SA-000-R-11136 Rev T01 3600 Fuel Hydrant Systems Spec Spec 31.10.2008

Sultanate of Oman
Ministry of Transport and Communications

Development of Salalah International Airport
Main Contract 5
Project Specification
Civil Works - 3600 Fuel Hydrant Systems
Special Specification
October 2008
Sultanate of Oman
Ministry of Transport and Communications
Development of Salalah International Airport
Main Contract 5
Project Specification
Civil Works - 3600 Fuel Hydrant Systems
Special Specification
October 2008
Report no. SA-000-R-11136

Issue no. T01
Date of issue 31.10 2008
Prepared FRA/PVN
Checked JMJ
Approved STJ/NIER
Main Contract 5 -Special Specification 1
Civil Works - 3600 Fuel Hydrant Systems, Project Specification
Table of Contents
3600 Fuel hydrant systems 5
3601 General 5
3601.1 Description 5
3601.2 Functional requirements and materials 9
3601.3 Installation and execution 10
3601.4 Testing and commissioning 10
3601.5 Documentation 12
3601.6 Operation and Maintenance 12
3602 Piping items 13
3602.6 Operation and maintenance 14
3603 Valves 14
3604 Valve operators 19
P:\61400\3_DOC\10_Tender_Doc\02_SA\CRN_55_MC 5_Civil & Building Works Salalah\Final\31.10.2008\03_Specifications\Civil Works\SA-

000-R-11136_Rev T01_3600_Fuel Hydrant Systems_Spec Spec_31.10.2008.DOC .
3605 Insulating couplings 22

3606 Flanges, bolts and gaskets 24
3607 Pit boxes 25
3608 Protective coating 27
3609 Transmitters 29
3610 Hydrocarbon detector 31

3611 Wall penetration seals 32
3612 Geomembrane 33
3613 Leak detection system 33
3614 Cathodic protection system 36
3615 Control and monitoring 51
3616 Emergency shutdown system 60


Revision Log 66

3600 Fuel hydrant systems
3601 General
3601.1 Description
Introduction
The Fuel Hydrant System (FHS) for Salalah International Airport is designed to
supply fuel to a traffic level of 2 million passengers per year (mppa),
corresponding to 6 departures in the peak hour, and simultaneously supply fuel
to 0.8 departing cargo aircrafts in the peak hour see below tabulation. The FHS
has been designed with two supply lines to form a ring connection to facilitate
fuel supply in case of repair or emergency situations.
The FHS is designed to allow expansion without interrupting the supply by

installing double valves at the ends of the supply lines.
The design assumption for fuel demand is based on the following distribution
percentages on aircraft categories and number of departures in the peak hour for
passenger and cargo aircraft respectively.
Passenger
Departures
2 mppa and C Aircraft D Aircraft E Aircraft F Aircraft
in peak
0.8 cargo percentage percentage percentage percentage
hour
departures
Passenger
aircraft 66.0 8.0 26.0 0.0 6
distribution
Cargo
aircraft 0.0 20.0 80.0 0.0 0.8
distribution
It is further estimated that each aircraft shall be refuelled to 60% of the nominal
fuel capacity of the aircraft and calculations made for dispenser capacities 45
l/s, 65 l/s and 75 l/s. Aircraft in category C and D are served by 1 dispenser
whereas aircraft in category E and F are served by 2 dispensers simultaneously.

Scope
The fuel supply system shall in the peak hour be able to deliver 940 m3/h with a
pressure drop of maximum 2.5 bar from valve chamber 01 to the outmost pit
valve and a maximum velocity of 2.5 m/s assuming a maximum start pressure
at the fuel farm of 12 bar.
The FHS comprises the supply lines from the connection to the Fuel Farm
Pump Station including the distribution system to the apron areas comprising
tees, bends, tees, block valves with actuators, manual valves, pit valves, drains,
vents, insulating flanges, spacers, cathodic protection system, control and
monitoring system, leak detection system, emergency and shutdown system and
cabling.
The Contractor shall, based upon the tender material drawings and
specifications, make the necessary shop drawings.
Excavation, dewatering if necessary, and backfilling works shall be included

with depths as shown in the longitudinal profiles. After backfilling, the
remaining soil shall be transported to a disposal yard.
Interfaces
The interface to the pump station is 10 m inside the Security fence at the first
block valve chamber as shown on dwg. No SA-986-303-P-60101.
The control and monitoring system will be terminated at cabinets with terminal
blocks in the Fuel Farms control room.
Further there are interfaces to civil works and pavement works.
Abbreviations
AC Alternating current
ACN Airport Community Network
API American Petroleum Institute
ATEX Equipment and Protective system intended for use in Potentially
Explosive Atmospheres
AWG American Wire Gauge
Class F900 Classification of gully tops according to EN 124
CP Cathodic Protection
D Diameter of a pipe
DC Direct current
DFT Dry Film thickness
DN Nominal diameter of a pipe

ESB Emergency Shutdown Button

ESD Emergency Shutdown system
FHS Fuel Hydrant System
FHSCMS Fuel Hydrant System Control and Monitoring System
FHSESD Fuel Hydrant System Emergency Shutdown System
GPU Ground Power Unit
HART Communication Protocol
HDPE High Density Polyethylene
HMI Human Machine Interface
IR Infrared
IR free Infrared free
LAN Local Area Network
LCD Liquid Crystal Display
LDS Leak Detection System
LED Light-emitting Diode
LEL Lower Explosion Limit
mA 10-3 amp
MTBF Mean Time between faults
MTTR Mean time to recovery
NACE National Association of Corrosion Engineers
NC Normally Closed
NDE Non Destructive Examination
NEMA National Electrical Manufactures Association
NO Normally Open
OPC OPC is a set of open standards providing connectivity between
industrial automation systems. The OPC standards are created
and maintained by the OPC Foundation.
PED Pressure Equipment Directive
PLC Programmable Logic Controller
PT Pressure transmitter
RJ45 Network cable connector type
SCADA Supervisory Control And Data Acquisition
STD Standard Wall thickness for piping
T/R Transformer/Rectifier
UPS Uninterruptable Power Supply

Standard and references

The project shall comply with following international standards and guidelines
and the codes and standards referred to the latest edition available on the date of
Invitation to Tender.
API/IP 1540 Recommended Practice, Design, Construction,

Operation and Maintenance of Aviation Fuelling
Facilities, IP Model Code of Safe Practice Part 7
AP/IP 1542 Identification markings for dedicated aviation fuel
manufacturing and distribution facilities, airport
storage and mobile fuelling equipment
AP/IP 1584 Four-inch hydrant system components and
arrangements
AP/IP 1585 Guidance in the cleaning of airport hydrant systems
IP 1594 Initial pressure strength testing of airport fuel
hydrant systems with water
IP Part 2 Design, construction and operation of distribution
installations, model code of safe practice
API 5L Specification for pipe line
API 6D Specification for pipeline valves (Gate, plug, ball
and check valves)
API 590 Steel line blanks
API 598 Valve inspection and testing
API 607 Fire test for soft-seated quarter-turn valves
API 1632 Cathodic protection of underground petroleum
storage tanks and piping systems
API 4716 Buried pressurized piping systems leak detection
guide
ASME B16.5 Pipe flanges and flanged fittings: NPS ½" trough
NPS 24
ASME B16.20 Metallic gaskets for pipe flanges - ring joint, spiral-
wound and jacketed
ASME B16.34 Valves flanged, threaded and welding end
ASME B31.3 Process piping. ASME code for process piping
ASTM A105/A105M Specification for carbon steel forgings for piping
applications
ASTM A106/A106M Specification for seamless carbon steel for high-
temperature service
ASTM A193/A193M Specification for alloy-steel and stainless steel
bolting material for high temperature service

ASTM A234 Specification for piping fittings of wrought carbon

steel and alloy steel for moderate and high
temperature service
BS EN 61508 Functional safety of
electrical/electronic/programmable safety-related
systems
DIN 30670 Polyethylene coatings of steel pipes and fittings
DIN 30672 External organic coatings for the corrosion
protection of buried and immersed pipelines for
continuous operating temperatures up to 50 degree
C - Tapes and shrinkable materials
DVGW 469 Pressure test methods for transmission and
distribution pipelines and gas supply stations
EN ISO 1461 Hot dip galvanized coatings on fabricated iron and
steel articles - specifications and test methods
EN ISO 8501-1 Preparation of steel substrates before application of
paints and related products
EN 10204 Type of inspection documents
IEC 69529 Degrees of protection provided by enclosures (IP
code)
IEC 60947-5-1 Low voltage switchgear and control gear - Part 5-1:
Control circuit devices and switching elements -
Electromechanical control circuit devices
NFPA 30 Flammable & combustible liquids handbook
NFPA 77 Static electricity
NFPA 407 Aircraft fuelling service
3601.2 Functional requirements and materials
Materials
The fuel supply system has been designed for the transport of Jet A-1 only, and
shall comply with the requirements in API/IP Recommended Practice 1540
The design pressure rating of the system, pipes, valves, fittings, flanges and
other items shall be 19.0 barg at 50 ºC (~ASME pressure rating class 150).
However, the operating pressure shall not exceed 14 barg as stated in API/IP
1584.
1 All piping materials, pipes, valves, fittings, flanges and other items
including instrumentation shall be purchased fully marked for
identification.

3601.3 Installation and execution

Particular requirements for installation and execution are stated in the relevant
Sub-sections of this document or on the Drawings.
3601.4 Testing and commissioning

The particular requirements to part-testing and -commissioning of the
individual parts of the fuel hydrant system are described in the relevant Sub-
sections of this document.
Requirements to hydrostatic testing with water, drying and commissioning of

the FHS as an entity are described in the following sections.
Hydrostatic testing with water

At a minimum of 3 weeks before commencement of pressure testing the
Contractor shall forward a written, detailed procedure specification for the
Engineer's approval. The Contractor shall supply and install all auxiliary
facilities necessary for the test, such as provisional piping, pigging facilities,
caps, fittings, flanges, gaskets, pumps and compressors and measuring
equipment.
After completion of construction of the fuel hydrant system the whole piping
system shall be pressure tested with water in accordance with DVGW 469 and
IP 1594.
The strength test pressure shall be 1.5 times the design pressure = 1.5 x 19 barg
= 28.5 barg and shall be held for a minimum period of 4 hours.
The pressure leak test shall be performed at a pressure of a minimum 1.1 x

Design pressure = 1.1 x 19 = 20.9 bar.
The Contractor shall obtain and pay for the necessary approvals by Authorities
as well as for the water for testing including disposal of water after pressure
testing.
All the low point drains shall be removed from the main line during the test to
allow for passage of spheres during water filling and subsequent drying of the
line. Hydrant pit valves shall not be installed before the line is emptied of water
and the line has been dried to the required criteria. Blind flanges with an option
to install vents shall be fixed.
The water used for the test shall be potable water quality.
In order to avoid the influence of temperature changes on the pressure test, the
line shall be temporarily covered with sand and backfilled to a depth before the
start of the test.
The pressure test will be witnessed by the Engineer.

The criteria for the approved test procedures are according to DVGW 469
Method B2.
The test report shall include:
• Official relevant
• Test programme, including longitudinal profiles and all information

needed to identify the test section
• Water filling report
• Tightness report including graphs for pressure and temperature variations,

records for continuous measurement of temperature etc.
• Fault report, if applicable
• Drying report with programme, measurement of the dew point,

observations during drying operations, if applicable
Dewatering and drying

At a minimum of 3 weeks before start of drying the system, the Contractor shall
forward a detailed procedure specification for the Employee's approval. The
Contractor shall install and supply all auxiliary facilities necessary for carrying
out the drying, such as provisional scraper traps, end caps, fittings, flanges,
gaskets, pumps, compressors, measuring equipment in addition to the supply of
drying and propelling media.
Immediately after approval of the pressure test the water shall be emptied from
the line. Pipeline laterals are designed to be sloped back to the main line in all
cases possible.
Soft foam spheres shall be used in trains in order to remove the residual water.
The water left at low points shall be removed by demounting the blind flange
and using a suction pump.
When a foam sphere no longer absorbs water, the line is considered void of free
water.
The hydrant system shall then be dried using dry air. Installation of the pit
valves shall await the completion of the drying process.
The moisture content of the dry air shall be continuously measured in the inlet
air.
The line shall be considered dry when dew point of- 10 C atmospheric pressure
have been reached.

