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STATE OF KUWAIT ََََََََََََََََََََََََ‫يت‬ ََََ ََََ‫دَول‬

َََََََََََََََََََََََََ ََ‫ـةَالكـََو‬
MINISTRY OF PUBLIC WORKS َ‫ََََعَاَمَة‬
‫زارةَاألشَغََالَال‬
َ ََََ ََ َ‫و‬

214 /‫العقدَرقمَهـَمَخ‬
َ‫انشاءَوانجازَوتأثيثَوصيانة‬
َ‫َمبنىَالركابَالجديد‬
َ َ)IIَ‫بمطارَالكويتَالدوليَ(المبنى‬
َ
Contract No. SPA/214
Construction, Completion, Furnishing, and Maintenance
for Kuwait International Airport
New Passenger Terminal (Terminal II)

َ ‫مستنداتَالعقد‬
Contract Documents

Document III-2 - Particular Specifications

Volume 10 of 11 (Part 2)
Division 33 - Utilities
Section 33 52 43 Aviation Fuel Distribution System

October 2015

Contracts and Documents Department ‫إدارة الوثائق والعقود‬


‫َاألشغالَالكويت‬:‫َبرقيا‬25380829َ‫َفاكس‬25385520َ‫َتليفون‬-10331َ‫ الكويت‬-َ‫ الصفاة‬8 .‫ب‬.‫ص‬
P.O. Box: 8, 13001 Safat, Kuwait –Tel: 25385520 Fax: 25380829- Cable Works Kuwait
Kuwait International Airport
The Passenger Terminal Building – Terminal-II

TABLE OF CONTENTS

DOCUMENT III-2 : PARTICULAR SPECIFICATIONS

DIVISION NO./ DESCRIPTION PAGE No.


SECTION NO.

Volume 1

DOCUMENT III-1 : GENERAL SPECIFICATIONS III-1/Page-1

DOCUMENT III-2 : PARTICULAR SPECIFICATIONS

DIVISION 1 – GENERAL REQUIREMENTS

Section 01 10 90 Special Notes, Priority of Documents Overriding Clauses etc. 01 10 90 -1 – 3 (BAD-2)


Section 01 11 00 Summary of the Work 01 11 00 -1 – 11(AD-7)
Section 01 14 00 Work Restriction 01 14 00 -1 – 7
Section 01 14 23 Safety Measures 01 14 23 - 1 – 7(AD-2)
Section 01 18 00 Project Utility Sources 01 18 00 -1 – 1(AD-7)
Section 01 26 00 Contract Modifications Procedures 01 26 00 -1 - 3
Section 01 29 00 Payment Procedures 01 29 00 -1 - 3
Section 01 31 13 Project Coordination 01 31 13- 1 - 2
Section 01 31 17 Mechanical and Electrical Coordination 01 31 17 -1 - 4
Section 01 31 19 Project Meetings 01 31 19 -1 – 3
Section 01 32 00 Construction Progress Documentation 01 32 00-1 – 12(AD-7)
Section 01 32 16 Construction Schedule & Progress Monitoring 01 32 16-1 - 10(AD-7)
Section 01 32 33 Construction Photographs 01 32 33 -1 - 2
Section 01 33 00 Submittal Procedures 01 33 00 -1 - 18(AD-7)
Section 01 33 23 Shop Drawings, Record Documents & As-Built Drawings 01 33 23 -1 - 4(AD-7)
Section 01 35 13 Building Information Model and Project Schedule Simulation 01 35 13 -1 – 9(AD-2)
Section 01 35 14 Special Conditions For Project in Kuwait Area 01 35 14 -1 – 4(AD-7)
Section 01 35 15 Project Information Management Software System (PIMSS) 01 35 15 -1 – 11(AD-7)
Section 01 35 20 Safety 01 35 20 -1 - 15
Section 01 40 00 Quality Requirements 01 40 00 -1 - 17
Section 01 41 00 Regulatory Requirements 01 41 00 -1 – 2
Section 01 42 00 Reference and Standards 01 42 00 – 1 - 7
Section 01 43 39 Mock-Ups 01 43 39 -1 - 3(AD-7)
Section 01 45 29 Testing Laboratory Services 01 45 29-1 – 5
Section 01 45 30 Field Laboratory 01 45 30 -1 – 3(AD-2)
Section 01 51 33 Temporary Telecommunications 01 51 33 -1 - 2
Section 01 52 00 Construction Facilities and Temporary Controls 01 52 00 -1 – 20
Section 01 52 13 Field Offices and Sheds 01 52 13 - 1 - 29(AD-7)
Section 01 54 00 Construction Aids 01 54 00 -1 - 5
Section 01 54 23 Scaffolding 01 54 23 -1 - 9

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SECTION NO.

Section 01 55 00 Vehicular Access & Parking 01 55 00 -1 - 2


Section 01 55 26 Traffic Control 01 55 26 -1 - 6
Section 01 56 00 Temporary Barriers and Enclosures 01 56 00 -1 - 2
Section 01 57 26 Temporary Indoor Air Quality Controls 01 57 26 -1 - 11(AD-7)
Section 01 58 00 Project Identification 01 58 00 -1 - 2
Section 01 58 16 Temporary Interior Signs 01 58 16 -1 - 1
Section 01 60 00 Product Requirements 01 60 00 -1 - 3
Section 01 71 23 Field Engineering 01 71 23 -1 - 3
Section 01 73 00 Execution 01 73 00 -1 - 4
Section 01 73 29 Cutting and Patching 01 73 29 -1 - 3
Section 01 74 00 Cleaning 01 74 00 -1 - 3
Section 01 74 19 Construction Waste Management 01 74 19 -1 - 12
Section 01 74 23 Final Cleaning 01 74 23 - 1- 2
Section 01 75 16 Start Up Procedure 01 75 16 -1 - 2
Section 01 77 00 Closeout Procedures 01 77 00 - 1 - 3
Section 01 78 00 Closeout Submittals 01 78 00 - 1 - 4
Section 01 78 23 Operation and Maintenance Data 01 78 23 -1 - 4
Section 01 78 26 Operation and Maintenance Period Duties 01 78 26 -1 - 7
Section 01 78 28 Information Technology Service Level Agreement Period Duties 01 78 28 -1 - 17
Section 01 78 36 Product Warranties and Guarantees 01 78 36 -1 - 5
Section 01 78 39 Project Record Documents 01 78 39 -1 – 2
Section 01 79 00 Demonstration and Training 01 79 00 – 1 - 6
Section 01 81 13 LEED Requirements with Appendix 01 81 13 – 1 - 19
Section 01 91 00 Commissioning 01 91 00 - 1 - 6
Section 01 91 10 Operational Readiness and Airport Transfer Duties 01 91 10 - 1 - 7

Volume 2

DIVISION 2 – EXISTING CONDITIONS

Section 02 21 00 Subsurface Utility Investigation 02 21 00-1 – 6


Section 02 21 10 Relocation and Diversion of the Existing Utilities 02 21 10 – 1 -5
Section 02 30 00 Subsurface Investigation 02 30 00 - 1 – 896

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Volume 3

Section 02 30 00 Subsurface Investigation 02 30 00 - 897 – 1737


Section 02 41 00 Demolition 02 41 00 – 1 – 3
Section 02 52 18 Hydrogen Sulphide Treatment 02 52 18 -1 - 2

Volume 4

DIVISION 3 - CONCRETE

Section 03 10 00 Concrete Forms and Accessories 03 10 00 -1 - 9


Section 03 20 00 Concrete Reinforcement 03 20 00 -1 - 6(AD-7)
Section 03 30 00 Cast-In-Place Concrete 03 30 00 -1 – 27(AD-7)
Section 03 35 00 Concrete Finishing 03 35 00 -1 - 19(AD-7)
Section 03 37 00 Cast-In-Place Concrete for Roof Structure 03 37 00 - 1 – 39(AD-2)
Section 03 38 00 Roof Structure Post Tensioning 03 38 00 – 1 – 9(AD-2)
Section 03 41 00 Structural Precast Concrete 03 41 00 - 1 – 7 (AD-7)
03 41 00 – 8 (BAD-2)
03 41 00 – 9 - 15(AD-7)
Section 03 41 01 Roof Structure Precast Concrete with CA Finish 03 41 01 -1 - 15 (AD-2)
Section 03 48 23 Concrete Bases, Foundation, Manholes Pits Etc. 03 48 23 -1 - 7(AD-7)
Section 03 49 00 Glass Fiber Reinforced Concrete (GFRC) 03 49 00 -1 - 6(AD-7)
Section 03 52 00 Lightweight Concrete Fill 03 52 00 – 1 - 3
Section 03 53 00 Concrete Topping 03 53 00 -1 - 9
Section 03 53 13 Architectural Floor Screed for Ancillary Buildings / Facilities 03 53 13 -1 - 4(AD-7)
Section 03 53 14 Self Leveling Screed for Ancillary Buildings / Facilities 03 53 14 – 1 – 3(AD-7)
Section 03 60 00 Grouting 03 60 00 – 1 – 5
Section 03 80 50 Testing of Water Retaining Structure 03 80 50 – 1 - 2

DIVISION 4 - MASONRY

Section 04 22 00 Concrete Unit Masonry 04 22 00 -1 - 19(AD-7)


Section 04 27 00 Glass Blocks for Ancillary Buildings / Facilities 04 27 00 – 1 – 4(AD-7)

DIVISION 5 - METALS

Section 05 05 13 Shop Applied Coatings for Metal 05 05 13 – 1 – 14(AD-7)


Section 05 12 00 Structural Steel 05 12 00 – 1 – 10
Section 05 12 01 Roof Structural Steel Framing 05 12 01 - 1 -26(AD-2)

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SECTION NO.

Section 05 31 00 Steel Decking 05 31 00 -1 - 6


Section 05 41 00 Structural Metal Stud Framing 05 41 00 – 1 – 53(AD-7)
Section 05 50 00 Metal Fabrications 05 50 00 -1 – 22(AD-7)
Section 05 50 50 Miscellaneous Metal Works for Ancillary Buildings / Facilities 05 50 50 -1 – 12(AD-7)
Section 05 51 00 Metal Stairs 05 51 00 – 1 – 24(AD-7)
Section 05 52 13 Pipe and Tube Railings 05 52 13 -1 – 23(AD-7)
Section 05 52 17 Railing Works for Ancillary Buildings / Facilities 05 52 17 – 1 -9(AD-7)
Section 05 73 00 Decorative Metal Railings 05 73 00 – 1 – 23(AD-7)
Section 05 75 00 Decorative Formed Metal 05 75 00 – 1 – 26(AD-7)

DIVISION 6 – WOOD, PLASTICS AND COMPOSITES

Section 06 10 00 Rough Carpentry 06 10 00 – 1 - 5


Section 06 41 00 Architectural Wood Case Work 06 41 00 -1 – 16(AD-7)
Section 06 42 16 Wood Paneling 06 42 16 – 1 – 18(AD-7)
Section 06 64 00 Plastic Panelling 06 64 00 – 1 – 8(AD-7)

DIVISION 7– THERMAL AND MOISTURE PROTECTION

Section 07 11 13 Bituminous Dampproofing 07 11 13 -1 - 4


Section 07 13 00 Sheet Waterproofing 07 13 00 -1 - 7(AD-7)
Section 07 13 13 PVC Sheet Waterproofing 07 13 13 – 1 – 8(AD-7)
Section 07 16 00 Cementitious Waterproofing 07 16 00 -1 - 5
Section 07 21 00 Thermal Insulation 07 21 00 -1 - 3
Section 07 24 00 External Insulated Finishing System Ancillary Buildings / Facilities 07 24 00 – 1 - 16(AD-7)
Section 07 42 13 Metal Wall Panels 07 42 13 – 1 – 70(AD-7)
Section 07 55 00 Composite Roofing System for Ancillary Buildings / Facilities 07 55 00 – 1 – 6(AD-7)
Section 07 61 13 Standing Seam Sheet Metal Roofing 07 61 13 – 1 – 89(AD-7)
Section 07 62 00 Flashing and Trim for Ancillary Buildings / Facilities 07 62 00 – 1 – 4(AD-7)
Section 07 70 00 Roof Accessories for Ancillary Buildings / Facilities 07 70 00 – 1 – 6(AD-7)
Section 07 81 00 Sprayed Fireproofing 07 81 00 – 1 – 11(AD-7)
Section 07 84 00 Firestopping 07 84 00 – 1 - 10
Section 07 92 00 Joint Sealants 07 92 00 -1 - 13
Section 07 95 13 Expansion Joint Cover Assemblies 07 95 13 – 1 – 6(AD-7)

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Volume 5

DIVISION 8 - OPENINGS

Section 08 11 00 Steel Doors and Frames for Ancillary Buildings / Facilities 08 11 00 -1 - 10(AD-7)
Section 08 11 13 Hollow Metal Doors and Frames 08 11 13 – 1 – 17(AD-7)
Section 08 13 00 Metal Doors 08 13 00 – 1 – 78(AD-7)
Section 08 14 16 Flush Wood Doors 08 14 16 – 1 – 16(AD-7)
Section 08 14 18 Flush Wood Doors for Ancillary Buildings / Facilities 08 14 18 – 1 – 6(AD-7)
Section 08 31 13 Access Doors and Frames 08 31 13 – 1 – 9(AD-7)
Section 08 33 23 Overhead Coiling Doors for Ancillary Buildings / Facilities 08 33 23 -1 - 5(AD-7)
Section 08 41 26 All Glass Entrances and Store Fronts 08 41 26 – 1 – 12(AD-7)
Section 08 43 24 Overhead Doors 08 43 24- 1 – 13(AD-7)
Section 08 44 13 Glazed Aluminium Curtain Walls 08 44 13 – 1 – 101(AD-7)
Section 08 44 19 Internal Glazed Steel Curtain Walls 08 44 19 – 1 – 17(AD-7)
Section 08 44 26 Structural Glass Curtain Wall (Appendix) 08 44 26 – 1 – 169(AD-7)
Section 08 52 00 Aluminium Windows for Ancillary Buildings / Facilities 08 52 00 – 1 – 10(AD-7)
Section 08 56 53 Security Windows 08 56 53 – 1 – 10(AD-7)
Section 08 63 00 Metal Framed Skylights 08 63 00 – 1 –92(AD-7)
Section 08 71 00 Door Hardware 08 71 00 – 1 – 16(AD-7)
Section 08 80 00 Glazing 08 80 00 – 1 – 19(AD-7)
Section 08 81 13 Decorative Glass Glazing 08 81 13 – 1 – 23(AD-7)
Section 08 83 00 Mirrors 08 83 00 – 1 – 8(AD-7)
Section 08 90 00 Louvers and Vents for Ancillary Buildings / Facilities 08 90 00 – 1 – 7(AD-7)
Section 08 91 19 Fixed Louvers 08 91 19 – 1 – 11(AD-7)

DIVISION 9 - FINISHES

Section 09 22 16 Non Structural Metal Framing 09 22 16 -1 – 5(AD-7)


Section 09 23 00 Gypsum Plastering 09 23 00 – 1 – 12(AD-7)
Section 09 24 00 Portland Cement Plastering 09 24 00 – 1 – 6(AD-7)
Section 09 29 00 Gypsum / Plaster Board 09 29 00 – 1 – 6(AD-7)
Section 09 29 50 Gypsum Board Ceiling for Ancillary Buildings / Facilities 09 29 50 – 1 – 7(AD-7)
Section 09 30 00 Tiling 09 30 00 – 1 – 18(AD-7)
Section 09 30 50 Floor and Wall Tiles for Ancillary Buildings / Facilities 09 30 50 – 1 – 9(AD-7)
Section 09 51 00 Mineral Fiber Ceiling Tiles for Ancillary Buildings / Facilities 09 51 00 – 1 – 6(AD-7)
Section 09 51 33 Acoustical Metal Pan Ceilings 09 51 33 – 1 – 25(AD-7)
Section 09 54 43 Stretched Fabric Ceiling System 09 54 43 – 1 – 15(AD-7)

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SECTION NO.

Section 09 62 50 Epoxy Coating 09 62 50 – 1 – 5(AD-7)


Section 09 62 53 Asphalt Flooring 09 62 53 – 1 – 11(AD-7)
Section 09 63 40 Stone Flooring 09 63 40 – 1 – 18(AD-7)
Section 09 63 50 Vanity Counter Stone Work for Ancillary Buildings / Facilities 09 63 50 -1 – 7(AD-7)
Section 09 64 00 Wood Flooring 09 64 00 – 1 – 12(AD-2)
Section 09 65 16 Resilient Sheet Flooring 09 65 16 – 1 – 13(AD-2)
Section 09 65 19 Resilient Tile Flooring 09 65 19 – 1 – 9(AD-7)
Section 09 66 16 Terrazzo Floor Tile for Ancillary Buildings / Facilities 09 66 16 – 1 – 5(AD-7)
Section 09 67 23 Resinous Flooring 09 67 23 – 1 – 11(AD-7)
Section 09 68 13 Tile Carpeting 09 68 13 – 1 – 10(AD-7)
Section 09 68 16 Sheet Carpeting 09 68 16 – 1 – 11(AD-7)
Section 09 68 50 Carpets for Ancillary Buildings / Facilities 09 68 50 – 1 – 7(AD-7)
Section 09 69 00 Access Flooring 09 69 00 – 1 – 15(AD-7)
Section 09 69 50 Raised Floor for Ancillary Buildings / Facilities 09 69 50 – 1 – 5(AD-7)
Section 09 72 00 Wall Coverings 09 72 00 -1 – 6(AD-7)
Section 09 77 23 Fabric Wrapped Panel 09 77 23 – 1 – 10(AD-7)
Section 09 84 10 Acoustical Wall Panel for Ancillary Buildings / Facilities 09 84 10 – 1 – 3(AD-7)
Section 09 91 13 Exterior Paintings 09 91 13 – 1 – 9(AD-7)
Section 09 91 23 Interior Paintings 09 91 23 – 1 – 12(AD-7)
Section 09 91 50 Paints and Coatings for Ancillary Buildings / Facilities 09 91 50 – 1 – 11(AD-7)
Section 09 96 00 High Performance Coatings 09 96 00 – 1 – 13(AD-7)
Section 09 96 13 High Performance Floor Coatings 09 96 13 – 1 – 10(AD-7)

Volume 6

DIVISION 10 - SPECIALTIES

Section 10 14 26 Panel & Totem Signage 10 14 26 – 1 – 23(AD-7)


Section 10 14 27 Signage for Ancillary Buildings / Facilities 10 14 27- 1 – 6(AD-7)
Section 10 14 28 Signage for Terminal Buildings 10 14 28- 1 – 6(AD-7)
Section 10 14 53 Traffic Signs 10 14 53 -1 – 3(AD-7)
Section 10 21 13 Toilet Compartments 10 21 13 – 1 – 13(AD-7)
Section 10 22 19 Demountable Partitions 10 22 19 – 1 – 13(AD-7)
Section 10 22 23 Portable Partitions Screens and Panels 10 22 23 – 1 – 22(AD-7)
Section 10 26 00 Wall and Door Protection 10 26 00 – 1 – 8(AD-7)
Section 10 28 00 Toilet, Bath and Laundry Accessories 10 28 00 - 1 – 7(AD-7)
Section 10 28 10 Toilet Accessories for Ancillary Buildings / Facilities 10 28 10 – 1 – 4(AD-7)
Section 10 44 00 Fire Protection Specialties 10 44 00 - 1 - 4(AD-7)

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SECTION NO.

Section 10 50 00 Lockers for Ancillary Buildings / Facilities 10 50 00 – 1 – 4(AD-7)


Section 10 67 00 Pantry Cabinets for Ancillary Buildings / Facilities 10 67 00 -1 – 5(AD-7)
Section 10 67 13 Kitchen Cabinets 10 67 13 - 1 – 7(AD-7)

DIVISION 11 – EQUIPMENT

Section 11 24 00 Maintenance Equipment – External Envelope 11 24 00 -1 – 24(AD-7)


Section 11 24 13 Internal Access and Maintenance 11 24 13-1 – 10 (AD-7)
Section 11 82 13 Airside Solid Waste Bins 11 82 13 - 1 – 3(AD-2)

DIVISION 12 – FURNISHINGS

Section 12 21 13 Roll Down Blinds 12 21 13- 1 – 42(AD-7)


Section 12 36 40 Vanity Counter Tops 12 36 40 - 1 – 5
Section 12 48 13 Entrance Floor Mats and Frames 12 48 13- 1- 9(AD-7)
Section 12 48 50 Entrance Mats for Ancillary Buildings / Facilities 12 48 50 – 1 – 2(AD-7)
Section 12 51 83 Custom Office Furniture 12 51 83 -1 – 35(AD-7)
Section 12 55 00 Proprietary Furniture 12 55 00 – 1 – 15(AD-7)
Section 12 93 00 Site Furnishings 12 93 00 – 1 – 9(AD-7)

DIVISION 13 - SPECIAL CONSTRUCTION

Section 13 10 00 Water Features 13 10 00 -1 – 14(AD-7)


Section 13 12 00 Water Feature –Fall & Fountain 13 12 00 – 1 – 5(AD-7)
Section 13 22 00 Safe Area 13 22 00 - 1 - 23(AD-7)
Section 13 31 00 Parking Shade Fabric Structure 13 31 00 – 1 – 13(AD-7)

DIVISION 14 - CONVEYING EQUIPMENT

Section 14 00 00 Conveying Equipment 14 00 00 -1 – 38(AD-7)


Section 14 21 00 Electric Traction Elevators 14 21 00 -1 – 17(AD-7)
Section 14 26 00 Vertical Carousels for Movement of Baggage Trolleys 14 26 00 – 1 – 7(AD-7)
Section 14 31 00 Escalators 14 31 00 -1 – 13(AD-7)
Section 14 32 00 Moving Walkways 14 32 00 -1 – 16(AD-7)

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SECTION NO.

DIVISION 21 - FIRE SUPRESSION

Section 21 00 00 Fire Suppression 21 00 00 -1 – 11(AD-7)


Section 21 05 00 Common Work Results for Fire Suppression 21 05 00 -1 - 09 (AD-7)
Section 21 05 13 Common Motor Requirements for Fire Suppression Equipment 21 05 13 -1 - 10(AD-7)
Section 21 05 16 Expansion Fittings and Loops for Fire Suppression Piping 21 05 16 -1 - 03(AD-7)
Section 21 05 29 Hangers and Supports for Fire Suppression Piping & Equipment 21 05 29 -1 - 15(AD-7)
Section 21 05 48 Vibration and Seismic Control for Fire Suppression
Pipe and Equipment 21 05 48 -1 - 08 (AD-7)
Section 21 05 53 Identification for Fire Suppression Piping and Equipment 21 05 53 -1 - 06(AD-7)
Section 21 08 00 Commissioning of Fire Suppression 21 08 00 -1 - 12(AD-7)
Section 21 11 00 Facility Fire Suppression Water Service Piping 21 11 00 -1 - 17(AD-7)
Section 21 12 00 Fire Suppression Standpipes 21 12 00 -1 - 06(AD-7)
Section 21 13 13 Wet Pipe Sprinkler Systems 21 13 13 -1 - 12(AD-7)
Section 21 13 39 Foam Water Systems 21 13 39 -1 - 12(AD-7)
Section 21 22 00 Clean Agent Fire Extinguishing Systems 21 22 00 -1 - 14(AD-7)
Section 21 30 00 Fire Pumps 21 30 00 -1 - 15(AD-7)

DIVISION 22 - PLUMBING

Section 22 00 00 Plumbing 22 00 00 -1 - 12(AD-7)


Section 22 05 00 Common Work Results for Plumbing 22 05 00 -1 - 13(AD-7)
Section 22 05 13 Common Motor Requirements for Plumbing Equipment 22 05 13 -1 - 18(AD-7)
Section 22 05 16 Expansion Fittings and Loops for Plumbing Piping 22 05 16 -1 - 06(AD-7)
Section 22 05 19 Meter and Gauges for Plumbing Piping 22 05 19 -1 - 08(AD-7)
Section 22 05 29 Hangers and Supports for Plumbing Piping and Equipment 22 05 29 -1 - 15(AD-7)
Section 22 05 48 Vibration and Seismic Control for Plumbing Piping & Equipment 22 05 48 -1 - 05(AD-7)
Section 22 05 53 Identification for Plumbing Piping and Equipment 22 05 53 -1 - 07(AD-7)
Section 22 07 00 Plumbing Insulation 22 07 00 -1 - 08(AD-7)
Section 22 08 00 Commissioning of Plumbing 22 08 00 -1 - 14(AD-7)
Section 22 11 16 Domestic Water Piping 22 11 16 -1 – 14(AD-7)
Section 22 11 19 Domestic Water Piping Specialties 22 11 19 -1 - 07(AD-7)
Section 22 11 23 Domestic Water Pumps 22 11 23 -1 - 09(AD-7)
Section 22 11 30 Aircraft Potable Water Supply System 22 11 30 -1 – 13(AD-2)
Section 22 11 35 Aircraft Potable Water and PCA - Pit Assemblies 22 11 35 -1 – 15(AD-2)
Section 22 12 00 Facility Potable Water Storage Tanks 22 12 00 -1 - 9(AD-7)
Section 22 13 16 Sanitary Waste and Vent Piping 22 13 16 -1 - 12(AD-7)
Section 22 13 19 Sanitary Waste Piping Specialties 22 13 19 -1 - 13(AD-7)

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SECTION NO.

