Product Design Product Design SpecificationSpecification

Eng. Nabil Ahmed MouradEng. Nabil Ahmed Mourad

B.Sc. Cairo University Mechanical Engineering.B.Sc. Cairo University Mechanical Engineering.M.Sc. Arts Et Metier, France, Thermodynamics.M.Sc. Arts Et Metier, France, Thermodynamics.Abu Dhabi Company for Onshore Oil Operation.Abu Dhabi Company for Onshore Oil Operation.

Engineering Services Department.Engineering Services Department.

March 2006March 2006

Product SpecificationProduct Specification

Table of ContentTable of Content• TypesTypes• StructureStructure• FormsForms• Typical Content of specificationTypical Content of specification• Preparation of specificationPreparation of specification• Continual improvement Continual improvement

Types of SpecificationsTypes of Specifications

International StandardsInternational StandardsIndustrial StandardsIndustrial StandardsCompany SpecificationCompany SpecificationProject / product specificProject / product specific

International StandardsInternational Standards

ISO DefinitionISO Definition

Document, established by Document, established by consensusconsensus and and approved by recognized body that approved by recognized body that provides for common and repeated use, provides for common and repeated use, rules, guidelines or characteristic for rules, guidelines or characteristic for activities or their results, aimed at the activities or their results, aimed at the achievement of the optimum degree of achievement of the optimum degree of order in given context.order in given context.

International StandardsInternational Standards

ExamplesExamples

• British Standards.British Standards. BS BS• American Petroleum Institute.American Petroleum Institute. API API• American Society for Mechanical Eng. ASMEAmerican Society for Mechanical Eng. ASME• Dutch Industrial Norm.Dutch Industrial Norm. DIN DIN• International Standard Organization ISOInternational Standard Organization ISO

Industry StandardsIndustry Standards

Document developed by a recognized Document developed by a recognized international industrial organization international industrial organization operating in specific industry to operating in specific industry to formalizes polices and provide rules and formalizes polices and provide rules and guidance for the initiation, generation guidance for the initiation, generation and maintenance of design and and maintenance of design and Engineering practices, learned over a Engineering practices, learned over a period of time and resulted from period of time and resulted from diversified application. diversified application.

Industry StandardsIndustry Standards

ExamplesExamples• Shell Shell DEPDEP• British Petroleum British Petroleum BPSBPS• Mobil StandardsMobil Standards MSMS• Exxon StandardsExxon Standards ESES

Local / Company StandardLocal / Company StandardDocument developed by an operating company Document developed by an operating company to provide technical guidance and to provide technical guidance and recommendations based on the experience recommendations based on the experience gained in the company, for specific operation, gained in the company, for specific operation, over a considerable period of time and in a over a considerable period of time and in a specific geographical location.specific geographical location.

ExamplesExamples•Gulf standard for cars.Gulf standard for cars.•Saudi Operation Specification.Saudi Operation Specification. SOSSOS•Petroleum Development Oman.Petroleum Development Oman. PODPOD

Project / Product SpecificationProject / Product Specification

Document developed to define the Document developed to define the technical requirements that apply for technical requirements that apply for specific project or product.specific project or product.

ExamplesExamples•Abu Dhabi North East Oil developmentAbu Dhabi North East Oil development•Rolls-Roys Cars.Rolls-Roys Cars.•GE refrigerators.GE refrigerators.•Masafi bottled water.Masafi bottled water.

Engineering Standards - StructureEngineering Standards - Structure

InternationalStandards

ProjectSpecification

ADCO EngineeringStandards

Industry

Progre

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e develo

pment

Progre

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Order o

f Pre

cedence

Order o

f Pre

cedence

Forms of Specification.Forms of Specification.

Stand-alone specificationsStand-alone specifications

Fully elaborated document contains all technical Fully elaborated document contains all technical requirement. They requires extensive efforts to requirement. They requires extensive efforts to prepare and maintain with lot of repetition.prepare and maintain with lot of repetition.Amendment to applicable standardsAmendment to applicable standards

Brief document referring to the existing Brief document referring to the existing standards and specify changes as applicablestandards and specify changes as applicableFunctional specifications.Functional specifications.

It is a statement of requirement.It is a statement of requirement.

Typical content of Specification.Typical content of Specification.

