You are on page 1of 34

(:J.~.~) ~~\.k.

a3 a5"~

KUWAIT OIL COMPANY (K.S.C.)

~~''''''''''''''''wU"'''':'

__1

A Subikllary oIlWwa1l Plllrolwm CctporetJon

STANDARDS PUBLICATION

KOCSTANDARD

FOR

WATER FOR

SITE HYDROSTATIC TESTING

AND LAY-UP

(Formerly 015-CG-1001)
DOC. NO. KOC-G-Oll

II

DOC.NO. KOC-G-011

Page 1 of 33

REV. 1

.. .,f---i

l....l... ,.v.Js>-.L..JI.L-.-J..~

A~ry~-f~IPo1~_~I1otr-

STANDARDS PUBLICATION

KOC STANDARD

FOR

TEST WATER FOR

SITE HYDROSTATIC TESTING

AND LAY-UP

DOC.NO. KOC-G-011

STANDARDS TEAM

DOC.NO. KOC-G-011

II

Page 2 of 33

REV. 1

KOC STANDARD

FOR

TEST WATER FOR

SITE HYDROSTATIC TESTING

AND LAY-UP

DOC.NO. KOC-G-011
(FORMERLY 01S-CG-1 001)

ISSUING AUTHORITY:

STANDARDS TEAM

Rev.

07 .09. 10

Issued as Final
KOC Standard

Task Force
(TF-G/08)

Date

Description

Prepared by
Tel. No. 66394

Snr. Engr. Stds.


Tel. No. 61407

/T-ej~~erslandardS
/,
..,.../fel. ~o. 61896

II

DOC.NO. KOC-G-011

Page 3 of 33

REV. 1

TABLE OF CONTENTS
Page No.
FOREWORD

1.0

SCOPE

2.0

APPLICATION

3.0

TERMINOLOGY
3,1 Definitions
3,2 Abbreviations

7
7
8

4.0

REFERENCE STANDARDS, CODES AND SPECIFICATIONS


4,1 Conflicts
4,2 List of Standards, Codes and Specifications

8
8
9

5.0

ENVIRONMENTAL CONDITIONS

10

6.0

HEALTH, SAFETY AND ENVIRONMENT

10

7.0

GENERAL TECHNICAL REQUIREMENTS

11

8.0

WATER SUPPLY AND ANALYSIS


8,1 Supply
8,2 Analyses
8,3 Filtration

12
12
13
13

9.0

WATER TREATMENT FOR HYDROSTATIC TESTING


9.1 General
9.2 Water Treatment for Carbon / Low Alloy Steel
Equipment and Pipelines
9.3 Water Treatment for Stainless Steel Equipment,
Pipelines and Tanks

14
14

10.0

WATER TREATMENT FOR LAY-UP


10.1 General
10.2 Wet Lay-up
10.3 Dry Lay-up
10.4 Inert Gas Lay-up
10.5 Ambient Lay-up

20
20
21
22
22
23

11.0

DISPOSAL OF TEST WATER

23

12.0

QUALITY ASSURANCE

25

16
18

Page 4 of 33

DOC.NO. KOC-G-011

13.0

14.0

REV. 1

DOCUMENTATION
13.1 General
13.2 Deliverables

25

APPENDICES

28-31

Annexure-I

: Typical Brackish Water Analysis

28

Annexure-II

: Ambient Seawater Quality Criteria

29

Annexure-III : Maximum Limits of Pollutants in Industrial Water


Waste Permissible to be Discharged in the Sea

30

Annexure-IV: Treated Waste Drainage Water Discharged into


Sewerage

31

ACKNOWLEDGMENT

25
26

32-33

DOC.NO. KOC-G-011

Page 5 of 33

REV. 1

FOREWORD
This document "KOC Standard for Test Water for Site Hydrostatic Testing and Lay-Up
(KOC-G-011, Rev. 1)" is intended to provide the minimum technical requirements for test
water to be used during hydrostatic testing and lay-up of eqUipment at KOC Facilities in
Kuwait. It includes also guidelines to dispose the Test Water after completion of hydrotesting
in order to protect the environment.
This Standard has been approved by Standards Team in consultation with Standards
Technical Committee (STC) for consistent use by KOC User Teams throughout for the
corporate engineering and operational functions of Kuwait Oil Company (K.S.C).
The purpose of this Standard sets out to achieve the following objectives:
a. To provide the basic requirements for test water, that has applicability in hydrostatic
testing and lay-up of Facility / Plant equipment including pressure vessels, atmospheric
vessels, drain sump vessels, drums, pipes, heat exchangers, pipelines and
aboveground tanks at Site, and to help ensure a consistent and effective approach in its
analysis , treatment and disposal in environmentally safe and acceptable way.
b. To cover the necessary aspects of supply, filtration, chemical analysis, chemical
treatment and disposal of test water for hydrostatic testing at Site so as to minimize the
need for technical clarifications and disputes .
c. This Standard supersedes 015-CG-1001 "KOC Engineering Group Specification
for The Use of Brackish Water for Site Hydrotesting of Equipment", which is now
withdrawn.
Feedback, comments or suggestions, derived from the application of this Standard at any
stage of design, purchase, installation, operation and testing are encouraged, and should
be directed to:
The Team Leader Standards
(Chairman, Standards Technical Committee)
Industrial Services Group, KOC
P. O. Box 9758, Ahmadi 61008
State of Kuwait
Task Force Responsible for This Standard
The Standards Technical Committee (STC) has entrusted the preparation of this Standard
to the Task Force l\lo. TF-G/08, conSisting of the following members:
Mr. Abdul R. AI-Shamari
Mr. Mirza Mohsin
Mr. Mohd . Imadi
Mr. N. Ramanathan
Mr. S.H. Shah
Mr. Saad Jaber
Mr. Bader AI-Qahtani
Dr. Waseem Siddiqi

Insp. & Corr. (N&W)


Standards Team
DeSign Team
Major Projects (EFP)
Gen . Projects Team
Construction Team
OTS (SK) Team
Health & Environment

TF Leader
Member
Member
Member
Member
Member
Member
Member

Tel.
Tel.
Tel.
Tel.
Tel.
Tel.
Tel.
Tel.

66394
61371
61102
66960
61190
61376
22384
71628

DOC.NO. KOC-G-011

III

Page 6 of 33

REV. 1

1.0

SCOPE

1.1

This Standard specifies the minimum requirements for the supply, pretreatment
using filtration, chemical treatment and chemical analysis of test water for use as a
Site hydrostatic testing medium at Kuwait Oil Company Facilities in the State of
Kuwait in order to control internal corrosion of facilities during and after hydrostatic
testing .

1.2

The Standard covers the disposal of the test water after completion of hydrostatic
testing or lay-up .

1.3

This Standard covers the test water to be used in Site hydrostatic testing of the
following components installed at KOC facilities within the production and export
operating areas:
a. Facility / plant equipment including pressure vessels, atmospheric vessels, drain
sump vessels, drums, pipes, heat exchangers and storage tanks;
b. All onshore and offshore pipelines installed outside facilities, which include but
not limited to crude oil pipelines, flow lines, gas and condensate pipelines, fuel
pipelines, water injection pipelines, drain sump vessels, and pig launchers /
receivers .

1.4

Lube oil systems and instrument air systems are not covered within this Standard as
water should not be used as a test fluid for these systems.

1.5

This Standard does not cover procedures / methods of carrying out the hydrostatic
testing or the performance / results of hydrostatic testing , which shall fully comply
with all relevant KOC Standards or Contractual requirements as specified in the
Project Scope of Work and Technical Specification of the Contract.