Section 22 13 29 Sanitary Sewerage Pumps 22 13 29 -1 - 05(AD-7)


Section 22 13 70 Aircraft Sanitary Sewer Vacuum System 22 13 70 -1 – 14(AD-2)
Section 22 13 75 Aircraft Sanitary Sewer - Pit Assemblies 22 13 75 -1 – 13(AD-2)
Section 22 13 80 Aircraft Blue Water System 22 13 80 -1 – 13(AD-2)
Section 22 14 13 Facility Storm Drainage Piping 22 14 13 -1 - 10(AD-7)
Section 22 14 23 Storm Drainage Piping Specialties 22 14 23 -1 - 2(AD-7)
22 14 23 -3(BAD-2)
22 14 23 -4 - 7(AD-7)
Section 22 14 29 Sump Pumps 22 14 29 -1 - 08(AD-7)
Section 22 15 00 Compressed Air System 22 15 00 -1 - 14(AD-7)
Section 22 32 00 Domestic Water Filtration Equipment 22 32 00 -1 - 06(AD-7)
Section 22 33 00 Electric Water Heaters 22 33 00 -1 - 05(AD-7)
Section 22 33 30 Solar Water Heating System 22 33 30 -1 - 14(AD-7)
Section 22 42 00 Commercial Plumbing Fixtures 22 42 00 – 1 – 22 (AD-7)

Volume 7

DIVISION 23 - HEATING, VENTILATING, AND AIR-CONDITIONING

Section 23 00 00 Heating, Ventilating, and Air-Conditioning (HVAC) 23 00 00 -1 - 31(AD-7)


Section 23 05 00 Common Work Results for HVAC 23 05 00 -1 - 08(AD-7)
Section 23 05 13 Common Motor Requirements for HVAC Equipment 23 05 13 -1 - 19(AD-7)
Section 23 05 16 Expansion Fittings and Loops for HVAC Piping 13 05 16 -1 - 05(AD-7)
Section 23 05 19 Meters and Gages for HVAC Piping 23 05 19 -1 - 08(AD-7)
Section 23 05 23 General Duty Valves for HVAC Piping 23 05 23 -1 - 13(AD-7)
Section 23 05 29 Hangers and Supports for HVAC Piping and Equipment 23 05 29 -1 - 13(AD-7)
Section 23 05 48 Vibration & Seismic Controls for HVAC Piping and Equipment 23 05 48 -1 - 13(AD-7)
Section 23 05 53 Identification for HVAC Piping and Equipment 23 05 53 -1 - 06(AD-7)
Section 23 05 93 Testing, Adjusting and Balancing for HVAC 23 05 93 -1 - 19(AD-7)
Section 23 07 13 Duct Insulation 23 07 13 -1 - 08(AD-7)
Section 23 07 16 HVAC Equipment Insulation 23 07 16 -1 - 05(AD-7)
Section 23 07 19 HVAC Piping Insulation 23 07 19 -1 - 07(AD-7)
Section 23 08 00 Commissioning of HVAC 23 08 00 -1 - 03(AD-7)
Section 23 09 00 Instrumentation and Controls for HVAC 23 09 00 -1 - 19(AD-7)
Section 23 09 23 Direct Digital Control System for HVAC 23 09 23 -1 - 18(AD-7)
Section 23 21 13 Hydronic Piping 23 21 13 -1 - 20(AD-7)
Section 23 21 16 Hydronic Specialties 23 21 16 -1 - 11(AD-7)
Section 23 21 23 Hydronic Pumps 23 21 23 -1 - 11(AD-7)
Section 23 23 00 Refrigerant Piping 23 23 00 -1 - 11(AD-7)

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Section 23 25 00 HVAC Water Treatment 23 25 00 -1 - 14(AD-7)


Section 23 31 00 HVAC Ducts and Casing 23 31 00 -1 - 12(AD-7)
Section 23 31 16 Pre-insulated HDPE Pipe for HVAC Buried Ducting 23 31 16 -1 – 18(AD-2)
Section 23 33 00 Air Duct Accessories 23 33 00 -1 - 09(AD-7)
Section 23 33 19 Duct Silencers 23 33 19 -1 - 07(AD-7)
Section 23 34 00 HVAC Fans 23 34 00 -1 - 14(AD-7)
Section 23 34 23 HVAC Power Ventilators 23 34 23 -1 - 12(AD-7)
Section 23 34 33 Air Curtains 23 34 33 -1 - 05(AD-7)
Section 23 34 43 Fire Ventilators 23 34 43 -1 - 10(AD-7)
Section 23 34 53 Smoke Curtains 23 34 53 -1 - 05(AD-7)
Section 23 36 00 Air Terminals Units 23 36 00 -1 - 07(AD-7)
Section 23 37 00 Air Outlets and Inlets 23 37 00 -1 – 3 (AD-7)
23 37 00 -4 (BAD-2)
23 37 00 -5 – 9 (AD-7)
Section 23 40 00 HVAC Air Cleaning Devices 23 40 00 -1 - 10(AD-7)
Section 23 64 16 Centrifugal Water Chillers 23 64 16 -1 - 24(AD-7)
Section 23 64 17 Centrifugal Water chillers for Aircraft PCA 23 64 17 -1 – 17(AD-2)
Section 23 64 26 Air Cooled Liquid Chillers 23 64 26 -1 - 12(AD-7)
Section 23 65 00 Cooling Towers 23 65 00 -1 - 13(AD-7)
Section 23 72 00 Energy Recovery Equipment 23 72 00 -1 - 11(AD-7)
Section 23 73 18 Air Handling Units for Aircraft PCA 23 73 18 -1 – 19(AD-2)
Section 23 74 13 Air Handling Units 23 74 13 -1 - 17(AD-7)
Section 23 81 19 Self-Contained Air Conditioners 23 81 19 -1 - 08(AD-7)
Section 23 82 16 Air Coils 23 82 16 -1 - 06(AD-7)
Section 23 82 19 Fan Coil Units 23 82 19 -1 - 06(AD-7)

Volume 8

DIVISION 25 – INTEGRATED AUTOMATION

Section 25 50 00 Integrated Automation Facility Controls 25 50 00 -1 – 72(AD-7)


Section 25 90 00 Integrated Automation Control Sequences 25 90 00 -1 – 100(AD-7)

DIVISION 26 - ELECTRICAL

Section 26 00 00 General Provision for Electrical Installation 26 00 00 -1 – 17(AD-7)


Section 26 01 00 Basic Materials and Methods 26 01 00 -1 – 3(AD-7)
Section 26 05 10 Wiring Devices 26 05 10 -1 – 6(AD-7)
Section 26 05 13 Medium Voltage Cables 26 05 13 -1 – 7(AD-7)
Section 26 05 15 Wires and Cables 26 05 15 -1 – 11(AD-7)

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SECTION NO.

Section 26 05 26 Earthing System (Grounding and Bonding) 26 05 26 -1 – 5(AD-7)


Section 26 05 29 Hangers and Support for Electrical Systems 26 05 29 -1 – 4(AD-7)
Section 26 05 33 Conduits (Raceway and Boxes) 26 05 33 -1 (AD-7)
26 05 33 -2 (BAD-2)
26 05 33 -3 – 7 (AD-7)
Section 26 05 36 Cable Trays 26 05 36 -1 – 4(AD-7)
Section 26 05 39 Trunking (Under Floor Raceway) 26 05 39 -1 – 10(AD-7)
Section 26 05 53 Identification for Electrical Systems 26 05 53 -1 – 5(AD-7)
Section 26 09 13 Power Management System 26 09 13 -1 – 63(AD-7)
Section 26 09 43 Lighting Control System 26 09 43 -1 – 17(AD-7)
Section 26 11 13 Switching Sub-stations 26 11 13 -1 – 63(AD-7)
Section 26 11 16 Secondary Unit Substation 26 11 16-1 – 14
Section 26 12 16 Dry Type Transformers 26 12 16 -1 – 11
Section 26 13 00 High Voltage Switchgear 26 13 00 -1 – 2 (AD-7)
26 13 00 -3 (BAD-2)
26 13 00 -4 – 15 (AD-7)
Section 26 14 00 Switch Fuse, Disconnectors and Fuse-Combination Units 26 14 00 -1 – 4(AD-7)
Section 26 23 13 Synchronizing Panels For LV Systems 26 23 13 -1 – 5(AD-7)
Section 26 24 00 Capacitor Banks 26 24 00 -1 – 25
Section 26 24 16 Panels and Boards 26 24 16 -1 – 3 (AD-7)
26 24 16 -4 (BAD-2)
26 24 16 -5 – 10 (AD-7)
Section 26 25 00 Busbar Trunking 26 25 00 -1 – 5(AD-7)
Section 26 25 10 Lighting Busway 26 25 10 -1 – 4(AD-7)
Section 26 26 00 Distribution Boards 26 26 00 -1 (AD-7)
26 26 00 -2 (BAD-2)
26 26 00 -3 – 5 (AD-7)
Section 26 31 00 Solar Photovoltaic System 26 31 00 -1 – 16(AD-7)
Section 26 32 13 Diesel Generator 26 32 13 -1 - 19(AD-7)
Section 26 33 23 Central Battery System 26 33 23 -1 - 6(AD-7)
Section 26 33 53 Uninterruptible Power System 26 33 53 -1 - 22(AD-7)
Section 26 33 54 Rack Mount UPS 26 33 54 -1 - 5(AD-7)
Section 26 36 23 Automatic Transfer Switch 26 36 23 -1 - 10(AD-7)
Section 26 41 00 Lightning Protection System 26 41 00 -1 - 7(AD-7)
Section 26 50 00 Lighting 26 50 00 -1 - 6(AD-7)
Section 26 51 00 Lighting Fittings 26 51 00 -1 - 91(AD-7)
Section 26 56 00 Exterior Lighting 26 56 00 - 1 – 12(AD-2)
Section 26 56 10 Apron Flood Lighting 26 56 10 - 1 -10(AD-2)
Section 26 56 20 Visual Docking Guidance System 26 56 20 - 1 – 13(AD-2)
Section 26 56 25 Poles and Masts 26 56 25 -1 – 8(AD-2)
Section 26 56 30 Aircraft Ground Power Unit – Pit Assemblies 26 56 30 - 1 – 14(AD-2)
Section 26 56 31 Aircraft Ground Power Unit – 400 Hz Converters 26 56 31 - 1 – 9(AD-2)
Section 26 60 90 Schedule of Points Summary 26 60 90 - 1 – 2

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SECTION NO.

Volume 9

DIVISION 27 - COMUNICATIONS

Section 27 05 00 Common Work Results for Communications 27 05 00 - 1 –38(AD-2)


Section 27 05 01 Common Work Results for Control and Operation Center 27 05 01 – 1 –17(AD-2)
Section 27 05 26 Grounding and Bonding for Communications Systems 27 05 26 -1 – 12(AD-2)
Section 27 11 00 Communication Equipment Room Fittings 27 11 00 -1 – 38(AD-2)
Section 27 13 00 Communication Backbone Cabling 27 13 00 – 1 – 23(AD-2)
Section 27 15 00 Communication Horizontal Cabling 27 15 00 – 1 – 27(AD-2)
Section 27 17 50 Communication Active Cable Management System 27 17 50 – 1 – 22(AD-2)
Section 27 17 60 Communication Service Charging System 27 16 60 – 1 – 18(AD-2)
Section 27 21 00 Data Communication Network Equipment 27 21 00 – 1 – 22(AD-2)
Section 27 21 13 Data Communications Firewalls 27 21 13 – 1- 13(AD-2)
Section 27 21 26 Data Communications Network Management 27 21 26 – 1- 14(AD-2)
Section 27 21 33 Data Communication Wireless Access Points 27 21 33 – 1 – 17(AD-2)
Section 27 22 00 Data Communication Hardware 27 22 00 – 1 – 26(AD-2)
Section 27 22 16 Data Communications Storage Area Network 27 22 16 -1 – 15(AD-2)
Section 27 31 00 Telephone System 27 31 00 – 1 – 20(AD-2)
Section 27 31 20 Public Safety Wireless System and Network 27 31 20 -1 – 15(AD-2)
Section 27 31 30 Mobile Telephone System and Network 27 31 30 – 1 – 16(AD-2)
Section 27 31 40 Distributed Antenna System 27 31 40 -1 – 13(AD-2)
Section 27 41 33 Multimedia Distribution System 27 41 33 – 1 – 13(AD-2)
Section 27 42 10 Dynamic Display System 27 42 10 – 1 – 34(AD-2)
Section 27 42 11 Electronic Displays 27 42 11 – 1 – 17(AD-2)
Section 27 42 20 Baggage Reconciliation System 27 42 20 – 1 – 23(AD-2)
Section 27 42 30 Common Use Passenger Processing System 27 42 30 – 1 – 23(AD-2)
Section 27 42 31 Common Use Self Service 27 42 31 – 1- 20(AD-2)
Section 27 42 32 Self Service Baggage Drop 27 42 32 – 1 – 21(AD-2)
Section 27 42 33 Self Service Boarding Gates 27 42 33 -1 – 17(AD-2)
Section 27 42 34 Local Departure Control System 27 42 34 - 1 – 19(AD-2)
Section 27 42 35 Travel Document Authorization System 27 42 35 -1 – 18(AD-2)
Section 27 42 36 Automated Boarder Control 27 43 36 – 1 – 25(AD-2)
Section 27 42 40 Airport Operational database 27 42 40 -1 – 25(AD-2)
Section 27 42 41 Information Broker 27 42 41 – 1 – 26(AD-2)
Section 27 42 50 Resource Management System 27 42 50 -1 – 19(AD-2)
Section 27 42 60 Information Kiosk 27 42 60 – 1 – 19(AD-2)
Section 27 42 70 Message Distribution System 27 42 70 – 1 – 13(AD-2)

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DIVISION NO./ DESCRIPTION PAGE No.


SECTION NO.

Section 27 42 80 Baggage Labelling and Tracking System 27 42 80 – 1 – 9(AD-2)


Section 27 51 16 Public Address and Mass Notification System 27 51 16 – 1 – 22(AD-2)
Section 27 51 17 Automated Voice Announcement System 27 51 17 – 1 – 11(AD-2)
Section 27 53 13 Clock System 27 53 13 – 1 – 14(AD-2)

Volume 10 (Part-A)

DIVISION 28 – ELECTRICAL SAFETY AND SECURITY

Section 28 05 00 Common Work Result for Electronic Safety and Security 28 05 00 - 1 - 33(AD-2)
Section 28 11 00 Security Management information System 28 11 00 – 1 – 30(AD-2)
Section 28 13 00 Security Access Control System 28 13 00 – 1 – 27(AD-2)
Section 28 13 10 Car Park Access Control System 28 13 10 – 1 – 3(AD-7)
Section 28 23 00 Video Surveillance System 28 23 00 – 1 – 23(AD-2)
Section 28 31 63 Fire Alarm & Detection System 28 31 63 -1 – 16(AD-7)
Section 28 33 00 Passenger and Baggage Screening System 28 33 00 – 1 - 14(AD-2)
Section 28 33 10 Hold Baggage Screening 28 33 10 – 1 - 12(AD-2)

DIVISION 31 - EARTHWORK

Section 31 00 00 Earthwork in Excavation, Fill and Disposal 31 00 00- 1 -6(AD-7)


Section 31 10 16 General Requirements of Earthwork and Site Preparation 31 10 16 – 1 – 10
Section 31 11 00 Clearing and Grubbing 31 11 00 - 1 -4(AD-2)
Section 31 22 19 Finish Grading 31 22 19 -1 – 1
Section 31 22 23 Area Grading 31 22 23 -1 – 2(AD-2)
Section 31 23 16 Excavation and Fill 31 23 16 - 1 – 9(AD-2)
Section 31 23 19 Dewatering 31 23 19 -1 – 2
Section 31 23 33 Trenching & Backfilling 31 23 33 - 1 - 3(AD-2)
Section 31 25 13 Sedimentation Control with Appendix 31 25 13 – 1 – 60(AD-7)
Section 31 31 16 Termite Control 31 31 16 – 1 – 3
Section 31 41 00 Earthwork Support (Shoring) 31 41 00 – 1 – 3
Section 31 66 13 Secant Pile Walls 31 66 13 – 1 - 13

DIVISION 32 – EXTERIOR IMPROVEMENTS

Section 32 01 90 Landscape Works 32 01 90 -1 - 4(AD-7)


Section 32 01 95 Landscape Maintenance 32 01 95 – 1 – 11(AD-7)
Section 32 05 43 Availability of Materials 32 05 43 -1 - 1(AD-2)

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DIVISION NO./ DESCRIPTION PAGE No.


SECTION NO.

Section 32 05 53 Construction Water 32 05 53 – 1 – 2(AD-2)


Section 32 11 16 Aggregate Sub-Base Courses 32 11 16 – 1 – 6(AD-2)
Section 32 11 23 Crushed Aggregate Base Course 32 11 23 – 1 – 7(AD-2)
Section 32 11 33 Portland Cement Stabilized Base Course 32 11 33 – 1 – 8(AD-2)
Section 32 12 16 Road Paving 32 12 16 – 1 – 2
Section 32 13 13 Portland Cement Concrete Pavement 32 13 13 – 1 – 24(AD-2)
Section 32 13 14 Concrete Paving Surface Treatment 32 13 14 -1 - 3(AD-2)
Section 32 13 74 Fuel Resistant Concrete Paving Joint sealant 32 13 74 – 1 – 3(AD-2)
Section 32 14 16 Interlocking Precast Concrete Unit Paving 32 14 16 – 1 – 4(AD-2)
Section 32 15 00 Aggregate Surfacing (Top Dressing) 32 15 00 – 1 – 2(AD-7)
Section 32 16 14 Precast Concrete Kerbs 32 16 14 – 1 – 3
Section 32 16 30 Concrete Curbs and Border Stones 32 16 30 – 1 – 2(AD-2)
Section 32 17 20 Airside Pavement Marking 32 17 20 – 1 – 8(AD-2)
Section 32 17 23 Roadway and Parking marking 32 17 23 – 1 – 2(AD-7)
Section 32 31 13 High Security Chain Link Fences and Gates 32 31 13 – 1 – 6(AD-7)
Section 32 31 15 Site Hoarding 32 31 15 -1 – 5(AD-7)
Section 32 80 00 Irrigation 32 80 00 -1 – 25(AD-7)
Section 32 90 00 Planting Procedure and Material 32 90 00 – 1 – 5
Section 32 91 00 Soil Preparation and Soil Mixes 32 91 00 – 1 – 4(AD-7)
Section 32 93 00 Plants 32 93 00 – 1 – 4
Section 32 93 01 Plant Procurement and Delivery 32 93 01 – 1 – 6(AD-7)
Section 32 95 00 Vegetated Roof Assemblies 32 95 00 – 1 – 9(AD-7)

DIVISION 33 – UTILITIES

Section 33 05 22 Microtunneling 33 05 22 -1 – 11(AD-7)


Section 33 11 13 Water Utility Distribution Piping 33 11 13 -1 – 16(AD-7)
Section 33 11 14 Fresh Water Utilities Piping (For External Use) 33 11 14 – 1 – 26(AD-7)
Section 33 12 19 Water Utility Distribution Fire Hydrants 33 12 19 -1 – 06(AD-7)
Section 33 30 00 Sanitary Sewerage Utilities 33 30 00 -1 – 14(AD-7)
Section 33 30 01 Sanitary Sewerage Utilities (For External Use) 33 30 01 -1 – 21(AD-7)
Section 33 40 00 Storm Drainage Utilities 33 40 00 -1 – 11(AD-7)
Section 33 40 01 Storm Drainage Utilities (For External Use) 33 40 01 -1 – 24(AD-7)
Section 33 40 33 Storm Water Detention Tank 33 40 33 - 1- 4(AD-7)
Section 33 40 50 Treated Sewerage Effluent (TSE) Lines 33 40 50 – 1- 26(AD-7)
Section 33 41 15 Un-plasticized Polyvinyl Chloride (UPVC) Pipe 33 41 15 – 1 - 5(AD-2)
Section 33 42 18 Pipes for Storm Sewers and Foul Water Lines 33 42 18 – 1 - 7(AD-2)
Section 33 42 20 Pipes for Storm Water Line 33 42 20 – 1- 5(AD-7)
Section 33 44 19 Storm Water Treatment Lines 33 40 50 – 1- 23(AD-7)

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DIVISION NO./ DESCRIPTION PAGE No.


SECTION NO.

