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Design and Engineering Manual DEM 1 – Application of Technical

Shell HSSE & SP Control Framework Mandatory
Process Safety Manual Restricted
Version 11, February 2015

To define the requirements in technical standards for design and construction that have a direct relationship to
Process Safety.

Who is this for?

• Business Leaders;
• Asset Managers, Project Managers and Wells Managers;
• Executive VP Projects & Engineering Services
• Delegated Technical Authorities; and
• Design and Engineering Practices (DEP) Custodians.

What situations are/are not covered?

This manual section applies to:
Assets that have process Hazards with RAM red Risks or yellow 5A or 5B Risks and that are used for exploring,
drilling, producing, processing, transporting or storing Hazardous Substances or energy, including:
• Shell Assets and Assets owned or operated by a Joint Venture in which Shell has a Controlling Interest, including:
 Wells;
 pipelines, including midstream and local gas distribution;
 Upstream production facilities including associated floating and fixed structures;
 refineries and chemical plants;
 gas liquefaction plants and re-gasification installations;
 coal gasification and gas/coal to liquid plants;
 product storage and handling facilities for:
o LPG installations, including large bulk storage installations at customer facilities road transport;
o aviation transport; and
o rail and ship loading and discharge.
• Assets owned or operated by a Joint Venture in which Shell does not have a Controlling Interest, if the Joint Venture
partners adopt this Manual following promotion by the Shell Shareholder Representative as stated in JV HSSE
• contracted 3rd party Assets, including temporary boilers, liquid nitrogen storage, and power generators; and
• land transport activities by vehicles used to transport Hazardous Substances.

Terms in green are included in the HSSE & SP Control Framework Glossary.
Terms in blue reference manuals and manual sections in the HSSE & SP Control Framework.
This document is not controlled when printed. See the Change Log for version control information.

This manual section does not apply to:
• small bulk consumer facilities, customers’ LPG installations and LPG cylinders;
• ships and other maritime vessels for which design and engineering requirements are covered by a STASCO
(Shell International Trading and Shipping Company Limited) accepted “Classification Society”;
• aircraft and aviation activities related to refuelling aircraft; and
• Abandonment Activities.

The Asset Manager, Project Manager or Wells Manager is Accountable for requirements 1 to 4 below.
1. Apply the mandatory Process Safety Design and Engineering requirements in the Shell Design And
Engineering Practices (DEPs) listed in Table 1 whenever designing or constructing New Assets or making
permanent or temporary Modifications to existing Assets.
1.1. For projects with a Project Headline Size less than $100 million (100% project cost) that do not involve
Unusual Risk, and for which the DEPs are not practicable, apply other recognised industry standards or
Company legacy standards. In case of such Derogation from DEM1, the Delegated Technical Authority
must approve the use of alternative standards, based on a documented risk assessment that
demonstrates that Process Safety risks are managed to ALARP. If alternative standards are non-existing,
use a documented Risk assessment methodology. Include the documented Risk assessment with the
Derogation request for approval by the Delegated Technical Authority.
1.2. Process Safety requirements in DEM1 DEPs, which refer to requirements in other Group documents, are
only mandatory if the referenced Group document is mandatory. When Process Safety requirements in
DEM1 DEPs refer to requirements contained in external industry codes and standards those requirements
are also treated as mandatory.
1.3. Through the use of the DEM1 Derogation Register and Reporting System, send a request for Derogation
to the Delegated Technical Authority, if and when a variance to mandatory DEP requirements is
observed or anticipated, including those invoked by 1.1.
1.4. Ensure all Derogations from mandatory DEP requirements for the Assets or projects are captured in the
DEM1 Derogation Register and Reporting System, for continuous improvement and for Risk awareness.
1.5. All project Derogations must identify the Asset it is applicable to.
1.6. Derogation from the application of Design and Engineering Manual 1 (DEM 1) in its entirety for Assets
owned or operated by a Joint Venture in which Shell does not have a controlling interest, and where the
Joint Venture partners have adopted this Manual, requires approval by those Joint Venture partners.
2. Apply the Version of the DEM1 DEPs that is valid at the time of end of Select (Decision Gate 3) for design of a
new Asset or modification to an existing Asset (capital project and/or Management of Change). Refer to
section Implementation Deadlines on this manual.
3. Approve at the end of Select (Decision Gate 3) how and where to apply Design and Engineering Manual 1
(DEM 1) to existing Assets affected by the project.
4. Confirm that the mandatory Process Safety requirements in the DEM1 DEPs are met for the construction of
new Assets and the modification of existing Assets.
4.1 Ensure all Derogations for the Asset are entered in the DEM1 Derogation Register and Reporting System.
The Executive VP Projects & Engineering Services is Accountable for requirements 5 to 8 below:
5. Appoint the Delegated Technical Authorities in Projects & Technology.
6. Set, or approve, competence criteria for other Delegated Technical Authorities, who are nominated in and
approved by a Business.
7. Appoint Custodians of the DEPs.