2.0

APPLICATION

2.1

For the application of test water to be used in Site hydrostatic testing, refer to
clauses 1.3 and 1.4 of this Standard.

2.2

The test water and its filtration , chemical analyses, chemical treatment and disposal
shall conform to the requirements of this Standard and the relevant standards and
codes mentioned herein .

2.3

Any exception or deviation from this Standard shall be brought to the attention of the
KOC Controlling Team with merits and justifications for review & consideration and
for necessary amendments by the Standards Team (if required).

2.4

Compliance with this Standard does not of itself confer immunity from legal or
statutory obligations.

DOC.NO. KOC-G-011

III

3.0

TERMINOLOGY

3.1

Definitions

Page 7 of 33

REV. 1

For the purposes of this Standard, the following definitions shall apply:
3.1.1

Ambient Lay-Up
During ambient lay-up, the Test System is completely drained off all standing test
water to remove all test water.

3.1.2

Chemical Manufacturer / Supplier


Any firm approved by KOC to manufacture / supply the chemicals required for the
treatment of test water.

3.1.3

Company
Means Kuwait Oil Company (KOC).

3.1.4

Dry Lay-Up
During dry lay-up, the Test System is completely drained off all standing test water,
and then dried to achieve the specified dew point before being shut-in under positive
pressure during the lay-up period .

3.1.5

Equipment
Equipment refers to the pressure vessels, drums, drain sump vessels, atmospheric
vessels, pig launchers / receivers and / or storage tanks subject to hydrostatic
testing.

3.1.6

Inert Gas Lay-Up


During inert gas lay-up, the test water is drained and the Test System is typically
charged with an inert gas to a pre-defined drying requirement and shut-in under
positive pressure, until it is ready for commissioning and start-up.

3.1.7

KOC Controlling Team


Any KOC Team that is responsible for implementing and controlling the project,
tasks or works as designated and authorized by KOC .

3.1 .8

Lay-Up
Lay-up is the period after successful hydrostatic testing when the test water is
completely drained, until the Test System is ready for commissioning and start-up.

3.1.9

Piping
Process or utility pipes that are installed inside the onshore / offshore facility.

DOC.NO. KOC-G-011

III

3.1.10

Page 8 of 33

REV. 1

Pipelines
All onshore and offshore pipelines installed outside facilities , which include but not
limited to crude oil pipelines, flow lines, gas and condensate pipelines, fuel pipelines,
and water injection pipelines.

3.1.11

Site
The KOC Site at wh ich hydrostatic testing will be conducted .

3.1.12

Wet Lay-Up
During wet lay-up, the Test System is allowed to remain full of treated test water until
ready for commissioning and start-up.

3.2

Abbreviations
API
CRA
EPA
HSE
ICT
ISO
KOC
MSDS
ppm
ppb

American Petroleum Institute

Corrosion Resistant Alloys

Environmental Public Authority, Kuwait

Health , Safety and Environment

Inspection and Corrosion Team

International Organization for Standardization

Kuwait Oil Company (K.S.C .)

Material Safety Data Sheet

Parts Per Million

Parts Per Billion

4.0

REFERENCE STANDARDS, CODES AND SPECIFICATIONS

4.1

Conflicts

4.1.1

In the event of conflicts between this Standard and any other National/International
standards and codes referenced herein , or other contractual or purchase
requirements , the same shall be brought to the attention of KOC Controlling Team in
liaison with ICT for their decision . In general, most stringent requirements shall apply
with the order precedence as given in clause 4.1.3 of this Standard .

4.1.2

In case further clarifications are required , the subject shall be brought to the
attention of KOC Standard Team and KOC Controlling Team .

4.1.3

Order of Precedence
In general, the following order / sequence of precedence shall apply:
a. Kuwait Government Rules and Regulations
b. KOC HSE Management System Requirements
c. This KOC Standard (KOC-G-011)

DOC.NO. KOC-G-011

Page 9 of 33

REV. 1

d. KOC Integrity Management Standard Requirements


e. KOC Fire & Safety Regulations

f.

KOC Technical Specifications

g. Project SpeCification and Data sheets


h. International codes and standards

i.
4.2

Contractor's / Manufacturer's / Supplier's standards and speCifications.

List of Standards, Codes and Specifications


The latest edition of the following standards, codes and specifications shall apply:

4.2.1

National/International Standards
API RP 45

Recommended Practice for Analysis of Oilfield Water

API RP 1110

Recommended Practice for Pressure Testing of Liquid Petroleum


Pipelines

API PUBL 1157 Hydrostatic Test Water Treatment and Disposal Options for Liquid
Pipeline Systems
EPA, Kuwait

4.2.2

Regulations implemented under Law No. 21 of 1995 as amended


by Law No.16 of 1996, Oct. 2001

KOC Standards and Procedures


KOC-G-007

KOC Standard for Basic Design Data

KOC HSE Management System


KOC Integrity Management Standard
KOC Fire & Safety Regulations
KOC Health & Safety Guidelines
KOC.SA.010
4.2.3

Procedure on Protective Clothing and Equipment

KOC Engineering Group Specifications


015-1 H-1 004

Pipeline Pigging and Hydrostatic Test

015-IH-1005

Pipeline Dewatering , Drying and Purging

DOC.NO. KOC-G-011

II

Page 10 of 33

REV. 1

5.0

ENVIRONMENTAL CONDITIONS

5.1

The environmental conditions in Kuwait are severe . Hydrostatic Testing at the


Facilities, where atmosphere is generally dusty and corrosive and may contain traces
of hydrogen sulphide, shall take place under high ambient temperatures and humidity.
Environmental conditions observed at the time of hydrostatic testing shall be recorded
and reported in the hydrostatic testing report submitted to KOC.

5.2

Refer to KOC-G-007 "KOC Standard for Basic Design Data", which provides general
design information regarding the environmental , site and utility supply conditions
prevailing throughout the Facilities.

6.0

HEALTH, SAFETY AND ENVIRONMENT

6.1

The Contractor shall employ necessary HSE procedures to protect personnel and
the surrounding environment during all on-site field work.

6.2

All MSDS requirements for the chemicals chosen for treatment and Kuwait EPA
regulations for the eco-friendly treatment and disposal shall be fully complied.

6.3

The Site shall be equipped with all required safety equipment related to the use of
chemicals such as emergency shower and eye wash station.

6.4

Selection of environmental friendly water source for hydrostatic testing shall be


guaranteed . Test water that could result in harming to humans must not be used for
hydrostatic testing, such as water containing hydrogen sulfide and other toxic gases
that can be released to the atmosphere with concentrations of 10 ppm hydrogen
sulfide or greater.

6.5

The use of chemical treatment is recommended to be eliminated or minimized.

6.6

Precautions must be applied during the use of any toxic or flammable chemicals.

6.7

It is a must to ensure that explosion will not happen due to mixing chemicals or due
to any other reasons such as mixing air and gas during lay-up.

6.8

All relevant safety requirements of the Manufacturer, KOC HSE Management


System Procedures, KOC Integrity Management Standard, and KOC Fire &
Safety Regulations shall be adhered to while performing work within KOC areas
for protection of personnel, adjacent equipments, properties, and
environment.

DOC.NO. KOC-G-011

Page 11 of 33

REV. 1

7.0

GENERAL TECHNICAL REQUIREMENTS

7.1

Hydrostatic testing should be scheduled as close to the commissioning of the


Equipment and / or Pipelines in order to minimize the requirements of chemical
treatment and corrosion risks .