In case the hydrant system can not be commissioned within one month after
drying, the piping system it shall be filled with nitrogen and sealed to a pressure
of 1 barg.
Pressure measurements of the nitrogen filled hydrant system shall be performed

at 2 week intervals. In case the pressure falls below 0.8 barg, the pressure shall
be re-established. In case the dew point at atmospheric pressure exceeds -5ºC
the Contractor shall within one week take action to re-establish the required
dew point of -10ºC.
After drying and before commissioning, a low-pressure test with dry, oil-free
air or nitrogen, to a pressure 0.5 barg, shall be carried out after installation of
valves and fittings, which were not included in the pressure test with water. The
duration of the test shall be a minimum of 1 hour.
Commissioning
The commissioning of the fuel hydrant system is part of the Contractors work
and shall be carried in accordance with the guidelines in API/IP 1540 Chapter
5.8 and API/IP 1585 Chapter 10.
The general procedures as regard testing and commissioning are described in

Special Specification - Civil Works, document no. SA-000-R-11130 and
SA-000-R-11131.
It shall be noted that the commissioning shall be coordinated with the

concessionaire for the Fuel Farm and Pump Station.
It is assumed that the Fuel Farm and the Pump Station are fully operational
when commissioning of the fuel hydrant system shall commence.
3601.5 Documentation
General requirements for testing and documentation are described in the above
mentioned Specification SA-000-R-11130, Sections 3003.4/3003.5.
Particular requirements for the Contractor's documentation are stated in the

relevant Sub-sections of this document.
3601.6 Operation and Maintenance
Spare parts and special tools

Particular requirements to the Contractor's supply of spare parts and special
tools will be stated in the relevant Sub-sections of this document.
Training
The Employers maintenance personnel shall be trained with regards to function,
operation and maintenance of the fuel hydrant system.

Particular requirements for the Contractors training of the Employers

maintenance personnel are stated in the relevant Sub-sections of this document.
3602 Piping items

3602.1 Description
Piping items shall include line pipes, casing pipes, bends, reducers, tees,
weldolets, flangeolets and end caps.

The piping materials for the fuel hydrants system shall be carbon steel in
accordance with ASTM 106-B Grade B or API 5L Grade B, Standard wall
(STD).
Materials for fittings shall be in accordance with ASTM A234-WPB.
Materials for forged fittings shall be in accordance with ASTM A105.
Long radius elbows (radius = 3.0 * D) shall be used for running flexible, soft
cleaning pigs through the system. Tees shall be barred when branches are more
than 0.5 * diameter of the header pipe.
Pipes shall be delivered with a shop or mill applied external coating for
corrosion protection of polyethylene, polypropylene. For details see section
3608 Protective Coating.
Furthermore pipes shall be delivered with a shop or mill applied internal epoxy
resin lining suitable for Jet A-1 as well as water. For details see section 3608
Protective coating.
Materials
Piping materials for fuel hydrants shall be carbon steel in accordance with
ASTM 106-B Grade B or API 5L Grade B, Standard wall (STD).
Materials for fittings shall be in accordance with ASTM A234-WPB.
Materials for forged fittings shall be in accordance with ASTM A105.
Hot formed bends

Reference is made to, Document. No. SA-000-R-11131 Section 3102.2.
Cold bends
Fabrication of cold bends is permitted assuming a suitable bending machine is
available on site and the coating of the pipes is left undamaged. Suitable and
well supporting matrices shall be used. Bending operations may only take place

when the coating over the last 12 hours has had a surface temperature not
higher than 40ºC measured on the sunlit side.
For pipes in dimension DN 300 (12") and less:
Each bending step shall have a length of 0.2 m and the maximum bending angle
per step is 0.75º. A straight length of min. 1.5 m shall be left at each end.

For details see, Document. No. SA-000-R-11131 Section 3101.5.

For details see, Document. No. SA-000-R-11131 Section 3101.6
All piping materials and components shall be supplied with certificates in
accordance with BS EN 10204: 2004, clearly marked with material quality and
manufacturer's name.
Materials to be documented by material certificates according to EN 10204 (or

equivalent) are defined below:
• Pipes, flanges and fittings for welded piping: Certificate 3.1
• Bolting and gaskets: Certificate 2.1
Requirements to certification, welding procedure, NDE etc. for welded

attachments shall be as for the parent pipe to which it is welded.
3602.6 Operation and maintenance

Not Applicable.
3603 Valves
3603.1 Description
Valves include main block valves (full bore) with electric actuator, hand
operated valves (full bore) in the supply system, drain and vent valves in the
block valve pits, hydrant pit valves, drain and vent units.
Main block valves with electric actuator, full bore DN250

The valves shall be bubble tight twin seal tapered plug valves, full bore pigable
with double block and bleed, fire safe closing, and with flanges according to.
ASME/ANSI B16.5 Class 150, raised face.

The valves shall be of the double trunnion design and top and bottom access for
easy replacement of seals.
The valves shall be equipped with a manual body bleed valve to verify the
bubble tightness when the valve is closed. The bleed valve shall be supplied
with a "goose neck" pipe to prevent drainage of the body liquid when opened.
The valve shall also be supplied with a valve cavity check, valve to the
upstream side.
The valves shall be equipped with locking devices and with position indicators.
The valve construction shall be in accordance with API 6D.
The material shall be:

• Body: ASTM A216-WCB
• Plug: ASTN A216-WCB
• Bonnet: ASTM A36
• Bolting: ASTM A193-B7 / A194-2H
All block valves, used for separation of leak detection sections and indicated on
the P&I diagram, shall be supplied with electric motor actuator. The
closing/opening times for these valves shall be in the interval 35 to 40 seconds.
Other block valves shall be gear operated and suitable for future installation of
electric motor actuators.
External surface treatment shall be manufacturer's standard painting system

with dry film thickness, minimum. 220 mym.
Block valves hand operated, full bore DN250

The valves shall be tight ball valves, full bore pigable, fire safe closing, and
with flanges according. ASME/ANSI B16.5 Class 150, raised face.
The valves shall be of the double trunnion design.
The valves shall be supplied with a valve cavity check, valve to the upstream
side.
The valves shall be equipped with locking device and with position indicators.
The valve construction shall be in accordance with API 6D.
The material shall be:

• Body: ASTM A216-WCB
• Plug: ASTN A216-WCB
• Bonnet: ASTM A36
• Bolting: ASTM A193-B7 / A194-2H

The block valves shall be gear operated and suitable for future installation of
electric motor actuators.
External surface treatment shall be manufacturer's standard painting system

with dry film thickness, minimum. 220 mym.
Drain, vent and instrument valves in the block valve pits and other valves
DN100 and below
The valves shall be ball valves with flanges in accordance. with ASME/ANSI
B16.5, Class 150, raised face.
Valves shall be full bore, fire safe with body of carbon steel, stem and ball of
stainless steel.
Valve construction shall be in accordance with ANSI B16.34
Instrument valves
Instrument valves for pressure transmitters shall be in accordance with Drawing
No. SA-986-000-P-60528.
Hydrant pit valves

Hydrant pit valves shall comply with the requirements of API /IP Specification
1584 and shall have an under-hydrant manual isolation valve, as shown on the
Hydrant pits, vents and drains Drawing. no. SA-986-000-P-60504.
The under-hydrant isolating valve shall have DN150 ANSI Class 300 inlet
valves and DN100 ANSI Class 150 outlet flanges. The inlet flange is bolted to
a standard DN150 riser pipe.
Hydrant pit valves shall have DN100 API standard adaptors, dust cap and with
DN100 ANSI Class150, RF base flange to fit the under-hydrant valve. The
hydrant pit valve shall be equipped with a stone guard strainer, size 10 mesh.
The hydrant pit valve shall be equipped with a dual pilot (air operated &
lanyard). The air supply shall be governed by a dead man button. The dead man
system shall also be used should an emergency occur.
Vent and drain units

For vents and drains not installed in a block valve pit, the vent and the drain
shall be installed as pre-assembled unit.
Each vent and drain unit shall include two DN40 (1½") fire safe ball valves and
a DN40 stainless steel tank unit adaptor with bleed valve and dust cap.

Each unit shall be fitted with a standard DN150 ANSI Class 300, raised face
flange for installation in a standard diameter 457mm (18") hydrant pit on top of
a DN150 pipe riser, see Drawing No. SA-986-000-P-60504.
Main block valves and hand operated valves with full bore DN300 and
above
The valves installed in concrete valve chambers shall have an insulating flange
connection on the upstream side and an insulating flange connection combined
with a spacer on the downstream side, see Drawing No. SA-986-000-P-60701.
The insulating flange connection insulated the valves from the cathodic
protected piping system.
The valves shall be supported in accordance with appropriate structural

specifications/codes.
Line spacers shall be in accordance with API 590 and Drawing No. SA-986-
000-P-60525, Insulating flange joint with spacer Class 150 and Drawing No.
SA-986-000-P-60526, Spacer for ASME flanges Class 150.
Main block valves with electric actuator full bore DN250

Material testing at the factory shall be according to API 6D.
Functional, pressure and leak tests shall meet the requirements of API 598 and
the fire test the requirement of API 607.
Supplemental test of double block and bleed valves: An air seat test in
accordance with test specified in API 598 shall be made at 20 bar and 3 bar
differential pressure. The test time shall be 15 minutes for each test. The
acceptance criteria are that no leakage is observed.
The leakage test shall be performed with pressure from both sides (backseat
test).
After installation of valves, the installed valve will be pigged and tested with
water up to 1.5 times the design pressure (28.5 barg). The Contractor shall
describe the necessary procedures, to be followed in connection with the
pressure test of the complete installation.
Block valves hand operated, full bore DN250

Material testing at the factory shall be according to API 6D.

Functional, pressure and leak tests shall meet the requirements of API 598 and
the fire test the requirement of API 607.
An air seat test in accordance with the test specified in API 598 shall be made
at 20 bar and 3 bar differential pressure. The test time shall be 15 minutes for
each test. The acceptance criteria is that no leakage is observed.
The leakage test shall be performed with pressure from both sides (backseat
test).
After installation of valves, the installed valve will be pigged and tested with
water up to 1.5 times the design pressure (28.5 barg). The Contractor shall
describe the necessary procedures, if any, to be followed in connection with the
pressure test of the complete installation.
Other valves
Other valves shall be tested in accordance with API 6D and API 598.
All valves
All valves shall be supplied with material certificates 3.1 according to BS EN
10204 for pressure testing retaining parts.
Remaining parts shall have 2.1 certificates according to BS EN 10204.
Test certificates for the completed valve shall be 3.1 in accordance with BS EN
10204 for valves bigger than DN25 and 2.2 for valves DN25 and below.
The certificate shall also include documentation for visual examination,

dimensional control, leakage test, hydrostatic test, functional test, painting test
etc.
The certificates shall be supplied as packages for each manufacture, type and
size of valves.
Valves shall be marked on their bodies with a unique serial number. The
nameplate shall additionally bear the control authority stamp. All other
markings shall be in accordance with API 6D.
Comprehensive operation and maintenance manuals shall be delivered with

each valves supplied as packages for each manufacture, type and size of valves.

Spare part and special tools

Comprehensive operation and maintenance manuals shall be delivered with the
valve.
A list of recommended tools, spare parts, lubricants etc. necessary for 2 years
operation shall be supplied with the valves.
For each type and size of valve DN200 and above, a start up kit and
recommended spare parts for 2 year operation shall be supplied for each 10
valves or part thereof.
For hydrant pit valves, an extended spanner shall be supplied for each 10 valves
or part thereof.
Training
The Contractor shall include a short course on bleeding the valve cavity on
valves DN250 and replacement of the valve seals in a line filled with fuel for
the double block and bleed valves.
3604 Valve operators

3604.1 Description
Manual valve operators

Manual valve operators for valves DN150 and above shall be with gear and
hand wheel. Valves DN100 and below will be with wrench.
An exception is the DN150 under hydrant valve which shall be wrench

operated.
Sizes for both hand wheel and wrench operated shall be taken into account
during installation in block valve pits and hydrant pits.
The gears shall have a position indicator showing "open - 1/2 - closed".
The gear box shall be furnished with the manufactures mark, full type no. and
number of turns from close to open.
Electric actuators
Electric actuators shall include necessary gear devices.
Outdoor located actuators shall be suitable for operation under the climatic
conditions in Oman.