8. Resolve conflicts that relate to the application of Design and Engineering Manual 1 (DEM 1) and/or conflicts
that relate to the approval of Derogations.
The Business Leader is Accountable for requirement 9 below:
9. Appoint the Delegated Technical Authorities in Upstream International, Upstream Americas or Downstream.
The Delegated Technical Authority is Accountable for requirement 10 below:
10. Approve or reject any request for Derogation from the individual Process Safety requirements in the DEM1
10.1. Evaluate a request for Derogation based on:
• Its justification;
• Its documented Risk assessment that demonstrates that Process Safety Risks are managed to ALARP;
• Its endorsement by a Qualified Technical Professional.
10.2. Approve or reject the request for Derogation, and in the case of rejection provide a justification for the
10.2.1. The Delegated Technical Authority cannot be the same person that raises the Derogation.
10.2.2. The Delegated Technical Authority cannot be the same person that endorses the Derogation
as a Qualified Technical Professional.
10.2.3. The Delegated Technical Authority must assess the request independently from the Asset or
Project from which the Derogation request is made.
10.2.4. The Delegated Technical Authority must approve or reject the risk assessment showing the
Process Safety Risk is mitigated to ALARP.
10.2.5. The Delegated Technical Authority must approve or reject the alternative standards that are
used in lieu of the DEPs.
10.2.6. The Delegated Technical Authority must approve or reject the Derogation within the DEM1
Derogation Register and Reporting System.
10.3. Address in the request for Derogation either a Deviation or a Non-Conformance.
10.3.1. Document Deviations before the design or construction work commences, including temporary
use of an alternative standards system.
10.3.2. Document Non-Conformances after completion of the design or construction work if it is
discovered that a requirement has not been met and record alternative means of meeting the
intent of that requirement.
10.4. Report all approved and rejected Derogations to the DEP Custodian and the Technical Standards Team
within one month.

The DEP Custodian is Accountable for requirement 11 below:

11. Review Derogations from the mandatory Process Safety requirements in the DEM1 DEPs for learning and,
where appropriate, update the DEPs.

Table 1 DEPs with Mandatory Process Safety Requirements
The table lists all DEPs that contain mandatory Process Safety requirements, and these are indicated with “SHALL
DEPs shaded orange are those which have remained from the previous revision of Design and Engineering Manual
1 (DEM 1). Many mandatory requirements within these DEPs have been revised.
DEPs shaded green are those which have been added by this revision.
DEPs are available at http://sww.shell.com/standards/
Future changes on DEM1 will be based on maintenance requirements for the DEPs.

Number Date of Issue Title Feb. 2015 Definition of temperature, pressure and toxicity levels Feb. 2011 Preparation of process flow schemes and process engineering flow schemes Feb. 2013 Preparation of safeguarding memoranda and process safeguarding flow
schemes Feb. 2011 Steam injection systems for safeguarding thermal cracking units Feb. 2015 Heat transfer fluid systems Feb. 2015 Fuel systems Feb. 2014 Formation pore pressure, fracture gradient (PP/FG) and borehole stability
prediction for exploration, appraisal and development wells, well entries, and
abandonments Feb. 2014 Formation tops, fault intersections, and fluid fill prediction for exploration,
appraisal, and development wells Feb. 2014 Prepare and maintain data in support of well emergencies – New wells and
new activities on existing wells Feb. 2015 Geohazards assessment for offshore exploration, appraisal and development
operations Feb. 2014 Geohazards and surface location assessment for onshore exploration,
appraisal and development operations Feb. 2014 Design a logging program Feb. 2013 Compaction and subsidence prediction Feb. 2013 Hydrogen sulphide prediction for produced fluids from new and existing wells
in oil and gas fields Feb. 2013 Sand failure assessment for wells to be completed and produced Feb. 2015 Planning and design of geophysical surveys Feb. 2013 Well stimulation Feb. 2013 Top-seal integrity assessment for primary recovery, waterflood, EOR and CO2
storage Feb. 2014 Nitrogen / Oxygen Supply and Distribution Systems Feb. 2013 Equipment in LPG processing installations Feb. 2013 Pressurised bulk LPG storage installations at processing facilities Feb. 2013 LPG bulk road, rail and pipeline transportation