7.2

Test water used as test fluid shall be treated for control of corrosion and bacteria when
applicable as per this Standard .

7.3

Prior to hydrostatic testing of a pipeline, all debris shall be removed from the pipeline
by using brush scrapers and magnetic scrapers or application of cleaning pigging .

7.4

In the case of pipelines, the requirements of 01S-IH-100S "KOC Engineering Group


Specification for Pipeline Dewatering, Drying and Purging" (or the latest KOC
Standard that replaces it) shall be adopted unless otherwise agreed in writing by
KOC.

7.5

Equipment(s) or pipelines constructed entirely of either non-metallic or internally


lined materials do not require chemical treatment of the test water at the time of
hydrostatic testing. However, the requirements for a partially either non-metallic or
internally lined systems shall be the same as those for internally unlined steel
equipment(s) or pipelines.

7.6

Piping systems for potable water (drinking water and raw water) shall be
hydrotested, using fresh potable water without any chemical treatment.
Other utility piping systems including CRA shall be hydrotested with low chloride
water without any chemical treatment except that the maximum chloride content for
hydrostatic test water shall be limited to 30 mgll at the time of introducing water into
the system .

7.7

Hydrostatic testing and lay-up procedures shall be compatible with the most corrosion
susceptible material as well as the corrosion resistant metallic / non-metallic material in
the system being tested .

7.8

The Contractor shall describe in the hydrostatic testing procedure the source and
quality of test water and details of the water treatment, including types of chemicals
to be used; dosing rates that are necessary to bring the water to the level of required
quality and details of monitoring program and sampling frequencies.
The Contractor shall describe the possibility of generating solid waste during
hydrostatic testing and shall submit the safe solid waste disposal procedure for KOC
approval.

7.9

All relevant KOC HSE requirements shall be included within the hydrostatic testing
procedure.

7.10

The disposal of the test water after use, including timing, rate of discharge, treatment
methods, and disposal location shall also be described in detail in the hydrostatic
testing procedure .

DOC.NO. KOC-G-011

II

Page 12 of 33

REV. 1

7.11

Stainless Steel equipment and piping shall be tested only with water having less
chloride as described in clause 9.3 of this Standard .

7.12

For equipment(s) that are fabricated and hydrotested outside the State of Kuwait,
hydrostatic testing and lay-up procedures shall be submitted for approval to KOC
Controlling Team. At least, one lay-up method as per clause 10.0 of this Standard shall
be utilized to prevent the equipment against internal corrosion during the shipping
period to the installation . Vapour phase corrosion inhibitor may be required .

7.13

When test water is removed from the Test System either at the end of the hydrostatic
testing or the end of the lay-up, the Test System shall be completely dried as per
015-1 H-1 005 "KOC Engineering Group Specification for Pipeline Dewatering, Drying
and Purging" (or the latest KOC Standard that replaces it). Nitrogen, sweet gas,
glycol or methanol shall be used for drying if drying cannot be completed within a
week. Air drying is not allowed except for small plant piping.

8.0

WATER SUPPLY AND ANALYSIS

8.1

Supply

8.1.1

The Contractor shall ensure the availability of sufficient amount of test water at Site
without disruption to hydrostatic testing or any KOC operations.

8.1 .2

Test water quality of intended hydrostatic testing waters shall be determined well
ahead of the actual testing date so that alternative test water sources with the required
treatment may be identified if the original source water fails to meet requirements.

8.1.3

Brackish water, obtained from Abdulliyah Water Centre or from the North Kuwait
Source Wells, can be used if approved by KOC Controlling Team, unless specific
dispensation is given by KOC to use seawater or any other source of water.

8.1.4

Sea water may only be used with approval from KOC Controlling Team, if there is no
other practical alternative.

8.1.5

Typical fluid analysis data for brackish water and seawater streams are presented
respectively in Annexure-I & " of this Standard.

8.1.6

Use of fresh / potable water or low chloride water shall be restricted to the applicable
conditions.

8.1.7

The Contractor shall establish the size of test piping, the availability and flow rate of
test water for each equipment or pipelines to be tested.

8.1 .8

For each equipment or section of pipeline to be tested, the Contractor shall use test
water from only a single source, to avoid the risk of scale and deposit formation.

8.1.9

Re-use of test water is encouraged by KOC when potable water or low chloride water
is used, when logistics permits and when the quantity under consideration is large
enough to achieve significant benefits by reduction in test water consumption and by
reduction of environmental impact.

DOC.NO. KOC-G-011

Page 13 of 33

REV. 1

The Contractor has to submit an effective strategy to the Controlling Team for the
management of reusing the test water for review and approval. All required tests,
analyses, filtration and chemical treatments shall be maintained as per the
requirements of this Standard.
8.2

Analyses

8.2.1

All laboratory analyses shall be performed by a KOC approved laboratory that has
been accredited and / or certified to ISO 17025. Laboratory and field analysis
instrumentations shall be approved by KOC Controlling Team / ICT and calibration
certificates shall be presented to KOC for acceptance. All Contractor's personnel
involved in the Site analyses shall be qualified and shall be subject to KOC approval.

8.2.2

The Contractor shall perform full chemical analyses of the test water source to
accurately determine all relevant parameters, including but not limited to oxygen
content, pH, chloride content, total suspended solids (TSS). total dissolved solids
(TDS), H2S concentrations, turbidity, appearance and measures of the
microbiological populations. Requirements for such sampling and analysis and
subsequent approvals of results shall be consulted' with KOC Controlling Team in
liaison with ICT.

8.2.3

The Contractor shall perform tests to determine whether the test water is corrosive,
biologically active for microbial growth and has scale forming tendency. Test
procedures and test results shall be submitted for approval by KOC Controlling Team
in liaison with ICT.

8.2.4

Detailed analytical test procedures covering all relevant parameters shall be submitted
to KOC Controlling Team to liaise with ICT for review and approval prior to performing
any test water analyses.

8.2.5

If reuse of test water is considered for application, analyses shall be undertaken to


comply with the requirements as described in clause 8.2.2 of this Standard; and also to
determine whether additional applications of corrosion and / or bacterial control are
needed to maintain the required concentrations and residuals as per this Standard.

8.3

Filtration

Test water shall be filtered prior to any hydrostatic testing to ensure that there is total
removal of all particles larger than 50 microns. Filters that do not allow particles above
50 microns shall be installed at the entry of the test water to the Test System.

DOC.NO. KOC-G-011

II

Il

Page 14 of 33

REV. 1

9.0

WATER TREATMENT FOR HYDROSTATIC TESTING

9.1

General

9.1.1

The Contractor shall submit to KOC Controlling Team for review and approval the
hydrostatic testing procedure as per clause 13.2.1of this Standard.

9.1 .2

Suitable chemical treatment shall be undertaken by the Contractor to inhibit corrosion


and biological growth. Wherever possible, chemicals shall be chosen which are easily
biodegradable and also not bio-accumulative so that after use they are not harmful to
the environment. The chemical vendor shall provide the MSDS indicating that the
chemicals are biodegradable for review and approval by KOC Controlling Team in
liaison with ICT.
The Contractor shall ensure the safe storage facility for all chemicals required for
hydrostatic testing as per KOC procedures. Storage facility shall be approved by KOC
Controlling Team.

