ring binders.

9.5.3 The Vendor/Contractor shall produce as-built documents revised to indicate field changes.

9.5.4 The Vendor/Contractor shall supply one set of mylar original drawings.

9.5.5 Electronic Data Format (EDF)

All documentation (drawings, calculations and Data Sheets etc) shall be produced by the
Vendor/Contractor in electronic format.
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The format shall be compatible with that used by the Owner and shall be agreed at the commencement of
the contract.

In addition to the 'hard copies' required under the contract, copies of the electronic records shall be issued
to the Owner for all approved documentation, this forming part of the Vendor/Contractor's contractual
obligations.

10.0 PRIOR TO SHIPMENT

10.1 Painting and Coatings

All bare surfaces which are exposed during transit or storage shall be given a coat of temporary rust
inhibiting material.

Surface preparation, painting and painting materials shall be in accordance with GES X.01, X.02 and X.03.

All machined or threaded surfaces of carbon steel and ferrous materials with an alloy content of less than
12 per cent chrome shall have a coating of rust inhibitor to protect against shipment and storage. This
should be of a type that will provide protection against an industrial environment and/or a salt-laden
atmosphere, and shall be easily removable using a standard solvent.

10.2 Spares

The Vendor/Contractor shall submit with his proposal a priced list of recommended spares for start-up and
two years operation for review by Owner.

10.3 Packing and Storage

This section describes the minimum requirement for the preservation and protection of the emergency
shower and eyewash facility during sea and land transportation and storage, prior to installation.
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The probable storage period will be specified in the order/enquiry and will extend from the time of
despatch to the time of unpacking at site. If the storage period is not stated, a minimum period of 24 months
shall be assumed. Packing to be suitable for sea freight.

(a) After mechanical completion at the works, the equipment shall be left in a clean dry condition.

(b) The Vendor/Contractor shall be responsible for loading and anchoring the item(s) to prevent
damage during shipment.

The Vendor/Contractor shall submit his procedures for packing and preservation for review by the Owner.

10.4 Shipping

Detailed shipping arrangements are covered by the Purchase Order/Contract.

The emergency shower and eyewash facility shall not leave the Vendor/Contractor's works for shipment
until the release has been approved by the Owner's Inspector.

10.5 Warranty

The Vendor/Contractor shall warrant all materials supplied against any defect for a period of twelve (12)
months after commissioning or twenty-four (24) months from the date of delivery to the site, whichever is
the shorter period, or for the period stipulated in the Purchase Order/Contract.

Should any item be found defective, the Vendor/Contractor shall be responsible for all costs associated
with restoring the emergency shower and eyewash facility to the standard specified by the Purchase
Order/Contract.

11.0 FIGURES SUB-INDEX

Figure 11.1 - Typical Arrangement: Emergency Shower and Eyewash Facility

Figure 11.2 - Typical arrangement: Enclosure