For above ground valves, the enclosure protection shall be a minimum IP 65.
For valves in block valve pits, protection it shall be a minimum IP 54.
The electric power supply to actuators will be 240 V, AC, 50 Hz
Electrical instrumentation will be 24 V, DC.
All electrical connections shall be minimum Pg 16/M20 and placed beneath the
terminal boxes.
The motors of electric actuators shall be attached to the housing of the gears
through bolting or other means enabling easy replacement of motors.
Actuators mounted on valves installed in cathodically protected lines shall be

electrically insulated from the valve or from connections to utility systems and
other external systems.
The actuators shall have a position indicator showing "open - 1/2 - closed".
The actuator shall possess a hand wheel for valve operation at upset condition.
The hand wheel shall declutch and may not rotate when under electric
operation.
Electrical actuators shall be protected against overload by means of torque limit

switches and temperature switches embedded in the motor windings.
The actuator shall posses a local switch for "remote-off-local" operation. In the
"local" position it shall be able to close, open and stop the valve motion by push
buttons on the actuator.
The actuator shall have "local text display", performance monitoring and data
logging including the valve torque signature.
It shall be possible to configure the actuator and transport log files with a
handheld communicator.
The actuator shall fulfil the requirements to the Ex-zone in which it is placed.
All valve chambers and pits are classified as Zone 1.
Manual valve operators

The Maximum break-away torque shall be 400 Nm and the maximum moving
torque 250 Nm. The gear shall be designed for at least 1.5 times maximum
break away torque.
The number of turns for operating the valve from open to closed shall normally
be less than 50 (DN150) and shall never exceed 200 (DN250).

Electric actuators
The number of turns of the hand wheel required to perform an opening or
closing operation shall not exceed 200. Closing shall be with clockwise
rotation.
The actuator shall be able to be operated with an average of 1,000 times per
year over a period of at least 10 years and a minimum of 1 operation every 3
months.

The actuator shall be mounted on the valve at delivery.

The actuator shall after mounting on the valve pass a factory test.
The factory test shall as a minimum include a functional test, test of the
specified open-close and close-open travel time, correct open and close
position, adjustment of the torque switches.
In the field at the cold commissioning, the same test as above shall be
performed from the control centre.
A certificate for a satisfactory factory test shall be issued. The certificate shall
conform to BS EN 10204, 3.1B

A handheld communicator shall be supplied for each 6 valves with electric
actuators or part thereof.
A software package for analysing the data from the electrical actuators shall be
supplied.
Training
The Contractor shall include a short course on configuring of the actuator and
downloading of log files as well as analysis of the files.

3605 Insulating couplings

3605.1 Description
Insulating couplings shall be applicable for fuel as Jet A-1 and for the design
and installation conditions of the location.
Construction
Bolted or threaded joints are not permitted. The design of welds joining
coupling element and pipe pup-pieces shall permit radiographic examination of
joining welds.
Seals shall be made from continuously moulded precision "O" rings of

dielectric material.
The bore shall not be less 96% of abutting pipe internal diameter.
Welding ends shall match abutting pipes.
Materials
Fully killed fine grain carbon steel conforming to recognized standard.
Seal and dielectric shall be inert to and resistant for blend of organic and
inorganic corrosion inhibitors, and biocide microbiological growth inhibitors
normally added to Jet A1.
The insulating coupling supplier shall obtain from the Contractor necessary
information regarding allowable inhibitors to ensure proper selection of seal
and dielectric material.
Surface treatment
The bore of the insulation coupling assemblies shall be lined with an approved
coating to be approved by the Engineer, with minimum DFT (Dry Film
Thickness) of 300 microns. This shall exhibit electrical and abrasion resistance
properties to prevent a decrease in electrical resistance across the isolation
coupling as caused by debris bridging the isolating ring.
The coating shall not bridge the insulating ring.
The coating shall be capable of resisting preheating to 150°C at the welding

end.
Marking
The approved couplings shall be marked as follows:

• Manufacturer's mark
• Contract identification number
• Allowable bending moment
• Material grade of pipe pup-pieces
• Unique coupling number
• Inspection authority mark

2 The couplings shall be installed according to the manufacturer's
recommendations.
3 Repair by welding on base materials is not permitted.
Inspection and testing
Non Destructible Examination (NDE)

4 All pressure retaining metal items shall be ultrasonically tested.
5 All forgings shall be magnetic particle tested over the entire surface.
6 All welds shall be 100% radiographic / ultrasonic tested.
7 Welding ends shall be ultrasonically tested to a minimum distance of 50

mm from the bevel end.
Hydrostatic testing
8 Each coupling shall be hydrostatic pressure tested to 1.7 times the system
design pressure as stated in the Data Sheet.
9 Initially, each coupling shall be subjected to 3 pressure cycles between

10% and 85% of the test pressure.
10 The pressure test is accepted with the full test pressure applied for a
minimum of 15 minutes for DN ≤ 450 mm and no leakage is detected.
Electrical test
11 The insulation couplings shall be electrically tested in a fully dried
condition.
12 An electric strength test at 5000 V AC, 50 Hz shall be applied for a period

of not less than one minute during which no puncture of coating or
formation of sparks may occur and the leak current differential shall not
exceed 2 mA.

13 Resistance test shall be by application of 500 V DC with a measured

electrical resistance greater than 1 MΩ.
Reference is made to Special Specification SA-000-R-11130
Reference is made to Special Specification SA-000-R-11130.

Reference is made to Special Specification SA-000-R-11130.
3606 Flanges, bolts and gaskets

3606.1 Description
Flanges shall be with raised face in accordance with ASME/ANSI B16.5.
Bolting and gaskets - other than insulating gaskets - shall be in accordance with
the recommendations of ASME/ANSI B16.5.
All bolt ends with nuts shall be protected from destructive corrosion with
corrosion inhibitor grease and protection caps.
Material
"Inch bolts" shall be used.
Material for flanges shall be to ASTM A105.
Material for bolts shall be to ASTM A193 GR B7
Materials for nuts shall be to ASTM A194 GR 2H
14 Bolts sizes M12 or ½" or larger shall be hot dip galvanized according to
BS EN ISO 1461.
15 Sizes less than M12 or ½" shall be zinc electroplated.
Insulating flange connection

Insulating bolt sleeves and washers shall be made of Mylar suitable to fit into
standard bolt holes of flanges to ASME/ANSI B16.5.
Insulating flange gaskets shall be full faced with the same internal diameter as
the pipe, an external diameter as shown on Drawing SA-986-000-P-60525.

Dielectric strength of the tightened flange joint shall be minimum 5,000 V in

dry air.

The Contractor shall forward calculations for bolt force and moments for
approval by the Engineer.
Insulating gaskets shall not be tightened with force above that recommended of
the supplier by the gaskets.

Dielectric strength of the tightened flange joint shall be minimum 5,000 V in
dry air.
All flange connections and other loose cable connections shall be checked for
tightness.
All piping materials and components shall be supplied with certificates in
accordance with BS EN 10204: 2004, clearly marked with material quality and
the manufacturer's name.
Materials to be documented by material certificates according to EN 10204 (or

equivalent) are defined below:
• Pipes, flanges, bolting and fittings for welded piping: Certificate 3.1
• Gaskets and insulating flanges: Certificate 2.1

Not applicable.
3607 Pit boxes

3607.1 Description
Pit boxes used for hydrant pit valves as well as for vent and drain units shall be
of a type with features as described in API/IP Recommended Practice 1540,
Chapter 5.4.
The pit boxes shall be of the environmental friendly type with positive sealing
between the inner catch chamber and the outer chamber to be cast into the pit
flagstone.
The pit box shall be supplied with a lockable cover which is secured to the pit
box.

The riser pipe shall form part of the inner chamber and shall be to DN150 API
5 L Grade B standard. weight, with DN150, Class 300, raised face, weld on
flange according to ASME/ANSI 16.5 and with stud bolts.
Functional requirements
The pit boxes shall be able to absorb both lateral and vertical movements
between the flagstone and the riser pipe.
Materials
The cover shall be made of non sparking material.
Both the inner and outer surface of the pit shall be protected with a fuel
resistant coating (epoxy)

The installation of the pit boxes shall be made strictly in accordance with the
manufacturer's instruction to fulfil the requirements for differential movements
between the inner catch chamber and the outer chamber cast into the flagstone.
Pit boxes shall be installed such that they project 50 mm above the general
apron. The slope away from the pit shall approximately be 4.0°.
Drain and vent units located in unpaved areas shall be installed such that they
project 60 mm above the surrounding terrain to prevent ingress of water.
The inner and outer part of the pit box shall be placed to allow a distance of 35
mm between the API connection of the pit valve and the closed cover.

At the hydraulic strength and leak test of the hydrant system, the hydrant pit
valve and the drain valves shall not be installed. The DN150 flanges shall be
capped with blind flanges.
The vent valve shall however be installed to allow venting of air before the test
is commenced.
After the hydraulic test, the hydrant pit valves and the drain valves shall be
installed.
After filling with fuel, all valves shall be checked for tightness and correct
function by drawing fuel from the system to a tank dispenser.

A certificate for compliance with API/IP recommendations shall be issued.
A general assembly drawing, and spare part list, recommended spare part list,
installation, operation and repair manual shall be supplied the Contractor.

Spill in pit boxes shall be cleaned up immediately.
All pit boxes shall as routine maintenance, be inspected once every month for
integrity and non reported spills.
3608 Protective coating

3608.1 Description
Factory coating for buried pipes and components

All buried pipes and components shall be coated externally with a factory
applied coating as follows:
• 3-layer polyethylene (PE) coating system for normal purpose pipes with
epoxy primer, adhesive layer and polyethylene layer
• Sintered polyethylene (PE) coatings
The coating shall be in accordance with DIN 30670 or a similar standard

approved by the Employees.
Cut back at pipe ends shall be 150 mm for pipes
Coating thickness shall be min. 2.5 mm.
Coating of field welds

All field joints (not factory coated components) shall be field coated with one
of the following types of coating:
• 3-layer butyl rubber tape (polyethylene film with butyl rubber on each
side) together with primer and when necessary, butyl rubber mastic,
thickness of tape 0.75 mm
or
• Hot-melt epoxy shrink sleeve system consisting of a heat shrinkable

polyethylene sleeve pre-coated with a hot-melt adhesive, together with a 2-
component, solvent free liquid epoxy primer. The closure strip shall be of

the temperature sensitive type that converts colour when the correct
temperature is reached.
Internal coating of pipes

All pipes equal to and bigger than DN 50 shall be delivered with a shop or mill
applied internal epoxy resin lining certified and suitable for Jet A-1fuel as well
as water. The lining shall posses a dry thickness of 110-150 µm achieved either
in a single coat or by application of two separate coats with an appropriate
overcoating interval.
Coating of installations in concrete valve chambers

Pipes, valves, valve supports etc. inside the concrete valve chambers shall be
painted to obtain a DFT (Dry Film Thickness) of minimum 250 mym. The
paint system shall be chosen from Special Specification: Specification 3100,
Chapter 3108 Protective coating.

Before application, the internal surface shall be abrasive blasted to a minimum
SA2.5 and a surface profile of 40-60 µm.

The detailed procedure for application shall be forwarded to the Engineer for
approval before start of the work.

All factory and field external coatings shall be checked with a "Holyday
detector" at a voltage of 15 kV plus 1 kV for each 1 mm of coat but not to
exceed 20 kV.
All the above mentioned checks shall be documented and be a part of the final
documentation.

A check of the protective coating is made at the functional check of the catodic
protection of the buried pipe.