9.1.3

The concentration of the chemical treatment shall be verified by appropriate


measurement techniques approved by KOC Inspection and Corrosion Team. The use
of excessive chemicals shall be avoided . Guideline concentrations of chemicals for
dosing shall be determined in accordance with the international practices and site
conditions.
In general, dOSing rates shall follow chemicals suppliers' recommendations as required
to prevent against corrosion . The Contractor may be requested by KOC to arrange with
approved independent laboratory for any testing requirement, put forward by the KOC
I&C Team to establish such dosing rates values.

9.1.4

The proposed chemical treatment including specific chemical formulations used as


individual component or combination of corrosion inhibitor, biocide and oxygen
scavenger, concentration of those chemicals and MSDS shall be submitted to KOC
ICT as part of the procedure for approval.

9.1.5

Treatment chemicals shall be injected continuously, in such a manner that their


concentration in test water is homogenous, in accordance with this Standard, while
the equipment/pipeline is being filled to ensure the proper application of treatment.

9.1.6

Where multiple treating chemicals are required , compatibility of chemicals shall be


ensured.

9.1 .7

Proper chemical injection methods shall be identified on the basis of chemicals


selected for application. Separate proportioning pumps, having an accuracy of not
less than 5% or more than 7% of KOC approved dosage rate, shall be used for each
chemical to avoid adverse reactions between the chemicals if multiple chemicals are
considered for treatment. Chemicals shall not be mixed prior to injection. Chemical
injection rates shall be verified by displacement gauges.

DOC.NO. KOC-G-011

Page 15 of 33

REV. 1

9.1.8

Injection points of different chemicals shall be positioned at least 2.0 m apart.


Concentrated chemicals shall not be mixed. The injection points shall be
upstream of the filling pumps to allow thorough mixing before entry into the test
system .

9.1.9

The pH of the test water shall be in the range 6.0 to 10.5 at the time of injection
into the equipment / pipeline. Sodium carbonate (soda ash) or sodium hydroxide
(caustic) may be added , as necessary, to satiSfy this requirement.

9.1 .10

Oxygen scavenger treatment shall be applied to the test water to prevent corrosion
occurring due to the presence of dissolved oxygen. Organically catalysed
ammonium or sodium bisulphite in liquid form are the examples for typical
oxygen scavenger. The dissolved oxygen in test water shall be accurately
measured, such that the appropriate dosage of Oxygen scavenger can be applied.
Oxygen must not be permitted to enter the Oxygen Scavenger holding tank.
Nitrogen blanketing may be required for ternporary storage of Oxygen Scavenger.

9.1.11

Biocide treatment shall be applied to the test water to prevent biomass solids buildup
and bio-corrosion occurring . Selection of environmental friendly biocides shall be
warranted where discharge to environmentally sensitive locations is considered.

Tetrahydroxymethyl Phosphonium Sulphate (THPS) and polymeric biguanide


based products are examples for such biocides. Under any circumstance,
biocide containing formaldehyde shall not be used. The dosage rate would
typically be expected in the range 200 - 500 ppm (active ingredient) .
9.1.12

Corrosion inhibitor treatment shall be applied to the test water to prevent corrosion
occurring due to the presence of corrosive species other than dissolved oxygen.

9.1.13

During the chemical treatment of test water, Oxygen scavenger shall be added first,
and all Oxygen shall be scavenged, before any biocide is added, to prevent adverse
interaction between the Oxygen scavenger and the biocide. The Contractor's
procedure shall clearly demonstrate compliance to this requirement.

9.1 .14

Chemical testing procedures shall be submitted to KOC Controlling Team for review
and approval.

9.1.15

Chemical content and activity shall be spot verified using the analysis type and test
methods complying with the requirements specified in clause 8.2 of this Standard at a
frequency approved by KOC Controlling Team in liaison with ICT or at least at
the beginning and end of short-duration hydrostatic testing .

9.1.16

If test water is transferred from one test section to another, the quality of water shall
be checked for compliance with the requirements specified in clause 8.2 .5 of this
Standard.
The Contractor shall submit to KOC Controlling Team for approval , a procedure to
achieve the speCified test water treatment and quality. No debris shall be permitted to
be transferred from one section to another.

DOC.NO. KOC-G-011

III

II

Page 16 of 33

REV. 1

9.2

Water Treatment for Carbon I Low Alloy Steel Equipment and Pipelines

9.2.1

General
a. In order to avoid excessive chemical usage, the Contractor should complete the
hydrostatic testing in a minimum period of time .
b. The Contractor shall submit to KOC Controlling Team for review and approval all
the necessary documents including the estimated duration of the hydrostatic
testing as per clause 13.2.1 of this Standard .
The Contactor shall ensure that the test water contact time will not exceed the
durations indicated in the subsequent clauses (c), (d), and (e) below for any
reasons including operational reasons. If there is any doubts to drain the water
within the specified period, chemicals shall be added regardless of the contact
time.
c. Control of corrosion caused by Oxygen is required, where total test water contact
time will exceed 14 days, and shall be achieved by the addition of an Oxygen
scavenger to the test water. Dosage shall be sufficient to maintain a residual
sulphite content of 20 mg/I and Oxygen concentration of less than 10 ppb.
d. Control of corrosion caused by bacterial action is required where total contact time
with brackish water will exceed 28 days, and this shall be achieved by the addition
of a biocide to the test water.
If seawater is used as the test medium, biocide shall be added irrespective of the
contact time.
e. Control of other forms of corrosion is required where total contact time with test
water will exceed 28 days, and this shall be achieved by the addition of a
corrosion inhibitor to the test water.
f. The pH of the test water shall be verified at the Site before the test water is
introduced into the test system.
g. It is strictly prohibited to exceed the periods indicated in paragraphs c, d, and e
above for the requirements of the chemical treatments to be injected in the Test
System; or otherwise the test water shall be drained completely and the
hydrostatic testing exercise shall be repeated fulfilling all requirements of the new
duration.
h. It is strictly prohibited to allow the test water to remain in the equipment and / or
pipeline for a period more that 60 days from the date of starting the test water
filling, otherwise lay-up shall be implemented as per clause 10.0 of this Standard.
Sea water is not allowed to be used as a test fluid, if the tested system is
intended for lay-up as per clause 10.1.3 of this Standard .
i. In case of Heat Exchangers, test water shall not remain more than 14 days after

completion of the hydrostatic testing . Lay-up shall be implemented as per clause


10.0 of this Standard.

Page 17 of 33

DOC.NO. KOC-G-011

j.

REV. 1

In case of Storage"Tanks, test water shall be fully drained after completion of the
hydrostatic testing.

k. The treatment of test water used for Storage Tanks shall be as indicated in
clause 9.2 .2 of this Standard.

I.

Test water filtration shall comply with the requirements of clause 8.3 of this
Standard .

m. The required chemical treatments and corrosion management parameters for


carbon and low alloy steels are indicated below in Table 1 of this Standard .
Table 1: Chemical Treatment and Corrosion Management Parameters for
Carbon and Low Alloy Steels
Parameters

Unit

Target Value

Dissolved Oxygen
Bacteria-SRB

ppb
Countlml

< 20

CounUml

< 100

<10

Planktonic

Total bacteria
Planktonic

Test Water
Contact Duration
days (D) ,
pH Modifier
Oxygen
Scavenger
Biocide
Corrosion Inhibitor

*
9.2.2

0-14

Chemical Treatment
Brackish Water
14<D<28
> 28

Required if pH is outside
6.0t010.5
None"
Required
Required

0-14

Sea Water
14<D<28

28<D<60

Required if pH is outside
6.0 to 10.5
None
Required
Required

None

Required

Required

Required

Required

None

Required

None

None

Required

Oxygen Scavenger shall be added to the test water of dry gas piping/pipe line system even
when the contact time is less than 14 days.