Section 33 46 23 Drainage Mat 33 46 23 – 1- 3(AD-7)


Section 33 46 26 Geotextile Drainage Filtration 33 46 26 – 1 – 3(AD-7)
Section 33 49 13 Storm Drainage Manholes, Inlets and Pits, Etc. 33 49 13 – 1 - 7(AD-7)
Section 33 49 16 Storm Drainage Manhole, Frame, Covers, etc.
in Service Utilities Corridor 33 49 16 – 1 – 5(AD-7)
Section 33 49 23 Concrete Surface Drain with Gratings inside
Service Utilities Corridor 33 49 23 – 1 – 4(AD-7)
Section 33 49 33 Concrete Surface Drain with Gratings 33 49 33 – 1 - 5(AD-2)
Section 33 52 00 Liquid Fuel Distribution 33 52 00 -1 – 21(AD-7)
Section 33 71 19 Underground Ducts 33 71 19 – 1 - 4(AD-7)

Volume 10 (Part-B)

Section 33 52 43 Aviation Fuel Distribution System 679 Pages

Volume 11

DIVISION 34 – TRANSPORTATION

Section 34 41 15 Traffic Signals and Signboards 34 41 15 – 1 – 3(AD-2)


Section 34 43 13 Airfield Signals 34 43 13 – 1 – 15(AD-2)
Section 34 43 26 Airfield Control Equipment 34 43 26 -1 – 10(AD-2)
Section 34 71 13 Beam Type Guard Rails 34 71 13 – 1 – 4(AD-7)
Section 34 71 14 Concrete Vehicle Barriers 34 71 14 -1 – 2(AD-2)
Section 34 71 19 Steel Protection Bollards 34 71 19 -1 - 2(AD-7)
Section 34 77 13 Passenger Boarding Bridges 34 77 13 – 1 – 37(AD-2)
Section 34 77 16 Baggage handling System with Appendix 34 77 16 – 1 – 124(AD-2)

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT

Section 41 22 00 Cranes and Hoists 41 22 00 -1 – 19(AD-7)

DIVISION 44 - POLLUTION AND WASTE CONTROL EQUIPMENT

Section 44 41 00 Grey Water Treatment Plants 44 41 00 -1 – 13(AD-7)


Section 44 41 01 Reverse Osmosis Treatment Plant 44 41 01 -1 – 12(AD-7)

October, 2015 Table of Contents TOC – 15/C


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

No. of
DOCUMENT NUMBER TITLE Rev.
Sheets
TENDER PACKAGE

TENDER DOCUMENTS
11775-SOW-EN-001 Construction Scope of Work 28 2
GENERAL

GENERAL
11775-DBM-EN-001 Design Basis Memorandum 23 0
11775-LST-EN-001 Codes and Standards List 9 0
PIPELINE

SPECIFICATIONS
11775-SPC-PL-001 Specification for Linepipe 24 0
11775-SPC-PL-002 Specification for Pipeline Forged Bends 10 0
Specification for Factor y Applied Polyethylene
11775-SPC-PL-003 16 0
Coating of Line Pipe
11775-SPC-PL-004 Specification for Cold Applied Tape Coating 6 0
11775-SPC-PL-005 Specification for Factory Applied Internal Lining 11 0
11775-SPC-PL-006 Specification for Heat Shrink Sleeves 12 0
Specification for Factory Applied Liquid Coating of
11775-SPC-PL-007 9 0
Fittings
MECHANICAL / PIPING

PIPING SCHEDULES / MTO / LIST / PROCEDURE


11775-SCH-ME-001 Tie-In Schedule 3 1
11775-SCH-ME-002 Valve schedule 11 0
11775-LST-ME-001 Line List 4 0
11775-PRC-ME-001 Tie-in Procedure 9 0
11775-MTO-ME-001 MTO for Mechanical Material 5 2
SPECIFICATIONS
11775-SPC-ME-001 Specification for Piping Materials 16 0
11775-SPC-ME-002 Specification for General Valves 8 1
11775-SPC-ME-003 Specification for Field Welding 18 0
11775-SPC-ME-004 Specification for Mechanical & Piping Installation 16 1
Specification for Cleaning, Testing and Drying of
11775-SPC-ME-005 23 0
Hydrant Pipework
Specification for the Installation of Buried Hydrant
11775-SPC-ME-006 23 0
Pipelines
11775-SPC-ME-007 Specification for Adaptors 5 0
11775-SPC-ME-008 Specification for Hydrant Pit Assemblies 6 0
Specification for the Storage, Handling and
11775-SPC-ME-009 8 0
Transport of Line Pipe and Fittings
11775-SPC-ME-011 Specification for Paint Works 28 0
DATA SHEETS
Data Sheet for Reduced Bore ‘Floating Ball’ Valves
11775-DAT-ME-001 3 0
- Class 150 RF - 2" to 12"
Data Sheet for Ball Valves - Class 150/800 - ½" to
11775-DAT-ME-002 3 0
1½ "
11775 Index List – Document only AD-2
9 March 2014 Page 1 of 3
DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

No. of
DOCUMENT NUMBER TITLE Rev.
Sheets
11775-DAT-ME-003 Data Sheet for Wafer Check Valve - CL150 3 0
Data Sheet for Lugged Pattern Butterfly Valve -
11775-DAT-ME-005 3 1
CL150
INSTRUMENTATION AND CONTROL

SPECIFICATIONS
11775-SPC-IN-001 Specifications for Field instruments 13 0
11775-SPC-IN-002 Specifications for Leak detection system 10 0
11775-SPC-IN-003 Specifications for Control System modification 14 0
11775-SPC-IN-004 Specifications for Fibre optic cable 9 0
11775-SPC-IN-005 Specifications for Instrument cable 9 0
11775-SPC-IN-006 Specifications for MOV Valves 16 0
11775-SPC-IN-007 Specification for RTU 14 0
DATA SHEETS
11775-DAT-IN-001 Data Sheets for Field instruments 10 0
11775-DAT-IN-002 Data Sheets for Fibre optic cables 3 0
11775-DAT-IN-003 Data Sheets for Instrument cables 4 0
11775-DAT-IN-004 Data Sheets for MOV & ESD Valves 6 0
11775-DAT-IN-005 Data Sheets for ESD Push Buttons 6 0
11775-DAT-IN-006 Data Sheets for Pressure Relief Valves 5 0
11775-DAT-IN-007 Data Sheets for GWR Level Transmitter 5 0
SCHEDULES / MTO
11775-SCH-IN-001 Instrument schedule 8 1
11775-SCH-IN-002 I/O schedule 8 1
11775-SCH-IN-003 Instrument JB Schedule 2 0
11775-SCH-IN-004 Instrument Cable Schedule 5 0
11775-MTO-IN-001 Instrument MTO 3 1
ELECTRICAL
SCHEDULES / MTO
11775-SCH-EL-002 Panel schedules - MOV DB 8 0
11775-SCH-EL-003 LV cable feeder schedule 2 0
11775-MTO-EL-001 Electrical MTO 5 1
SPECIFICATIONS
11775-SPC-EL-001 Specification for Electrical Cable 7 0
11775-SPC-EL-002 Specification for Electrical installations 16 0
11775-SPC-EL-003 Specification for Electrical Bulk Material 13 0
11775-SPC-EL-004 Specification for Distribution boards 8 0
DATA SHEETS
11775-DAT-EL-001 Data Sheets for Cables 4 0
11775-DAT-EL-002 Data Sheets for Distribution boards 4 0
CIVIL & STRUCTURAL

SPECIFICATIONS
11775-SPC-CI-001 Civil Works Specifications 68 0
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9 March 2014 Page 2 of 3
DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

No. of
DOCUMENT NUMBER TITLE Rev.
Sheets
MTO
11775-MTO-CI-001 Civil / Structural MTO 6 A
CATHODIC PROTECTION
SPECIFICATIONS
11775-SPC-CP-001 Specification for Materials 16 0
11775-SPC-CP-002 Specification for Installation 10 0
OTHERS
List of
11775-LST-01-001 contractors, Vendors and Suppliers For Aviation 7 0
Fuelling Package AD-1

11775 Index List – Document only AD-2


9 March 2014 Page 3 of 3
Design of New
Hydrant System
(Package #7)

Codes and
Standards List
Head Office:
Penspen Group Limited
3 Water Lane
Richmond upon Thames
Surrey
TW9 1TJ
United Kingdom
Kuwait Aviation Fuelling Co
Regional Office:
Penspen International Limited
P.O. Box 46562
Abu Dhabi
United Arab Emirates

11775-LST-EN-001 Rev 0
DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

1. Introduction

1.1 Purpose

The New Hydrant System and associated facilities will be designed in accordance
with the latest issued International Codes and Standards as listed below and in
accordance with the specific standards as mentioned in each section of the Design
Basis.

Should the Contractor wish to propose equivalent alternative codes and standards
then it shall be the Contractors responsibility to demonstrate to KAFCO how the
proposed code/standard is equivalent, or more stringent, than the listed
code/standard.

KAFCO reserves the right to reject any proposed alternative code without the
provision of a reason for the rejection.

1.2 Definitions

The following definitions apply in this Document:

Company Kuwait Aviation Fuelling Company. Responsible for supplying


fuel to aircraft at Kuwait International Airport and tendering of
procurement and construction packages.

Consultant The Consultant employed by KAFCO to provide consultancy


services including design and preparation of ITB
documentation for the project.

Contractor The Contractor employed by KAFCO to undertake the


construction of the project.

2. International Codes and Standards

2.1 General

JIG 1: Guidelines for Aviation Fuel Quality Control and Operating Standards for
Into-plane Fuelling Services (Issue II)

JIG 2: Aviation Fuel Quality Control and Operating Standards for Airport Depots
and Hydrants (Issue II).

2.2 Piping/Mechanical Codes

ASME B16.5 Pipe Flanges and Flanged Fittings

ASME B16.9 Factory Made Wrought Steel Butt Welding Fittings

ASME B16.10 Face-to-Face & End-to-End Dimensions for Valves

ASME B16.11 Forged Fittings, Socket Welding and Threaded

ASME B16.20 Metallic Gasket for Pipe Flanges-Ring Joint, Spiral Wound &
Jacketed

11775-LST-EN-001 Rev 0 Page 3 of 9


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

ASME B16.21 Non-Metallic Flat Gaskets for Pipe Flanges

ASME B16.25 Butt Welding Ends

ASME B16.34 Valves, Flanged, Threaded and Welding End

ASME B16.47A Large Diameter Steel Flanges

ASME B16.48 Steel Line Blanks

ASME B31.3 Process Piping

ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and


other Liquids

ASME B36.10M Welding & Seamless Wrought Steel Pipes

ASME B36.19M Stainless Steel Flanges

ASME B46.1 Surface Roughness

ASME VIII Pressure Vessel Code Div 1 – Rules for Construction of


Pressure Vessels

API 5L Specification for Linepipe

API 6D Specification for Pipeline Valves

API 6FA Specification for Fire Test for Valves

API 520 P1 Sizing, Selection and Installation of Pressure Relieving


Devices in Refineries Part 1 – Sizing and Selection

API 521 Guide for Pressure - Relieving and Depressurising Systems

API 594 Check Valves: Flanged, Lug, Wafer and Butt-welding

API 598 Valve Inspection and Testing

API 599 Metal Plug Valves – Flange Threaded and Welding Ends

API 600 Steel Gate Valves – Flanged and Butt-Welding Ends, Bolted
Bonnets

API 601 Metallic Gaskets

API 607 Testing of Valves – Fire Type Testing for Soft Seated Quarter
Turn Valves

API 608 Metal Ball Valves – Flanged, Threaded and Welding Ends

API 609 Butterfly Valves: Double Flanged, Lug- and Wafer-Type

API 610 Centrifugal Pumps for Petroleum, Petrochemical and Natural


Gas Industries

API 650 Welded Tanks for Oil Storage

API 676 Positive Displacement Pumps - Rotary

API 1102 Steel Pipelines Crossing Railroads & Highways

11775-LST-EN-001 Rev 0 Page 4 of 9


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

API 1581 Specification and Qualification Procedure for Aviation Jet Fuel
Filters/Separators

API/IP 1590 Specification and Qualification Procedures for Aviation Fuel


Microfilters

BS 1414 Specification for Steel Wedge Gate Valves

BS 1560-3 Specification for Steel Flanges

BS 1868 Steel Check Valves (Flanged and Butt Welding Ends) for the
Petroleum, Petrochemical and Allied Industries

BS 1873 Specification for Steel Globe and Globe Stop and Check
Valves (Flanged and Butt-Welding Ends) for Petroleum,
Petrochemical and Allied Industries

BS 2594 Specification for Carbon Steel Welded Horizontal Storage


Tanks

BS 3381 Specification for Spiral Wound Gaskets

BS 3974 Specification for Pipe Supports

BS 4515 Specification for Welding Steel Pipelines on Land and


Offshore

BS 5351 Specification for Steel Ball Valves for Petroleum,


Petrochemical and Allied Industries

BS 5352 Steel Wedge Gate, Globe and Check Valves 50 mm and


Smaller

BS 5514 Reciprocating Internal Combustion Engines: Performance

BS 6072 Method for Magnetic Particle Flaw Detection

BS 6755 Part 1 Testing of Valves. Specification for Production Pressure


Testing Requirements

BS 6755 Part 2 Specification for Fire Type – Testing Requirements

BS EN 1435 Methods for Radiographic Examination of Fusion Welded


Circumferential Butt Joints in Steel Pipes

ASTM A105 Carbon Steel Forgings, for Piping Components

ASTM A106 Seamless Carbon Steel Pipe for High-Temperature Service

ASTM A193/M Alloy-Steel and Stainless Steel Bolting for High Temperature
or High Pressure Service and Other Special Purpose
Applications

ASTM A194/M Carbon and Alloy Steel Nuts for Bolts for High Pressure or
High Temperature Service, or Both

ASTM A234/M Piping Fittings of Wrought Carbon Steel and Alloy Steel for
Moderate and High Temperature Service

11775-LST-EN-001 Rev 0 Page 5 of 9


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

ASTM A182/M Forged or Rolled Alloy and Stainless Steel Pipe Flanges,
Forged Fittings, and Valves and Parts for High-Temperature
Service

ASTM A216/M Standard Specification for Steel Castings, Carbon, Suitable for
Fusion Welding, for High-Temperature Service

ASTM A240/M Chromium and Chromium-Nickel Stainless Steel Plate, Sheet,


and Strip for Pressure Vessels and for General Applications

ASTM A285/M Pressure Vessel Plates, Carbon Steel, Low- and Intermediate-
Tensile Strength

ASTM A307 Carbon Steel Bolts and Studs, 60 000 PSI Tensile Strength

ASTM A312/M Seamless, Welded and Heavily Cold Worked Austenitic


Stainless Steel Pipes

ASTM A403/M Wrought Austenitic Stainless Steel Piping Fittings

MSS SP-25 Standard Marking System for Valves, Fittings, Flanges and
Unions

MSS SP-68 High Pressure Butterfly Valves with Offset Design

MSS SP-72 Ball Valves With Flanged or Butt-welding Ends for General
Service

MSS SP-75 Specification for High Strength Wrought Fittings

IP Model Code of Safe Practice

Part 2: Design, Construction and Operation of Distribution


Installations
Part 7: Airport Safety Code

MIL-C-4556 D Coating Kit, Epoxy, for Interior of Steel Fuel Tanks

OISD 118 Layouts for Oil and Gas Installations

2.3 Fire Protection Codes

IP Model Code of Safe Practice

Part 19: Fire Precautions at Petroleum Refineries and Bulk


Storage Installations

NFPA 10 Portable Extinguishers

NFPA 11 Foam Extinguishing Systems

NFPA 11 Sprinkler Systems

NFPA 15 Water Spray Fixed Systems

NFPA 16 Deluge Foam-Water Systems

NFPA 20 Standard for the Installation of Stationary Pumps for Fire


Protection

NFPA 30 Flammable Liquids Code

11775-LST-EN-001 Rev 0 Page 6 of 9


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

NFPA 72 Fire Alarms

2.4 Electrical Codes

IEC 60079-14 Electrical Installation in Hazardous Areas (Other than Mines)

IEC 60529 Specification for degrees of protection provided by enclosures

BS 5467 Specification for XLPE Insulated Cables

BS 5501 Electrical Apparatus for Potentially Explosive Atmospheres

BS 6651 Protection of Structures against Lightning

BS 7430 Code of Practice for Earthing

BS 7671 Requirements for Electrical Installations – IEE Wiring


Regulations 16th Edition

IEC 60502 Specification for XLPE Insulated Power Cables

IP Model Code of safe Practice

Part 1: Electrical Safety Code


Part 15: Area Classification Code for Petroleum Installations

Kuwait MEW Regulations

2.5 Cathodic Protection Codes

ASTM B418 Cast & Wrought Galvanic Anodes for Use in Saline
Electrolytes

BS 7361 Cathodic Protection

MIL-A-18001 J Anodes, Corrosion Preventive, Zinc; Slab, Disc, & Rod


Shaped.

NACE RP 0169-92 Control of External Corrosion on Underground or Submerged


Metallic Piping Systems

2.6 Instrumentation & Control Codes

BS EN 837-1 Bourdon Tube Pressure and Vacuum Gauges

BS EN 3740/41 Sound power levels of noise sources


IEC 60079-14 Electrical installation in Hazardous Areas (Other than Mines)

IEC 60751 Industrial Platinum Resistance Thermometer Sensors

BS 5308 Instrument Cables

IEC 60529 Specification for degrees of protection provided by enclosures.

BS 5501 Electrical Apparatus for Potentially Explosive Atmospheres

BS 6651 Protection of Structures against Lightning

BS 6739 Code of Practice for Instrumentation in Process Control


Systems: Installation Design and Practice.

11775-LST-EN-001 Rev 0 Page 7 of 9


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

BS 7430 Code of Practice for Earthing

BS 7671 Requirements for Electrical Installations – IEE Wiring


Regulations 16th Edition

EIC CCI P/3 Instrument Panels

IP Model Code of Safe Practice

Part 1: Electrical Safety Code

Part 15: Area Classification Code for Petroleum Installations

IP 202/69 Petroleum Measurement Manual, Part 2: Tank Calibration

Section 1: Vertical Cylindrical Tanks - Measurement Methods

ISA S5.1 Instrumentation Symbols and Identification

2.7 Civil Codes

Kuwait Standard Specifications for the design of roads and drainage systems

Kuwait MEW Code of Practice

BS 4 Structural steel sections


BS EN 124 Gully and manhole tops for vehicular and pedestrian
areas.
BS EN 197-1 Cement

BS EN 295-1 Vitrified Clay Pipes and Fittings


BS EN 752 Drain and sewer systems outside buildings
BS 812 Testing aggregates
BS 882 Specification for aggregates from natural sources for
concrete

BS EN 934 Concrete Admixtures


BS 1200 Building sands from natural sources
BS 1377 Methods of test for soils for civil engineering purposes

BS EN ISO 1461 Hot dip galvanized coatings on fabricated iron and steel
articles
BS 1881 Testing Concrete

BS 2499 Hot-applied joint sealant systems for concrete


pavements
BS 3506 Specification for unplasticized PVC pipe for industrial
uses
BS 4027 Specification for sulfate-resisting Portland cement
BS 4211 Specification for ladders for permanent access

11775-LST-EN-001 Rev 0 Page 8 of 9


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

BS 4254 Specification for two-part polysulphide based sealants


BS 4449 Specification for carbon steel bars for the reinforcement
of concrete
BS 4479 Design of articles to be coated

BS 4483 Steel Fabric for the Reinforcement of Concrete

BS 5212 Cold applied joint sealant systems for concrete


pavements
BS 5328 Method of specifying concrete, including ready mixed
BS 5395 Stairs, ladders and walkways
BS 5950 Structural use of steelwork in building
BS 6031 Code of practice for earthworks
BS 6180 Barriers in and about buildings

BS 8004 Code of Practice for Foundations

BS 8110 Structural use of concrete


BS 8666 Specification for scheduling, dimensioning, bending and
cutting of steel reinforcement for concrete
BS EN ISO 9000 Quality management and quality assurance standards
Series

BS ISO 10931 Plastic piping systems for industrial applications


BS EN 22063 Metallic and other inorganic coatings Thermal spraying
- Zinc, aluminium and their alloys

2.7.1 Other Standards

UK Department of Specification for Highway Works Part 3


Transport

CIRIA Report 97: 1983 - Trenching Practice

CIRIA Report 113: Control of Groundwater for Temporary Works

11775-LST-EN-001 Rev 0 Page 9 of 9


Design of New
Hydrant System

Specification for
Linepipe

Head Office:
Penspen Group Limited
3 Water Lane
Richmond upon Thames
Surrey
Kuwait Aviation Fuelling Co TW9 1TJ
United Kingdom

Regional Office:
Penspen International Limited
P.O. Box 46562
Abu Dhabi
United Arab Emirates

11775-SPC-PL-001 Rev 0
DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Contents

1. Introduction
1.1 Scope of Document
1.2 Project References and Applicable Standards
1.3 Definitions and Abbreviations
1.4 Documentation
1.5 Quality System
1.6 Personnel
1.7 Purchaser Inspection
1.8 Compliance
1.9 Traceability and Certification
1.10 Delivery
1.11 Storage and Shipment
1.12 Pipe for Induction Bending
1.13 Pipe Mill selection and qualification of manufacturing procedure

2. Scope

3. Conformity

4. Information to be Supplied by the Purchaser


4.1 General Information
4.2 Additional Information

5. Manufacturing

6. Acceptable Criteria
6.11 Dimensions, Mass and Tolerances

7. Inspection
7.2 Specific Inspection

8. Marking
Annex A Specification for Welded Jointers
Annex B Manufacturing Procedure Qualification for PSL 2 Pipe
Annex C Treatment of Surface Imperfections and Defects
Annex D Repair Welding Procedure
Annex E Non-destructive Inspection for Other than Sour Service or
Offshore Service
Annex F Requirements for Couplings (PSL 1 only)
Annex G PSL 2 Pipe with Resistance to Ductile Fracture Propagation
Annex H PSL 2 Pipe Ordered for Sour Service
Annex I Pipe Ordered As “Through the Flowline” (TFL) Pipe
Annex J PSL2 Pipe Ordered for Offshore Service
Annex K Non-destructive Inspection for Pipe Ordered for Sour Service
and/or Offshore Service
Annex L Steel Designations
Annex M Correspondence of Terminology Between ISO 3183 and its
Source Documents
Annex N Identification / Explanation of Deviations
Annex O API Monogram
Appendix I: Chemical Requirements for Product Analysis
11775-SPC-PL-001 Rev 0 Page 2 of 15
DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

1. Introduction

1.1 Scope of Document

This specification defines the minimum requirements for the purchase of carbon
steel seamless or submerged arc welded line pipe for the new hydrant system at
Kuwait International Airport (KIA) and shall supplement API 5L forty fourth edition
2007 including errata and addendums 1 and 2 (2009 and 2010).

The numbering of sections 1 – 14 inclusive in this Specification corresponds with


the section numbering of API 5L, except where indicated as an additional clause.
Paragraphs or parts of paragraphs contained in API 5L, and which remain
unaffected by the requirements of this Specification, shall remain fully applicable.
Paragraphs contained in API 5L and not listed in this Specification shall remain
fully applicable.

Standards equivalent to those referred to herein shall not be substituted without


written approval from the Purchaser. Approval of equivalent standards will not, in
any way, remove responsibility from the Supplier to meet the requirements of the
Standards referred to and amended herein, in the event of conflict. The Supplier
shall equip himself with copies of all the reference specifications referred to in this
specification and shall make them readily available to all fabrication, testing and
inspection personnel involved on the work.

1.2 Project References and Applicable Standards

1.2.1 Project References

The following documentation shall be read in conjunction with and form part of this
specification.

11775-SPC-PL-005 Specification for Factory Applied Internal Lining

11775-SPC-PL-003 Specification for Factory Applied Polyethylene


Coating of Linepipe

1.2.2 Applicable Standards

This Specification makes reference to the latest edition of the following documents
which shall be applicable as referenced.

API 5L Specification for Line Pipe

ISO 9001 Quality management systems – Requirements

EN 10204 Materials. Types of inspection documents

11775-SPC-PL-001 Rev 0 Page 4 of 15


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

1.3 Definitions and Abbreviations

1.3.1 Definitions

Purchaser: KAFCO (Kuwait Aviation Fuel Company) or their appointed agent or


representative.

Supplier: The vendor, manufacturer or supplier of the equipment defined in this


specification.

Inspection Agency: An independent inspection body (other than any inspection


department of the Supplier or any inspection agency sub-contracted by him) or its
members, who shall be appointed by Purchaser and thus notified to Supplier.

Inspector: The Purchaser’s representatives or members from the Purchaser’s


elective Inspection Agency for the time being or from time to time duly appointed in
the writing by the Purchaser to act as its representatives for the purpose of the
Contract shall be referred to herein as the “Inspector”.

Mill: The plants, mills, workshops, laboratories or other locations where the
fabrication, inspection and testing of steel and pipes is to be performed complete
or in part.

Contract: The material requisitions, material specifications, etc issued by the


Purchaser and attached to the Contract.

Approval: Authorisation in writing given by Purchaser to Supplier to proceed with


the performance of a specific part of the work without releasing in any way
Supplier from any of its obligations or liabilities under the Contract or at law;
Approve, Approved and Approval shall be construed accordingly.