Number Date of Issue Title Feb. 2013 Cylinder filling plants and bulk transfer facilities for depots and filling plants Feb. 2013 Pressurised bulk storage installations for LPG – at depots, filling plants and
large bulk customers Feb. 2013 ESD systems for loading and discharging liquefied gas carriers Feb. 2014 LPG Storage and vehicle fuelling installations at retail sites Feb. 2014 CNG vehicle fuelling installations Feb. 2014 LNG storage and fuelling installations at retail and commercial sites Feb. 2011 Carbon steel corrosion engineering manual for upstream facilities Feb. 2014 Wet H2S requirements for downstream pressure vessels and piping Feb. 2013 Metallic materials – Prevention of brittle fracture in new assets Feb. 2011 Materials and fabrication requirements for 2¼Cr-1Mo, 2¼Cr-1Mo-¼V, 3Cr-
1Mo & 3Cr-1Mo-¼V heavy wall pressure vessels (amendments/supplements
to API RP 934-A) Feb. 2013 Technical Requirements for the Supply of Components in 6Mo Austenitic,
22Cr Duplex and 25Cr Super Duplex Stainless Steel Feb. 2013 Materials and fabrication requirements for 1¼Cr-½Mo pressure vessels
(amendments/supplements to API RP 934-C and API RP 934-E) Feb. 2011 Welding on pressurized pipes (amendments/supplements to API Standard
1104) Feb. 2015 Welding of metals, based on ISO standards Feb. 2015 Safe vapour control for wastewater collection and treatment systems Feb. 2015 Steam, condensate and boiler feed water systems Feb. 2013 Water-tube boilers Feb. 2015 Gas turbine heat recovery steam generators Feb. 2011 Chemical injection systems for upstream production facilities Feb. 2011 Loading facilities for bulk road vehicles Feb. 2013 Positive Material Identification (PMI) program Feb. 2015 Gaseous oxygen systems Feb. 2014 Shell and tube heat exchangers; selection and application Feb. 2014 Shell and tube heat exchangers (amendments/supplements to ISO
16812:2007) Feb. 2012 Plate and frame heat exchangers (amendments/supplements to ISO 15547-
1:2005) Feb. 2011 Printed circuit heat exchangers - Design and fabrication Feb. 2011 Brazed aluminium plate-fin heat exchangers (amendments/supplements to ISO
15547-2:2005) Feb. 2013 Chilling Systems Feb. 2013 Hairpin-type heat exchangers (amendments/supplements to ISO

12212:2012) Feb. 2014 Closed circuit cooling systems
Number Date of Issue Title Feb. 2014 Air-cooled heat exchangers – Selection and application Feb. 2014 Air-cooled heat exchangers (amendments/supplements to ISO 13706:2011) Feb. 2014 Equipment criticality in pressure vessel design Feb. 2014 Unfired Pressure Vessels Feb. 2011 Fired heaters (amendments/supplements to ISO 13705) Feb. 2015 Shaft sealing systems for centrifugal and rotary pumps
(amendments/supplements to API 682) Feb. 2015 Dry gas seals for rotating equipment Feb. 2015 Centrifugal pumps (amendments/supplements to ISO 13709) Feb. 2013 Sealless centrifugal pumps (amendments/supplements to API 685) Feb. 2013 Reciprocating positive displacement pumps (amendments/supplements to API

674) Feb. 2014 Axial, centrifugal, and expander compressors (amendments/supplements to
API Std 617) Feb. 2011 Reciprocating compressors (amendments/supplements to API 618) Feb. 2011 Rotary-type positive displacement compressors (amendments/supplements to