Water Treatment for Carbon & Low Alloy Steel Storage and Atmospheric Tanks
shall comply with the following :
a. Completely internally lined storage tanks at the time of the hydrostatic testing do
not require chemical treatment. However, it is mandatory to remove the test
water from the tank immediately after completion of the hydrostatic test.
b. Tanks that are not internally lined at the time of hydrostatic testing and will be
internally lined after the hydrostatic testing do not require chemical treatment.
However, it is mandatory to remove the test water from the tank immediately
after completion of the hydrostatic testing .
c. Tanks that are not internally lined at the time of hydrostatic testing and will not be
internally lined after the hydrostatic testing, do not require chemical treatment.
However, it is mandatory to remove the test water from the tank immediately
after completion of the hydrostatic testing . Sea water is not allowed as test
fluid.

DOC.NO. KOC-G-011

Page 18 of 33

il

REV. 1

The test water shall not be kept in the tank for a period more than 60
calendar days including the filling time, or otherwise the test water shall be
drained completely regardless of completing the hydrostatic testing. No
deviation is allowed.

d. If seawater is allowed by the Controlling Team in liaison with ICT to be used as


the test medium, biocide shall be added, no matter how long the contact time will
be.
For completely internally lined storage tanks, seawater cannot be used as test
medium unless the lining system is suitable for sea water service. Biocide
treatment is not required.
For tanks that are not internally lined at the time of hydrostatic testing and will
not be internally lined after the hydrostatic testing, Sea water is not allowed as
test fluid.

e. The test water quality shall be analyzed and evaluated by the Contractor and
shall be submitted to KOC Controlling Team for review and acceptance.
9.3

Water Treatment for Stainless Steel Equipment, Pipelines and Tanks

9.3.1

General
a. Only low chloride water shall be used as test water in contact with all types of
stainless steel or those which are lined with stainless steel.
b. The maximum chloride content for test water shall be limited to 30 mgll at the
time of introducing the test water into the system .
c. The chloride content and pH of the test water shall be verified at the Site before
the test water is introduced into the test system.
d. Corrosion Inhibitors need not be added for hydrotesting of process eqUipment
fabricated entirely from stainless steels.
e. Test water filtration shall comply with the requirements of clause 8.3 of this
Standard.
f. If the tested system is made of carbon and / or low alloy steel along with
stainless steels, the system shall be treated as per the requirement of clause 9.2
of this Standard for carbon: or shall be maintained with the above reqUirements
of clause 9.3.1 of this standard for low alloy steel .
g. It is strictly prohibited to allow the test water to remain in the equipment / pipeline
for a period more than 60 days from the date of starting the test water
filling.
h. Lay-up shall be implemented as per clause 10.0 of this Standard .

!I

DOC.NO. KOC-G-011

9.3.2

Page 19 of 33

REV. 1

Water Treatment for Stainless Steel Equipment & Pipelines


a. If contact time of the test water is less than four (4) days, chemical

treatment is not required.

b. Where contact time of total test water will exceed four (4) days, Oxygen
scavenger shall be added to the test water, such that a residual sulphite
content of 20 mgll is maintained during the whole period.
Samples of the test water shall be analyzed by the Contactor on weekly basis to
maintain the test water specifications. Failure to maintain the test water
specifications will subject test water for rejection; and complete drainage and
then refilling.
c. Biocide shall be added to the test water where total contact time of test water
will exceed 14 days .
d. Storage tanks that are not designed to take positive pressure (such as open-roof
tanks, floating-roof tanks or API atmospheric cone roof tanks) cannot be sealed
off from air. Chemical treatment is impractical and therefore not required.

It is mandatory to remove the test fluid from the systems as completely as


possible immediately after completion of the hydrostatic test.
e. It is strictly prohibited to exceed the periods indicated in clauses (b) and (c)
above for the requirements of the chemical treatments to be injected in the Test
System; or otherwise the test water shall be drained completely and the
hydrostatic testing process shall be repeated .
f. Samples shall be taken from each chemical tank at the end of the filling in order
to ensure that no contamination has taken place.
g. The required chemical treatments for all types of stainless steels are indicated in
Table 2 of this Standard below.

Table No.2: Chemical Treatment Required for Stainless Steels


Parameters
Dissolved Oxygen
Bacteria-SRBPlanktonic
Total Bacteria
Planktonic

Unit
ppb

Target Value

Count / ml

< 10
<10

Count / ml

< 100

Chemical Treatment
Test Water Contact
Duration, days (D)
Oxygen Scavenger
Biocide

4<0<14

14<0<60

Required
None

Required
Required

~I

DOC.NO. KOC-G-011

Page 20 of 33

REV. 1

10.0

WATER TREATMENT FOR LAY-UP

10.1

General

10.1 .1

Lay-up shall not be implemented unless a written approval is obtained from KOC
Controlling Team. Lay-up shall be implemented, unless the start-up date is within
60 days from introduction of the test water.

10.1.2

If the tested system is planned for lay-up, sea water is not allowed to be used
as a test fluid.

10.1 .3

Lay-up procedure including lay-up method shall be submitted to KOC Controlling


Team for review and approval.

10.1.4

In the case of Transit, Transfer and Gas Pipelines, the requirements given in
01S-IH-100S "KOC Engineering Group Specification for Pipeline Dewatering, Drying
and Purging" (or the latest KOC Standard that replaces it) shall be adopted unless
otherwise specified by KOC .

10.1.5

In case of completely internally lined or entirely fabricated with non-metallic material


systems, no lay-up procedure is required.

10.1.6

In the case of heat exchangers, lay-up shall commence within 14 days of


introduction of the test water. The test system shall be completely dried as per clause
7.13 of this Standard prior to start up of the lay-up

10.1 .7

In the case of stainless steel equipment, lay-up shall commence within 60 days of
introduction of the test water. The test system shall be completely dried as per clause
7.13 of this Standard prior to stat up the of the lay-up,

10.1.8 In the case of storage tanks, the test water shall be removed from the system at the
end of the hydrostatic testing and the system shall be completely dried as per clause
7.13 of this Standard. No lay-up is required.
10.1 .9

In case of potable water systems, the lay-up requirements shall comply with the
relevant clauses of this Standard as below:
a. Clause 10.3 for dry lay-up;
b. Clause 10.4 for inert gas lay-up using nitrogen and
c. Clause 10.5 for ambient lay-up

10.1 .10

In the case of dry gas piping / pipeline system, wet lay-up or dry lay-up shall be the
preferable methods. The system shall be pressurized with dry nitrogen .

10.1.11 When required, one of the lay-up methods as described in clauses 10.2 to 10.4 of
this Standard shall be followed as a component of the hydrostatic testing . The
preferred methods are wet and dry lay-ups.

DOC.NO. KOC-G-011

Page 21 of 33

REV. 1

10.1.12 Use of ambient or inert gas lay-up for equipment and tanks will only be considered in
extraordinary cases, if both of the wet or dry lay-up methods cannot be
implemented , as justified by the Contractor to KOC satisfaction.
10.1.13 The time duration between termination of lay-up and start-up of the test system shall
be less than 60 days, except for clause 10.1.14 below. Upon termination of the
lay-up, the test system shall be completely dried as per clause 7.13 of this Standard.
10.1.14 In the case of heat exchangers and stainless steel equipment, the time duration
between termination of lay-up and start-up of the test system shall be less than 14
days. Upon termination of the lay-up, the test system shall be completely dried as per
clause 7.13 of this Standard.
10.2

Wet Lay-Up

10.2.1

Wet lay-up shall be only utilized if total drainage can not be verified by visual
inspection or other reliable means, as justified by the Contractor to KOC satisfaction.