Throughout this document the following terminology is used:

“must” signifies a legal or statutory requirement


“shall” signifies a requirement made mandatory by this Specification
“may” signifies a feature which is discretionary in the context in which it is
applied
“will” signifies a feature which the Supplier may assume to be already
present

11775-SPC-PL-001 Rev 0 Page 5 of 15


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

1.3.2 Abbreviations

As detailed in API 5L and the following:

API American Petroleum Institute

ASTM American Society for Testing and Materials

ASME American Society of Mechanical Engineers

CMTR Certified Mill Test Report

CE Carbon Equivalent

CS Carbon Steel

DD Detailed Design

DP Design Pressure

DT Design Temperature

ISO International Standards Organisation

LSAW Longitudinal Submerged Arc Welding

MPS Manufacturing Procedure Specification

NDT Non-Destructive Testing

OD Outside Diameter

PHS Pipe History System

PSL Product Specification Level

QCP Quality Control Plan

SMLS Seamless

SMYS Specified Minimum Yield Strength

TPI Third Party Inspection

UOE Pipe manufactured by U-pressing, O-pressing and Expansion

11775-SPC-PL-001 Rev 0 Page 6 of 15


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

1.4 Documentation

The documentation required with the tender, during pipe manufacture and on
completion of the works is specified in the Contract.

In addition the following details shall be provided with the Tender:

• Production Schedule / Delivery Schedule


• Type of pipe to be provided
• Previous track record of supply of linepipe including statistics and histograms
of dimensional tolerances, chemical analysis and mechanical properties.
• Name and locations of steelmakers, plate/coil mills / slab mill, and API
pipemills.
• Steel making casting techniques, de-sulphurising and degassing.
• Slab/Plate/coil manufacturing methods including details of specialised cooling
and heat slab treatment and ultrasonic testing procedures.
• Method of Testing and Acceptance Criteria for Centreline Segregation
• Manufacturing procedures including, traceability and skelp splitting, heat
treatment, frequency of power supply, pipe forming, welding procedures, non
destructive testing procedures including Ultrasonic Scan Pattern, Calibration
and Acceptance criteria, cold expansion and hydrostatic testing procedures
and a flow diagram describing manufacturing route procedures.
• For SAW pipe, details of welding process, brand, classification, size of filler
metal and flux, welding speed, number of electrodes, polarity, current voltage
for each wire, number of welding passes and method of weld seam tracking.
• Quality documentation (ISO 9001), Quality Assurance Manual, and typical
quality/inspection plan.
• Dimensional Tolerance Inspection Procedures
• Pipe marking proposals.
• Pipe Tracking Methodology including Purchaser Bar Coding Requirement.
• Storage, handling, transport and shipping procedures for pipes.
• Proposed aim chemical analysis and mechanical test results.
• Weldability Test Specification and results of past weldability tests
• Sample material tracking report and proposed pipe numbering system.
• Details of Pipe History System (PHS).
• Description of Proposed Sealing end caps and Bevel Protectors.
• All deviations/qualifications to the specification.

11775-SPC-PL-001 Rev 0 Page 7 of 15


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

1.5 Quality System

The Quality Assurance Manual shall be submitted to the Purchaser for Approval.
The Supplier shall establish and maintain a quality assurance system in
accordance with ISO 9001, ISO 9002 or an approved equivalent. The Supplier
shall submit, within the timescale specified in the SDRL, a detailed
quality/inspection plan to the Purchaser for approval.

1.6 Personnel

All inspection Personnel employed by the Supplier shall be qualified to ASNT


Level II or an equivalent scheme approved by the Purchaser. A level III qualified
Inspector shall be available at the mill for overall supervision.

1.7 Purchaser Inspection

All procedures shall have prior approval of the Purchaser. All qualification tests
shall take place under the supervision of the Inspector.

The Supplier shall ensure that the Inspector has full and free access to all parts of
the Mill during all fabrication stages.

Inspection by the Inspector shall be carried out during pipe production in order to
avoid any special or additional handling. Inspection will be made in such a manner
to avoid delay in pipe production insofar as the pipes which are presented to him
meet the specified requirements.

The Inspection Agency shall finalise its inspection by the application of a special
stamp (or indelible paint marking, when so previously agreed) on the accepted
pipes. Die stamping is permitted only on the bevel surface.

The Purchaser reserves the right to re-check tests carried out by the Supplier. For
this purpose, the Purchaser may request the delivery of samples or specimens for
analysis in an independent laboratory chosen by the Purchaser.

The Supplier shall provide all necessary office accommodation, facilities, test
equipment and assistance as required by the Inspector. The Supplier shall provide
unhindered inspection access to all work sites and plant used.

In the event that defective plates, pipes or welds are detected during the
Purchaser’s inspection the Supplier shall mutually agree on additional inspection
requirements, the cost of which, shall be borne by the Supplier.

1.8 Compliance

This specification adopts sampling as a method to determine batch compliance.


Nevertheless, the Supplier is responsible to ensure and certify that all pipes meet
the requirement of this specification.

1.9 Traceability and Certification

Supplier shall maintain heat and/or lot identity, by establishing direct correlation of
the material to a heat and / or lot and cast strands or ingot by physical markings on
the item and by also documenting the heat number or code on the Certified Mill
Test Report (CMTR) as defined by EN 10204, Metallic Products Types of
Inspection Documents, paragraph 3.1, Type B – Test Certificate.

11775-SPC-PL-001 Rev 0 Page 8 of 15


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Each pipe shall be assigned unique identification. A system for identification and
tracing of pipes shall be developed and submitted for acceptance. The system
shall be based on bar codes or have the same functionality as barcodes.

A copy of all applicable CMTRs shall be included with each shipment of linepipe in
addition to being submitted to Purchaser in accordance with the corresponding to
this Specification and the Contract.

Supplier’s quality system and procedures shall provide methods for assuring that
each piece of line pipe supplied is traceable to the CMTRs and that the CMTRs
are verified to be in accordance with the material specification.

Full certification of the results of inspection and testing shall be provided by


Supplier. Certification shall cover all results required by this specification. All
certificates shall be marked with sufficient information to enable full traceability to
items it represents and the relevant specifications and procedures.

1.10 Delivery

The Supplier shall be responsible for all activities including transportation,


intermediate storage, etc until safe delivery of materials to the Purchaser. Any
damage to the items during storage or transport shall be at Supplier’s cost.

1.11 Storage and Shipment

Supplier shall be responsible for the storage of linepipe if partially delivered at


Supplier’s works until the whole lot is delivered to the designated Stores /
Locations.

Supplier shall submit in the MPS to Purchaser for review and approval, information
detailing the proposed method of handling, stacking, and securing line pipe lengths
during manufacture, storage, and shipment. No welding of temporary attachments
for handling, stacking, or securing shall be permitted. All handling, loading, and
unloading of pipe shall be performed in such a safe manner as to avoid
mechanical damage and corrosion and entry of any debris or foreign matter. Due
to transport limitations joint lengths should be a maximum of 12 m.

Supplier shall fit sealing plastic end caps and straps to both ends of the linepipe
joints, and these shall not be removed at any time except for application of anti
corrosion coating, and they shall be replaced immediately after these operations.
These caps shall have provision for strapping from outside .50%. Spare caps shall
be included in the scope.

1.12 Pipe for Induction Bending

Where induction bending is specified in the Contract the Supplier shall select or
otherwise arrange for the provision of the required number of suitable linepipes,
whose wall thickness and mechanical properties after bending shall never be less
than that specified in the Contract. The Supplier shall determine the thickness and
chemical analysis required to achieve this. The pipes shall be clearly marked “For
Induction Bending” and shall be stored and transported separately from the
remainder of the consignment.

11775-SPC-PL-001 Rev 0 Page 9 of 15


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

1.13 Pipe Mill selection and qualification of manufacturing procedure

It is anticipated that the manufacturing pipe mill will have extensive documented
experience of line pipe manufacture of similar diameter, wall thickness, grade and
end application.

Approval of the manufacture procedure specification and qualification of the


manufacturing procedure shall be in accordance with this specification (Annex B).

2. Scope

Applicable, Add:

The Supplier’s scope shall include, but not be limited to, manufacture, inspection,
testing, supply, shipment, all documentation, coordination with Sub-Suppliers
(including expediting), certification and delivery of the linepipe sizes and quantities
stated in the Contract and Appendix II.

Supplier shall be responsible for all of the required coating, storage, handling,
transportation and delivery of the items to the Purchaser’s designated location.

Notes:

(1) Linepipe specified as bare shall be painted externally with an epoxy primer, to
prevent corrosion during storage, handling and transportation.
(2) The line pipe shall be suitable for service conditions listed in and Appendix II.
(3) The line pipes shall have both ends bevelled and shall be supplied with fully
sealing hookable end caps that act as bevel protectors to protect the bevel
end of the pipe during handling and transportation.

3. Conformity

Applicable, add:

Any case of apparent conflict between the requirements of this Specification and
any other relevant documents shall be notified to the Purchaser. Unless otherwise
agreed the following descending order of precedence shall apply:-

1st This Specification


2nd Other Project Specifications
3rd The Codes and Standards listed in this specification
4th Other API, ASME, ANSI, BS Codes or Standards as appropriate

This specification shall in no way release the Supplier from the final guarantee as
to the materials, apparatus, workmanship and the performance.

11775-SPC-PL-001 Rev 0 Page 10 of 15


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

4. Information to be Supplied by the Purchaser

Replace:

4.1 General Information

a) The required quantity of pipe shall be specified in the Contract.


b) All linepipe shall be supplied to PSL 2.
c) The line pipe shall be supplied as detailed in the Contract and Appendix II.
d) The pipe shall fully comply with API 5L.
e) The pipe grade shall be as detailed in the Contract.
f) Outside diameter and wall thickness shall be as detailed in the Contract.
g) Pipe length and length tolerances shall be as detailed in Appendix II and the
Contract.
h) The following annexes shall apply to this order:
Annex B, Annex C, Annex D, Annex E, Annex G, Annex L, Annex M, Annex N,
Annex O and Bibliography.

i) The pipeline minimum design temperature shall be as stated Appendix II


(additional to API 5L)

4.2 Additional Information

a) Items that are subject to mandatory agreement, if applicable:


None Applicable
b) Items that apply as prescribed, unless otherwise agreed:
4) The chemical composition limits for the linepipe (footnotes c, e, f, g, h and i shall
comply with Table J.1 and Appendix I unless otherwise agreed (see clause 9).

7) The tolerance on pipe length shall be agreed with Purchaser.

9) When a standard API bevel is specified the width of the root face of the bevel
shall be 1.6mm+1mm – 0mm.

12) Repair welding after cold expansion is not acceptable.

c) Items that apply if agreed:


1) The delivery condition shall be as specified in the Annexes.

7) Jointers shall not be permitted.

8) The test temperature for Charpy testing of the pipe body shall be -10 Deg C.
The shear fracture area shall be measured on each pipe body specimen and
shall be 100%.

9) The shear area for the pipe body is 100%.

12) Drop-weight tear tests (DWTT) are required for pipelines with a pipe diameter of
DN 400 (16 inch) or greater designated for multiphase sour fluids and gas
service and shall be conducted at the minimum design temperature. DWTT is
not required for Jet A1 service.

11775-SPC-PL-001 Rev 0 Page 11 of 15


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

15) For a distance of at least 200 mm from each pipe end, the outside bead shall be
removed by grinding such that it does not extend above the adjacent pipe
surface by more than 0.5mm.

16) The Supplier shall supply weldability data for the type and grade of steel and
pipe concerned. The Purchaser will be seeking conclusive proof that pipe of the
highest specified carbon equivalent (IIW and Pcm) can be welded using the
intended manual, semi automatic and mechanised field welding procedures. If
Supplier does not have proof of weldability of the type and grade of pipe
concerned, Supplier shall perform a weldability test programme (to be approved
by Purchaser) prior to the start of line pipe production.

25) The specified wall thickness shall be used for determination of the required test
pressure.

27) The use of internal diameter measurement to determine diameter and out of
roundness shall be agreed before the order for pipe is placed.

28) The methods to be used for determining all pipe dimensions shall be agreed
with Purchaser before the order for pipe is placed.

30) The Purchaser may specify additional markings. Additionally marking shall be
based on bar codes or a system having the same functionality.

31) The type and location of markings shall be agreed with the Purchaser.

32) Stamping shall be confined to the end bevel face using low stress stamps
unless otherwise stated.

37) Where specified in the Contract the pipe shall be coated externally in
accordance with the Contract and specification 11775-SPC-PL-003.

40) Annex B applies to this order.

42) Ultrasonic inspection, using compressions and shear wave techniques, shall be
applied to a full 50mm circumferential band at each pipe end to ensure this area
is free of laminar and planar imperfections and micro cracks.

43) Seamless pipe shall be tested as specified for laminations.

44) The longitudinal seam of SAW pipe shall be ultrasonically tested as specified.

46) For SAWL and seamless pipe, ultrasonic inspection, as specified, shall be used
to test the pipe body for laminar imperfections.

47) Ultrasonic testing of the plate edges and weld seam is required as specified.

50) The pipe line is not in sour service. Annex H does not apply.

54) The pipeline is on land and Annex J does not apply except where specified
otherwise in this specification (see clauses 7.2c point 55, 7.2b point 4. Clauses
9, 9.11, 10.2 and Annex B).

55) To ensure the pipe is fully weldable in the field using either manual automatic or
semi automatic welding, it is necessary to modify the chemical analysis, carbon
equivalents and pipe dimensional tolerances (see clause 9). The pipe shall be
hardness tested in accordance with Annex J. The full pipe body of seamless

11775-SPC-PL-001 Rev 0 Page 12 of 15


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

pipe shall be ultrasonic tested for lamination in accordance with an in house


procedure approved by the Purchaser.

56) Fluoroscopic examination shall not be acceptable.

5. Manufacturing

Applicable, add:

Pipe up to size 12” diameter (Nominal Bore) shall be seamless (SMLS). Pipe of
size 14”Diameter and above shall be Submerged Arc Welded (SAW) pipes and
shall have one longitudinal seam made by the Automatic Submerged Arc Welding
Process. The longitudinal weld seam shall include at least one pass made on the
inside and at least one pass made on the outside in accordance with clause API
5L.

Seamless pipe (SMLS) can be cold worked and straightened provided the total
strain does not exceed 1.5%.

Longitudinal submerged arc welded pipe (SAWL) manufactured by the UOE


process is preferred. This process involves U-pressing, O-pressing and cold
expansion.

During steel manufacture all slabs shall be hot scarfed.

Plate shall be thermo mechanically control rolled. After final rolling of plate the
longitudinal edges of the plate shall be machined to remove a minimum width of
material equal to plate thickness. A band along the plate at the machined edges
and the ends shall be visually and ultrasonically examined in accordance with API
5L for laminations and inclusion clusters. The plate body shall be visually and
ultrasonically scanned for laminations and inclusions clusters.

6. Acceptable Criteria

Applicable, add:

The pipeline may be welded in the field using a combination of automatic welding,
semi automatic and manual welding and the linepipe must provide good
weldability.

The chemical analysis and carbon equivalent of the all plate, and seamless pipe
for pipelines shall comply with Table J.1 and Appendix II and a detailed analysis
shall be agreed with the pipe Supplier at the bid stage before an order is placed.
In addition the carbon equivalent based on CE (IIW) shall not exceed 0.40%. The
Charpy energy values for pipe, weld and heat affected zones is specified in
Appendix II.

9.10.5 Geometric Deviations

Applicable, add:

All pipe with cold formed dents with a sharp bottom gouge and all sharp gouges
(without dents) deeper than 1mm shall be rejected.

11775-SPC-PL-001 Rev 0 Page 13 of 15


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

6.11 Dimensions, Mass and Tolerances

Applicable, add:

To ensure the pipe is weldable using automatic welding techniques the


dimensional tolerances of all pipe shall comply with Annex J.

In addition the tolerance limit on internal diameter within 100mm of the pipe end
shall be + - 1.6mm. The internal out of roundness within 100mm of the pipe end
shall not exceed 2mm for an 8” pipe and 3mm for a 16” pipe.

Peaking of the pipe body shall not deviate by more than 1.5mm from the design
form when measured over an arc of not less than 200mm.

The tolerance on wall thickness shall, as a minimum, comply with API 5L but the
actual tolerances which apply to a particular pipe order shall be agreed at the bid
stage.

7. Inspection

Applicable, add:

7.2 Specific Inspection

In addition to the tests specified in Table 18, all pipe including pipe shall be macro
hardness tested in accordance with Annex J. Each pipe shall be fully visually
inspected.

7.2.6 Hydrostatic Test

Applicable, add:

The test pressure shall correspond to a stress of 100% of specified minimum yield
strength (S = 100%). Test pressure shall be held for a minimum of 20 seconds.

8. Marking

Applicable, add:

In addition to the marking specified on the pipes, the Supplier shall supply the
Purchaser with lists of pipes produced stating pipe identification numbers, heat
numbers, dimensions, weights of lots of pipes or individual pipe lengths, purchase
order numbers, type of certificates issued and any further items that may be
indicated on the Contract.

The minimum information to be marked on each pipe joint shall be:

• Supplier's Name
• API 5L Grade
• Pipe OD (in inches)
• Wall Thickness (in mm)
• Lot and Heat Number
• Pipe Joint Number
• Pipe Length (in m)

11775-SPC-PL-001 Rev 0 Page 14 of 15


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

The marking methods and information and methods of preserving the marking that
will be used shall be presented to Purchaser for approval.

Unique pipe numbers shall be allocated sequentially, and marked on the pipes by
hard stamping on the bevel. Unless specified otherwise on the Contract, marking
shall be located as follows. For pipe diameters DN 450 (18 inch OD) and larger, all
paint markings shall be on the inside surface. For smaller pipe diameters the paint
marking shall be on the outside surface.

Paint for stencil markings shall not contain more than 0.025% by mass of lead,
zinc and copper. It shall also be free from chlorides, other halogens and zinc.
Maximum permitted chloride content shall be 100 ppm. The sequence of marking
shall be in the same order as listed above.

The pipes shall be dispatched only after a Release Certificate has been issued by
the INSPECTION AGENCY.

Mill Certificates shall be supplied at the time of dispatch of the pipes.

The full production report as above shall be transmitted to the Purchaser without
delay after completion of pipe production. The latest date of submission of this
report shall be agreed at the bid stage.

11775-SPC-PL-001 Rev 0 Page 15 of 15


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Annex A Specification for Welded Jointers

Not applicable

Annex B Manufacturing Procedure Qualification for PSL 2 Pipe

Applicable, add:

Qualification shall be in accordance with clause B.3 and B.4. The frequency of
testing shall be specified by the Purchaser but this shall include at least two pipes
from two casts of each wall thickness pipe grade, diameter, or source of steel,
steel plate or coil. In addition to the mechanical tests specified Charpy tests shall
be taken from the fusion line, fusion line +2mm and fusion line +5mm positions.
For information, additional Charpy tests shall be carried out at stepped reductions
in temperature, to establish the transition temperature for the steel.

Testing shall also include hardness testing in accordance with Annex J. During
tensile testing of the weld the yield stress shall also be measured.

Annex C Treatment of Surface Imperfections and Defects

Applicable, add:

No weld repairs shall be permitted within 300 mm of the pipe ends. Repair of pipes
with cracks are not permitted

Annex D Repair Welding Procedure

Applicable

Annex E Non-destructive Inspection for Other than Sour Service or


Offshore Service

Applicable

Annex F Requirements for Couplings (PSL 1 only)

Not Applicable

Annex G PSL 2 Pipe with Resistance to Ductile Fracture Propagation

Applicable

11775-SPC-PL-001 Rev 0 Page 1 of 2


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Annex H PSL 2 Pipe Ordered for Sour Service

Not Applicable

Annex I Pipe Ordered As “Through the Flowline” (TFL) Pipe

Not Applicable

Annex J PSL2 Pipe Ordered for Offshore Service

Table J.1, Clause J.4.3, Clause J.6 and Clause J.7 are applicable.

Annex K Non-destructive Inspection for Pipe Ordered for Sour Service


and/or Offshore Service

Not Applicable

Annex L Steel Designations

Applicable

Annex M Correspondence of Terminology Between ISO 3183 and its


Source Documents

Not Applicable

Annex N Identification / Explanation of Deviations

Applicable

Annex O API Monogram

Applicable to all pipe specified by outside diameter

11775-SPC-PL-001 Rev 0 Page 2 of 2


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Appendix I: Chemical Requirements for Product Analysis

Chemical Requirements for Product Analyses

Maximum Permitted Alloy Maximum variation


Element Content, wt% on agreed Notes
SAWL SMLS composition
C 0.15 0.15 0.03
Mn 1.30 1.40 0.30
Si 0.45 0.45 0.25
P 0.015 0.015
S 0.003 0.005
V 0.08 0.08 0.02 1
Nb 0.05 0.05 0.02 1
Ti 0.04 0.04 0.02 1
Cr 0.20 0.30 0.05 2
Mo 0.10 0.35 0.05 2
Ni 0.35 0.40 0.10 2
Cu 0.40 0.40 0.10 2
Al 0.05 0.06 - 3
N 0.012 0.012 - 3
B 0.0005 0.0005
Ca 0.006 0.006 - 4
CE 0.39 0.40 - 5
Pcm 0.21 0.23 - 6

1. V+Nb+Ti shall not exceed 0.15%.


2. Cr+Mo+Ni+Cu shall not exceed 0.6%.
3. The total Al: N ratio shall not be less than 2:1.
4. Calcium shall be a minimum 2 times the Sulphur content in the range of
0.0015 - 0.003 %).
5. CE = C + Mn/6 + (Cr+Mo+V)/5 + (Ni+Cu)/15.
6. Pcm = C + Si/30 + (Mn + Cu +Cr)/20 + Ni/60 + Mo/15 + V/10 + 5B.