Technical requirementTechnical requirement

Process - Design - Material - TestingProcess - Design - Material - TestingCode requirementCode requirementHealth Safety and EnvironmentHealth Safety and EnvironmentCustomer needsCustomer needsMarket requirementMarket requirementManufacturer-ability/Construct-abilityManufacturer-ability/Construct-abilityOperability / MaintainabilityOperability / MaintainabilityQA / QC requirementQA / QC requirement

Development of Product Development of Product specificationspecification

•Preparation.Preparation.

This is the most critical engineering activities where customer This is the most critical engineering activities where customer requirements are defined by experienced engineers. requirements are defined by experienced engineers. Review.Review.

This includes the multi discipline review for checking This includes the multi discipline review for checking correctness, completion and maximizing value.correctness, completion and maximizing value.Approval.Approval.

Authorization of the document by the most senior technical Authorization of the document by the most senior technical authority in the organization.authority in the organization.Revision control.Revision control.

A mechanism that control the changes to specification and A mechanism that control the changes to specification and sustaining the technical integrity of the specification. sustaining the technical integrity of the specification.

Preparation of SpecificationPreparation of Specification • Define the basic functions using Verbs and Nouns Define the basic functions using Verbs and Nouns

Ex. * Pump - Water Ex. * Pump - Water * Cool - Air * Cool - Air

* Transport - Goods * Cut - Metal * Transport - Goods * Cut - Metal • Define the basic duties using quantities and Define the basic duties using quantities and

units.units.

Ex. * Flow 1000 M3 / hr.Ex. * Flow 1000 M3 / hr.

* Inlet Temp. 40.0 Degree * Inlet Temp. 40.0 Degree Centigrade.Centigrade.

* Inlet Pressure 2.0 bars* Inlet Pressure 2.0 bars

* Outlet Pressure 20 bars. * Outlet Pressure 20 bars.

Tank / pump Assembly

Tank Motor Pump Pipeline (60 Tank Motor Pump Pipeline (60 Km)Km)

+ 80m+ 80m

+ 30 m+ 30 m

+ 120 m+ 120 m

+ 95 m+ 95 m

AA BB

79 m79 m

Pump and motor sizingPump and motor sizing

PPBB = P = PLL + H + Hdisch. disch. ++ P P valvesvalves + P + P piping piping KN/m2KN/m2

Pump sizing:Pump sizing:

PPAA = (P1 + H = (P1 + Hsuc.suc.) - ( P) - ( Pvalvesvalves + P + Ppipingpiping) KN/m2) KN/m2

P P pumppump = P = PBB - P - PAA KN/m2KN/m2

Power = V x PPower = V x Ppump pump / (/ ()kWkW

PPBB is the calculated pressure or the shut off is the calculated pressure or the shut off pressure which ever is higher.pressure which ever is higher.

Motor SizingMotor Sizing

P P motormotor = (API factor x Power) / = (API factor x Power) /

Select the nearest higher standard motorSelect the nearest higher standard motor

Preparation of SpecificationPreparation of Specification

• Check process conditionsCheck process conditions

Ex. * Water composition * Alkalinity/AcidityEx. * Water composition * Alkalinity/Acidity

* Solid content* Solid content * Gas/water ratio. * Gas/water ratio.• Operation conditionsOperation conditions

Ex. * Fixed / Variable duties * Variances.Ex. * Fixed / Variable duties * Variances.

* Site conditions * Reliability. * Site conditions * Reliability. • Determine design featuresDetermine design features

Ex. * Pump type * Driver type.Ex. * Pump type * Driver type.

* Protection systems * installation.* Protection systems * installation.

Wind LoadWind LoadWind pressures on closed or fully clad structures at Wind pressures on closed or fully clad structures at high Z is Pzhigh Z is Pz

Pz = 0.637 x (Uz)2 x Cf x K (KN/m2)Pz = 0.637 x (Uz)2 x Cf x K (KN/m2)Uz = F x VUz = F x V1010 x (Z/10) 1/y x (Z/10) 1/yF and y vary with gust duration as follows:F and y vary with gust duration as follows:CategoryCategory TopographyTopography F3F3 F10F10 yy 1 Extreme exposure1 Extreme exposure 1.51.5 1.31.31414 2 Open country with2 Open country with 1.71.7 1.41.4 11 11 low obstruction.low obstruction. 3 Built up areas with3 Built up areas with 2.02.0 1.61.6 88 high obstructionhigh obstruction V10 is the mean hourly speed (m/s) at high of 10 m.V10 is the mean hourly speed (m/s) at high of 10 m.Cf the shape coefficientCf the shape coefficientK Correction factor for aspect ratio (L/W of the object)K Correction factor for aspect ratio (L/W of the object)