3609 Transmitters
3609.1 Description
Temperature Transmitter and sensor

The temperature sensors shall be PT 100 ohm.
The type chosen shall be of a type which has both a 4 - 20mA and a protocol
outlet, HART.
The transmitter shall fulfil the requirements for Zone 1 due to possible Jet A1
vapours in the valve chambers.
Transmitters and sensors for the measuring of fuel temperature will be placed
in a concrete underground valve chamber with a temperature range 0-50 °C.
Reference is made to instrument Drawings No. SA-986-000- P-60528.
Pressure transmitter
The type chosen shall be of a type which has both a 4 - 20mA and a protocol
outlet, HART. The transmitter shall be supplied with an instrument and block
valve and bleed valve attached direct to the instrument.
The instrument valve shall be stainless steel AISI 316L.
The transmitter shall fulfil the requirements for zone 1 due to possible Jet A1
vapours in the valve chambers.
Transmitters and sensors for measuring of fuel temperature will be placed in a

concrete underground valve chamber with a temperature range 0-50 °C.
Temperature transmitter and sensor

The minimum requirements to transmitters are:
• Accuracy:± 0.2 % of span/0.2°C or better
• Repeatability± 0.1 % of span/0.1°C or better
• Long term stability± 0.1 % of reading/0.1°C for 24 months
• 4 wire sensor connection
• The transmitter shall fail at high temperature.
Pressure Transmitters
The minimum requirements to transmitters are:
• Accuracy:± 0.04 % of full scale or better
• Repeatability:± 0.04 % of full span or better
• Long term stability ± 0.05 % of full scale or better for 10 years

• The transmitter shall fail at low pressure.

• All wetted materials shall be AISI 316L
The power supply shall be 24 V DC
Temperature transmitter and sensor

Installation, fuel: The temperature transmitter must be installed in a
thermowell with approved heat conduction. The
thermowell shall be installed at an angle of 90° from
top of the piping.
The location of the fuel temperature transmitters has to
be decided on the basis of the actual layout of the
hydrant pipelines.
When the thermowell is connected to cathodically
protected piping, the transmitter must be electrically
isolated from the thermowell.
Pressure transmitter
Installation, fuel: Each section shall have a pressure measurement. The
pressure transmitter shall be installed at an angle of 45°
from the top of the pipe with the possibility of venting
of air.
When the pressure tapping is connected to cathodically
protected piping, the transmitter must be electrically
isolated from the tapping.

All transmitters shall be calibrated for the specified pressure span and specified
temperature range.
Both the mA and the protocol shall be calibrated.
The commissioning shall be made as for other instruments as described in

Special Specification SA-000-R-11130.
The calibration shall be documented with a certificate confirming to BS EN
10204 3.1.
Certificate of conformity to PED shall be supplied.
Certificate conformity to ATEX shall be supplied.


The instrument shall be maintained as specified in the LDS Contractor's
documentation.
3610 Hydrocarbon detector

3610.1 Description
In each concrete underground valve chamber, a hydrocarbon detector capable
to measure vapour of Jet A1 shall be installed. The detector shall be of a type
with IR sensor.
The detector does not require to have display at the sensor but shall have a
plug-in connection for a handheld terminal and display unit to be used during
maintenance checks.

The measuring range shall be calibrated from 0 - 100 % of Lower Explosion
Level (LEL) for Jet A1.
+
Measuring error shall be within − 5%.
The measuring output signal shall be 4 - 20 mA.
The detector shall fail low.
Ambient temperature in the valve chamber is 0-50 °C.
Power supply shall be 24 V DC.
The chamber is classified as Zone 1.

No special requirements are necessary.

The sensors shall be calibrated from factory for the range specified. The
calibration shall be made with Jet A1.
At commissioning, the detectors shall be checked at the specified warning

level, the alarm level and at 100 % of range.
The sensors shall be supplied with a factory calibration certificate for Jet A1.

The sensors shall be supplied with a certificate of conformity to ATEX.

A handheld terminal and remote display unit shall be supplied for each 5
sensors or part thereof.
Training
The Contractor shall include a short course on calibration and testing of the
sensors.
3611 Wall penetration seals

3611.1 Description
All pipe penetrations through external walls shall be sealed.
Proposed: BWM, Flexicraft, LinkSeal

The seals shall be water tight and hydrocarbon resistant.
Seals to be installed below ground level shall be rated at 5 m water column.
The seal design shall permit axial pipe movement due to thermal expansion or
contraction.

The seals shall be installed in accordance with an installation procedure
approved by the manufacturer and the Engineer.

After installation the seals shall be visually inspected and the inspection shall
be documented.
Upon completion of visual inspection the seal tightness shall be hydro-tested to

the specified water column pressure in accordance with approved procedure.
The hydro-test report shall be included with the final documentation.
After installation, the seals shall be visually inspected by the Engineer.


Not applicable
3612 Geomembrane
3612.1 Description
A geomembrane shall be installed below the fuel lines as it appears from
drawing SA-986-000-P-60506 in order to protect the environment from
contamination in case of a leakage in the pipeline. .

The membrane shall have a thickness of min. 1.5 mm and shall be tight and
resistance against Jet A1.

The geomembrane sections shall be welded together to form tight barrier
against jet A1 in case of a leakage in the pipeline. The membrane shall follow
the sloping of the pipelines (min. 0.3 %). The membrane shall be installed in a
bedding according to the manufacturers recommendations.
The membrane shall at low points be drained to a concrete drainwell with F900
cover, diameter 600 mm. The drainwell shall be equipped with a level alarm.

The welding of the membrane shall be numbered and visually inspected before
backfilling. Likewise shall the connections from the low points to the drain
wells be visually inspected before backfilling can take place. The results of the
visual inspections shall be documented by photos and report notes for each
welding/connection.
The results of the inspections shall be gathered in a numbered file with clear
reference from the drawings to the documentation.

Not applicable.
3613 Leak detection system

3613.1 Description
Below is outlined the basic requirements for a Leak Detection System (LDS) as
applicable to the Fuel Hydrant System (FHS).

Scope of work
The LDS shall in this stage cover a total length of lines of pipes approx. 4,200
m corresponding to a total volume of approx. 185 m3.
The Contractor shall himself verify the exact length and volume from the
Drawings.
The LDS system shall be easy expandable to cover a total length of 6,000 m in
later stage.
For first stage the total FHS has tentatively been divided into 4 discrete sections
on the basis of Double Block and Bleed valves and temperature and a pressure
transmitter on the downstream side of the valves see P&ID Drawing number
SA-986-000-P-60701.
The accuracy is evaluated to be best fulfilled by a static LDS.
The work includes provision of a complete, operating LDS including vendor

specific detailed design, installation, testing, training and documentation.
The supply shall also include equipment, necessary software and hardware
including computer, screens and printers.
Design
The LDS system shall be chosen among the systems in API Publication 4716,
Buried Pressurized Piping Systems Leak Detection Guide" preferably among
the systems based upon:
• Pressure decay - dual pressure
• Volumetric - dual pressure
• Pressure decay with temperature compensation.
The Contractor shall forward a comprehensive description of the system he will

supply describing: functionality, flexibility, instrumentation requirements,
requirements for operator training and integration in the SCADA system, ref.
Clause 3614.1.
The system shall:
• have a proven track record documented by a List of References of similar

installations in airports
• be able to comply with the requirement recommended by The Institute of

Petroleum, maximum leakage of 0.04 litres/hour/m3
• The system shall preferably be able to monitor several pipeline sections in

parallel

• A trained operator shall be capacity of operating the system having

attended the Contractor's training course
Interfaces
The LDS must be capable of interfacing with the Main Contract MC-6
regarding control and monitoring, which shall be accomplished through the
SCADA system described in Sub-section 3615, Control and monitoring
General Requirements
• The offered LDS shall be able to detect a leakage of min. 0.04 l/m3 within
1 hour.
• The system shall be able to support other sections in parallel
• The LDS shall be able to handle complex pipeline geometry
• A trained operator shall be able to operate the system having attended the
Contractor's training course
• Make use of standard instrumentation equipment
• The LDS can be hosted in the SCADA server. Alternatively the Contractor
can choose to host the LDS in a separate computer with a network
connection to the SCADA server.

The Contractor shall describe the installation procedures to be followed with
emphasis on critical procedures which may influence reliability and accuracy.

The Contractor shall supply a description of the testing and commissioning
procedures to be followed and a time schedule showing the duration of this
phase.
The Contractor shall forward an example from a similar installation covering
the documentation supplied as:
• System Manual for the LDS
• Operators Manual
• Other relevant documentation


The Contractor shall forward other documents of relevance for his particular
LDS system.
3614 Cathodic protection system

3614.1 Description
Scope of work
The cathodic protection (CP) system shall inhibit corrosion of the underground
steel components, primarily coated pipes, of the fuel hydrant system.
The CP system shall cover the fuel hydrant system installations for stage 1,
expandable to provide sufficient protection for the future extensions of the fuel
hydrant system, Stage 2.
For information only, the amount of coated steel pipe surface to be protected is
approximately:
• Stage 1: 3,500 m2
• Stage 2: 1,500 m2
The Contractor shall himself calculate the area and determine the coating
breakdown factor for Stage 1 based on the amount, type and size of pipe work
and coating actually to be installed by him.
The work includes provision of a complete, operating impressed current

cathodic protection (CP-) system, including vendor-specific detailed design,
supply, installation, testing, commissioning, training and documentation.
The system shall provide cathodic corrosion protection of the entire fuel
hydrant system described in the sub-sections above. The CP-system shall be
designed for extension in parallel with the extension of the fuel hydrant system.
The cathodic protection system shall consist of the following Sub-systems:
• The power supply system consisting of the transformer-rectifiers (T/R) and

the associated control system for automatic local and remote system
control and operation
• The anode system
• The cathode system
• Test systems
The cathodic protection system shall also include cables, connectors, splices,
corrosion protection test stations, LV power supply cabling, and any other

components, apparatus or plant and all work required for a complete operating
system to provide the specified protection.
Design basis
The cathodic protection system shall be of the impressed current type,
providing sufficient current to the pipes and structures to be protected with the
current sufficiently distributed, so that the selected criteria for CP system
operation are effectively achieved.
The impressed current cathodic protection system shall be designed,

manufactured and installed in accordance with ISO 15589-1, API 1632, BS EN
12954 or equal standard to the Engineer's approval, the applicable local
regulations, and the requirements of this Special Specification shall be
complied with.
The CP system shall be automatically controlled by the T/R unit supplemented

with an overall remote, central CP control and monitoring system.
The installation shall meet the specified protection criteria for 25 year's service
life.
The entire CP system shall be designed for an availability in terms of MTBF

and MTTR of minimum 99.99 %.
General information about the existing soil conditions in and around Salalah
International Airport is given in the report: "Geothecnical and Geological
Interpretative Report - August 2008", Document No. SA-000-G-10001.
Standards and references

The referred codes and standards are intended to provide an acceptable level of
quality for materials and products. In case of conflict between these standards
and the text of this Specification, the Specification text shall govern.
The latest revision of the referred codes and standards published at the time of
Tender shall be used wherever applicable. In case of conflict, the Contractor
shall propose plant conforming to one group of codes and standards always
maintaining this Special Specification as the prevailing document.
API 1632 Cathodic Protection of Underground Petroleum

Storage Tanks and Piping Systems
BS EN 60076 Specification for power transformers
BS EN 12954 Cathodic protection of buried or immersed metallic structures -

General principles and application for pipelines
BS EN 13509 Cathodic protection measurement techniques
BS EN 13636 Cathodic protection of buried metallic tanks and related piping

BS EN 14505 Cathodic protection of complex structures
BS EN 50162 Protection against corrosion by stray current from direct current

systems
ISO 15589-1 Petroleum and natural gas industries -- Cathodic protection of

pipeline transportation systems -
Part 1: On-land pipelines
NACE SP 01 69 Control of External Corrosion of Underground or Submerged

Metallic Piping Systems
NACE SP 01 77 Mitigation of Alternating Current and Lightning Effects on Metallic

Structures and Corrosion Control Systems
NACE RP 01 93 External Cathodic Protection of On-Grade Metallic Storage Tank

Bottoms
NACE RP 02 85 Corrosion Control of Underground Storage Tank Systems by

Cathodic Protection
NACE SP 02 86 Electric Isolation of Cathodically Protected Pipelines
NACE SP 05 72 Design, Installation, Operation, and Maintenance of Impressed

Current Deep Ground Beds
Abbreviations and acronyms

Abbreviations and acronyms generally used in the project are listed in the
General Contract Requirements. Specific for the cathodic protection Work are:
API American Petroleum Institute

NACE National Association of Corrosion Engineers (USA)
CP Cathodic protection
NEMA National Electrical Manufactures Association (USA)
T/R Transformer-rectifier
Symbols, terms and definitions

Symbols, terms and definitions shall be as specified in BS EN 12954 with the
following additions:
Anode: The positive electrode of the cathodic protection system.
Cathode: The negative electrode of the cathodic protection system, which is the
structure to be protected.
Cathodic protection: A process of protecting a metallic structure from corrosion

by installing an impressed current system or sacrificial anode system that
makes the protected structure cathodic and thus resistant to corrosion.