API 619) Feb. 2015 Packaged reciprocating gas compressors (amendments/supplements to ISO
13631) Feb. 2011 Special purpose steam turbines (amendments/supplements to ISO 10437) Feb. 2015 Lubrication, shaft-sealing and oil-control systems and auxiliaries
(amendments/supplements to ISO 10438) Feb. 2014 Gas turbines for the petroleum, chemical, and gas industry services
(amendments/supplements to API STD 616) Feb. 2012 Pipeline transportation systems – pipeline valves (Amendments/supplements to
ISO 14313) Feb. 2015 Hydraulic systems for the operation of on/off valves in protective functions Feb. 2012 Instrument air supply Feb. 2015 Piping class – Basis of design Feb. 2015 Piping – General requirements Feb. 2015 Piping classes – Refining and chemicals Feb. 2015 Piping classes – Exploration and production Feb. 2014 Water injection in downstream hydroprocessing units for corrosion control Feb. 2014 Design of injection points, injection systems, and corrosive mix points for
Downstream processing applications Feb. 2015 Piping classes – CSA Z662 Feb. 2014 Shop and field fabrication of piping Feb. 2011 Hot-tapping on pipelines, piping and equipment Feb. 2015 Pipeline engineering (amendments/supplements to ISO 13623)

Number Date of Issue Title Feb. 2015 Riser design Feb. 2011 Design of multiple-pipe slug catchers Feb. 2015 Design of pipeline pig trap systems Feb. 2011 Glass-fibre reinforced plastic pipeline and piping systems Feb. 2011 Line pipe induction bends (amendments/supplements to ISO 15590-1) Feb. 2013 Welded and seamless duplex and super duplex stainless steel line pipe
(amendments/supplements to API Spec 5LC) Feb. 2013 Weldable martensitic stainless steel line pipe for use in oil and gas operations
(amendments/supplements to API Spec 5LC) Feb. 2013 Line pipe for critical service (amendments/supplements to ISO 3183:2012
and API SPEC 5L 45th edition) Feb. 2012 High Density Polyethylene Pipelines and Piping Systems for Oilfield
Applications Feb. 2014 Hydrostatic pressure testing of new pipelines Feb. 2014 Heating, ventilation and air conditioning for plant buildings Feb. 2015 Process Control Domain – Enterprise industrial automation information
technology and security Feb. 2011 Instrumentation symbols and identification on process engineering flow
schemes Feb. 2013 Instrumentation control and protection for fired equipment Feb. 2013 Safeguarding and instrumented protective functions for rotating equipment Sep. 2014 Fire, gas and smoke detection systems Feb. 2013 Control valves – Selection, sizing, and specification Feb. 2015 Selection and procurement of actuators for On-Off valves Feb. 2015 Instrumentation of depressuring systems Feb. 2015 Telecommunications for onshore facilities Feb. 2015 Telecommunications for offshore facilities Feb. 2014 Instrumented protective functions (IPF) Feb. 2014 Alarm management Feb. 2014 Electrical engineering design Feb. 2013 Electrical engineering design for North American application Feb. 2011 Static DC uninterruptible power supply (DC UPS) units Feb. 2011 Static A.C. uninterruptible power supply unit (static A.C. UPS unit) Feb. 2012 Design and fabrication of AC Uninterruptible power supplies for North
American applications Feb. 2012 Design and fabrication of DC Uninterruptible power supplies for North
American application Feb. 2011 Navigational aids for fixed offshore structures Feb. 2011 Earthquake design for onshore facilities – Seismic hazard assessment
Number Date of Issue Title Feb. 2015 Drainage systems and primary treatment facilities Feb. 2015 Design of blast resistant onshore buildings, control rooms and field auxiliary
rooms Feb. 2013 Portable blast resistant modules Feb. 2011 Siting of onshore occupied portable buildings Feb. 2012 Inflatable blast resistant shelters Feb. 2015 Passive fire protection for onshore facilities Feb. 2011 Vertical steel storage tanks – Selection design and construction (amendments/
supplements to EN14015) Feb. 2015 Full containment refrigerated LNG tanks Feb. 2015 Field erected aboveground vertical storage tanks (amendments/supplements
to API Standard 650) Feb. 2012 Full Containment Refrigerated LPG Tanks Feb. 2015 Shop fabricated vertical storage tanks (amendments/supplements to API STD
650 – Annex J) Feb. 2015 Membrane type refrigerated LNG tanks Feb. 2011 Mounded horizontal cylindrical vessels for pressurised storage of LPG at
ambient temperatures (amendments/supplements to EEMUA 190) Feb. 2012 Vessel Integrity, Marine Systems – Requirements for Selection and Operation
of Vessels (Endorsement of DNV RP-H104) Feb. 2011 Metocean design and operating considerations (endorsement of ISO 19901-
1:2005) Feb. 2011 Offshore production installations basic surface process safety systems Feb. 2014 Design of offshore topsides facilities against fire and blast loading
(amendments/supplements to API RP-2FB) Feb. 2014 Design of seawater systems for offshore and onshore Feb. 2015 Diesel oil systems Feb. 2011 Site specific assessment of mobile offshore jack-up units Feb. 2011 Drain systems for offshore installations Feb. 2011 Design of offshore temporary refuges Feb. 2012 Offshore topsides structures (amendments/supplements to ISO 19901-
3:2010) Feb. 2014 Fixed concrete offshore structures (amendments/supplements to ISO 19903-
2006) Feb. 2013 Seismic design procedures and criteria – offshore (amendments/supplements
to ISO 19901-2) Feb. 2011 Fixed steel offshore structures (amendments/supplements to ISO
19902:2007) Feb. 2015 Firewater pumps for offshore installations Feb. 2014 HVAC for offshore installations (amendments/supplements to ISO 15138)