Preparation of SpecificationPreparation of Specification• Select MaterialSelect Material

Ex. * ServiceabilityEx. * Serviceability * Availability * Availability

* Manufacturing* Manufacturing * Maintenance * Maintenance

* Durability * Durability * Cost. * Cost.• TestingTesting

* Criticality* Criticality * Mech. String test. * Mech. String test. * * Performance test * Durability test.Performance test * Durability test.

• Code requirementCode requirement

Basically listing the applicable codes and standardsBasically listing the applicable codes and standards

Preparation of SpecificationPreparation of Specification• HSE requirementHSE requirement

Ex. * Noise level Ex. * Noise level * Safe distance* Safe distance

* Leaks / Vents* Leaks / Vents * Safeguarding* Safeguarding• Customer needsCustomer needs

Ex. * Service-life Ex. * Service-life * Availability * Availability

* Utilities * Utilities * Painting* Painting

* Dimensions* Dimensions * Weight* Weight• Market requirements.Market requirements.

Consider your competitors, Customer expectation and Consider your competitors, Customer expectation and market trends.market trends.

Noise LevelNoise LevelNoise level in building shall not exceed the Noise level in building shall not exceed the following: following:

AreaArea MASP MASP db(A)db(A)Areas in workshops and machinery house 70Areas in workshops and machinery house 70Workshop officesWorkshop offices 60 60Control roomsControl rooms 50 50Offices and conference roomsOffices and conference rooms 45 45AccommodationAccommodation 40 40HVAC equipmentHVAC equipment 10 10

Notes: Notes: 1) If noise has an impulsive and or tonal character, 1) If noise has an impulsive and or tonal character, the above limits should be lowered by 5 db(A)the above limits should be lowered by 5 db(A) 2) Noise generated by the user of the various area 2) Noise generated by the user of the various area need not to be considered.need not to be considered.

Safe distanceSafe distance

NormalNormal

Blast proofBlast proof

Blast resistanceBlast resistance

200 m 300 m > 500 m

Preparation of SpecificationPreparation of Specification•ManufacturingManufacturing

The proposed design should be checked for ease of The proposed design should be checked for ease of manufacturing i.e. the industry can realize the product at manufacturing i.e. the industry can realize the product at the most cost effective matter using proven technologies the most cost effective matter using proven technologies with minimum risk.with minimum risk.• Operability / MaintainabilityOperability / Maintainability

The design should provide operation friendly product that The design should provide operation friendly product that will deliver its objective over the intended service life will deliver its objective over the intended service life without any major break down or excessive frequent without any major break down or excessive frequent maintenance efforts.maintenance efforts.

Preparation of SpecificationPreparation of Specification• Quality AssuranceQuality Assurance

Assess the supplier by requesting information on:Assess the supplier by requesting information on:

- Quality system- Quality system - Technical know-how- Technical know-how

- Production capacity- Production capacity - Financial status- Financial status• Quality controlQuality control

Specify the Q/C requirement in the requisitionSpecify the Q/C requirement in the requisition

- Periodic audits- Periodic audits - Inspection- Inspection

- Witnessing tests- Witnessing tests - Review Q/C documents - Review Q/C documents

- Audit Q/C procedure - Certification- Audit Q/C procedure - Certification

Continual ImprovementContinual Improvement•New TechnologyNew Technology

Latest industrial developments that enhance value.Latest industrial developments that enhance value.Customer feedbackCustomer feedback

User feed back is the most valuable information for User feed back is the most valuable information for improvementimprovementCompetitive specificationCompetitive specification

Benchmark with others to be the world classBenchmark with others to be the world classMarket trendsMarket trends

Reading the future market trends will make you the Reading the future market trends will make you the front runner. front runner.

RememberRemember

• Standards exist Standards exist

* to be used* to be used

* to be critically examined* to be critically examined

* to be modified if not suitable* to be modified if not suitable• We are most at risk with complex We are most at risk with complex

systems whether during manufacturing, systems whether during manufacturing, use or modify. Standards are our save use or modify. Standards are our save guarding system.guarding system.