Coating: Electrically insulating covering bonded to a metal surface for

protection against corrosion by preventing contact between the electrolyte and
the metal surface.
Current density: Electric current per unit area of an electrode surface.
Electrical continuity, existing: Physical state of a structure such that a current

circulating within it does not produce a significant voltage drop.
Electrical continuity, achieved: Electrical continuity achieved as relevant of this

work is defined as a closed electrical path using metallurgically fused joints
between metal components such that electrical current does not flow between
the metallic components through the electrolyte, be it water, concrete or soil
Electrolyte resistivity: The specific resistance of the electrolyte assuming that

the electrolyte is homogenous. Note: Usually expressed in ohm.metre (Ω•m).
Insulation: Material with low electrical conductivity used to provide electrical

isolation.
Insulating joint: The same as isolating joint.
OFF potential: In these Specifications, also referred to as instant-off potential.
Protection potential: Structure to electrolyte potential for which the metal

corrosion rate is acceptable.
Reference electrode: An electrode of which the potential is accurately

reproducible and which serves as a basis of comparison in the measurement of
other electrode potentials.
Service life: The time until safety, serviceability and acceptable appearance of
the structure or its main components falls below a defined minimum level or
requires unduly high costs for maintenance and repair.
Shield: Conductive or non-conductive structure or object, which modifies the

protection current distribution on a structure to be protected.
Silver/silver chloride reference electrode: Reference electrode consisting of

silver, coated with Silver Chloride, in an electrolyte containing a fixed
concentration of Chloride ions.
Stray current corrosion: Corrosion caused by electric current from a source

external to the intended electrical circuit, for example, extraneous current in the
earth.
Test station: Installation that provides measuring and test facilities for the
buried structure. Such installations will include cabling and structure
connections.

Zinc electrode: Measuring electrode made from sufficiently pure zinc.
Interfaces
The CP Works have indirect interfaces with Main Contract MC 6 regarding
remote control and monitoring, which shall be accomplished through the
SCADA system described in Sub-section 3615.
General
The cathodic protection system shall be based on the impressed current
principle.
The CP system shall be centrally monitored through the fuel hydrant system
control- and monitoring system (FHSCMS) and associated SCADA system.
Remote measuring and data acquisition shall be possible through the same
system.
Protection requirements
The system shall achieve a minimum pipe-to-soil instant off potential of minus
850 mV with reference to a saturated copper-copper sulphate reference cell
above the underground metallic components of the piping.
This potential shall be obtained over 95 percent of the metallic area without the
instant off potential exceeding minus 1200 mV.
The synchronous interruption for measuring instant off potentials shall be

obtained with the use of the built in pulse generating current interrupters.
Design current densities for protection of the metallic structure shall be in

accordance with the appropriate BS EN standard or NACE Recommendation
depending on the metallic structure. In case of conflict, BS EN shall prevail. If
current densities from trial polarization are available these results shall be used.
The current requirement shall be calculated as 110% to 150% of the maximum

current demand depending on the geometry and the coating of the structure.
The coating breakdown factor shall be taken into consideration corresponding
to BS EN standard or NACE Recommendations. In case of conflict BS EN
shall prevail.
Interference currents on neighbouring underground structures are to be

minimized or the structures are to be made electrically continuous with the
protected structures. Measurements shall be carried out in accordance with BS
EN 50162 to document that there are no deleterious effects from the cathodic
protection. Where the Contractor chooses to mitigate interference by bonding
the protected structure (the fuel pipe) to the neighbouring structure, the current

required for protection of the neighbouring structure shall be included in the

maximum current demand mentioned in the paragraph above.
Anode system
The anode system shall consist of the anodes (impressed current type), anode
ground bed, associated power distribution cables and all hardware for
placement of the anodes. The anode system may consist of different anode
types specific for the particular structure being protected or the specific
application.
Anodes shall be high silicon cast-iron anodes installed in low-resistance

carbonaceous backfill. The Contractor may propose other types if supported by
full technical specifications and documentation of advantages above high
silicon cast iron anodes for the Engineer's consideration.
Silicon cast-iron anodes shall have the following composition (% by weight):
• Silicon: 14.20 - 14.75
• Carbon: 0.70 - 1.15
• Chromium: 3.25 - 5.00
• Manganese: 1.50 max.
• Molybdenum: 0.20 max.
• Copper: 0.50 max
• Iron: Balance
The resistance between the anode cable and the anode shall be less than
0.005 ohm.
The anode-to-soil resistance shall be less than 2 ohm.
Cathode system
The cathode system shall consist of the negative cabling from the rectifier to
the buried metal structures (fuel pipes, etc.) to be protected as well as structure
continuities.
Monitoring and control system

The monitoring and control system shall consist of reference electrodes, test
stations, and test connections to the structure/pipes.
Anode circuit requirements

The impressed current anode system shall provide protection against corrosion
for a minimum of 25 years. Provisions shall be incorporated for ease of anode
replacement. The design and installation of all elements shall be made such that
no major maintenance shall be required under normal operation.
The design of the impressed current anode system shall contain sufficient
redundancy, such that no anode is made inoperative during one random break

in the power feed. The anode assembly and its attachment shall be designed to
have a high resistance to mechanical damage.
Anode spacing shall provide sufficient current distribution to the entire

structure to be protected with the operational criteria effectively obtained while
minimizing over-potentials on the protected structures or stray currents on
nearby structures. To improve the current distribution and to prevent over-
protection, dielectric shields may be used.
The anodes shall be designed to provide efficient protection for a minimum of

25 years. This shall allow for 20% deterioration of the coating efficiency or the
coating breakdown percentage after 25 years as calculated by the Contractor,
whichever is the highest during this period, without exceeding the
manufacturer's recommended maximum anode current density.
Cathode circuit requirements

All other adjacent buried underground metallic structures shall be made
electrically continuous with the protected metallic structure to minimise stray
current corrosion.
Local increases in metal density as well as other electrical interference shall be

considered when developing the cathodic protection design.
If it may be appropriate not to cathodically protect certain metal items adjacent

to the protected metallic structure. Electrical isolation and avoiding stray
current corrosion of such items shall be addressed during the CP system design.
Monitoring and control requirements

Test stations for potential measurements shall be provided to facilitate the CP
system monitoring. Adequate reference electrodes shall be installed and
positioned such that they represent the most exacting geometric configuration.
Such locations include, but are not limited to:
• Metallic structure crossing.
• Lengths with metal sleeve pipes.
• Sacrificial anode installations.
• Road crossings.
• Potential areas of stray currents on other buried metallic structures or

components.
Reference electrodes shall preferably be Cu/CuSO4 type for permanent

installation in soil. They shall include a chloride ion trap to prevent
contamination by ground water, and have a long time stability of a minimum of
±10 mV at 3 mA load for a minimum of 10 years.

If, in the Contractor's opinion, his range of Cu/CuSO4 reference electrodes are
not suitable for the chemical environment of the soil, Ag/AgCl or packaged
zinc type electrodes may be proposed for the Engineer's approval.
Each reference electrode shall be accompanied by its own discrete test link
connection to the metallic structure being monitored, positioned adjacent to the
reference electrode. The test stations shall be permanently wired to the
transformer-rectifiers for remote measuring and data acquisition. For long
distances between the test station and the T/R, 4-20 mA transmitters should be
used for the transmission of the potential measuring signals.
Transformer-rectifiers (T/R)
The specifications for switchboards as given in Section 4000: Electrical
installations, shall apply where relevant.
The transformer-rectifiers shall comply with the requirements stated below.
General
The transformer-rectifiers shall provide fully controllable DC output to the
anodes.
The transformer-rectifier units shall as a minimum consist of a transformer,

rectifying elements, transformer tap adjuster, terminal blocks, DC output
voltmeter, DC output ammeter and overcurrent protection for each DC circuit,
variable resistors, an AC power-supply circuit breaker, lightning arresters for
both input and output, all wired and assembled in a cabinet. The overall
efficiency of the rectifier shall be not less than 65 % when operated at
nameplate rating.
Each transformer-rectifier shall be mounted in a panel or cubicle with

protection by enclosure minimum IP 54 for outdoor mounting and minimum IP
2X for indoor mounting. For outdoor mounting the enclosure shall be sun-
shaded. The assembly shall be air-cooled by natural ventilation. For outdoor
mounting, the Contractor may, as an alternative, propose oil-cooled T/R along
with technical justification for the Engineer's approval.
All transformer rectifier enclosures shall be lockable and shall be capable of

being opened with the same key.
Rectifying elements shall be silicon diodes connected to provide full-wave

rectification. Silicon diodes shall be protected by selenium surge cells or
varistors against over-voltage surges and by current-limiting devices against
over-current surges.
Transformer-rectifiers shall be rated to operate continuously at maximum rated

output under the site conditions prevailing. They shall be designed to provide a
minimum operational life of 25 years without major maintenance.

The transformer rectifiers shall be switchable between constant voltage with

current limit and constant current with voltage limit or constant potential with
voltage and current limit.
Synchronized output current interruption facilities shall be incorporated into the

units to enable ohmic corrected ("IR free") electrochemical potentials to be
measured by means of total system instant off.
The transformer rectifiers shall have provisions to connect hardware systems

with the fuel hydrant system control and monitoring system.
Each transformer rectifier shall have an external identification plate to clearly

identify it with an unambiguous number in accordance with the project's
component numbering system, and also the anodes it supplies DC current to.
Controls and connections

Each transformer-rectifier shall as a minimum be equipped with the following:
• Digital meters, showing output current and voltage.
• Set values for current, voltage and potential control modes.
• Two pairs of 4 mm terminals or sockets to enable measurement of output

voltage and output current by an external digital voltmeter.
• A suitably rated circuit breaker for operation at the ambient temperature

shall be provided on the main input to provide short circuit and thermal
overload protection.
• Lamps, LED’s or other equal means of indicating AC power ON and DC

output ON.
• Integrated cyclic timer for interruption for "on/off" testing. The timer shall
include a synchronization system which will enable synchronized instant
off within each section of the fuel hydrant system being protected. The
interruption facility shall be rated to safety switch 200 A DC.
• Interface to the fuel hydrant system control and monitoring system
Current measurement shall be by voltage drop across a 0.01 ohm shunt resistor
(0.5%). Voltage measurement shall be by precision resistor (0.5%) fitted in a
voltage divider configuration to attenuate voltages of 50 to 2 V. The
multiplying factor and attenuation factor shall be clearly marked in each case.
DC positive output to the anodes shall be taken from a common output, via a
suitably rated copper bus bar or similar, to the anode cables.
DC negative output to the protected structures shall be taken from a common

terminal via a suitable copper bus bar.