11775-SPC-PL-001 Rev 0 Page 1 of 1


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Appendix II: Pipeline Design Data for Linepipe

Sl No. Item Values/Details

1 Nominal Pipeline Size, inch 24”

2 Wall Thickness 9.53 Sch 20

3 Design temp Max/Min, °C 50 / -5

4 Medium Jet A1 Fuel

5 Service Non-Sour service.

6 Type of Pipe SAWL

7 Pipe End Bevel Modified API 5L

8 Pipe Delivery Condition SMLS - Quench and tempered or alternative


heat treatment approved by Company
To be agreed between Company and
9 Pipe Length and Length Tolerances Contractor (joint lengths should be a
maximum of 12 m)
Charpy Energy Values (Average and
10 Minimum) for Transverse 10mm x 5mm 40J / 30J
Specimens

11 Factory applied Polyethylene Coating 11775-SPC-PL-003


12 Factory applied Internal Lining 11775-SPC-PL-005

11775-SPC-PL-001 Rev 0 Page 1 of 1


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Appendix III: Pipeline Design Data for 20” Diameter Linepipe

Sl No. Item Values/Details

1 Nominal Pipeline Size, inch 20”

2 Wall Thickness 9.53 Sch 20

3 Design temp Max/Min, °C 50 / -5

4 Medium Jet A1 Fuel

5 Service Non-Sour service.

6 Type of Pipe SAWL

7 Pipe End Bevel Modified API 5L

8 Pipe Delivery Condition SMLS - Quench and tempered or alternative


heat treatment approved by Company
To be agreed between Company and
9 Pipe Length and Length Tolerances Contractor (joint lengths should be a
maximum of 12 m)
Charpy Energy Values (Average and
10 Minimum) for Transverse 10mm x 5mm 40J / 30J
Specimens

11 Factory applied Polyethylene Coating 11775-SPC-PL-003


12 Factory applied Internal Lining 11775-SPC-PL-005

11775-SPC-PL-001 Rev 0 Page 1 of 1


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Appendix IV: Pipeline Design Data for 16” Diameter Linepipe

Sl No. Item Values/Details

1 Nominal Pipeline Size, inch 16”

2 Wall Thickness 9.53 Sch 30

3 Design temp Max/Min, °C 50 / -5

4 Medium Jet A1 Fuel

5 Service Non-Sour service.

6 Type of Pipe SAWL

7 Pipe End Bevel Modified API 5L

8 Pipe Delivery Condition SMLS - Quench and tempered or alternative


heat treatment approved by Company
To be agreed between Company and
9 Pipe Length and Length Tolerances Contractor (joint lengths should be a
maximum of 12 m)
Charpy Energy Values (Average and
10 Minimum) for Transverse 10mm x 5mm 40J / 30J
Specimens

11 Factory applied Polyethylene Coating 11775-SPC-PL-003


12 Factory applied Internal Lining 11775-SPC-PL-005

11775-SPC-PL-001 Rev 0 Page 1 of 1


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Appendix V: Pipeline Design Data for 12” Diameter Linepipe

Sl No. Item Values/Details

1 Nominal Pipeline Size, inch 12”

2 Wall Thickness 9.53 Sch STD

3 Design temp Max/Min, °C 50 / -5

4 Medium Jet A1 Fuel

5 Service Non-Sour service.

6 Type of Pipe SMLS

7 Pipe End Bevel Modified API 5L

8 Pipe Delivery Condition SMLS - Quench and tempered or alternative


heat treatment approved by Company
To be agreed between Company and
9 Pipe Length and Length Tolerances Contractor (joint lengths should be a
maximum of 12 m)
Charpy Energy Values (Average and
10 Minimum) for Transverse 10mm x 5mm 40J / 30J
Specimens

11 Factory applied Polyethylene Coating 11775-SPC-PL-003


12 Factory applied Internal Lining 11775-SPC-PL-005

11775-SPC-PL-001 Rev 0 Page 1 of 1


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Appendix VI: Pipeline Design Data for 8” Diameter Linepipe

Sl No. Item Values/Details

1 Nominal Pipeline Size, inch 8”

2 Wall Thickness 7.04 Sch 30

3 Design temp Max/Min, °C 50 / -5

4 Medium Jet A1 Fuel

5 Service Non-Sour service.

6 Type of Pipe SMLS

7 Pipe End Bevel Modified API 5L

8 Pipe Delivery Condition SMLS - Quench and tempered or alternative


heat treatment approved by Company
To be agreed between Company and
9 Pipe Length and Length Tolerances Contractor (joint lengths should be a
maximum of 12 m)
Charpy Energy Values (Average and
10 Minimum) for Transverse 10mm x 5mm 40J / 30J
Specimens

11 Factory applied Polyethylene Coating 11775-SPC-PL-003


12 Factory applied Internal Lining 11775-SPC-PL-005

11775-SPC-PL-001 Rev 0 Page 1 of 1


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Appendix VII: Pipeline Design Data for 6” Diameter Linepipe

Sl No. Item Values/Details

1 Nominal Pipeline Size, inch 6”

2 Wall Thickness 7.11 Sch 40

3 Design temp Max/Min, °C 50 / -5

4 Medium Jet A1 Fuel

5 Service Non-Sour service.

6 Type of Pipe SMLS

7 Pipe End Bevel Modified API 5L

8 Pipe Delivery Condition SMLS - Quench and tempered or alternative


heat treatment approved by Company
To be agreed between Company and
9 Pipe Length and Length Tolerances Contractor (joint lengths should be a
maximum of 12 m)
Charpy Energy Values (Average and
10 Minimum) for Transverse 10mm x 5mm 40J / 30J
Specimens

11 Factory applied Polyethylene Coating 11775-SPC-PL-003


12 Factory applied Internal Lining 11775-SPC-PL-005

11775-SPC-PL-001 Rev 0 Page 1 of 1


Design of New
Hydrant System
(Package #7)

Specification for
Pipeline Forged
Bends Head Office:
Penspen Group Limited
3 Water Lane
Richmond upon Thames
Surrey
TW9 1TJ
United Kingdom
Kuwait Aviation Fuelling Co
Regional Office:
Penspen International Limited
P.O. Box 46562
Abu Dhabi
United Arab Emirates

11775-SPC-PL-002 Rev 0
DESIGN OF NEW HYDRANT SYSTEM

1. Scope

This Specification gives the additional requirements to ASME B16.9 and


MSS SP 75, as appropriate, for the design, manufacture, testing and supply of
forged pipeline bends suitable for welding to API 5L line pipe using manual
metallic arc welding with cellulosic electrodes and a downward welding technique.
The aforementioned forged pipeline bends are for the new hydrant system at
Kuwait International Airport. (KIA)

2. Precedence

Any case of apparent conflict between the requirements of this Specification and
any other relevant documents shall be notified to the Company. Unless otherwise
agreed the following descending order of precedence shall apply:-

1st This Specification


2nd Other Project Specifications
3rd The Codes and Standards listed in this specification
4th Other API, ASME, ANSI, BS Codes or Standards as appropriate

3. References

The following documentation shall be read in conjunction with and form part of this
specification.
11775-SPC-ME-009 Specification for the Storage, Handling and Transportation
of Linepipe and Fittings
11775-SPC-PL-005 Specification for Factory Applied Internal Lining

4. Definitions

The “Company” is KAFCO (Kuwait Aviation Fueling Company) or their appointed


agent or representative.

The “Supplier” is the vendor, manufacturer or supplier of the equipment defined in


this specification.

The “Contractor” is the organization employed by the Company or their appointed


agent or representative in order to carry out the Work.

Throughout this document the following terminology is used:

“must” signifies a legal or statutory requirement


“shall” signifies a requirement mage mandatory by this Specification
“may” signifies a feature which is discretionary in the context in which it is
applied
“will” signifies a feature which the Supplier may assume to be already
present

11775-SPC-PL-002 Rev 0 Page 3 of 10


DESIGN OF NEW HYDRANT SYSTEM

5. Codes and Standards

This Specification makes reference to the latest edition of the following documents
which shall be applicable as referenced.

API 5L Specification for Linepipe.

ASME B16.5 Pipe Flanges and Flanged Fittings.

MSS SP 75 Specification for High Test Wrought Butt Welding Fittings.

ASME B16.9 Factory-Made Wrought Steel Buttwelding Fittings.

ASME B31.3 Process Piping.

ASME IX Boiler and Pressure Vessel Code: Welding and Brazing


Qualifications

For the complete list of applicable codes and standards, refer to Codes and
Standards List (Document No: 11775-LST-EN-001)

6. Specific Technical Requirements

6.1 Storage, Handling and Transportation

Storage, handling and transportation of linepipe and bends shall be carried out in
accordance with Specification 11775-SPC-ME-009.

6.2 Design

All bends shall be designed to MSS SP 75/ASME B16.9 and the additional
requirements of this Specification.

6.3 Dimensions

Diameter, wall thickness, angles, quantities and coating requirements shall be as


stated in the Purchase Order.

With his tender the Contractor shall provide sketches of the bends. The sketches
shall detail all dimensions with tolerances and weld end preparation details to MSS
SP 75/ASME B16.9. The Contractor shall demonstrate that the bends provided
can be welded, in accordance with ASME IX, to the linepipe ordered for the
Project. The additive effect of the dimensional tolerances of both the bends and
the linepipe on bore misalignment shall be taken into account. In the field the
misalignment of the bores at the weld fit up stage shall not exceed 0.50mm.

11775-SPC-PL-002 Rev 0 Page 4 of 10


DESIGN OF NEW HYDRANT SYSTEM

6.4 Base Materials

6.4.1 Chemistry Requirements

The steel used in the manufacture of bends shall be made by the electric arc
furnace process or basic oxygen process, fully killed and of a fine grain size. The
chemical analysis shall comply with the following:-

Carbon 0.20% max


Manganese 0.8% to 1.60%
Sulphur 0.010% max
Phosphorus 0.025% max
Silicon 0.15% to 0.4%
Copper 0.35% max
Aluminum 0.025% to 0.060%
Nitrogen 0.012% max
Calcium 0.006% max

In addition the following limits on combinations shall apply to materials.

Mn Cr + Mo + V Ni + Cu
C.E. = C + + + = 0.42% Max
6 5 15

Ni + Cr + Mo = 0.30% Max
V + Nb + Ti = 0.15% Max
An analysis shall be required for each heat of steel used and from one completed
bend from each heat. If any bend analysis fails to meet the requirements above,
the whole heat shall be rejected.

6.4.2 Inspection Requirements

Plate or pipe material used to form the bends, shall be ultrasonically tested for
lamination using a procedure and acceptance criteria approved by the Company.

6.4.3 Material Certificate

Certified material test reports shall be submitted for each heat of pipe used to form
the bends.

6.5 Manufacture of Bends

6.5.1 Manufacturing Procedure Specification (MPS)

The Contractor shall submit a MPS to the Company which shall include but not
necessarily be limited to the following information:

a) Steel manufacture
b) Pipe manufacture
c) Welding procedure specification and procedure qualification record for
bends with longitudinal welds (API 5L and ASME VIII)
d) Forging procedure with temperatures, holding times etc

11775-SPC-PL-002 Rev 0 Page 5 of 10


DESIGN OF NEW HYDRANT SYSTEM

e) Final heat treatment


f) Non-destructive testing
g) Mechanical testing
h) Dimensional tolerance measurement
i) Marking and identification
6.5.2 Heat Treatment

Bends shall be supplied in the normalised or quenched and tempered condition.

Heat treatment charts shall be provided with the final documentation.

6.5.3 Weld End Bends

The ends of the bends shall be machined with a bevel of 30° + 5° -0 and a root
face of 1.5 mm + 1.0 mm – 0mm.

6.5.4 Longitudinal Weld

Where bends are formed from material with a longitudinal weld, the weld shall lie
within 5° of the neutral axis.

6.5.5 Weldability

The Contractor shall submit full detail of the suitability of the proposed material for
field welding. This shall include authenticated data that bends of the same
chemical analysis, carbon equivalent and manufacturing procedure have been
satisfactorily welded by manual metallic arc welding using cellulosic electrodes
with the stove pipe technique, without the need for post weld heat treatment.
Details of the cold cracking susceptibility of the material and confirmation that the
hardness of the field heat affected zone did not exceed 248 (HV10) is required.

6.6 Mechanical Properties of Completed Bends

The following tests shall be carried out on one fitting in every heat. Specimens
shall be taken from both the inner and outer radius.

i) Tensile Tests

The yield strength, tensile strength, elongation and reduction in area shall
be determined in the bend material using round bar transverse body
specimens and again in any weld by a round bar transverse weld
specimen as in API 5L.

ii) Guided Bend Tests

These shall be conducted on any longitudinal weld in accordance with API


5L but with a former radius equal to three times the nominal wall
thickness.

11775-SPC-PL-002 Rev 0 Page 6 of 10


DESIGN OF NEW HYDRANT SYSTEM

iii) Hardness Tests

These shall be on the parent metal, the HAZ and weld metal of any
longitudinal weld on a macro - section of the finished bend. The
acceptance level shall be 248 HV10 for any weld and 220 HV10 for the base
material.

iv) Fracture Toughness Tests

All grades and diameter of bends shall be Charpy tested in accordance


with MSS SP75.

6.7 Non-Destructive Testing (NDT)

Final NDT shall be carried out after heat treatment using procedures approved by
the Company.

Each fitting shall be blast cleaned to SA2½ (SIS 055900) and examined internally
and externally for surface defects to the standard required by API 5L.

Longitudinal welds shall be 100% X radiographed with fine grain film giving a
sensitivity of 1.5% or better. Film Density within the weld region shall be between
2 and 3. The testing and acceptance criteria shall be in accordance with API 5L.

No weld repairs shall be permitted to the body of the bend.

No more than two repairs in any weld seam shall be permitted and a maximum of
5% of the seam length may be repaired. Any bend repaired by welding will be
heat treated after repairs have been completed. The welding procedure shall be
submitted to the Company for approval.

The complete surface at each end of the bend shall be examined for laminations
using an ultrasonic technique and acceptance criteria approved by the Company.
Any lamination protruding into the bevel shall be rejected.

All external surfaces of the bends shall be 100% MPI tested to API 5L. Cracks or
any defect likely to interfere with the coating operation shall be cause for the bend
to be rejected.

The weld bevel shall be examined using an approved wet magnetic particle
method in accordance with API 5L. Lamination or defects in the weld bevel are
not acceptable.

Each completed bend shall be hardness tested using an approved portable


instrument. Hardness readings shall not exceed 248 HV10.

6.8 Tolerances

Each bend shall be checked to ensure it complies with the dimensional tolerances
listed in Clause 6.3.

The tolerance on nominal internal diameter (OD - 2 times nominal wall thickness)
at the weld bevels shall be ± 1.5 mm. If the external surfaces of the two
components are not aligned, the weld shall be tapered between the two surfaces
with a slope not steeper than 1:4. as per ASME B31.3.

11775-SPC-PL-002 Rev 0 Page 7 of 10


DESIGN OF NEW HYDRANT SYSTEM

Ovality at weld ends. A ring type internal gauge 5 mm less than the bend nominal
diameter shall pass freely through the ends of the bend.

Maximum wall thickness at the weld end shall not exceed the nominal by more
than 10%.

Internal Ovality. Two 13 mm aluminum gauging plates, each of 95% of the nominal
inside diameter of the matching pipeline diameter and rigidly held apart as
specified in Table 1.

Where this is not practicable because the gauge length exceeds the major chord
of the bend the Contractor shall provide alternative proposal with the bid for
Company approval.
o
The tolerance on the specified bend angle shall be ± 0.75 . The maximum out of
o
plane deviation shall be 5mm for bend angles up to 45 and 10mm for angles
o o
between 45 and 90 .

Table 1

Nominal Diameter Mandrel Length Gauge Plate Diameter


(inch) (mm) (mm)
6 150 140
8 150 190
10 150 242
12 150 290
14 250 320
16 400 367
18 500 411
20 600 460
24 750 552

Notes:

1. The aluminium alloy shall contain less than 6% Mg.

2. The actual gauge plate length measured at any point round the
circumference shall not vary by more than 1mm.

6.9 Marking

All bends must be identifiable against appropriate test certificates. An


identification plate shall be attached to the bends giving the following information:

a) Manufacturers Name

b) Name of Company and Purchase Order Reference Number

c) Angle of Bend
11775-SPC-PL-002 Rev 0 Page 8 of 10
DESIGN OF NEW HYDRANT SYSTEM

d) Unique Bend Identification Number

e) Material Grade

Die stamping on the bends shall not be permitted. The top dead centre line at
each end of the bend shall be clearly marked to facilitate lining up in the field.

6.10 Company Inspection

The Contractor shall secure the services of a reputable Third Party Inspection
Agency to carry out inspection and witnessing of manufacturing and testing
operations in accordance with the approved Inspection & Test Plan. The Third
party Inspection Agency proposed by the Contractor shall be subject to the
Company’s approval prior to order placement. All costs and expenses associated
with the Third Party inspection shall be borne by the Contractor. The Contractor
shall also be responsible for notifying and coordinating with the Third Party
Inspector to ensure that the requirements of the Inspection & Test Plan are
fulfilled.

An Inspector representing the Company may also be present at the Supplier’s


works throughout the sequence of operations involved in the manufacture of the
bends, from receipt of the pipes to the load-out of the bends and surplus pipe.

They shall have free entry to all those parts of the Supplier’s facilities that involve
the manufacture of the bends. All reasonable facilities shall be afforded to them to
enable them to ascertain that the product is being furnished in accordance with the
Specification.

6.11 Field Welding Procedure Test Pieces

Test pieces to qualify the field welding procedures are required in every case. The
quantity required shall be agreed with the Company and shall be stated on the
Purchase Order.

6.12 Coating and Lining

Where indicated in the Purchase Order, the Bends shall be externally coated and
internally lined in accordance with the applicable Project specifications referenced
in section 3.

6.13 Documentation

Documentation to be submitted for approval by the Company shall include the


following:

i) Prior to Order

Name and location of Third Party Inspection Agency


Proposed Inspection & Test Plan indicating levels of inspection and
witnessing by Supplier and Third Party Inspector.

ii) Prior to Manufacturing:

Data sheets/Bend Drawings with Dimensional Tolerances


Inspection & Test Plan(s)

11775-SPC-PL-002 Rev 0 Page 9 of 10


DESIGN OF NEW HYDRANT SYSTEM

iii) Final Documentation:

Data sheets/Bend Drawings


Manufacturing Record Book
Coating Records where applicable

11775-SPC-PL-002 Rev 0 Page 10 of 10


Design of New
Hydrant System
(Package #7)

Specification for
Factory Applied
Polyethylene
Coating of Linepipe Head Office:
Penspen Group Limited
3 Water Lane
Richmond upon Thames
Surrey
TW9 1TJ
United Kingdom

Regional Office:
Kuwait Aviation Fuelling Co Penspen International Limited
P.O. Box 46562
Abu Dhabi
United Arab Emirates

11775-SPC-PL-003 Rev 0
DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

1. Scope

1.1 General

This specification describes the requirements for a factory applied 3-layer extruded
polyethylene external coating to be provided to the linepipe for the new hydrant
system at Kuwait International Airport (KIA). This coating system is qualified for
maximum operating temperature of 85 °C.

All coating materials shall be applied in accordance with the Supplier’s


recommendations and the Contractor shall ensure that copies of such
recommendations are available to the Company and those of the Contractor's
personnel involved in this Work.

2. Precedence

Any case of apparent conflict between the requirements of this Specification and
any other relevant documents shall be notified to the Company. Unless otherwise
agreed the following descending order of precedence shall apply:-

1st This Specification


2nd Other Project Specifications
3rd The Codes and Standards listed in this specification
4th Other API, ASME, ANSI, BS Codes or Standards as appropriate

3. References

The following project documents and drawings shall be read in conjunction with
and form part of this specification:

Documents -

11775-SPC-PL-001 Specification for Linepipe


11775-SPC-ME-009 Specification for Storage, Handling and Transportation of
Linepipe & Fittings

4. Definitions

The ‘Company’ is KAFCO (Kuwait Aviation Fuelling Company) or their appointed


agent or representative.

The ‘Consultant’ is Penspen Limited or their appointed agent or representative.

The ‘Relevant Authority’ is any statutory authority, company, agency, contractor or


other party who may be affected by the Work.

The ‘Contractor’ is the organization employed by the Company or their appointed


agent or representative in order to carry out the Work.

11775-SPC-PL-003 Rev 0 Page 3 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

The ‘Supplier’ is the vendor, manufacturer or supplier of equipment and/or


materials defined in this specification.

The “Work” is the extension of the new hydrant system at Kuwait International
Airport (KIA).

Throughout this document the following terminology is used:

“must” signifies a legal or statutory requirement


“shall” signifies a requirement made mandatory by this Specification
“may” signifies a feature which is discretionary in the context in which it is
applied
“will” signifies a feature which the Contractor may assume to be already
present.

5. Codes and Standards

This Specification makes reference to the latest edition of the following documents
which shall be applicable as referenced.

API 5L Specification for Line Pipe


ASTM 4940 Standard Test method for Conductimetric Analysis of
Water Soluble Contamination of Blasting Abrasives.
ASTM D-1693 Standard Test Method for Environmental Stress-Cracking
of Ethylene plastics
ISO 306 Plastics. Thermoplastic materials. Determination of Vicat
softening temperature (VST)
ISO 527 Plastics. Determination of tensile properties
ISO 868 Plastics and Ebonite. Determination of indentation
hardness by means of a Durometer (Shore Hardness)
ISO 1133 Plastics. Determination of the melt mass-flow (MFR) and
the melt volume-flow rate (MVR) of thermoplastics.
ISO 2808 Paints and varnishes. Determination of film thickness.
ISO 8501-All parts Preparation of Steel Substrates before Application of
Paints and Related Products - Visual assessment of
surface cleanliness
ISO 8502-3 Preparation of Steel Substrates before Application of
Paints and Related Products - Test for the assessment of
surface cleanliness. Assessment of dust on steel
surfaces prepared for painting (pressure-sensitive tape
method).
ISO 8502-9 Preparation of Steel Substrates before Application of
Paints and Related Products - Test for the assessment of
surface cleanliness. Field method for the conductometric
determination of water soluble salts.

11775-SPC-PL-003 Rev 0 Page 4 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

ISO 8503-All parts Preparation of Steel Substrates before Application of


Paints and Related Products - Surface roughness
characteristics of blast cleaned steel substrates
ISO 9001 Quality management systems. Requirements
ISO 11124-All parts Specification for metallic blast-cleaning abrasives
ISO 11357-2 Plastics. Differential scanning calorimetry (DSC).
Determination of glass transition temperature.
ISO/DIS 21809-1 Petroleum and natural gas industries – External coatings
for buried or submerged pipelines used in pipeline
transportation systems – Part 1: Polyolefin coatings (3-
layer PE and 3-layer PP)

6. Technical Requirement

6.1 Coding System

The coating system shall be a 3-layer extruded high density bi-modal polyethylene
(PE) system fully suitable for the maximum operating temperature and other
service conditions advised by the Client. The total thickness of the coating will vary
according to the each pipeline diameter and wall thickness.

The coating system of each linepipe diameter shall meet the requirements of
Table 1.

Pipe Powder Co-polymer Extruded Total


Diameter Epoxy Layer Adhesive Polyethylene Coating
(mm) (mm) (mm) Thickness
(mm)
24’’ 0.35 0.15 1.7 2.2
20”, 16”, 12” 0.35 0.15 1.3 1.8
8”, 6” 0.35 0.15 1 1.5

Table 1: Coating System Thicknesses

6.2 General

The Contractor shall maintain a quality assurance system which complies with ISO
9001 to ensure that all requirements of this specification and contract documents
are met.

The Contractor shall submit written procedures for all activities required by this
specification for review and must receive approval from the Company prior to
commencement of any coating operations.

All certification, test results, reports and any other documentation submitted shall
be in English

6.3 Procedure Qualification Trial (PQT)

Prior to commencement of any coating operations, the Contractor shall undertake


a PQT which will include all preparation, coating and inspection procedures.

11775-SPC-PL-003 Rev 0 Page 5 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

The PQT shall utilise pipes of the same dimensions as those to be coated during
production. A minimum of 5 pipes shall be coated and tested. Requirements for
material data sheets, frequency of testing and inspection, methods and acceptance
criteria are contained in Appendix B:

The pipes shall be coated as follows:

- One third of pipe shall be FBE primed only.


- One third of the pipe shall be FBE primed and adhesive copolymer coated
only.
- The last third of the pipe shall be FBE primed, copolymer adhesive coated
and HDPE coated.

The PQT shall be witnessed by the Company. The results from the PQT shall be
recorded by the Contractor and submitted to the Company for approval. The
Company shall have the right to witness the performance of tests and to examine
the results of any tests conducted.

Production will only commence when the Company has accepted the test results in
writing.

6.4 Materials

All materials shall be totally suitable for the coating system specified and the
pipeline usage advised by the Company. The Supplier shall ensure all details of
the primer, adhesive layer and polyethylene to be applied are available for review
and approval prior to commencing coating production. These details shall as a
minimum include those identified in Appendix B:

The Supplier shall retain samples of each powder batch for a period of one year.
The sample shall be sufficient size for the following tests if required:

FBE Powder:

- Instrumental analysis, IR and DTA


- Gel Time
- Moisture Content
- Bond Tests
- Cathodic Disbonding Test

Grafted Adhesive/PE:

- Density
- Moisture content
- Melt index
- Elongation @ break

Materials for pipe coating shall be unloaded in a manner to prevent damage or loss
and shall be stored in a manner to preserve their condition, prevent loss and permit
easy access for checking.

11775-SPC-PL-003 Rev 0 Page 6 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

6.5 Manufacturing & Inspection Procedures

The Contractor shall submit both a Coating Manufacturing Procedure and


an Inspection & Test Plan to the Company for agreement prior to the start of
coating operations.