10.2.2

Upon verification of the proper residual sulphite level as per clause 10.2.3 below and
completion of successful hydrostatic testing, the test system shall remain full of the
treated test water under positive pressure, until the test system is ready for
commissioning and start-up.

10.2.3

Oxygen scavenger shall be added to the test water at the starting of the hydrostatic
testing. A minimum residual sulphite level of 20 ppm and Oxygen
concentration of less than 10 ppb shall be established throughout the test system,
including dead legs. Test water sample(s) shall be analyzed at the pertinent
location(s) and test results documented in the hydrostatic testing report. Once
compliance is established, the test system shall remain closed . Further testing is
required at intervals of 90 days.
A new wet lay-up shall be initiated in the event of any leaks or loss of positive
pressure leading to Oxygen ingress or if the Oxygen concentration exceeds 10
ppb or the minimum sulphite level is being compromised.

10.2.4

An approved biocide shall be added to the test water at the starting of hydrotesting
at the dosage rate specified in clause 9.1.10 of this Standard.

10.2.5

An approved corrosion inhibitor shall be added to the test water at the starting of
hydrotesting at a dosage rate typically in the range of 500 - 1000 ppm .
The actual dosage rate to be applied shall be proposed by the Contractor for KOC
Controlling Team approval, based on technically justified advice from the Chemical
Manufacturer / Supplier.

10.2.6

Positive pressure shall be maintained during the wet lay-up, to prevent Oxygen
ingress, within the range 2-10% of maximum allowable operating pressure, but
need not exceed 350 kPa (50 psig). The positive pressure shall be maintained by
use of nitrogen, sweet hydrocarbon gas or hydrostatic pressure.

III

DOC.NO. KOC-G-011

Page 22 of 33

REV. 1

10.2.7

The positive pressure shall be monitored with a standard pressure gauge calibrated
as per KOC standard procedure that can withstand the equipment/pipelines
maximum allowable operating pressure .

10.2.8

Pressure relief devices shall be provided in each test system , when necessary,
during the lay-up period and prior to the start of operations when hydrostatic
pressure is used to maintain positive pressure.

10.3

Dry Lay-Up

10.3.1

The system shall be completely drained and free from all standing test water. Total
drainage is an essential step in achieving dry lay-up . If total drainage cannot be
verified by visual inspection or other reliable means (e .g. utilizing drains at all low
points), dry lay-up shall not be considered .

10.3.2

The test system shall be dried to a dew point of -1C (30F) or less at all exit
points by the most convenient method (e.g . methanol swab, blowing heated dry air
or nitrogen through the test system or use of a vacuum) . The test system shall then
be shut in for a period of not less than 12 hours to allow any remaining moisture
to come to equilibrium with the dry air. Exit dew points shall then be measured
again , and , if fou nd to be above _1C, the drying procedure shall be repeated.

10.3.3

If dry air is used to achieve the specified dew point, it shall be replaced with either
nitrogen or sweet hydrocarbon gas as a final step before shut-in.

10.3.4

When the required dew point is reached, the test system shall be shut-in and a
positive pressure shall be maintained as per clauses 10.2.6 and 10.2.7 of this
Standard during the lay-up period .

10.3.5

The dew point shall be measured after one week of shuting-in the test system. If the
dew point is found to be more than _1C (30F) at the lay-up pressure, the
system shall be dried again , and then a new wet lay-up shall be initiated .

10.4

Inert Gas Lay-Up

10.4.1

Upon completion of a successful final hydrostatic testing, the test water shall be
displaced with an inert gas (nitrogen is preferred), until no test water drains out of
the system . If total drainage cannot be verified by visual inspection or other reliable
means (e.g., utilizing drains at all low points), inert gas lay-up shall not be
considered .
Note that draining the bulk of test water out of the test system and
attempting to replace the volume with an inert gas by either repeated re
pressurizing or sweeping shall not be considered as inert gas lay-up.
However, in the case of pipelines, sweeping with inert gas driven scraper pigs is
considered acceptable , subject to compliance with KOC Engineering Specification
015-IH-1005.

DOC.NO. KOC-G-011

Page 23 of 33

REV. 1

10.4.2

When complete test water displacement by inert gas has been achieved , the test
system shall be shut-in under positive pressure as per clauses 10.2.6 & 10.2.7 of
this Standard, until the test system is ready for commissioning and start-up.

10.5

Ambient Lay-Up

10.5.1

Ambient lay-up shall not be permitted under the following circumstances:


a.
b.
c.
d.

Where any component of the test system has been fabricated in stainless
steel materials .
Where no corrosion allowance has been provided.
Where the antiCipated pitting corrosion cannot be tolerated.
Where rust particulates cannot be tolerated for any reason .

10.5.2

The test system shall be closed after ensuring total drainage of test water. Any
standing test water shall be swept out. Where total drainage cannot be verified by
visual inspection or other reliable means (e.g. utilizing drains at all low points),
ambient lay-up shall not be considered .

10.5.3

A vacuum breaker and pressure relief vent shall be installed and shall be made
functional during the lay-up period unless it is demonstrated that the system will not
collapse under vacuum. Setting up the vacuum breaker shall be part of the
hydrostatic testing procedure and shall depend on the system design pressure.

11.0

DISPOSAL OF TEST WATER

11.1

On completion of the hydrostatic testing, the test water shall be safely disposed off to a
KOC approved location in a manner not harmful to the environment. The procedures
to be adopted shall be in compliance with the applicable KOC environmental
guidelines and Kuwait EPA regulations .

11 .2

The test water must not be disposed off in a manner which leads to flooding the area
/ facility / enclosure .

11 .3

Disposal plan for the test water shall be submitted to KOC Controlling Team for review
and approval. The procedure shall show the types of chemicals to be injected into the
test water along with their impacts to the environment.

11.4

The test water shall be treated in such a manner that no harmful residues are
allowed to soak into the surrounding environment and the underground
aquifers.
If the test system contains harmful residues such as oil or iron residue as a result of
hydrostatic testing of a system that has been in operation, the test water shall be
treated in a manner that will render it not harmful to the environment.

11 .5

The disposed test water quality shall comply with the State of Kuwait EPA
restrictions for the maximum concentration of salts and other contaminants
permitted in waste water.

III

DOC.NO. KOC-G-011

Page 24 of 33

REV. 1

To dispose the test water into the sea, it should be treated to the standard specified in
Annexure III of this Standard.
To dispose the test water into the sewage (KOC/Municipality) system, it should be
treated to the standard specified in Annexure IV of this Standard .
11.6

If KOC Controlling Team allows the disposal of test water into disposal evaporating
pit(s), temporary security fencing shall be provided by the Contractor around the
disposal pits.
Whenever chemicals have been injected to the test water, waterproof lining, approved
by State of Kuwait EPA, shall be installed at the bottom and sides of the pit to prevent
water seepage to the surrounding. Upon completion of evaporation, the disposal pit
linings shall be disposed off at previously approved location I hazardous waste
treatment facility at Shuaiba, after obtaining prior approval of the testing procedure.
Fencing around the disposal pit(s) shall be removed , and the Site shall be reinstated to
its original state.
The Contractor's hydrostatic testing procedure shall include the design and procedure
for the construction of such disposal pit(s) and shall be submitted to KOC Controlling
Team for review and approval.
The pit deSign shall ensure that no water is able to seep into the underlying soil
strata and also overflow during the period of usage.