Terminals shall be clearly marked + ve ANODE XXX” and – ve STRUCTURE

XXX (where XXX is the relevant anode or structure identification) as shown
on the Drawings.
All cabling between transformer rectifiers and signal processing equipment

required for synchronization of the instant off operations shall be provided by
the Contractor.
Electronic components
To protect against atmospheric corrosion, all electronic component assemblies
shall be encapsulated in epoxy resin or varnishes as recommended by the
component manufacturer and shall be approved by the Engineer.
Transformers shall be double-wound in accordance with BS EN 60076. The

windings shall be separated by an earthed metallic screen or mounted on
separate limbs of an earthed core. They shall be suitable for continuous use at
the specified ratings.
The rectifiers shall be silicon type with suitable AC surge protection. Semi-
conductor fuses shall be used to protect the rectifiers on the AC side and metal
oxide varistors on the DC side. Rectifiers shall be rated for continuous
operation at the maximum design outputs with a peak inverse voltage of at least
800 V. Varistors shall be compatible with the rectifier peak inverse voltage
levels.
Electrical performance specification

The current and voltage rating of the transformer rectifiers shall be as designed
and needed to meet the design protection requirements. The transformer
rectifiers shall comply with the following electrical performance specifications:
Primary power supply 415/240 V a.c. +5 % / -15 %,

50 Hz +3 % - 5 %.
AC ripple in DC output Maximum 2% of DC output.
DC current control Ratings to meet CP system requirements as
appropriate. All output controls shall be
stepless.
DC control limit At maximum DC output rating.
DC control mode Constant current, constant voltage or
constant potential mode with manual and
automatic adjustments.
DC current stability 2% of set current or 50 mA whichever is
the greater.
DC current measurement Across 0.01 ohm, 0.5% shunt resistor.
DC voltage measurement Across precision resistor (0.5%) to
attenuate voltages from 50 to 2 V.

Activation time to achieve DC Maximum 250 ms from activation to full

interruption and remake shutdown. Maximum 500 ms from
activation to full operational current output.
Interruption facility, local Manual selectable switch to cover periods
of 3 to 120 seconds independently for both
"On" and "Off" cycles.
Interruption facility, remote DC interruption and remake initiated from
the fuel hydrant control system specified in
clause 3615: Control and monitoring.
Recording time The instant off potential shall be recorded
250 ms after DC interruption.
Meters shall be accurate to within plus or minus 2 % of full scale. Separate

meters shall be 60 mm nominal size or larger.
The transformer-rectifier shall be capable of supplying voltage and current

outputs of 30% above expected, i.e. calculated ultimate, needs for both Stage 1
and 2 construction of the fuel hydrant system.
The transformer-rectifier shall be equipped for transmitting fault signals and

output current signals to the fuel hydrant control and monitoring system.
Cables and connections

Cable sizes shall preferably be metric. AWG sizes, if used in standardised
factory-built assemblies, shall not be less than the equivalent metric sizes
specified herein.
The factory-mounted anode cables shall be min. 10 mm2 stranded copper cable
insulated to minimum 600 V. The inner insulation of anode head- or deep well
anode cables shall be chlorine- and hydrogen resistant, such as Halar or
fluorocopolymer.
Cables for connecting the anodes / anode beds with the transformer-rectifier
shall be minimum 25 mm2 stranded copper wire with 600 V heavy-duty
insulation.
All anode cables shall have an outer jacket of high molecular weight
polyethylene; min. thickness 1.6 mm. PVC insulation or PVC- jackets shall not
be used.
Cathode cables - between the transformer-rectifier and the pipes - shall be

minimum 25 mm2 stranded copper cable, insulation type to be selected by the
Contractor.
Test wires shall be minimum 2.5 mm2 insulated stranded and screened copper
cables. Test cables longer than 100 m, notably cables from test stations to

transformer-rectifiers, shall have helically twisted conductors or are equal

means of providing the best immunity against electromagnetic interference.
The insulation type shall be suitable for direct burial and may be selected by the
Contractor.
Cables for test signals transmitted at 4-20 mA are specified in Sub-section

3615.
Test stations
Test stations for insulation level measurement shall be provided for each buried
insulated joint of the pipeline system. Such test stations may be used also for
testing the pipe-to-soil potential, otherwise separate test stations for such
measurements shall be provided for each individual isolated section of the
pipeline system, or per maximum 500 m whichever is the smallest distance, and
where indicated on the Drawings.
The test stations shall be factory-made by a manufacturer specialised in

equipment for cathodic protection.
General
T/R units, cables and monitoring and control systems shall be installed in
accordance with the requirements given for electrical installations in Special
Specification 4000.
The T/R units and cables shall be installed as indicated on the Drawings.
Anode systems
The anode systems shall be installed in accordance with the Contractor’s
method statement for installation, as shown on the Contractor's shop drawings
and as described in this Specification. The Employer's design is based on
vertical tubular type anodes with the anodes located minimum 8 m below
ground surface level.
If the Contractor's design requires more than one anode in the positions
indicated on the Drawings, or in other positions selected by the Contractor, the
distance between adjacent anodes shall be greater than 10 m.
The Contractor shall perform a survey of the appointed anode locations in

relation to other structures and shall select the final locations of the anodes to
minimize interference with building- and other underground facilities.
Lead wires shall be securely connected to the anodes, preferably at the centre,
and inspected for damage. Care shall be taken to avoid all cable damage during
installation.

Buried underground anodes shall be backfilled once placed within an earth

contact backfill material, or be pre-packaged in canisters.
Multi-anode beds shall not be placed under paved areas. Single anodes or well-
mounted anodes shall, where placed under paved areas, provide future access
that will not require subsequent repair of the pavement. For example by
removable cast iron covers Class F900 or equal.
Underground anode cables shall not be directly buried, but shall run in buried
high density polyethylene (HDPE) ducts.
Minimum distances from taxiway centrelines of minimum 60 m indicated on

the Drawings must not be violated, as they are specified in order to ensure a
clearance of 57.5 m during future replacement of the anode, which is necessary
for allowing aircraft traffic on the taxiway during the work operation.
Cathode systems
System negative connections shall be made in accordance with the Contractor’s
method statement, as shown on the Shop Drawings and as described in this
Specification.
The wire to structure/pipe connection shall be by exothermic welding process.
The method of providing bonds shall be at the discretion of the Contractor.

However, the methodology and procedure must be provided to the Engineer for
review and approval prior to commencement.
The DC resistance between each connection shall be measured and recorded. If

the measured resistance is greater than 0.5 ohm, an additional system negative
connection shall be made at a location approved by the Engineer until the
measured resistance is less than 1 ohm.
Reference electrodes and test stations

The reference electrodes shall be installed in accordance with the Contractor’s
method statement, as shown on the Shop Drawings and as described in this
Specification.
Each reference electrode point shall be mounted in a shallow pit with a cover,
placed vertically above the buried pipe.
The reference electrodes shall be installed at predetermined locations. The

reference electrodes shall be placed at the level of, and parallel to, the protected
structure/pipe. At this location, an instrument negative connection shall also be
provided and connected to the buried metallic structure/pipe in the manner
described above for system negative connections.
If a nearby metallic structure is intended to be electrically isolated from the

cathodic protection system, capabilities for monitoring this structure for stray

current shall be provided. Capabilities shall be provided for evaluating current

pick up by nearby structures as well as means of tying the structure into the CP
system.
The test stations shall be placed at easily accessible locations as close as

possible to the connection points to the pipeline.
For insulating joint testing one test lead from each side of the joint shall be
brought to the test station.
For potential testing, one test lead shall be brought from the pipe and one test
lead shall be brought from a reference electrode point to the test station.
Each test station and sensing electrode shall be connected to the pertinent
transformer/rectifier for automatic potential control and for conveying the
measurements to the central control and monitoring system.
General
Testing and commissioning shall be performed in a systematic manner,
comprising the relevant of the procedures described in Special Specification
3000: Electrical and Mechanical Works - General requirements.
Inspection, verification and testing shall as a minimum comprise the items and
methods specified in the relevant standards, ISO 15589-1, API 1632 or BS EN
12954.
Transformer rectifier inspection and testing

All test procedures shall be submitted to the Engineer for approval. The
following tests shall be carried out by the manufacturer and test reports and
certificates shall be submitted to the Engineer for approval.
Factory acceptance testing shall be conducted at the manufacturer’s works to

demonstrate the compliance of transformer rectifiers with the Specification and
to prove full functional compliance and fitness-for-purpose. The tests shall be
arranged to represent realistic on-site working conditions.
The following tests shall be performed as a minimum:
• All power circuits and apparatus shall withstand a power frequency voltage
test at 2000 V for 1 minute between AC and earth.
• 500 V megger insulation tests comprising:
• primary to secondary
• primary to earth

• DC positive to earth
• DC negative to earth
In all cases the measured resistances shall be greater than 1 MΩ.
Site tests shall as a minimum include:
• Tests to demonstrate performance of the current interruption facility

including time to activation and synchronization of the cyclic timers to
within 250 ms between all transformer rectifiers shall be included.
• DC output load checking on site as per the designed voltage and current
requirements; the transformer rectifiers shall perform satisfactorily at the
ranges of voltage and current up to the maximum designed values.
• Functional tests of the communication with the fuel hydrant system control
and monitoring system (FHSCMS).
Any other tests to prove compliance with the Specification, as specified in other
relevant standards and approved by the Engineer.
General
The Contractor shall provide documentation in accordance with the general
requirements for documentation as described in Section 3000: Electrical and
Mechanical Works - General requirements.
Specific requirements to documentation for the CP plant are:
• Data sheets for all components of the CP plant
• The Contractor's survey report(s) describing soil conditions and

topological findings
• The Contractor's calculations of required currents, voltages, anode sizes,

etc.
• The Contractor's workshop drawings
• "As built" layout drawings of the structure including neighbouring

structures that are relevant to the cathodic protection
• Cathodic protection design with "as built" installation drawings and all
details pertaining to the cathodic protection of the structure
• Results of interference tests carried out on neighbouring installations

• Details of equipment operation and adjustment and the results of all

measurements carried out before and after commissioning;
• Description of the installations with details and references to materials
• Information necessary for the correct operation and maintenance of the

installations e.g. frequency of system checks.

Not applicable.
3615 Control and monitoring

3615.1 Description
Configuration of control and monitoring system

The FHS shall be controlled and monitored by a control and monitoring system,
in the following text, referred to as FHSCMS.
The FHSCMS configuration shall comprise a PLC system and a SCADA

system as shown in Drawing No. SA-986-000-P-60532. The Contractor shall
develop this configuration in detail taking into account the specific features of
the chosen hard- and software products.
The Contractor may choose to host the Leak Detection System, LDS, in a
separate computer or integrate it in the SCADA system as shown on the
Drawing.
PLC system
The PLC system shall comprise the following parts:
• A PLC central unit which carries out automatic control and monitoring
functions, including valve switching in connection with leak detection.
• A number of geographically distributed input/output subsystems (I/O

subsystems) which communicate with the field equipment. There shall also
be an I/O subsystem for signal exchange with the Fuel Farm and the
pumping station.
• A Local Area Network, the Process LAN, which enables communication

between the PLC central unit and the I/O subsystems.
• An Operator Panel which is connected to the PLC central unit, either

directly or through the Process LAN. The Operator Panel shall be a colour
LCD of touch-screen type, minimum 17" screen size.

The Process LAN shall be a VLAN within the framework of the Airport
Community Network, ACN. An RJ45 outlet for connection to the ACN will be
provided in each room where FHSCMS equipment shall be placed.
PLC signal interface

The signal interface between the PLC system and the process equipment can be
either Profibus DP or parallel input/output signals.
Profibus DP shall be used for control and monitoring of valve actuators. The
signal interface to other equipment shall be parallel input/output signals.
The specifications of parallel input/output signals shall be as follows:
Abbreviation Description
BI Binary input from potential free contact, 0 - +24 V

BO Binary output, 0 - +24 V, to potential free interposing relay with
diode for transient suppression
AI Analogue input, 4 - 20 mA, two-wire connection to potential free
transmitter
AO Analogue output, 4 - 20 mA, potential free output circuit
The specific signals are listed in the signal schedule, Drawing No. SA-986-000-
P-60533.
SCADA system
The SCADA system comprises the following parts:
• A SCADA server which communicates with the PLC system. The SCADA
shall be installed in Data Centre 1.
• A Leak Detection System (LDS), an OPC server and a web server. The
Contractor may choose whether these sub-systems shall be hosted in the
SCADA server or whether they shall be hosted in separate computers
which shall be installed in Data Centre 1.
• A Local Area Network, the Presentation LAN, which enables

communication between the SCADA server and the HMI equipment. The
Presentation LAN shall be a VLAN within the framework of the Airport
Community Network, ACN. The connections to the Presentation LAN
shall be through RJ45 outlets as described above for the PLC system.
• A SCADA Operator Station with a colour display, minimum 19" screen

size, a keyboard and a pointing device (mouse or equivalent). The SCADA
system shall be configured for operation with two operator stations so that
a second operator station with the same functionality as the first one can be
added by simple addition of hardware.