The Coating Manufacturing Procedure shall describe all works associated with the
coating manufacture including:

1. The coating materials, including all material properties as stated in


Appendix B;
2. Surface preparation – general information;
3. Coating application, including the control of essential process parameters;
4. Inspection & testing – general information;
5. Coating repairs;
6. Preparation of pipe ends after coating;
7. Marking and documentation;
8. Handling and storage of coated pipes.

The Inspection and Test Plan (ITP) shall describe all the inspection, testing and
calibration procedures that are applicable to this project. ‘Witness’ and ‘Hold’
points shall be clearly identified. The ITP shall also include a format for the daily
log.

6.6 Pipe Transportation and Storage

Transportation and storage procedures of bare linepipe shall ensure the pipe is
maintained in a fully satisfactory condition, with no detriment to the subsequent
coating system. Procedures shall be fully in accordance with relevant project
specifications.

6.7 Pipe Receipt and Storage

Materials for pipe coating shall be unloaded in a manner to prevent damage or loss
and shall be stored in a manner to preserve their condition, prevent loss and permit
easy access for checking.

6.8 Surface Preparation

All preparation and coating of the pipe shall be carried out in a fully enclosed
weatherproof building.

Abrasive cleaning shall not be carried out when the metal surface is less than 3°C
above the ambient dew point or when the relative humidity is greater than 85%.

Before abrasive blast cleaning, pipe surfaces shall be free of all surface
contamination. Oil, grease or similar contaminants shall be removed with a solvent
or detergent. Salt contamination, chemical cleaning agents and remaining
detergents shall be washed off with fresh, potable water. Any water used for such
purposes shall be checked for pH which shall be within the range 6.5 to 7.5. Pipes
shall be dry before abrasive blast cleaning.

11775-SPC-PL-003 Rev 0 Page 7 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

The pipes shall be cleaned by automatic rotary blast cleaning. Only dry abrasive
materials shall be employed and the abrasive shall be maintained free from dust,
salts and other impurities. The preferred blasting medium shall be steel grit. The
grit shall contain sulphates and chlorides less than 100 ppm and carbonates less
than 2%. Proper particle size of grit shall be supplied to produce the required clean
angular surface profile. Any surface which in the opinion of the Company is
unsatisfactory shall be re-blasted.

The standard required at the time of coating shall be a minimum of ISO 8501-1
grade Sa 2½, with a surface profile of 70 + 20 microns peak to trough height. Each
pipe shall be visually inspected to check compliance with this standard.

The number of points at which the surface profile shall be measured shall be as
determined in the qualification of the procedure. Any surface which in the opinion
of the Company is unsatisfactory shall be re-blasted.

Pipes shall be free of chloride contamination. Prior to commencement of blast


cleaning ten pipe joints selected at random from the pipe storage area shall be
tested for chloride contamination in accordance with ISO 8502-9. Where chloride
contamination on pipes is identified, the blast cleaning of the pipe surface shall be
subsequently treated with phosphoric acid. Fresh water wash shall be tested for
3
the presence of residual chlorides which shall be no greater than 40 mg/m . The
results of these tests shall be used by the Company to determine whether all pipes
shall be washed prior to surface preparation.

The condition of the pipe shall be checked for manufacturing and handling defects
during cleaning. Defects detrimental to the coating process shall be removed by
gentle grinding. Any grinding shall not violate API 5L or relevant project
specifications.

Any pipe which has not been coated within four hours of blasting, or before visible
re-rusting occurs, shall be re-blasted.

Immediately before the application of the coating, all surfaces to be coated shall be
rendered free of dust and grit by blowing off the surface with clean dry air or by
vacuum extraction.

6.9 Coating Application

The pipe shall be coated strictly in accordance with the material Supplier’s
application procedures.

Each batch of material shall be completely used in date sequence in which it has
been manufactured. Material that has expired shall not be used.

For all processes the preheating temperatures and extrusion temperatures shall
comply with the requirements set in the application procedures and all equipment
shall be able to maintain uniform temperatures throughout the coating process.
Temperatures shall be continuously monitored and recorded at selected points by
means of surface pyrometer or other alternative method agreed upon with the
Company. The heating process shall be demonstrated during the pre-qualification
programme, and shall be subject to the Company approval. Any pipes coated
during temperature deviations shall be marked and subject to additional testing to
the satisfaction of the Company.

The coating application process shall be such as to ensure a fully satisfactory


interlayer bonding at all parts of the circumference of the line pipe. This shall in
particular apply to the longitudinal and the region adjacent to the edges of the final
weld cap. Absence of voids and interlayer bond shall be verified by means of
peeling tests or partial stripping of coating along the longitudinal.

11775-SPC-PL-003 Rev 0 Page 8 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

There shall be no voids or air entrapments at any location, including alongside the
seam weld, if presented.

The pipe shall be provided with a minimum coating thickness in accordance with
Table 1 Section 6.1 of this specification.

The Inspection methods and its relevant frequency during production shall be in
accordance with Appendix B:

6.10 Coating Cut-back

The PE coating shall be removed over a length of 150 mm -0 + 10 mm at each


pipe end. The PE shall be bevelled to an angle not exceeding 30° measured in
direction of pipe axis. The cut back shall be measured from the root face of the
pipe to the beginning of the coating bevel.

The FBE layer shall extend 15 mm + 5 mm beyond the toe of the PE bevel.

Precautions shall be taken to avoid any disbondment at the cut-back during


transport and storage of coated pipe. The transition zone between pipe and
coating shall be protected from ingress of moisture by applying a band of varnish or
other sealant on the coating and bare pipe.

6.11 Coating Repairs

In the event that problems are detected or repairs are needed, Contractor shall
take immediate steps to correct the situation.

Scars, dents, damaged areas and holidays shall be cleaned by removing all dust,
scale, dirt or other foreign materials or loose coating using hand tools.

Repairs are to be made by means of a repair procedure approved prior to


commencement of work. Any pipe subject to a coating repair shall be fully re-
examined in accordance with inspection and testing requirements detailed in
Appendix B:.
2
The defect area shall not exceed 10 cm and the total number of defects to be
repaired shall not exceed 1 defect/m2 of coated surface unless otherwise agreed
by the Company. Where the size or number of defects exceeds these limits. The
affected pipe shall be stripped and recoated in accordance with the agreed
procedures.

6.12 Inspection and Testing Plan (ITP) and Daily Log

The Contractor shall develop and agree with the Company an ITP which identifies
all pipe preparation, coating application and quality control activities in a
consecutive order, including process parameters that are relevant to each activity.
Reference shall be made to the applicable standards or Contractor’s procedures,
frequencies and acceptance criteria that shall apply for each process control and
inspection/testing activity and actions in case of non-conformities.

A Daily Log shall be used to record all inspection and testing data, process
parameters and calibration of equipment for quality control.

The ITP and Daily Log shall meet the requirements detailed in Appendix B:

11775-SPC-PL-003 Rev 0 Page 9 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

6.13 Identification Numbering

6.13.1 Pipe Number

All pipes will be allocated a unique serial number at the pipe mill. The coated pipe
shall be marked (including the serial number) as specified in API 5L and the
appropriate project linepipe specification as agreed with the Company.

Pipe serial numbers shall not be die-stamped.

6.13.2 Pipe Tally

The Contractor shall maintain comprehensive tallies of the serial numbers of the
pipes received, pipes taken for coating, pipes accepted or rejected at the pre-
coating inspection stage, pipes accepted after coating and pipes which have been
rejected during the coating stage and put aside or recycled through the process.

All such tallies shall be maintained strictly in the correct sequence and the date and
time of recording shall be included wherever relevant and/or required by the
Contractor.

6.13.3 Pipe Markings

If the original stenciled serial numbers cannot be maintained and protected


throughout the coating process, then the Contractor shall propose a procedure for
the re-application of the serial number.

6.13.4 Identification Bands

Where so specified by the Company the Contractor shall mark each end of each
pipe with neatly painted bands of colour 50mm wide around the circumference. Up
to 3 bands of different colours may be required. Different colour combinations may
be required for each type of pipe/coating combination.

6.14 Reporting

Reports shall be kept of all relevant data for each individual pipe joint. This shall
include, but not be limited to, the following:-

(1) Material batch numbers and certificates detailing all the information
required for each batch as defined in this specification.
(2) Details of blasting abrasive, measurement of surface profiles, surface
preparation standard and recording of environmental conditions prevailing
during blasting.
(3) Recording of steel surface defects and repairs.
(4) Surface temperature of pipe prior to coating.
(5) Results of all tests as defined in this Specification.
(6) Details of repairs to coating defects exposed during testing and the repair
techniques used.
(7) Details of rejected pipe, with reasons for failure.
(8) Information on pipe which, after rejection, requires complete recycling.

Such information shall be submitted daily by the Contractor to the Company.

11775-SPC-PL-003 Rev 0 Page 10 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Coating pipe which is submitted to the Company for approval shall not be accepted
unless accompanied by the above information. Failure to supply such information
shall be cause for rejection.

6.15 Storage and Delivery of Pipe

The handling & storage of linepipe shall be carried out in accordance with the
project specification 11775-SPC-ME-009.

The greatest care is to be taken at all times to avoid damage to the pipe, the
prepared welding end or the coating. Pipes may be stacked in tiers such that no
damage is or could be caused to the pipe, or its coating.

Pipe shall be carefully lowered to limit impact effects and stacked in such a way,
that water and mud cannot accumulate within the pipe.

If the pipe is delivered to the Contractor with end caps, these are to be carefully
removed and replaced after coating is complete and after the ends have been
inspected by the Company for damage. Damage end caps are to be replaced to
the satisfaction of the Company.

11775-SPC-PL-003 Rev 0 Page 11 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Appendix A: Data Sheet for Service Condition

A.1 Design Temperature Conditions:

Above ground piping (not shaded): +10 to +85°C

Above ground piping (shaded): +50°C max

Buried piping: -5 to +50°C (at 1.2 metre below ground)

A.2 Process Parameters:

Fuel Type: Jet A-1 (aviation-kerosene)

Fluid Velocity (max): 3.5 metres/sec

Design Pressure: 16 barg (225 psig)

Flange Rating: ANSI Class 150

Hydrant Pit Isolation Valves: ANSI Class 300

11775-SPC-PL-003 Rev 0 – Appendix A Page 12 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Appendix B: Materials Certificates and Inspection and Testing

B.1 Materials

B.1.1 Certification

Each batch of material supplied to the Contractor shall be accompanied by a


certificate stating that all the tests required have been carried out on every batch
and that the results are in accordance with this Specification.

The Contractor shall issue the Company with copies of all related certificates prior
to using the material for coating pipe. Material for which no satisfactory test
certificates have been received shall not be used for coating pipe.

Batch certificates shall contain the information given in the following Table with test
methods and acceptance criteria.

Coating Material
Content
FBE Primer Adhesive PE top coat
Identification of manufacturer X X X
Product identification X X X
Batch identification X X X
Date & place of manufacturing X X X
Density X X X
Melt flow rate X X
Gel time X
Particle size X
Moisture/water content X X X
Carbon black content X
Pigment dispersion X
Thermal characteristics X
Reactive site content X

B.1.2 Approved Materials

The Contractor shall ensure that the material supplier submits data sheets for the
approved material, together with recommendations for storage and coating
application procedures, which will ensure that the pipes when coated will meet all
the requirements of this Specification.

Data sheets submitted by the Supplier shall include acceptable values for the
following properties,

a) FBE Primer
- colour
- maximum thickness ISO 2808
- storage temperature min & max
- shelf life at storage temperature

11775-SPC-PL-003 Rev 0 – Appendix B Page 13 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

- minimum glass transition temperature ISO 11357


b) Adhesive
- colour
- storage temperature min & max
- shelf life at storage temperature
- elongation at break ISO 527
- tensile yield strength ISO 527
- Vicat softening point ISO 306

c) Polyethylene
- colour
- storage temperature min & max
- shelf life at storage temperature
- elongation at break ISO 527
- tensile yield strength ISO 527
- Vicat softening point ISO 306
- hardness ISO 868
- ESCR ASTM D-1693

B.2 Inspection and Testing


Inspection and testing shall be carried out in accordance with the agreed
procedures and shall meet the requirements of the following Tables A and B.

Table A – Requirements for inspection of surface preparation

Test Frequency Frequency


Properties Requirements
Method Qualification Production
Surface
Visual free of
condition before each pipe each pipe
inspection contaminations
blasting
Surface conductive 5 pipes at start
salt content
condition after measurement each pipe of production
max. 20 mg/m2
blasting ISO 8502-9 and 1 pipe/shift
Environmental as determined at time of
calculation once every 4 h
conditions measurement
Pipe
min 3 oC above the dew
temperature thermocouple once every 4 h
point
before blasting
conformity to certificate
Size, shape and visual +
compliance to
properties of certification once 1/day
manufacturing/ working
abrasive ISO 11124
procedures
Water soluble
conductivity
contamination ASTM 4940 once 1/shift
max. 60 mS/cm
of abrasives
Surface
roughness of
ISO 8503-4 50 to 100 µm each pipe every 1 h
blasted surface
(Rz/Ry5)
Visual
inspection of
ISO 8501-1 grade Sa 2½ each pipe each pipe
blasted surface

Presence of
dust after dust ISO 8502-3 max. class 2 each pipe every 1 h
removal

11775-SPC-PL-003 Rev 0 – Appendix B Page 14 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Test Frequency Frequency


Properties Requirements
Method Qualification Production
Pipe condition no rust, pipe temperature
monitoring continuously continuously
prior to coating at least 3 above dew point
Temperature of compliance to
extruded thermometer manufactures/working once every 1 h
adhesive & PE procedures
Preheating compliance to
temperature thermometer manufactures/working each pipe every 5th pipe
before coating procedures

Table B – Requirements for inspection and testing of applied coating

Test Frequency Frequency


Properties Requirements
Method Qualification Production
Minimum FBE min 350 µm
ISO 2808 at start up each start up
thickness See Note 1
ISO/DIS
Degree of cure 21809-1
∆Tg < +3 oC at start up each start up
FBE Annex D
ISO 11357-2
Minimum
adhesive to be agreed min 150 µm on pipe body at start up each start up
thickness
visual/
Appearance ISO/DIS
See Note 2 continuously continuously
and continuity 21809-1
Annex B
Minimum total ISO/DIS
According to pipeline
thickness of 21809-1 each pipe every 10th pipe
diameter
coating Annex A
ISO/DIS
Impact once per PE
21809-1 >7 J/mm 3 pipes/duty
resistance batch
Annex E
ISO/DIS
> 15 N/mm @ 23 oC
Peel strength 21809-1 3 pipes/duty every 4 h
> 3 N/mm @ 80 oC
Annex C
ISO/DIS
< 0.2 mm @ 23 oC
Indentation 21809-1 once each PE batch
< 0.4 mm @ 80 oC
Annex F
Elongation at
ISO 527 > 400 % once each PE batch
break
ISO/DIS
Cathodic
21809-1 < 7 mm See Note 3 once 1/day
disbondment
Annex H
ISO/DIS
Flexibility 21809-1 no cracking once -
Annex I
In process
∆MFR max 20 % between
degradation of ISO 1133 once at start up
raw and extruded material
PE
Cutback measuring 150 mm + 10 mm each pipe each pipe
visual/
once for
Coating repairs holiday no holidays each defect
demonstration
detection

11775-SPC-PL-003 Rev 0 – Appendix B Page 15 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Notes:-

1. A total of 12 readings taken at four equally spaced longitudinal lines. All readings must pass
minimum.
2. Coating shall be free of defects and discontinuities, delamination, separations and holidays.
Demo to detect 1 mm dia defect, voltage set @ 10 kV/mm coating thickness, up to 25 kV max.
3. Test to be carried out for 28 days @ 23 oC and -1.5V or 24 hours @ 65 oC and -3.5 V oC
and -3.5 V

11775-SPC-PL-003 Rev 0 – Appendix B Page 16 of 16


Design of New
Hydrant System
(Package #7)

Specification for
Cold Applied Tape
Coating Head Office:
Penspen Group Limited
3 Water Lane
Richmond upon Thames
Surrey
TW9 1TJ
United Kingdom

Kuwait Aviation Fuelling Co Regional Office:


Penspen International Limited
P.O. Box 46562
Abu Dhabi
United Arab Emirates

11775-SPC-PL-004 Rev 0
DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

1. Scope

This specification covers the requirements for cold applied tape coating for the new
hydrant system at Kuwait International Airport (KIA).

2. Precedence

Any case of apparent conflict between the requirements of this Specification and
any other relevant documents shall be notified to the Company. Unless otherwise
agreed the following descending order of precedence shall apply:-

1st This Specification


2nd Other Project Specifications
3rd The Codes and Standards listed in this specification
4th Other API, ASME, ANSI, BS Codes or Standards as appropriate

3. References

The following project documents shall be read in conjunction with and form part of
this specification:

11775-SPC-PL-003 Specification for Factory Applied Polyethylene Coating


of Linepipe

4. Definitions

The ‘Company’ is KAFCO (Kuwait Aviation Fuelling Company) or their appointed


agent or representative.

The ‘Consultant’ is Penspen Limited or their appointed agent or representative.

The ‘Relevant Authority’ is any statutory authority, company, agency, contractor or


other party who may be affected by the Work.

The ‘Contractor’ is the organization employed by the Company or their appointed


agent or representative in order to carry out the Work.

The ‘Supplier’ is the vendor, manufacturer or supplier of equipment and/or


materials defined in this specification.

The “Work” is the extension of the new hydrant system at Kuwait International
Airport (KIA).

Throughout this document the following terminology is used:

“must” signifies a legal or statutory requirement


“shall” signifies a requirement made mandatory by this Specification
“may” signifies a feature which is discretionary in the context in which it is
applied
“will” signifies a feature which the Contractor may assume to be already
present.

11775-SPC-PL-004 Rev 0 Page 3 of 6


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

5. Codes and Standards

This Specification makes reference to the latest edition of the following documents
which shall be applicable as referenced.

ISO 8501-1 Preparation of Steel Substrates before Application of Paints


and Related products – Visual Assessment of Surface
Cleanliness:
Rust grades and preparation grades of uncoated steel
substrates and of steel substrates after removal of previous
coatings.
AWWA C209 Cold Applied Tape Coatings for the Exterior of Special
Sections, Connections, and Fittings for Steel Water
Pipelines.
SSPC The Steel Structures Painting Council
SSPC -SP 1 Solvent Cleaning
SSPC -SP 3 Power Tool Cleaning
SSPC -SP 6 Commercial Blast Cleaning

6. Technical Requirement

6.1 Material Acceptance

Prior to commencement of the coating operations, the Contractor shall submit to


the Company all necessary data sheets, test certificates and material safety data
sheets for the proposed coating materials and procedures for approval.

6.2 Materials

Tape shall be a cold applied, self-adhesive type, comprising of a bituminous resin


adhesive on a PVC backing layer. Tapes with butyl rubber adhesives shall not be
used.

The total thickness of the tape shall be 1.65mm and the minimum PVC film
thickness shall be 0.75 mm.

The tape width and grade shall be suitable to conform to the size and shape of the
structure being wrapped. In general medium or light duty tapes shall be used for
pipe diameters equal to 75mm or less and also for tees and other irregular fittings.
The following guidelines shall apply to the tape widths:

 Pipe diameters 100mm to 300mm Tape widths 50mm to 100mm


 Pipe diameters greater than 300mm Tape widths 100mm to 150mm

The primer material shall be manufactured by the tape manufacturer, or as


recommended by the tape manufacturer, and shall be a fast drying compound
suitable for application by brush or spray.

Mastic filler shall be suitable for profiling and be that recommended and/or
manufactured by the tape manufacturer.

11775-SPC-PL-004 Rev 0 Page 4 of 6


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

6.3 Surface Preparation

The preferred method of surface preparation for metal surfaces shall be abrasive
blast cleaning. The minimum blast clean grade shall be Sa2 as per ISO 8501-1
(equivalent to SSPC-SP6, commercial grade). After blast cleaning the metal
surface shall be inspected and any burrs, slivers or scabs removed by grinding
without compromising the minimum wall thickness of the pipe or fitting.

Power wire brushing in accordance with ISO 8501-1 St 3 (equivalent to SSPC-SP3)


may be used where the surface has been previously blast cleaned in mill or shop
conditions removing all millscale. Care shall be taken to avoid producing a
polished or burnished metal surface during wire brushing. Oil or grease on the
surface shall be removed before wire brushing by solvent cleaning as per SSPC-
SP1.

Hand wire brushing shall not be used for metal surface preparation.

The overlap area of factory coated pipe ends or fittings shall be lightly abraded by
abrasive blasting or wire brushed for a minimum distance of 100 mm. At girth weld
joints the factory coating shall be bevelled.

6.4 Coating Application

Immediately prior to primer application the surface shall be totally dry and free of all
dust and loose dirt. The primer shall be applied in accordance with the tape
Supplier’s recommendations.

All surfaces to be wrapped shall be primed and allowed to dry. Primer application
shall be limited to that amount that can be wrapped during the working day, after
which re-priming or stripping and re-priming will be required.

After surface preparation and priming, all protrusions and indentations shall be
profiled with mastic filler before tape wrapping.

Where cable connections are to be coated, cable tails shall be secured to the pipe
with a lap of tape and then the connection profiled with mastic.

Tape shall be applied in a spiral fashion by hand or hand-operated machines with


sufficient tension to give constant adherence without wrinkles or air pockets. Air
pockets should be smoothed out as application proceeds.

Application of the tape wrap shall comply with one of the following methods :

• The tape shall be spirally wrapped in a single application with a minimum of a


55% overlap. This is the recommended method.
• The tape shall be spirally wrapped with a minimum overlap of 25mm. This
shall be repeated as a second, separate application. The second layer shall
extend onto the adjoining factory coating one wrap beyond the first layer (i.e.
shall not finish at the same point) and be arranged such that the 25mm
overlap areas do not coincide. (Note: The 25mm overlap is generally used for
self-adhesive tapes and non-bituminous tapes and commonly employed in the
wrapping of water pipes.)

The interleaving film/paper shall be removed as wrapping proceeds. All discarded


materials shall be cleared from site.

The tape wrapping shall start and finish to give a minimum overlap of 75 mm onto
adjoining factory applied coating. Both the start and final wrap shall be at either the
3 o’clock or 9 o’clock position, with the tape pointing down. On completion of the
wrap, the surface of the tape shall be smoothed by hand to ensure complete
sealed overlaps and absence of air pockets under the tape.

11775-SPC-PL-004 Rev 0 Page 5 of 6


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

All tape wrap areas shall have a minimum of three and a half circumferential pipe
laps.

6.5 Coating Repairs

Where directed by the Company damaged factory applied coating shall be repaired
using the tape system.

Edges of the factory applied coating at the damage area shall be lightly abraded
and feathered. If bare steel is exposed then the area shall be blast cleaned to Sa2
or power brushed to St 3 standard as per ISO 8501-1. The prepared area shall be
then primed and, if necessary, mastic filler used to restore the original thickness of
the factory applied coating.

The complete area shall then be spirally tape wrapped with the wrapping beginning
and finishing a minimum of 100mm from the edge of the damaged area. A 55%
overlap shall be used on repair areas.

6.6 Inspection and Testing

The tape coated pipe shall be visually inspected for smoothness and conformity to
the pipe or fitting. Air pockets, voids and wrinkles shall not be permitted.

Adhesion tests may be carried out on selected sample areas at the discretion of
the Company’s representative. The applied tape shall be inspected to confirm that
effective bond is formed between the pipe surface and the tape. Adhesion tests
shall not be carried within 24 hours of completion of wrapping.

All tape wrapped areas shall be subject to 100% holiday inspection. The electrical
inspection shall be carried out in accordance with the procedure outlined in Section
5.2 of AWWA C209. The operating voltage shall be calculated as per AWWA
C209 but limited to a maximum of 15,000 volts.