11 .7

KOC may allow the Contractor from case-to-case to dispose the untreated test water
with chemicals or fresh I low chloride test water into the desert or into the unlined
disposal evaporating pit(s) .

11 .8

Only if it is specified in the Contract, KOC Controlling Team may allow the Contractor
to dispose the test water into any operating facility I water disposal plant. The
Contractor shall ensure that Oxygen content will be less than 20 ppb at the time of
injection, unless specified otherwise.
Retreatment with Oxygen scavenger shall be carried out as necessary to achieve the
specified Oxygen content. Also, the Contractor shall ensure that the total suspended
solids (TOS) will be less than 20 ppm at the time of disposal, unless specified
otherwise. Re-treatment with filtration shall be carried out as necessary to achieve the
specified total suspended solids.

11.9

Where the test water will be disposed off to a location other than an operating facility, it
shall be noted that compressed air may be bubbled through test water treated with
Oxygen scavenger alone to consume the residual sulphite and thereby avoid
creation of any disposal problem.
Biocides and corrosion inhibitors used in test water are toxic materials and pH
modifiers may also be toxic. Use of these chemical additives will require a disposal
procedure to be developed for KOC Controlling Team approval. The procedure
should comply with the local environmental regulations enforced by the State of
Kuwait EPA.

DOC.NO. KOC-G-011

III

Page 25 of 33

REV. 1

11.10

Volumes of the test water to be disposed to close piping network shall be considered in
order to avoid flooding or operating upsets.

11.11

The disposal of any solid waste shall comply with the State of Kuwait EPA restrictions
and the disposal of solid waste procedure as well as the disposal location shall be
submitted to KOC Controlling Team for approval.

11 .12

If the hydrotest water is potable and without any chemical addition, it should be
reutilized in next hydrotest. This may require temporary storage. Attempt should be
made to utilize the water for gardening purposes in co-ordination with KOC Ahmadi
Team .

11.13

Water should not be discharged to sea as per KEPA Appendix 12 Criteria.

12.0

QUALITY ASSURANCE

12.1

The Contractor shall operate a quality system, preferably based on ISO 9000 series
of standards, to support achievement of the requirements of this Standard . The
Contractor shall demonstrate compliance by providing a copy of accredited
certificate and a copy of their quality manual.

12.2

Verification of the Contractor's quality system is normally part of the pre-qualification


procedure and is, therefore, not detailed in the core text of this Standard.

12.3

All personnel involved in the test water treatment for hydrostatic testing shall be
qualified to carry out such activities. CV's shall be submitted for KOC Controlling
Team for approval.

12.4

All test water quality laboratory and field testing procedures including the types of
testing methods and equipments shall be submitted to KOC Controlling Team for
review and approval .

12.5

Calibration certificates of all testing eqUipment shall be submitted to KOC Controlling


Team Representatives.

13.0

DOCUMENTATION

13.1

General

13.1.1

All correspondence, instructions, data sheets, drawings, calculations or any other


written information shall be in the English language. In case of dual languages, one
language shall be English .

13.1.2

All dimensions, units of measurement, and physical constants shall be in


accordance with KOC Standard KOC-G-007, unless otherwise specified in the
project speCifications.

13.1.3

In addition to hard copies, all documents (text, specifications, data sheets, and
drawings) shall be provided in the form of electronic files in the approved software
formats (latest version of Microsoft Word, Excel, AutoCAD and PDF-Acrobat) .

il

DOC.NO. KOC-G-011

Page 26 of 33

REV. 1

13.2

Deliverables

13.2.1

Prior to carrying out any the hydrostatic testing, the Contractor shall submit to KOC
Controlling Team for review and approval all the necessary documents including the
hydrostatic testing procedure, which shall include but not limited to the following:
a. Hydrostatic Testing Procedure;
b. Hydrostatic Testing Water Treatment & Disposal Procedure;
c. Reference standards, codes and specifications;
d. System to be tested including material of construction and lining
specifications (if applicable);
e. Hydrostatic testing media;
f. Estimated duration of the hydrostatiC testing;
g. Type of required chemical treatment;
h. Chemical manufacturer data sheet;
i. Chemical MSDS;
j. The Laboratory responsible for chemical analyses;
k. Test water chemical analysis including test type and methods;
I. Chemical testing procedure;
m. Test water analysis procedure;
n. Test water analysis devices/equipment;
o. Chemical injection dosages calculation;
p. Test water monitoring and sampling frequencies ;
q. Evidence of chemicals' compatibility;
r. Location of injection points;
s. Sampling locations/identifications;
t. Lay-up method;
u. Disposal procedure; and design of disposal pit, if applicable;
v. Pipeline dewatering, drying and purging procedure;
w. HSE
procedure
including
chemical
handling,
hazard
and
risk
assessment, risk management, environment impact assessment and its
managements, and operational control activities including and not limited
to
mechanical
handling,
safety
handling,
personnel
protective
equipments and emergency procedures ..

13.2.2

In addition, all required project documents as per the Contract specifications


shall be submitted to KOC Controlling Team for review and approval.

13.2.3

All deviations and non-conformances with this Standard shall be brought to


the KOC Controll ing Team(s) for review and approval.

13.2.4

The Contractor shall submit to KOC Controlling Team post completion of


hydrostatic testing documents including and not limited to the following:
a. Quantity of test water used ;
b. Total consumption of injected chemicals for treatment;
c. Test water chemical analysis conducted prior to introducing the test water and
during the hydrostatic testing period;
d. Hydrostatic testing pressure and contact time ;
e. Lay-up results ;

II

DOC.NO. KOC-G-011

Page 27 of 33

f. Disposal location;
g. Any deviations / non-conformances;
h. Analysis Reports:
Report shall include but not be limited to the following:
i)
Name of test equipment;
ii)
Types of injected chemicals;
iii) Source of test water and its previous use, if any;
iv) Sample point identification ;
v)
Who collected the sample;
vi) When the sample was collected;
vii) When the sample was analyzed;
viii) Test method or standard and device;
ix) Results;
x)
Credentials of responsible personnel.

REV. 1

Page 28 of 33

DOC.NO. KOC-G-011
14.0

REV. 1

APPENDICES
ANNEXURE-I
(Informative)
~-----------------------------------------------------,

Typical Brackish Water Analysis


Analysis

Unit

Test Results

Sodium Na

PPM

3349

Calcium as Ca

PPM

4160

Magnesium as Mg

PPM

923.4

Total Iron as Fe

PPM

0.66

Potassium as K

PPM

24

Barium as Ba

PPM

<1.0

Strontium as Sr

PPM

24

Phophorus as P

PPM

0.35

Chloride CI

PPM

3950

Carbonate as C0 3

PPM

NIL

Bicarbonate as HC0 3

PPM

183

Sulphate as S04

PPM

1200

Fluoride as F

PPM

Silica as Si02

PPM

12.4

Nitrate as N0 3

PPM

19.4

Nitrite as N02

PPM

0.6

Sulphide as S

PPM

0.004

Phosphate as P04

PPM

1.07

Total Chlorine as CI 2

PPM

0.01

Sodium Chloride as NaCI

PPM

6517

Caustic Alkalinity as CaC0 3

PPM

NIL

Total Alkalinity as CaC0 3

PPM

150

Oxygen Content

PPM

Oil in Water Content

PPM

NIL

Dissolved H 2 S

PPM

NIL

Dissolved CO 2

PPM

35

6.4

pH at 25C
TSS

PPM

NIL

TDS

PPM

6300

Mmhos/CM

9000

Electrical Conductivity
Specific Gravity at 60 OF

1.002

DOC.NO. KOC-G-011

Page 29 of 33

REV. 1

ANNEXURE II

(Informative)

-- - - -.
Ambient Seawater Quality Criteria
- - . - -..