• A laser type colour printer, format A3/A4, for hard copy of reports, curves
and screen copies. The printer shall also be able to function as black/white
and colour photocopier and scanner.
General functionalities of FHSCMS

The FHSCMS shall comply with the general requirements in Document No.
SA-000-O-11143, 4300 Control and monitoring systems.
The PLC system shall carry out automatic control and monitoring functions.
The SCADA system shall provide a user-friendly Human-Machine Interface

(HMI) for operation of the FHS, reporting and analysis. The HMI of the LDS
shall be integrated with the HMI of the SCADA system.
The SCADA system shall acquire and record operational data in an SQL
compliant historical data base, and it shall be provided with facilities for
presenting the acquired data in lists and reports for documentation of the
operation of the FHS, including Cathodic Protection and Leak Detection. The
data to be recorded include but are not limited to:
• All actions by operators with identification of the person.
• All changes of equipment state (for example activation/deactivation of

valve limit switch)
• Operating hours and numbers of operations for equipment subject to wear

(for example operating hours and number of starts for pump motors, and
number of open/close operations of actuators for switching valves).
• Time series of analogue measurements
• Other operational data relevant for operation and maintenance.
SCADA Human Machine Interface (HMI)

The Contractor shall implement a SCADA HMI which makes it possible to
operate the entire FHS, including the Leak Detection System, through one
SCADA operator station. The HMI shall be in conformance with the
requirements of Document No. SA-000-O-11143.
The HMI shall also monitor the state of the Emergency Shutdown System,
FHSESD, as specified in Section 3616.2.
Report generator
The SCADA system shall be provided with a report generator as described in
Document No. SA-000-O-11143.

The scope of supply shall include at least 5 (five) preconfigured reports. The
requirements to these reports will be defined by the Employer during
implementation.
Operator Panel
The Operator Panel shall be able to function as an emergency operator station if
the SCADA system should fail. It shall enable user-friendly visualisation,
monitoring and control of all the equipment connected to the PLC, including
display and monitoring of the FHSESD. It shall not function as HMI for the
LDS, but it shall display all the pressure and temperature measurements used
by the LDS.
The Operator Panel shall provide the same colour graphic interface as the
SCADA operator station for display and issuing of operator commands, with
the modifications required by the use of a touch screen instead of a mouse.
Alarms shall be displayed and acknowledged in an alarm list on the Operator

Panel.
An event list shall not be displayed on the Operator Panel.
Overview of FHSCMS tasks

The FHSCMS shall support the efficient and reliable execution of the following
operating tasks:
1 Tasks for FHS
1.1 Control of hydraulic configuration

1.2 Leak Detection
1.3 Display and monitoring of temperatures and pressures
1.4 Monitoring of hydrocarbon concentration
1.5 Monitoring of ESD system
2 Tasks for Cathodic Protection
2.1 Monitoring of equipment for cathodic protection

2.2 Test of Cathodic Protection.
The above-mentioned tasks are described in the following sections.
Control of hydraulic configuration

It shall be possible to control the hydraulic configuration of the FHS by
opening and closing the block valves by operator commands at the SCADA
operator station.
There shall also be implemented automatic programs for isolation of system

sections for leak detection (see below).

The FHSCMS shall monitor by means of "Valve open" and "Valve closed"
feedback signals that each "Open" or "Close" command is executed within a
predefined maximum time corresponding to the travel time of the valve
actuator.
Leak detection
Leak detection, as described in Section 3613, shall be performed by the Leak
Detection System (LDS). If the Contractor chooses to host the LDS in a
separate computer there shall be a network connection between the LDS
computer and the SCADA server.
The leak detection shall be executed automatically upon activation by an

operator command at the SCADA operator station. This also includes the
automatic PLC program for isolation of the section of the hydrant system which
is being tested for leaks.
Display and monitoring of temperatures and pressures

The SCADA HMI shall display all temperature and pressure measurements in
the hydrant system and the pumping station.
All pressure measurements shall be monitored so that an alarm is activated if

the pressure falls below a lower limit. The limit values shall be individually
adjustable for each temperature measurement.
The FHSCMS shall be able to record 6 measurement values (temperatures

and/or pressures) as time series with 1 minute intervals. The measurements
shall be stored in the historical data base for 10 days after which they shall be
overwritten by new measurements.
The measurements shall be aggregated to maximum, minimum and average

values which shall be stored in non-volatile memory for the following time
intervals:
• 15 minutes values: To be stored for 100 days
• 1 hour values: To be stored for 400 days
It shall be possible to display the stored measurement values as curves as a

function of time with free selection of the time interval to be displayed.
Monitoring of hydrocarbon concentration

The CMS shall monitor hydrocarbon concentration in each valve chamber by
an analogue signal for hydrocarbon concentration. The measured concentration
shall be displayed as per cent of Lower Explosion Level (LEL) for Jet A1 fuel.
The SCADA system shall issue a low priority alarm if the signal exceeds a
specified warning level and a higher priority alarm if the signal exceeds a
specified alarm level. It shall be possible for an authorised operator to change
the two alarm levels.

Monitoring of ESD system

The CMS shall monitor the status of the ESD system. Refer to Section 3616.2.
The monitoring shall include the following:
• Indication of activated ESBs by alarms. It shall be clearly indicated in the

alarm messages which ESBs have been activated, and the active ESBs
shall also be indicated by graphical symbols on the HMI displays which
show the state of the FHS.
• Indication of erroneous combinations of contact signals from an ESB (both
signal contacts open or closed). It shall be clearly indicated which ESBs
generate erroneous signal combinations.
• Indication of faults in the FHSESD, for example loss of redundancy in

communication or failure of an input/output unit. The fault indication shall
be selective such that it immediately identifies the unit which has failed.
• Indication of suppression of ESD Function (position of suppression switch)

and of the state of the suppressed ESD signals. See Section 3616.2.
Monitoring of equipment for cathodic protection

The FSHCMS shall monitor the following signals for each of the transformer-
rectifiers (T/R) described in Section 3614.2. For each T/R unit the following
signals shall be monitored:
Signal interface for monitoring of T/R unit
No. Signal Description

type
1 BI Common status indication (alarm), Ready/Fault,

"Ready" = closed contact
2 AI DC output current 1 (see Note)
Note A T/R unit can be equipped with 1, 2 or 3 current outputs with a current
measurement for each output. Tentative values of the specific numbers of
current outputs for the individual T/R units are specified in the signal schedule,
Drawing No. SA-986-000-P-60533. The contractor shall verify these tentative
values and correct them as required.
Test of cathodic protection

It shall be possible to test the cathodic protection by switching a T/R unit
temporarily off and record the resulting change of potential as a function of
time.
The T/R unit shall be switched off and on by operator commands at the
FHSCMS SCADA system. The signal interface for this shall be as follows for
each T/R unit:

Signal interface for switching T/R unit on and off

type
1 BO Switching on (pulse for activation of interposing relay in T/R unit,

see Note below)
2 BO Switching off (pulse for activation of interposing relay in T/R unit,
see Note below)
3 BI State of T/R unit , On/Off ("On" = contact closed)
Note: Pulse length shall be defined in accordance with the requirements of the T/R
unit, 1 s is assumed as a starting point.
The potential is measured at a number of test stations, each of which transmits a

4-20mA measuring signal to a PLC input/output subsystem. The test station
connections to the input/output subsystems are provisionally specified in the
signal schedule, Drawing No. SA-986-000-P-60533. The Contractor shall
verify these provisional connections and correct them as required.
The signal interface for a test station shall be as follows:
Signal interface for test station

type
1 AI 4-20mA signal for potential, 2-wire connection, galvanic isolation

in test station. The Contractor shall define the potential range
which corresponds to the 4-20mA signal range.
The FHSCMS shall record the potentials for all test stations as time series and
store the values as time series in the historical data base. The sampling interval
and the number of measurements to be stored shall be defined by the Contractor
in accordance with the requirements for the test and to the satisfaction of the
Engineer. It shall be possible to display the stored potential values as curves as
functions of time with free selection of the time interval to be displayed.
External interfaces of FHSCMS

The FHSCMS shall exchange data with the systems stated below.
Interface to CMS of Fuel Pumping Station

The PLC shall exchange on-line variables with the Fuel Pumping Station as
parallel I/O signals through an I/O subsystem. The I/O signals are specified in
the signal schedule, Drawing No. SA-986-000-P-60533.
The Contractor shall establish a shielded multicore signal cable from the I/O
subsystem to a terminal block in a junction box established by the contractor
responsible for the Fuel Pumping Station. The junction box shall be placed in
the equipment room where the FHSCMS is placed.

Interface to FHSESD
Refer to the Section "Monitoring of ESD system" above.
Interface to Airport SCADA system

The FHSCMS shall be monitored by the Airport SCADA System. The
monitoring interface and the scope of monitored variables are specified in the
Documents No. SA-000-E-11663 and SA-000-E-11669.
Remote access to FHSCMS data

The web server with connection to the ACN shall enable remote clients with
standard internet browsers to read on-line and stored data in the SCADA server.
The purpose of this is to provide operating personnel with remote insight in the
state of the FHS, and to enable remote acquisition of data for analysis.
Central equipment
The FHSCMS central equipment shall be placed in rooms which are provided
by the contractor which implements the Fuel Farm and the pumping station.
The rooms will be provided ready for use with all building installations,
including air conditioning.
In general the electrical installations shall comply with the requirements stated
in Section 4000, Electrical Installations.
Equipment Room and control room

The central PLC equipment shall be installed in a panel which shall be placed
in an equipment room. There will be minimum 8 m2 of floor space in the
equipment room which shall also contain the central equipment for the
FHSESD system (see Section 3616). The maximum ambient temperature in the
equipment room will be +30 oC. The PLC panel shall be of the metal clad type,
obtaining the minimum degree of protection required by IP42. The panel shall
provide cable access by the use of cable glands.
The panel shall, in all other ways, comply with the requirements stated in
Section 4000, Electrical Installations.
The HMI equipment shall be placed in a control room. The ambient

temperature in the control room will be within the range 15 - 25 oC.
The Contractor shall provide furniture for the HMI equipment. The furniture
shall be of good quality office standard subject to the acceptance of the
Engineer. The following furniture items shall be included:
• One (1) terminal table for the operator station. Width * Depth = ca. 1.8m *
0.9m, height adjustable.

• Two (2) office chairs on wheels
• One (1) bookshelf. Width * Height * Depth = ca. 1m * 2m * 0.3m.
• One (1) table or cabinet for support of the printer/copier (only if necessary
for elevation of printer/copier to normal working height for a standing
person). Dimensions to be agreed with the Engineer.
The details about the furniture shall be agreed with the Engineer.
The contractor which implements the Fuel Farm and the pumping station shall
provide the following:
• UPS power for the FHSCMS equipment in the equipment room and the
control room.
• Cable paths for the FHSCMS inside the Fuel Farm and the pumping
station. This includes cable paths for all types of cables, including power
supply cables, signal cables and data cables.
• Signal interface to CMS of Fuel pumping station (through terminal block

in junction box as specified in section 3615.2).
• RJ45 outlets in the equipment room and the control room, and the
associated data cabling. The VLAN connections through the ACN will be
established by Main Contract 6.
The Contractor shall liaise with the contractor which implements the Fuel Farm
and the pumping station, and with Main Contract 6, for the clarification of the
details of the above-mentioned interface. The Engineer shall supervise this
process and receive copies of all documentation.
I/O subsystems and cabling

The I/O subsystems shall be situated in equipment rooms at suitable locations
relatively to the controlled/monitored equipment. The equipment rooms are
listed in Drawing No. SA-986-000-P-60533.
The remote I/O unit, including all necessary components such as

communication modules, I/O modules, safety barriers, power supply terminals
etc. shall be built in a metal clad panel. The panel and installations in
connection with the valve chambers shall be designed to comply with the
ATEX directive.
The wiring between the I/O subsystems and the valve chambers shall be based
on the types of signal cable mentioned below.
• For binary signals (0 - 24 VDC): Shielded multicore cables with one

twisted pair of conductors for each signal.