11775-SPC-PL-004 Rev 0 Page 6 of 6


Design of New
Hydrant System
(Package #7)

Specification for
Factory Applied
Internal Lining
Head Office:
Penspen Group Limited
3 Water Lane
Richmond upon Thames
Surrey
TW9 1TJ
United Kingdom

Kuwait Aviation Fuelling Co Regional Office:


Penspen International Limited
P.O. Box 46562
Abu Dhabi
United Arab Emirates

11775-SPC-PL-005 Rev 0
DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

1. Introduction

This specification is for the factory application of an internal lining to linepipe with
nominal diameters of 4” and greater. This specification shall also apply for the
application of an internal lining to bends and tee-pieces, hereby referred to as
fittings.

The linepipe will be used to transport aviation fuel (Jet A-1). The lining shall be a
two-pack epoxy resin that shall have no deleterious effects on aviation fuel or fuel
additives.

All coating materials shall be applied in accordance with the Supplier's


recommendations and the Contractor shall ensure that copies of such
recommendations are available to the Company and those of the Contractor’s
personnel involved in this work.

2. Precedence

Any case of apparent conflict between the requirements of this specification and
any other relevant documents shall be notified to the Company. Unless otherwise
agreed, the following descending order of precedence shall apply:

1st This specification.

2nd Other project specifications included in this specification.

3rd The codes and standards listed in this specification.

4th Other (API, ASME, ANSI, BS) codes or standards, as appropriate.

3. References

The following project documents are referenced within this specification:

11775-SPC-PL-001 Specification for Linepipe

11775-SPC-ME-009 Specification for Storage, Handling and Transport of Line


Pipe & Fittings

4. Definitions

The ‘Company’ is KAFCO (Kuwait Aviation Fuelling Company) or their appointed


agent or representative.

The ‘Consultant’ is Penspen Limited or their appointed agent or representative.

The ‘Relevant Authority’ is any statutory authority, company, agency, contractor or


other party who may be affected by the Work.

The ‘Contractor’ is the organization employed by the Company or their appointed


agent or representative in order to carry out the Work.

11775-SPC-PL-005 Rev 0 Page 3 of 11


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

The ‘Supplier’ is the vendor, manufacturer or supplier of equipment and/or


materials defined in this specification.

The “Work” is the extension of the new hydrant system at Kuwait International
Airport (KIA).

Throughout this document the following terminology is used:

“must” signifies a legal or statutory requirement


“shall” signifies a requirement made mandatory by this Specification
“may” signifies a feature which is discretionary in the context in which it is
applied
“will” signifies a feature which the Contractor may assume to be already
present.

5. Codes and Standards

This specification makes reference to the following codes, standards and


regulations.

API 5L Specification for Line Pipe


Paints and Varnishes. Examination and Preparation of
BS EN ISO 1513
Samples for Testing
BS EN ISO 1514 Paints and Varnishes. Standard Panels for Testing
BS EN ISO 1518 Paint and Varnishes. Scratch Test
Paints and Varnishes. Determination of Flow Time by Use of
BS EN ISO 2431
Flow Cups
Paints and Varnishes. Determination of Resistance to
BS EN ISO 2812-1
Liquids- Part 1 General Methods
BS EN ISO 3696 Water for Laboratory Use. Specification and Test Methods
Specification for Temperatures and Humidities for
BS EN 23270 Conditioning and Testing Paint, Varnishes and their Raw
Materials
Paints and Varnishes. Determination of Through-dry State
BS EN 29117
and Through Dry Time. Method of Test
BS EN 45014 General Criteria for Supplier’s Declaration of Conformity
BS 1134 Assessment of Surface Texture
BS 3900 Method of Test for Paints
Preparation of Steel Substrates before Application of Paint
BS 7079
and Related Products
DEF STAN 80- Paint, System, for the Interior of Bulk Fuel Tank and Fittings,
97/3 Two Pack. (MoD Defence Standard)
Turbine Fuel Aviation: Kerosene Type, Containing Fuel
DEF STAN 91-87 System Icing Inhibitor. NATO Code F34. Joint Service
Designation: AVTUR/FSII

11775-SPC-PL-005 Rev 0 Page 4 of 11


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Environmental Part 1 PG6/23 (97), Secretary of States Guidance- Coating


Protection Act of Metal and Plastics. Method of Measurement of Volatile
1990 Appendix 3 Organic Compound Content of Coating
Determination of Thermal Oxidation Stability of Gas Turbin
IP 323
Fuels. JFTOT Method
Methods of Test for Petroleum and its Products. Petroleum
IP 540 Products. Gum Content of Light and Middle Distillate Fuels.
Jet Evaporation Methods
Preparation of Steel Substrates before Application of Paints
ISO 8502-9 and Related Products - Tests for the Assessment of Surface
Cleanliness.

6. Technical Requirement

6.1 Prequalification

Prior to commencement of the coating operations, the Contractor shall submit to


the Company all necessary details of the proposed coating materials and
procedures for qualification and approval.

Where the Company considers that the Contractor has not satisfactorily
demonstrated that the proposed coating materials and procedures will meet the
requirements of this specification, the Contractor shall undertake a pre-qualification
test programme in accordance with DEF STAN 80-97 Issue 4, Table 1. The
acceptable criteria for the coating material shall meet the requirements of this
table.

The test programme shall be proposed by the Contractor and witnessed by the
Company. The results shall be recorded by the Contractor and submitted to the
Company for approval.

6.2 Pipe Transportation and Storage

Transportation and storage procedures of bare linepipe shall ensure the pipe is
maintained in a fully satisfactory condition, with no detriment to the subsequent
coating system. Procedures shall be fully in accordance with relevant project
specifications.

6.3 Materials

The paint coating shall be a two pack epoxy resin based material cured with
polyamide, amine or amine adduct resin.

The paint shall not contain metallic zinc, aluminium, lead, copper or copper alloys.

The Contractor shall submit a declaration of conformity that the product fully
complies with the requirements of this specification and in accordance with BS EN
45014.

The paint shall be tested, and pass, the requirements of Test 13 - Determination of
effect on and resistance to aviation fuels as per DEF STAN 80-97 Annex G. A
Certificate of Conformity from an accredited laboratory may be submitted for
acceptance during pre-qualification.

11775-SPC-PL-005 Rev 0 Page 5 of 11


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

The Contractor shall ensure that all materials supplied for the coating operation
shall be suitably marked, giving the following information:

- The name of the manufacturer


- Name and type of material.
- Batch number.
- Date of manufacture and expiration.
- Reference to the manufacturer's product and safety data sheets.
- Storage conditions (i.e. min & max temperature range).

Material which is supplied without the above information shall be rejected and
removed from site. Replacement material shall be supplied at the expense of the
Contractor.

All paint shall be kept under cover in conditions as recommended by the


manufacturer. Paint coating materials shall not be shipped or stored in any
manner that will affect application or performance characteristics. Material shall
not be used after the expiration date.

The Contractor shall handle, mix and thin the coating materials in strict accordance
with the Suppliers written recommendations. All material preparation shall be
carried out at a place near to where the coating work is to be done.

The pigmented component materials shall be mixed to a homogeneous state


before any material is withdrawn from the shipping container. All paint shall then
be thoroughly prepared by mechanically mixing the component parts to ensure that
a homogeneous mixture is obtained. For 5 litre containers, hand mixing will be
permitted. Only thinners of a quality and quantity recommended by the Supplier
shall be used.

Two pack paints have a certain length of pot life. Paints of this type shall not be
used after the stated pot life. New material shall not be added to any old material
left in the pot.

6.4 Surface Preparation

All preparation and coating activities shall be carried out in a fully enclosed
weatherproof building.

Pipes shall be effectively free of chloride contamination before abrasive blasting


commences. To verify this, pipes shall be tested for salt contamination prior to
abrasive blasting. Ten pipe joints selected at random from the pipe storage area
shall be tested for soluble chlorides; the results of these tests shall be used by the
Company to determine whether all pipes shall be washed (using chloride free
potable water) prior to surface preparation. Separate samples shall be taken from
both the internal and the external surfaces of each test pipe. Chloride
2
contamination shall not exceed 2 µg/cm .

Abrasive cleaning shall not be carried out when the metal surface is less than 3°C
above the ambient dew point.

The pipes shall be cleaned using a retractable lance with an abrasive fan. Only dry
abrasive materials shall be employed. The abrasive shall be maintained free from
dust, salts and other impurities. The standard required at the time of lining shall be
a minimum of grade Sa 2½, with a surface profile of 40 ± 10 microns peak-to-
trough height.

11775-SPC-PL-005 Rev 0 Page 6 of 11


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Each fitting shall be visually inspected to check compliance with this standard. The
surface profile shall be measured by replica tape method or any other suitable
method in accordance with BS 1134-1 at an average frequency of at least one pipe
in ten and one fitting in three.

The number of points at which the surface profile shall be measured shall be as
determined in the qualification of the procedure. Any surface which in the opinion
of the Company is unsatisfactory shall be re-blasted.

During production, and after blasting, pipes / fittings shall be tested for residual
chloride levels in accordance with ISO 8502-9 at an average frequency of one pipe
2
in ten. If the chloride contamination exceeds 2 µg/cm , the Company reserves the
right to specify additional testing on previously coated pipe, to reject such coated
pipe, and to invoke additional measures to avoid or remove such contamination.

Any pipe or fitting which has not been coated within four hours of blasting, or
before visible re-rusting occurs, shall be re-blasted.

Immediately before the application of the lining the internal surfaces to be lined
shall be rendered free of dust and grit by blowing off the surface with filtered, dry
air or by vacuum extraction. The surface cleanliness shall be checked in
accordance with ISO 8502-3 using the adhesive tape method at an average
frequency of at least one pipe in ten and every fitting.

Coating cutback shall be 25 mm ± 5 mm from both ends of each pipe joint and
fitting.

6.5 Lining Application

The minimum dry film thickness shall be 350 microns.

The lining shall be applied using airless spray painting equipment strictly in
accordance with the paint Supplier’s recommendations. One or more coats may
be applied to achieve the required coating thickness; for application of multiple
coats the paint Supplier’s re-coating times (with reference to the relative humidity
and temperature) shall be strictly adhered to.

Adequate filters shall be present in the equipment to ensure that foreign


substances or detrimental particles are not carried to the application surfaces.

The paint line to the spray guns should be equipped with a pressure gauge fitted
with a pulsation damper. The location of this gauge shall be downstream of all
pressure drop causing devices, and preferably as near to the gun tips as is
practicable. All compressed airlines shall have vapour traps.

The surface to be lined shall be maintained at a temperature of at least 3°C above


the dew point of the surrounding atmosphere at all times during the coating
operation. During coating application the humidity shall not exceed 85%.

Coating material deposited on bevel ends shall be removed immediately after


coating by solvent cleaning.

6.6 Inspection and Testing Plan (ITP) and Daily Log

The Contractor shall develop and agree with the Company an ITP which identifies
all pipe preparation, coating application and quality control activities in a
consecutive order, including process parameters that are relevant to each activity.
Reference shall be made to the applicable standards or Contactor’s procedures,
frequencies and acceptance criteria that shall apply for each process control and
inspection/testing activity and actions in case of non-conformities.

11775-SPC-PL-005 Rev 0 Page 7 of 11


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

A Daily Log shall be used to record all inspection and testing data, process
parameters and calibration of equipment for quality control.

The ITP and Daily Log shall meet the requirements detailed in Appendix A.

6.7 Lining Repairs

In the event that problems are detected or repairs are needed, Contractors shall
take immediate steps to correct the situation.

All repairs to the lined pipe shall be made at the Contractor's expense. Pipes /
2
fittings with lining defects greater than 50 cm shall be rejected for complete
stripping and relining.

Scars, dents, defects and any damaged areas shall be prepared by abrading of
exposed metal substrate until equivalent to Sa2½ grade and roughening of the
surrounding coating. Loose paint, dust and any other surface debris shall be
removed from the repair area.

The appropriate number of coats shall be applied to restore the specified coating
thickness using materials and procedures approved by the Contractor.

In the event that problems are detected or repairs are needed, Contractor shall
take immediate steps to correct the situation.

6.8 Identification Numbering

6.8.1 Mill Numbers

All pipes will be allocated a unique serial number at the pipe mill. The coated pipe
shall be marked (including the serial number) as specified in 11775-SPC-ME-009
and API 5L.

6.8.2 Pipe Tally

The Contractor shall maintain comprehensive tallies of the serial numbers of the
pipes received, pipes taken for coating, pipes accepted or rejected at the pre-
coating inspection stage, pipes accepted after coating and pipes which have been
rejected during the coating stage and put aside or re-circulated through the
process.

All such tallies shall be maintained strictly in the correct sequence and the date and
time of recording shall be included wherever relevant and/or required by the
Company.

6.8.3 Protection of Pipe Numbers

If the original stenciled serial numbers cannot be maintained and protected


throughout the coating process, then the Contractor shall propose a procedure for
the re-application of the serial number.

6.9 Reporting

Reports shall be kept of all relevant data for each individual pipe joint and fitting.
This shall include, but not be limited to, the following:-

(1) Material batch numbers and certificates detailing all the information required
for each batch as defined in this specification.

11775-SPC-PL-005 Rev 0 Page 8 of 11


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

(2) Details of blasting abrasive, measurement of surface profiles, surface


preparation standard and recording of environmental conditions prevailing
during blasting.

(3) Recording of steel surface defects and repairs.

(4) Surface temperature of pipe prior to coating.

(5) Results of all tests as defined in this Specification.

(6) Details of repairs to coating defects exposed during testing and the repair
techniques used.

(7) Details of rejected pipe, with reasons for failure.

(8) Information on pipe, which after rejection, requires complete recycling.

Such information shall be submitted daily by the Contractor to the Company.

Coating pipe, which is submitted to the Company for approval, shall not be
accepted unless accompanied by the above information. Failure to supply such
information shall be cause for rejection.

6.10 Storage and Delivery of Pipe

Refer to project specification 11775-SPC-ME-009 for storage and handling of


linepipe.

The greatest care is to be taken at all times to avoid damage to the pipe, the
prepared welding end or the coating. Pipes may be stacked in tiers such that no
damage is or could be caused to the pipe, its lining or coating.

Pipe shall be carefully lowered to limit impact effects and stacked in such a way,
that water and mud cannot accumulate within the pipe.

End caps are to be carefully removed and replaced after lining is complete and
after the ends have been inspected by the Company for damage. Damage end
caps are to be replaced to the satisfaction of the Company.

11775-SPC-PL-005 Rev 0 Page 9 of 11


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Appendix A: Inspection and Testing

Inspection and testing shall be carried out in accordance with the agreed
procedures and shall meet the requirements of tables A.

Table A – Test Requirements

Properties System/Substrate Requirements Method of Test

Viscosity increase ≤ Annex B of DEF STAN 80-


Pot Life -
a factor of 2 97/3

Visual, 24 hours after


application of the final coat
Smooth, opaque
Application
System, burnished steel finish, free from Visual after force drying
Properties and
300 × 100 mm or larger runs, sags or other each coat at (60 ± 2) °C for
Finish
defects one hour and allowed to cool
before application of the
next coat.
Single coat, burnished a) Primer ≤ 4 hours
Hard-dry time BS EN 29117
tinplate b) Finish ≤ 16 hours
No signs of
System, burnished Annex C of DEF STAN 80-
Fitness for recoat incompatibility
tinplate 97/3
between the coats
BS 3900: Part D1 under
Colour (final finish Single coat, burnished
White diffuse daylight, 24 hours
coat only) tinplate
after application

No sagging at a dry
film thickness of:
Resistance to
Single coat, glass Annex D of STAN 80-97/3
sagging
Primer 100 µm
Finish 250 µm
Surface
roughness of System, burnished
40 ± 10 microns BS 1134
blasted surface tinplate
(Rz/Ry5)
BS 3900: Part D5, 60°
Specular gloss Single coat, burnished
20-50 gloss units geometry gloss meter, 24
(finish only) tinplate
hours after application

Presence of dust System, burnished


max. class 2 ISO 8502-3
after dust removal tinplate

Surface condition salt content conductive measurement


System
after blasting max. 2 µg/cm2 ISO 8502-9

The needle shall not BS EN ISO 1518, using a


Scratch System, burnished
penetrate the top load of 1500 g, 7 days after
Resistance tinplate
coat application of the final coat
System, abrasive BS 3900: Part E7, paint film
No cracking or loss
Impact Resistance blasted steel, 5 mm upwards, 7 days after
of adhesion
thick application of the final coat
Resistance to No blistering, BS 3900: Part F9 for a
Single coat, burnished
humidity (primer corrosion or other period of 10 days, 7 days
steel
only) signs of breakdown after application
No blistering,
System, abrasive Annex E of DEF STAN 80-
Resistance to softening, corrosion
blasted steel, 3 mm 97/3, 14 days after
liquid fuel/water or other signs of
thick application of the final coat
breakdown

11775-SPC-PL-005 Rev 0 Appendix A Page 10 of 11


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Properties System/Substrate Requirements Method of Test

Resistance to System, abrasive No blistering, Annex F of DEF STAN 80-


immersion in blasted steel, 3 mm corrosion or other 97/3, 14 days after
artificial sea water thick signs of breakdown application of the final coat

No softening,
blistering or other
System, abrasive defects.
blasted steel, Classification 0

150 ×150 × 3 mm Fuels top remain Annex G of DEF STAN 80-


within specification 97/3, 14 days after
(6 panels required, limits application of the final coat
Effects on aviation
painted both sides and
fuels
edged with the material Existent gum
under test) content shall not
increase by more
than 3mg/100ml

11775-SPC-PL-005 Rev 0 Appendix A Page 11 of 11


Design of New
Hydrant System

Specification for
Heat Shrink
Sleeves
Head Office:
Penspen Group Limited
3 Water Lane
Richmond upon Thames
Surrey
TW9 1TJ
United Kingdom

Kuwait Aviation Fuelling Co Regional Office:


Penspen International Limited
P.O. Box 46562
Abu Dhabi
United Arab Emirates

11775-SPC-PL-006 Rev 0
DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

1. Introduction

This specification covers the requirements for a heat-shrink sleeve system to


provide corrosion protection to girth weld joints in a welded steel pipeline for the
new hydrant system at Kuwait International Airport (KIA).

The heat-shrink sleeve system shall be a 3-layer system and suitable for field
application to linepipe with a 3-layer polyethylene factory coating.

This specification may also be applicable for the site repair of the factory coating
which has been damaged over areas greater than 100 cm² or 20cm length.

Buried Fittings shall be coated with factory applied liquid coating system as per
11775-SPC-PL-007.

2. Procedence

Any case of apparent conflict between the requirements of this Specification and
any other relevant documents shall be notified to the Company. Unless otherwise
agreed the following descending order of precedence shall apply:-

1st This Specification


2nd Other Project Specifications
3rd The Codes and Standards listed in this specification
4th Other API, ASME, ANSI, BS Codes or Standards as appropriate

3. References

The following documentation shall be read in conjunction with and form part of this
specification.

11775-SPC-PL-003 Specification for Factory Applied Polyethylene Coating


of Line Pipe

11775-SPC-PL-007 Specification for Factory Applied Liquid Coating of


Fittings

11775-SPC-PL-001 Specification for Linepipe

4. Definitions

The ‘Company’ is KAFCO (Kuwait Aviation Fuelling Company) or their appointed


agent or representative.

The ‘Consultant’ is Penspen Limited or their appointed agent or representative.

The ‘Relevant Authority’ is any statutory authority, company, agency, contractor or


other party who may be affected by the Work.

11775-SPC-PL-006 Rev 0 Page 3 of 12


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

The ‘Contractor’ is the organization employed by the Company or their appointed


agent or representative in order to carry out the Work.

The ‘Supplier’ is the vendor, manufacturer or supplier of equipment and/or


materials defined in this specification.

The “Work” is the extension of the new hydrant system at Kuwait International
Airport (KIA).

Throughout this document the following terminology is used:

“must” signifies a legal or statutory requirement


“shall” signifies a requirement made mandatory by this Specification
“may” signifies a feature which is discretionary in the context in which it is
applied
“will” signifies a feature which the Contractor may assume to be already
present.

5. Codes and Standards

This Specification makes reference to the latest edition of the following documents
which shall be applicable as referenced.

ISO 8501-1 Preparation of Steel Substrates before Application of


Paints and Related Products - Visual Assessment of
Surface Cleanliness

ISO 8502-2 Preparation of Steel Substrates before Application of


Paints and Related Products - Tests for the
Assessment of Surface Cleanliness

ASTM D149 Dielectric Breakdown Voltage and Dielectric Strength of


Solid Electrical Insulating Materials at Commercial
Power Frequencies

ASTM D257 DC Resistance or Conductance of Insulating Materials

ASTM D570 Water Absorption of Plastics

ASTM D638 Tensile Properties of Plastics

ASTM D792 Density and Specific Gravity (Relative Density) of


Plastics by Displacement

ASTM D870 Water Immersion Test for Organic Coatings on Steel

ASTM D1000 Pressure-Sensitive Adhesive-Coated Tapes for


Electrical and Electronic Applications

ASTM D1002 Apparent Shear Strength of Single-Lap-Joint


Adhesively Bonded Metal Specimens by Tension
Loading
ASTM D1044 Resistance of Transparent Plastics to Surface Abrasion

ASTM D2240 Rubber Property-Durometer Hardness

11775-SPC-PL-006 Rev 0 Page 4 of 12


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

ASTM D2671 Heat-Shrinkable Tubing for Electric Use

ASTM E28 Softening Point by Ring-and-Ball Apparatus

ASTM G8 Cathodic Disbonding of Pipeline Coatings

ASTM G42 Cathodic Disbonding of Pipeline Coatings Subjected to


Elevated Temperatures

DIN 30672 Coatings of Corrosion Protection Tapes and Heat


Shrinkable Material for Pipelines (Operating
o
Continuously at Temperatures up to 50 C)

Alyeska Tape Shear Test

6. Technical Requirements

6.1 System Description

The heat-shrink sleeve shall consist of a cross-linked and stretched polyolefin


backing coated with a heat-activated adhesive. As a 3-layer system, an epoxy primer
shall be applied to the steel cutback area and force cured prior to the sleeve
application.

The sleeve shall be supplied in one piece, wraparound sleeve incorporating an


attached closure method designed to bond the underlap and overlap.

The epoxy primer shall be a 2 component, solvent free epoxy suitable for roller or pad
application and shall be supplied or approved by the sleeve supplier. The epoxy
primer shall be applied to the steel cutback area only.

The sleeve system shall be suitable for the maximum design temperature of the
linepipe which for the buried hydrant network is 50°C.

The heat-shrink sleeve shall have met all the minimum performance requirements of
Table 1 in Appendix A.

6.2 Prequalification

Prior to commencement of the coating operations, the Contractor shall submit to


the Company all necessary details of the proposed coating materials and
procedures for qualification and approval. This shall include, but not be limited to,
the following:

• Complete details of the coating materials including quality control and


Suppliers data, certification and safety sheets. Also details of materials for
repair of damaged areas.

• Inspection and testing including typical reports, instrument and equipment


types, together with methods of calibration and operation.

• Repair techniques and materials to be used.

• Sample of recording and reporting formats including laboratory reports and


certificates.

11775-SPC-PL-006 Rev 0 Page 5 of 12


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Where the Company considers that the Contractor has not satisfactorily
demonstrated that the proposed coating materials and procedures will meet the
requirements of this specification, the Contractor shall undertake a pre-qualification
test programme.

The test programme shall be proposed by the Contractor and witnessed by the
Company. The results shall be recorded by the Contractor and submitted to the
Company for approval.

6.3 Sleeve Application Training

The Contractor shall ensure that all members of the field joint coating crews are
qualified and experienced in the application of sleeve systems. Training by
representatives of the sleeve Supplier shall be provided where relevant experience
cannot be demonstrated.