Number Date of Issue Title Feb. 2013 Subsea pipeline valves (amendments/supplements to ISO 14723) Feb. 2014 High pressure subsea valves (Amendments/supplements to section 7.10 of
ISO 13628-4/API 17D) Feb. 2015 Generic design and analysis for steel catenary risers and catenary umbilical
systems for offshore structures
DWS Feb. 2012 Design and analysis of top tension risers for deepwater offshore floating structures (based on API RP 2RD / ISO WD 13628-12)
DWS Feb. 2011 Technical specification for elastomeric flexible joints for use in deepwater offshore dynamic riser applications Feb. 2014 Welding of deepwater pipelines, flowlines and steel catenary risers
(amendments and supplements to API 1104) Feb. 2014 Welding of subsea hardware and tie-in components (Amendments/
supplements to ASME Boiler and Pressure Vessel Code section IX) Feb. 2011 Dynamically positioned (DP) vessels for construction, drilling/completions/well
intervention activities – Selection and operation Feb. 2015 Single point mooring (SPM) systems Feb. 2015 Mobile mooring systems (amendments to API RP 2SK, API RP 2SM and API RP
2I) Feb. 2015 Onshore production installations – Basic process safety systems Feb. 2015 Selection of materials for life cycle performance (upstream equipment)
including H2S-containing environments (amendments and supplements to ISO
15156) Feb. 2012 Specification for nickel base alloy 625 plus (UNS N07716) and alloy 725
(UNS N07725) for oil and gas drilling and production equipment Feb. 2011 Specification for nickel base alloy 718 (UNS N07718) for oil and gas
drilling and production equipment (amendments/supplements to API Standard
6A718) Feb. 2014 Produced water treatment and injection facilities Feb. 2011 Welding of pipelines and related facilities (amendments/supplements to ISO
13847:2000) Feb. 2015 Welding of duplex and super duplex stainless steel pipelines
(amendments/supplements to ISO 13847)) Feb. 2014 Welding of CRA-clad or CRA-lined pipe materials (amendments/supplements
to API STD 1104:21st edition) Feb. 2013 Inspection and functional testing of instruments Feb. 2014 Shop and field pressure testing of piping systems Feb. 2013 Hazard and operability (HAZOP) study Feb. 2013 Area classification (amendments/supplements to IP 15) Feb. 2015 Layout of onshore facilities Feb. 2015 Layout of offshore facilities Feb. 2014 Area classification and electrical equipment spacing for North American
application (amendments/supplements to API RP505/API RP500)