• For analogue signals (4 - 20 mA): Shielded multicore cables with one

twisted pair of conductors for each signal.
• For Profibus DP (for control of actuators): Special approved cable for

Profibus communication.
The number of cores in the above-mentioned multicore cables shall be

sufficient for 160% of the foreseen maximum number of signals.
The contractor which implements the equipment rooms will provide UPS
power for the FHSCMS equipment. However, the Contractor in charge of the
FHSCMS shall establish the wiring between the power supply points and the
FHSCMS equipment.
The contractor which implements the equipment rooms will also provide the
RJ45 outlets and the associated cabling for the Process LAN. The VLAN
connectivity through the ACN will be established by Main Contract 6.
Valve chambers are classified as hazardous areas which involve complete

potential bonding of all electrical conducting elements in the valve chambers.
Each valve chamber shall be equipped with a potential bonding bar. The
equipotential bonding shall comply with the requirements stated in Section
4000, Electrical Installations.

Refer to the Document No. SA-000-O-11143, 4300 Control and monitoring
systems.
systems.

systems.
3616 Emergency shutdown system

3616.1 Description
The Emergency Shutdown System of the FHS, referred to as FHSESD, shall be
separate from the FHSCMS. The FHSESD shall ensure that the activation of an
ESD pushbutton (called ESB) results in the activation of a shutdown signal to
the Emergency Shutdown System (ESD) of the Fuel Pumping Station.
The overall configuration of the FHSESD is shown in Drawing No. SA-986-

000-P-60534.

The FHSESD system shall comprise ESBs at the aircraft stands, a number of
geographically distributed input/output units, a central unit and a high integrity
communication network, the ESD LAN, which transmits the signals from the
ESBs to the central unit.
The ESD system receives 0 - 24 V DC signals from the ESBs. The signals from
the ESB are connected to input/output units situated in equipment rooms at
suitable locations within the Airport area. They shall be transmitted over the
ESD LAN to the central unit which issues the shutdown control signal to the
ESD of the Fuel Pumping Station.
The I/O signals of the FHSESD are listed in the signal schedule, Drawing No.
SA-986-000-P-60535.
Transmission of shutdown signals

Each ESB shall comprise two signal contacts, an NC and an NO contact, which
both are connected to an input/output unit of FHSESD. The FHSESD central
unit shall activate the shutdown signal to the Fuel Pumping Station if it detects
the opening of an NC contact or the closure of an NO contact.
The transmission of a shutdown signal from the ESB to the ESD of the Fuel
Pumping Station shall be executed with a certified integrity corresponding to
SIL2 according to BS EN 61508.
The shutdown signal from the FHSESD central unit to the ESD of the Fuel
Pumping Station shall be duplicated for maximum reliability. It shall comprise
two signals which are transferred in parallel:
1 One NO contact (open when power is off) which shall be opened for
activation of shutdown.
2 One NC contact (closed when power is off) which shall be closed for
activation of shutdown.
The time elapsed between the activation of an ESB and the activation of the
shutdown signal to the ESD system of the Fuel Pumping Station shall not
exceed 4 seconds.
The FHSESD shall be fail safe so that any internal fault which threatens the
integrity of the ESD function will result in the activation of a shutdown signal
to the ESD of the Fuel Pumping Station.
The communication network shall be laid out with a redundant configuration so

that a single fault in the network - including the interruption of a cable or a
failure of a communication unit - will not compromise the ESD functionality.
Faults which disable a part of the FHSCMS (for example one input/output unit)

but do not compromise its general function shall not activate an ESD, but they
shall be communicated to the FHSCMS as described below.
Link to FHSCMS
The FHSCMS shall receive information on the state of the FHSESB through a
serial communication link. The Contractor can choose either a Modbus or a
Profibus connection for this purpose. The following information shall be
transmitted to the FHSCMS:
• Information about which ESBs have been activated (one bit per ESB). This
information shall be used for indication and for possible supplementing
automatic control actions.
• If both contacts of an ESB are open or closed, then the FHSESD shall
transmit an error bit for this ESB to the FHSCMS for diagnostic purpose.
• Information on the state of the doubled shutdown signal to the Fuel

Pumping Station (state of both the NO and the NC signal as described
above). This information is intended for test purposes as described in the
section "Suppression of ESD function" below.
• Information about faults or unavailabilities of parts of the FHSESD,

including loss of redundancy (for example interruption of the fibre optical
cable between two input/output units). This information shall be so
selective that it identifies the failed unit (for example a failed input/output
unit or a failed communication link).
Suppression of ESD function

It shall be possible to suppress the shutdown signal from the FHSESD central
unit to the Fuel Pumping Station. The suppression can be used for two different
purposes:
1 To enable a test of the FHSESD without causing a shutdown of the Fuel

Pumping Station.
2 To enable the continuation of fuel supply through the FHS in case of a

fault in the FHSESD.
The suppression shall be imposed by manual operation of a switch in the signal

circuit. The switch shall be placed in the equipment cabinet containing the
FHSESD central unit. It shall be easily accessible, clearly marked and covered
by a removable shroud in order to prevent accidental activation. The position of
the switch shall be indicated by an auxiliary contact with connection to an I/O
subsystem of the CMS.
When the suppression switch has been activated, the state of the shutdown
signals (both the NO and the NC signal) shall be communicated to the
FHSCMS.

The suppression of shutdown due to a fault in the FHSESD shall be considered

a short-time emergency measure which shall enable the continuation of fuelling
operations until the failure has been remedied. During such a suppression
period, special arrangements must be made by the Operator in order to ensure
shutdown in dangerous situations by other means.
Emergency shutdown buttons

An ESB shall be provided at each aircraft stand covering the entire fuel hydrant
system for the first phase of development (Stage 1).
The ESBs shall be placed conspicuously and easily accessible at their

respective locations:
• An ESB at a ramp tower shall be mounted on the wall of the ramp tower.
• An ESB at a location where there is no ramp tower shall be mounted on the

enclosure of the power supply board which supplies the Ground Power
Unit (GPU) and the Preconditioned Air Unit (PCA) at the respective
location.
The ESB shall be mounted in positions between 1.0 m and 1.5 m above the
standing surface in front of the ESB. The location shall be selected to prevent
accidental activation. If this is unfeasible or incompatible with the requirement
of visual exposure, the pushbutton shall be shrouded.
Each ESB shall, as a minimum comply, with the following requirements:
1 Conform to IEC 60947-5-1 or equivalent standard approved by the

Employer.
2 Be equipped with one normally open and one normally closed contact with
positive action. At least one of the contacts shall change status on
activation of the pushbutton, even in case of contact welding.
3 The contacts shall be gold plated or similarly treated to prevent build-up of

resistance in the normally closed contacts.
4 The activation mechanism shall be a mushroom-head latching pushbutton

with a diameter of min. 35 mm. Reset of an activated pushbutton shall
require operation by a key. The locks of all ESB shall be identical, i.e.
shall be released by the same key.
5 The enclosure shall be minimum IP 66 to IEC 60529.
ESB wiring system

For each ESB, both the normally open and the normally closed contact shall be
connected to an input/output unit of the FHSESD. The connection cables shall

be 4 core, min. 2.5 mm2 copper conductor, steel wire armoured cables with
heavy duty XLPE jacket.
All cables shall be installed underground, drawn into ducts under paved areas
and mechanically protected by concrete tiles or equal where directly buried.
All cables installed above ground shall run in heavy duty conduits of
galvanised or stainless steel for mechanical protection.
Availability of FHSESD
The FHSESD shall be available 99.5 % of the time on a yearly basis,
corresponding to maximum 44 hours of unavailability per year due to
maintenance, failure and repair.
The ESB system shall be considered to be available if all its parts - including
the ESBs, the input/output units, the ESD LAN and the central unit - function
correctly. Otherwise it shall considered to be unavailable.
Unavailability shall be calculated from the time when the service organisation
in charge of the FHSESD, is informed of the unavailability to the time when the
FHSESB is declared available again.
Planned tests of the FHSESD in order to check that it is still functioning

correctly, shall not be included in the availability calculation.
Reserve capacity
Each input/output unit shall be configured with hard- and software providing a
reserve capacity for connection of extra ESBs, either 20 % of the foreseen
number of ESBs according to Drawing No. SA-986-000-P-60535 or two ESBs,
whichever number is greater.
Furthermore it shall be possible to expand the number of ESBs connected to

each input/output unit up to at least 200 % of the foreseen number according to
Drawing No. SA-986-000-P-60535 by uncomplicated addition of hardware
modules in the equipment cabinet. The ESD LAN and the central unit shall be
able to function with the total number of ESBs resulting from such an
expansion for all input/output units.
It shall be possible to expand the system with at least 4 (four) additional

input/output units with a total number of ESBs which is at least 100 % of the
foreseen total number according to Drawing No. SA-986-000-P-60535.

Installation and execution of the FHSESD shall comply with the requirements
in EN BS 61508, SIL2.

The enclosures for the FHSESD equipment shall be separate from the
enclosures for the FHSCMS equipment.
The central equipment of the FHSESD shall be installed in an equipment room

which is provided by the project which implements the Fuel Farm and the
pumping station. This technical room shall also contain the central equipment
for the FHSCMS. Refer to section 3614.3.
The input/output units shall be placed in equipment rooms as specified in

Drawing No. SA-986-000-P-60535 and shall be supplied with 240VAC from a
UPS.

systems.
Testing and commissioning of the FHSESD shall comply with the requirements
systems.
Documentation of the FHSESD shall comply with the requirements in EN BS

61508, SIL2.

systems.
Operation and maintenance of the FHSESD shall comply with the requirements

Revision Log
Date Issue Description
31.10.2008 T01 Issued for Tender


SA-000-R-11136 Rev T01 3600 Fuel Hydrant Systems Spec Spec 31.10.2008

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SA-000-R-11136 Rev T01 3600 Fuel Hydrant Systems Spec Spec 31.10.2008

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Sultanate of Oman

Ministry of Transport and Communications

Report no. SA-000-R-11136

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3605 Insulating couplings 22

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3616.3 Installation and execution 64

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3600 Fuel hydrant systems

The FHS is designed to allow expansion without interrupting the supply by

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Excavation, dewatering if necessary, and backfilling works shall be included

Further there are interfaces to civil works and pavement works.

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ESB Emergency Shutdown Button

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Standard and references

API/IP 1540 Recommended Practice, Design, Construction,

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ASTM A234 Specification for piping fittings of wrought carbon

3601.2 Functional requirements and materials

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3601.3 Installation and execution

3601.4 Testing and commissioning

Requirements to hydrostatic testing with water, drying and commissioning of

Hydrostatic testing with water

The pressure leak test shall be performed at a pressure of a minimum 1.1 x

The pressure test will be witnessed by the Engineer.

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The test report shall include:

• Test programme, including longitudinal profiles and all information

• Water filling report

• Tightness report including graphs for pressure and temperature variations,

• Fault report, if applicable

• Drying report with programme, measurement of the dew point,

Dewatering and drying

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Pressure measurements of the nitrogen filled hydrant system shall be performed

The general procedures as regard testing and commissioning are described in

It shall be noted that the commissioning shall be coordinated with the

Particular requirements for the Contractor's documentation are stated in the

3601.6 Operation and Maintenance

Spare parts and special tools

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Particular requirements for the Contractors training of the Employers

3602 Piping items

3602.2 Functional requirements and materials

Materials for fittings shall be in accordance with ASTM A234-WPB.

Materials for forged fittings shall be in accordance with ASTM A105.

Materials for fittings shall be in accordance with ASTM A234-WPB.

Materials for forged fittings shall be in accordance with ASTM A105.

Hot formed bends

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For pipes in dimension DN 300 (12") and less:

3602.3 Installation and execution

3602.4 Testing and commissioning

Materials to be documented by material certificates according to EN 10204 (or

Requirements to certification, welding procedure, NDE etc. for welded

3602.6 Operation and maintenance

3603.2 Functional requirements and materials

Main block valves with electric actuator, full bore DN250

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The valve construction shall be in accordance with API 6D.