...

I
Pollutants

Chemical Symbol Unit

Maximum Limit
6.5-8.5

pH

33-42

Dissolved Oxygen

mg/L

>4

Total Suspended Solids

mg/L

32.8

Salinity

Phosphate

P0 4

jJg/L

33.7

Ammonia

NH3

jJg/L

60

ppm

Hydrocarbons
Cadmium

Cd

j.Jg/L

0 .7

Nickel

Ni

j.Jg/L

20.0

Nitrate

N0 3

jJg/L

94.7

Mercury

Hg

j.Jg/L

0.37

Iron

Fe

jJg/L

91.3

Copper

Cu

jJg/L

15.5

Lead

Pb

jJg/L

12.0

jJg/L

9.4

Silicate

Si0 3

j.Jg/L

893.2

Nitrate

N0 2

jJg/L

33.7

Vanadium

II

DOC.NO. KOC-G-011

II

REV. 1

Page 30 of 33
ANNEXURE-III
(Normative)

Maximum Limits of Polutants in Industrial Water Waste


Permissible to be Discharged into the Sea _ _ _ _ _--1
I
I'
Pollutants
Color
pH
Temperature
Bilogical Oxygen Demand
Chemical Oxygen Demand
Oil/grease
Total Suspended Solids
Total Soluble Soilds
Phosphate
Ammonia
Nitrate
Total Kaldal Nitrogen
Total Nitrogen
Total Recoverable Phenol
Fluorides
Sulfides
Chlorine
Dissolved Oxygen
Turbidity
Floatables
Aluminium
Arsenic
Barium
Boron
Berylium
Cadmium
Cyanides
Chromium
Nickel
Mercury
Cobalt
Iron
Antimony
Copper
Manganese
Zinc
Lead
Lithium
Molybdenum
Vanadium
Silver
All herbicides
Most probable number of total Coliform

Chemical Symbol

Unit

Maximum Limit
clear

6-8

pH

DC
BOD (5 days 20C)
COD
TSS
PO
NH3-N
N03

F
S
CI2
DO

AI
As
Ba
B
Br
Cd
Cn
Cr
Ni
Hg
Co
Fe
Sb
Cu
Mn

Zn
Pb
Li
Mo
V
Ag

mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
NTU
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
MP/N/100 ml

* The subtraction of the external and internal water temperature entry and exit point.

*10
30
200
10
10
1500
2
3.0
30

5
30
1.0

25
0.5
0 .5
>2
50
Nil
5
0.1
2
0 .75
0.1
0.01
0.1
0 .2
0 .2
0 .001
0.2
5
0 .2
0.2
2
0.2
2.5
0 .01
0 .1
0.1
0.2
1000

REV. 1

Page 31 of 33

DOC.NO. KOC-G-011

ANNEXURE-IV
(Normative)

Treated Waste Drainage Water Discharged into Sewerage


~----------

----

Chemical Symbol

Unit

Maximum Limit

BOD5 (5 day, 20 C)

mg/L

400

Chemical Oxygen Demand

COD

mg/L

750

Total Suspended Solids

TSS

mg/L

300

Total Recoverable Phenol

mg/L

Fluorides

mg/L

1000

Sulfides

mg/L

10

Arsenic

As

mg/L

0.1

Cadmium

Cd

mg/L

0.1

Cyanides

Cn

mg/L

0.1

Chromium

Cr

mg/L

1.0

Nickel

Ni

mg/L

0.2

Mercury

Hg

mg/L

0.002

Copper

Cu

mg/L

0.5

Zinc

Zn

mg/L

2.0

Lead

Pb

mg/L

0.5

Silver

Ag

mg/L

4.0

Tar& Tar Oil

mg/L

Nil

Floating Oil & Grease

mg/L

Emulsified Oil & Grease

mg/L

Most probable number of total coliform

MPNI 100 ml

1000

Most probable number of faecal coliform

MPN /100 ml

100

Pollutants
Biological Oxygen Demand

Phenol

Egg parasites

Nil

Worm parasites

Nil

DOC.NO. KOC-G-011

REV. 1

Page 32 of 33

II

ACKNOWLEDGEMENT

This Standard has been approved by the Standards Technical Committee (STC) consisting
of the following:
Mr.
Mr.
Mr.
Mr.
Mr.
Mr.
Mr.
Mr.
Mr.
Mr.
Mr.
Mr.
Mr.
Mr.

Hamzah Ahmad
Mohd . Emam
S. Kumar
A. Unnikrishnan
N. Ramanathan
Daniel Pino
Abdul R. AI-Shamari
Haithem Aboughaith
Gopal Murti
Mohd . Aslam Imadi
G. Unnikrishnan
Fahad AI-Qattan
Abdulla AI-Yousef
Richard Arthur

Standards Team
Insp. & Corr. Team (S&E)
Standards Team
Standards Team
Major Projects IV Team
Utilities Team
Insp. & Carr. Team (N&WK)
Gen . Projects Team
Opns. Tech . Svcs. (WK) Team
Design Team
Design Team
HSE System Team
Project Mgmt. Team (NK)
Info . System Planning Team

Chairman
Deputy Chairman
Secretary/Mem ber
Member
Member
Member
Member
Member
Member
Member
Member
Member
Member
Member

The draft of this Standard had been circulated to the KOC User Teams for review and the
responses were received from the following:
ENGINEERING GROUP

GAS MGMT. GROUP

Team Leader Design

Team Leader Gas Opns. (S&EK)

AHMADI SERVICES GROUP

EXPORT & MARINE OPNS. GROUP

Team Leader Project Design

Team Leader Export Tech . Svcs

Team Leader Utilities

Team Leader HSE (E&MO)

NDUSTRIAL SVCS. GROUP

OPERATIONS GROUP (WK)

Team Leader Insp. & Corr. (S&EK)

Team Leader Opns . Tech . Svcs. (WK)

Team Leader Insp. & Corr. (N&WK)

Team Leader Maintenance (WK)

OPERATIONS GROUP (NK)

SECURITY & FIRE GROUP

Team Leader MSR (NK)

Team Leader Fire

HSE GROUP

OPNS. SUPPORT GROUP (S&EK)

Team Leader HSE Systems

Team Leader OTS (S&EK)

Team Leader H&E

Team Leader HSE (S&EK)

Team Leader Safety

DOC.NO. KOC-G-011

Page 33 of 33

REV. 1

Task Force Responsible for This Standard

The Standards Technical Committee (STC) has entrusted the preparation of this
Standard to the Task Force No. TF-GI08, consisting of the following members:
Mr. Abdul R. AI-Shamari
Mr. Mirza Mohsin
Mr. Mohd . Imadi
Mr. N. Ramanathan
Mr. S.H. Shah
Mr. Saad Jaber
Mr. Bader AI-Qahtani
Dr. Waseem Siddiqi

Insp. & Corr. (N&W)


Standards Team
Design Team
Major Projects IV
Gen. Projects Team
Construction Team
OTS (SK) Team
Health & Environment

TF Leader
Member
Member
Member
Member
Member
Member
Member

Tel.
Tel.
Tel.
Tel.
Tel.
Tel.
Tel.
Tel.

No. 66394
No. 61371
No. 61102
No . 66960
No . 61190
No . 61376
No. 22384
No. 71628