Number Date of Issue Title Feb. 2015 Relief devices – Selection, sizing and specification Feb. 2015 Design of pressure relief, flare and vent systems (Amendments/supplements to
API RP 520 Part II and API STD 521 Chapter 5) Feb. 2012 Overpressure and underpressure – Prevention and protection Feb. 2011 Emergency depressuring and sectionalizing Feb. 2011 Flare details (amendments/supplements to ISO 25457) Feb. 2014 Interlocking systems for pressure relief valves Feb. 2015 Fire protection systems for offshore facilities Feb. 2015 Assessment and design of the fire safety of onshore installations Feb. 2015 Active fire protection systems and equipment for onshore facilities Feb. 2013 Static electricity Feb. 2013 Lifeboats and rescue boats (amendments/supplements to SOLAS, LSA and
DNV-OS-E406) Feb. 2011 Control and mitigation of fires and explosions on offshore production
installations (amendments/supplements to ISO 13702:1999) Feb. 2011 Offshore production installations – Requirements and guidelines for emergency
response (amendments/supplements to ISO 15544:2000) Feb. 2012 Engineering Information Specification (EIS)

Portfolio Requirements Specifications (PRS)

The following PRS documents are technical standards that are approved for application to a specific business
portfolio. They contain technical requirements (including the applicable DEM1 requirements) that have been pre-
selected from the DEPs and fully rationalized for application within the specific business and enable the business
to meet DEM1.
Number Date of Issue Title Feb. 2015 Marine LNG fuel bunkering stations Feb. 2015 Surface facilities for North American Onshore Unconventionals

Implementation Deadlines
Projects before DG3 on July 1, 2015 are expected to use Version 11 DEM1 DEPs.
Projects beyond DG3 on July 1, 2015 may chose to do gap assessments of their existing design and engineering
standards against the Version 11 DEM1 DEPs.
Application of the DEM1 DEPs remains part of the Process Safety audit scope.
• All DEM1 (Version 11) DEPs will be in scope for audit from July 1, 2015 onwards.
• For newly added DEM1 DEPs, audit will be done against Work in Progress criteria (e.g. resourced plan, well
underway) until December 31, 2015.
Businesses may choose to do gap assessments of their existing design and engineering standards against the new
DEM1 manual.

While process safety incidents are rare, their potential to cause injury and even death, as well as damage to the
environment, our business and our reputation is well known. Avoiding a major process safety-related incident within
our asset base is a priority and requires a Group-wide approach.
The HSSE & SP Standards are part of the HSSE & SP Control Framework and are applicable across all businesses
for ventures under operational control. The HSSE & SP Control Framework gives line management practical tools to
help with risk identification, drives the implementation of associated controls and provides the means to assess the
effectiveness of these controls.

Design and Engineering Manuals and Practices

The HSSE & SP Standards (effective October 1, 2008) include the requirement to establish a single set of
mandatory Shell Design and Engineering Manuals (DEMs) for use in the design and modification of new and
existing assets. The EVP Engineering Services in Shell Projects & Technology is accountable for establishing and
maintaining the DEMs.
This Version 11 will become mandatory effective July 1, 2015. This Version 11 will apply to DEPs v39.

DEM1 is a supporting document for the HSSE & SP Standards. It includes a list of DEPs that specify the mandatory
Process Safety requirements needed to manage RAM RED, 5A or 5B process safety risks for design and construction.
In order to complete the verification of the process safety requirements, there has been a phased transition for DEPs
to become listed in this Design and Engineering Manual, DEM1.
Phase 1: Initial selection of 74 DEPs that have a direct relationship to process safety – mandatory as of January 1,
Phase 2: Review all DEPs and issue of 126 DEM1 DEPs on March 1, 2011.
Phase 3: Review remaining regional and local standards such as EGGs, ESTGs, SEPCo Engineering Standards,
and EP Well specific design manuals, etc. during rationalization with the DEPs.
Completed as of February15, 2013.
This manual will subsequently be reviewed and updated if required, on an annual basis.
If you have any queries regarding the Design and Engineering Practices or the HSSE Control Framework, please
Mia Zager, PTE/DTST, Shell Standards Manager
Eamon Chandler, PTS/S, Manager Group Process Safety
Anne McKinney, PTE/DTST, DEM1 Standards Engineer

For Further Information
Technical Standards Web Portal
DEPs Online
DEM1 User’s Guide
DEM1 Implementation