6.4 Sleeve Materials

The sleeve system shall have the following nominal physical properties:

Property Unit Value


Backing Colour Black
Minimum Backing Recovery 20%
Epoxy Primer Thickness microns 100 min
Recovered Sleeve Thickness mm 2.9 min
Adhesive Thickness (as supplied) mm 1.4 min
Backing Thickness (as supplied) mm 1.0 min

The sleeve width shall be wide enough so as to overlap onto the mainline coating
by a minimum of 50mm on each side of the weld joint in the recovered condition
(once installed).

6.5 Application Equipment

The following equipment shall be required as part of the application procedure:

• Blast cleaning equipment for preparation of the steel surface.


• Propane torches or an induction coil heater to suit the pipeline diameter.
• Digital thermocouple probe and meter for pipe surface temperature
measurement.
• Propane torch system as recommended by sleeve Supplier.
• Hand tools as recommended by the sleeve Supplier.

6.6 Surface Preparation

The joint area shall be abrasive blast cleaned to Sa 2½ as per ISO 8501-1 with a
surface profile of 70 ± 20 microns peak-to-trough height.
o
The edges of the factory coating shall be bevelled to approximately 30 prior to any
cleaning action.

11775-SPC-PL-006 Rev 0 Page 6 of 12


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Before abrasive blast cleaning, the pipe surfaces shall be inspected and cleaned of
all surface contamination and fully dry. Oil, grease or similar contaminants shall be
removed with a solvent or detergent.

Abrasive blast cleaning shall not be carried out when the metal surface is less than
3°C above the ambient dew point or when the relative humidity is greater than
85%.

Only dry abrasive materials shall be employed and the abrasive shall be
maintained free from dust, salts and other impurities. Water traps, oil traps and
filters shall be used on all blast cleaning equipment.

Each joint shall be visually inspected to check compliance with this standard.
Surface profile shall be measured by replica tape method for the first 10 pipe joints
and then as per the approved application procedure.

The number of points at which the surface profile shall be measured shall be as
determined in the qualification of the procedure. Any surface which in the opinion
of the Company is unsatisfactory shall be re-blasted.

The factory applied coating on either side of the joint shall be prepared by light
abrasive blasting to provide a mechanical key. The prepared areas shall be a
circumferential strip of approximately 50mm width.

Prepared surfaces shall be protected from conditions of high humidity, rainfall and
dust. The blast cleaning of nearby joints shall not be allowed to contaminate
coating application. Any surface contaminated shall be cleaned and re-blasted.

Any pipe joint which has not been coated within four hours of blasting or before
visible re-rusting occurs shall be re-blasted.

Immediately before the application of the coating system the external surfaces to
be coated shall be rendered free of dust and grit by blowing off the surface with
clean dry air.

6.7 Primer Application

Primer shall not be applied during rain, dust or when the relative humidity exceeds
85%. If the humidity rises above this level, coating application shall be suspended.

The joint area shall be pre-heated using propane torches or an induction coil
heater to the temperature recommended by the sleeve Supplier. The temperature
shall be checked using a digital thermometer. Tempilstiks (or other temperature
indicator crayons) shall not be used on any part of the prepared surface.

The epoxy primer shall be applied to the steel surface using pad or roller to achieve
a minimum dry film thickness of 100 microns. Wet film thickness gauges shall be
used as a check during application. The primer shall be fully cured by post heating
– using propane torches or an induction coil heater - as recommended by the
Supplier.

The dry film thickness of the primer shall be checked for the first 10 field joints and
then at the frequency stated in the approved application procedure.

6.8 Sleeve Application

The sleeve shall be applied as per the Supplier’s installation instructions.

11775-SPC-PL-006 Rev 0 Page 7 of 12


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Heating of the sleeve shall be carried out by a propane torch. To promote uniform
and rapid heating, the torch shall be of a size and type recommended by the sleeve
Supplier.

Smoothing of the sleeve shall be carried out by both gloved hand and rollers to
ensure the sleeve is smooth, wrinkle free and with no trapped air pockets.

7. Materials Supply

Each batch of material supplied by the Supplier shall be accompanied by quality


control documentation and test certificates covering the properties in accordance
with this Specification.

The Contractor shall issue the Company with copies of all certificates related prior
to using the material for coating pipe. Material for which satisfactory test
certificates have not been received shall not be used for coating pipe.

All materials supplied for coating field joints and coating repairs shall be marked
with the following minimum information:

a) Name of the Manufacturer.


b) Material name.
c) Batch number.
d) Date of manufacture.
e) Safety data sheets.
f) Maximum recommended storage temperature.
g) Shelf life.

The coating materials shall be handled and stored in accordance with the
Supplier’s recommended instructions.

8. Inspection and Testing

8.1 General

The Company shall have the right to inspect at all times, any tools, instruments,
materials or equipment used or to be used in the manufacturing process.

The Company shall have the right to condemn any or all tools, instruments,
materials, equipment or work which does not conform to this Specification.

Any condemned material not conforming to this Specification shall be replaced by


the Contractor at no expense to the Company. Any condemned tools, instruments
or equipment shall be replaced or rectified.

8.2 Visual Inspection

Each pipe joint shall be visually inspected to ensure that:

• The sleeve is in full contact with the steel at the cutback and mainline
coating.

• Adhesive has flowed (‘oozed’) beyond both sleeve edges.

11775-SPC-PL-006 Rev 0 Page 8 of 12


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

• No mechanical damage has occurred in the sleeve backing i.e. tears, cuts,
cracks or holes.

The sleeve shall indicate even recovery and be free of blisters, wrinkles, pinholes,
scratches or any other irregularities and shall exhibit no signs of overheating or
absence of adhesion to the joint surface of factory applied coating.

8.3 Holiday Testing

Each pipe joint shall be subject to holiday testing with an approved holiday
detector, set at 5kV + 5kV per mm of recovered sleeve thickness.

The setting of the detector shall be checked once every four hours with a high
voltage voltmeter and the Contractor shall demonstrate that the setting is
satisfactory for detecting pinholes and similar minor defects.

Holidays shall be marked and repaired using the repair procedure from this
Specification.

8.4 Peel Test

Peel tests shall be carried out as per the procedure outlined below. Testing shall
be carried out using Peel Clips and Peel Gauges recommended by the sleeve
Supplier. The Peel Test shall form part of the qualified application procedure.

The inspection frequency shall be stated in the procedure but shall not be less than
2 joints per day for the first week. Satisfactory results shall allow lower inspection
frequency in-line with the qualified application procedure.

Peel testing of a pipe joint shall be carried out after 24 hours has elapsed after
sleeve application. Testing should be carried out in the cooler part of the morning
o
and as close to 25 C as possible.

The following test procedure shall be used:

• Make a 25mm (1”) width x 150mm (6”) length outline with a pen or marker in
the circumferential direction of the sleeve at the site(s) chosen for the field
peel test procedure.
• Using a utility knife, cut the outline down to the steel or factory coating
surface.
• Using a suitable prying tool, pry up the first 50mm (2”) of the peel strip.
• Using a digital thermometer, measure and record the temperature at the
point of peeling. Note: Use the sleeve to record the date, customer, joint ID
(if available), temperature and result. Option - photograph the completed
peel test and include with any relevant report.
• Attach the peel gauge to the peel clamp and pull at a minimum rate of
100mm (4”) per minute. This translates to a total time of 1 minute to peel the
entire test strip that has been prepared.

The results shall be assessed as follows:

• Record the value in units of N/cm (or pli).


• Compare the peel value with the appropriate DIN 30672 specified peel value
as published on the supplier’s product data sheet and/or available literature.
• Record the mode of failure (i.e. cohesive, adhesive from backing or adhesive
from the substrate).
• Record the pressure of air voids (if applicable, minor, moderate, major).
11775-SPC-PL-006 Rev 0 Page 9 of 12
DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

After removal, the bulk of the adhesive shall still adhere to the primed surface and
the adhesive layer remaining shall be essentially free from voids. Voids will only be
acceptable if they are not interconnected.

There shall be no loss of any primer from the pipe surface with removal of the
sleeve.

9. Coating Repairs

9.1 General

Repairs shall be made by the repair procedure and repair materials approved prior
to commencement of work. The Contractor shall submit the procedures to the
Company for approval. The defect size and coating repair methods outlined below
shall form the basis of the detailed repair procedures.
2
• Damage/defects up to 1.0cm - PE melt sticks, with epoxy primer if
pipe steel is visible.
2
• Damage up to 300mm or 100cm - Polyethylene repair patches pre-
coated with hot melt mastic adhesive.
2
• Damage greater than 100cm - Application of complete heat shrink -
sleeve system.

Any pipe subject to a coating repair procedure shall be fully re-examined in


accordance with the inspection and testing requirements of this specification.
2
9.2 Defects up to 1.0cm

The area shall be abraded using emery paper. The hot melt material shall then be
spread over the area with the aid of heat from a propane torch or hot air gun. The
repair material shall be smoothed out flush with the polyethylene coating.
2
9.3 Defects up to 100cm

The damaged coating shall be cut back to sound coating, the exposed area shall
be cleaned using solvent or detergent and dried. The repair area shall be abraded
using emery paper to provide a key for the repair material. The repair area shall
include the surrounding good polyethylene coating for a distance of at least 75mm
beyond the damaged area.

Any damage or defects in the epoxy-primer shall be made good in accordance with
Section 6.7 and the coating thickness re-tested.

A hot melt mastic shall then be applied to the exposed area and smoothed down
using a spatula and propane torch.

The polyethylene patch material, pre-cut to size so that it overlaps the damaged
area and extends by at least 50mm onto the abraded sound coating (but not onto
the area which has not been cleaned and roughened), shall then be flame brushed
on the adhesive side until the adhesive becomes glossy then applied over the
damaged area.

Heat shall then be applied to the patch to fuse the patch onto the surface.
Entrapped air shall be rolled out using silicone rollers.

11775-SPC-PL-006 Rev 0 Page 10 of 12


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

2
9.4 Defects over 100cm

The damaged coating shall be cut back to sound coating and the exposed area re-
coated with a complete heat shrink sleeve, including epoxy primer, in accordance
with all the requirements of this specification.

10. Reporting

The Contractor shall deliver to the Company a comprehensive bound original


document record, with completion of additional copies as specified in the Scope of
Work, containing, but not limited to, the following information:

a) Supplier’s documentation for the field joint material, together with any
technical queries and subsequent concessions.

b) Supplier’s quality assurance and quality control procedures approved by


the Company.

c) Supplier’s batch certificates for all coating materials.

d) Supplier’s technical data sheets for all coating materials.

e) Pre-qualification test reports.

Daily logs shall be submitted by the Contractor to the Company containing the
following information:-

• Pipe joints completed

• Results of all inspection tests as defined in this specification.

• Details of all repairs to coating defects.

Coated pipe which is submitted to the Company for approval shall not be accepted
unless accompanied by the above information. Failure to supply such information
shall be cause for rejection.

11775-SPC-PL-006 Rev 0 Page 11 of 12


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Appendix A: Table 1 Material Properties

Test
Property Unit Required Values
Method
o o
Softening Point ASTM E28 C ( F) 85 (185) minimum
Adhesive

o 2
Lap Shear Strength @ 23 C ASTM D1002 N/cm psi 100 (145) minimum
o
@ 65 C (0.05 in/minute) 5 (7) minimum
o 2
Lap Shear Strength @ 23 C DIN 30672 N/cm 160 minimum
o
@ 65 C (10mm/minute) 6 minimum
Specific Gravity ASTM D792 n/a 0.93
Tensile Strength ASTM D638 MPa (psi) 18 (2610) minimum
Ultimate Elongation ASTM D638 % 580 minimum
Heat Aging - Elong @ Break ASTM D638 % 300 minimum
1
Backing

o
Heat Shock - 4 hrs @ 250 C ASTM D2671 Visual Pass
Hardness ASTM D2240 Shore D 44 minimum
Abrasion Resistance ASTM D1044 mg 50 minimum
15
Volume Resistivity ASTM D257 ohm-cm 10 minimum
Dielectric Voltage Breakdown ASTM D149 kV/mm 20 minimum
Impact Resistance DIN 30672 Class C Pass
Indentation Resistance DIN 30672 Class C Pass
Peel Strength ASTM D1000 N/cm (pli) 100 (58) minimum
o
Peel Strength @ 23 C DIN 30672 N/cm 25 minimum
o
Peel Strength @ 65 C (100mm/min) 3 minimum
(Metal and Mainline Coating)
1
Sleeve

2 o
Cathodic Disb @ 23 C ASTM G8 mm radius 6 maximum
2 o
Cathodic Disb @ 65 C ASTM G42 mm radius 15 maximum
Hot Water Immersion ASTM D870 Visual Pass
Water Absorption ADTM D570 % 0.1 maximum
o o
Low Temp Flexibility ASTM D2671C C ( F) -26 (-15) maximum
o
Alyeska Shear @ 65 C TP-206 No movement Pass

1 - Standard ‘L’ thickness

2 - Results as a 3-layer system (with Epoxy)

11775-SPC-PL-006 Rev 0 Page 12 of 12


Design of New
Hydrant System

Specification for
Factory Applied
Liquid Coating of
Fittings Head Office:
Penspen Group Limited
3 Water Lane
Richmond upon Thames
Surrey
TW9 1TJ
United Kingdom

Kuwait Aviation Fuelling Co Regional Office:


Penspen International Limited
P.O. Box 46562
Abu Dhabi
United Arab Emirates

11775-SPC-PL-007 Rev 0
DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

1. Introduction

This specification is for the factory application of a coating on bends, valves, tees
and other linepipe ancillary items that will be installed below ground. The coating
shall be a 2-pack, 100% solids type (i.e. multi-component liquid) such as a liquid
epoxy, polyurethane or epoxy-urethane hybrid.

The preferred application method is by plural component airless spray, however


hand application using brush or roller is permitted using the appropriate grade of
coating material.

2. Precedence

Any case of apparent conflict between the requirements of this specification and
any other relevant documents shall be notified to the Purchaser. Unless otherwise
agreed, the following descending order of precedence shall apply:

1st This specification

2nd Other project specifications included in this specification

3rd The codes and standards listed in this specification

4th Other (API, ASME, ANSI, BS) codes or standards, as appropriate

3. References

The following project documents are referenced within this specification:

None referenced.

4. Definitions

The “Purchaser” is the Kuwait Aviation Fuelling Company (KAFCO), or their


appointed agent or representative.

The “Supplier” is the vendor, manufacturer or supplier of the equipment defined in


this specification.

Throughout this document the following terminology is used:

“must” signifies a legal or statutory requirement

“shall” signifies a requirement made mandatory by this specification

“may” signifies a feature which is discretionary in the context in which it is


applied

“will” signifies a feature which the Supplier may assume to be already


present

11775-SPC-PL-007 Rev 0 Page 3 of 8


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

5. Codes and Standards

This specification makes reference to the following codes, standards and


regulations.

ISO 8501-1 Preparation of steel substrates before application of paints and


related products – Group A. Visual assessment of surface
cleanliness.
Part A1: Rust grades and preparation grades of uncoated
steel substrates and of steel substrates after overall removal of
previous coatings.

ISO 8502-2 Preparation of steel substrates before application of paints and


related products – Group B. Methods for the assessment of
surface cleanliness.
Part B2: Method for determination of chlorides on cleaned
surfaces.

ISO 8502-3 Preparation of steel substrates before application of paints and


related products – Group B. Methods for the assessment of
surface cleanliness.
Part B3: Assessment of dust on steel surfaces prepared for
painting (pressure-sensitive tape method).

ISO 8503-2 Preparation of steel substrates before application of paints and


related products – Group C. Surface roughness characteristics
of blast cleaned steel substrates.
Part C2: Method for grading of surface profile of abrasive blast
cleaned steel using a comparator.

ISO 8504-2 Preparation of steel substrates before application of paints and


related products – Group D. Methods for surface preparation
Part D2: Abrasive blast cleaning.

ISO 2808 Paints and varnishes – Determination of film thickness.

ISO 4624 Paints and varnishes – Pull off test for thickness.

ASTM D5162 Practice for discontinuity (holiday) testing of non-conductive


protective coating on metallic substrates.

DIN 30671 Thermoset Plastic Coatings for Buried Steel Pipes.

6. Technical Requirements
6.1 Pre-qualification

Prior to commencement of the coating operations, the Supplier shall submit to the
Purchaser all details of the coating materials and procedures for qualification and
approval. These details shall include :
• The data sheets for the proposed coating materials, including grades.
• Application method to be used.
• Project specific coating procedure, including inspection activities.
• Evidence of previous experience of applying similar coatings to pipeline
accessories.

11775-SPC-PL-007 Rev 0 Page 4 of 8


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

6.2 Materials

The coating shall be a solvent free (i.e. 100% solids), two component liquid resin,
the resin may be an epoxy, polyurethane or an epoxy-polyurethane hybrid.

The properties of the cured coating film shall, in general, meet the requirements of
DIN 30671, and the Supplier shall furnish all information as detailed in Appendix A.

All materials shall be kept under cover and in conditions as stipulated by the paint
manufacturer. Paint coating materials shall not be transported or stored in a
manner that will have a deleterious effect on the application or performance
characteristics. Materials shall not be used after the expiry date.

The Supplier shall handle, mix and thin the coating materials in strict accordance
with the paint manufacturer’s requirements. All material preparation and mixing
shall be carried out at a place near to where the coating application is to be done.

6.3 Surface Preparation

All preparation and coating shall be carried out in a fully enclosed weatherproof
building.

The surface preparation shall be by abrasive blast cleaning. Only dry abrasive
materials shall be employed in accordance with ISO 8504-2. Suitable abrasives
are chilled iron grit or shot, or non metallic abrasives such as aluminium oxide,
garnet etc. The abrasive shall be free from oil, grease, moisture, chlorides etc.
Re-used abrasives shall be clean, sharp and free from contaminants.

Abrasive cleaning shall not be carried out when the metal surface is less than 3°C
above the ambient dew point.

The surface shall be prepared to grade Sa 2½ as defined in ISO 8501-1, all items
shall be visually inspected to check compliance with this standard. The surface
profile shall have a peak-to-trough height of 75 ± 25 microns; this shall be
measured in accordance with ISO 8503-2, or other method as approved by the
Purchaser. Every item shall be checked, the number of points at which the surface
profile shall be measured shall be as determined in the coating procedure.

Any surface which in the opinion of the Purchaser is unsatisfactory shall be re-
blasted.

The condition of all surfaces shall be checked for manufacturing and handling
defects before and after abrasive blasting. Defects detrimental to the coating
process shall be removed by grinding; grinding shall not reduce the wall thickness
below that permitted in the relevant project specification.

Any surface which has not been coated within four hours of blasting, or before
visible rusting occurs, shall be re-blasted. Any surface which in the opinion of the
Purchaser is unsatisfactory shall be re-blasted.

Immediately before the application of the coating the external surfaces to be


coated shall be rendered free of dust and grit by blowing off the surface with clean
dry air or by vacuum extraction.

The surfaces shall be tested for the presence of chlorides and dust in accordance
with ISO 8502-2 and ISO 8502-3 respectively. The Supplier shall detail the method
and frequency in the coating procedures.

11775-SPC-PL-007 Rev 0 Page 5 of 8


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

6.4 Coating Application Conditions

Coating application shall only be applied to clean dry surfaces only. Condensation,
precipitation, water vapour or any other forms of contamination on the blasted
surface are not acceptable.

Coating application shall take place only when all the following environmental
conditions are complied with:
• The ambient temperature is above 5ºC
• The surface to be coated is at least 3ºC above the dew point of the
surrounding atmosphere at all times during the coating operation
• The relative humidity is less than 85%

In addition, coating application shall not be carried out when there is visible
airborne dust or wind blown sand or contamination in the coating area.

In cold weather conditions the substrate temperature shall be checked against the
material’s curing requirements, if necessary pre-heating shall be carried out as per
the manufacturer’s instructions.

6.5 Coating Application

6.5.1 General

The dry film thickness shall be:

Nominal range (averaged) 1000 to 1500 microns


Minimum at any single point 750 microns

The number of passes or coats shall be sufficient to achieve the nominal dry film
thickness. The paint manufacturer’s over coating times shall be strictly adhered to,
both minimum and maximum where appropriate.

For items intended for welding (i.e. pipes, bends or pup pieces) the coating shall be
left off the ends for a distance of 125 mm ± 25 mm to permit a field welded joint to
be made without any damage to the factory coating.

6.5.2 Spraying

This is the preferred method of coating application, especially for items with
complex shapes and surfaces.

The coating shall be applied using plural component, airless spray equipment in
strict accordance with the paint manufacturer’s requirements and
recommendations.

Adequate filters shall be present in the equipment to ensure that foreign


substances or detrimental particles are not carried to the application surfaces. All
compressed airlines shall have vapour traps.

The paint line to the spray guns should be equipped with a pressure gauge fitted
with a pulsation damper. The location of this gauge shall be downstream of all
pressure drop causing devices, and preferably as near to the gun tips as is
practicable.

11775-SPC-PL-007 Rev 0 Page 6 of 8


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

6.5.3 Hand Application

Mixing shall be carried out as stipulated by the coating manufacturer for the mixing
ratios and temperatures. Where recommended or for larger quantities, special
mixing impellers shall be used to ensure a uniform mix without entrained air.

Coating application shall be completed within the pot-life of the mixed material.
Unused material shall be discarded.

Disposable tools shall be used for application of the coating, this includes brushes,
spatulas and short nap mohair rollers as appropriate

6.6 Inspection and Testing

6.6.1 Surface Cleanliness

All surfaces shall be free from dust or chloride contamination. Three items shall be
tested at random per shift for surface contamination in accordance with ISO 8502-
2
2 and ISO 8502-3. No surface shall have in excess of 2 µg/cm chloride. The dust
rating shall not exceed 3.

6.6.2 Visual Inspection

Every pipe shall be visually inspected. The coating shall be generally smooth and
uniform appearance (colour and gloss), the coating shall be free of blisters,
pinholes, protuberances and scratches or any other irregularities.

6.6.3 Coating Thickness

All items shall have their coating thickness tested. The thickness shall be
measured at several locations to obtain an average value for each item. The
average value shall comply with the nominal range. No value shall be less than the
minimum. The number of measurements shall be dependent on the size and
complexity of the surface, the Supplier shall detail the number of thickness
measurements on each item in the coating procedure.

Coating thickness shall be measured using an non-destructive instrument


approved by the Purchaser and in accordance with ISO 2808. Instruments shall be
calibrated at least once per 8 hour period or work shift, whichever is the shortest
period.

Wet film thickness checks shall be carried out during coating application in
accordance with ISO 2808 Method 7B. Dry film thickness checks shall be carried
out on the cured coating in accordance with ISO 2808 Method 6.

6.6.4 Coating Adhesion

One item from each shift, or per 5 items, whichever is the more frequent, shall be
tested for adhesion of the coating. The coating adhesion at a randomly selected
location on the item shall be determined by the following method.

Using a heavy-duty short-bladed knife two incisions of approximately 15 mm in


length shall be made in the coating. The incisions shall fully penetrate the coating
through to the steel surface and shall cross through each other to form an 'X' with
an angle of intersection of approximately 30 degrees. Commencing at the
intersection, an attempt shall be made to lift the coating from the steel substrate
using the blade of the knife.

11775-SPC-PL-007 Rev 0 Page 7 of 8


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Peel-away from the point of intersection of more than the critical dimension, or
brittle break-away of flakes of more than the critical dimension in size, shall be
deemed a failure. The critical dimension shall be 2 mm unless specified otherwise
by the Purchaser. Cohesive failures, caused by voids leaving a honeycomb
structure on the pipe surface shall be deemed a failure.

6.6.5 Holiday Testing

The Contractor shall holiday detect 100% of the coated surface in accordance with
ASTM D5162. The testing shall be carried out by means of a holiday detector
supplied by the Supplier of a type approved by the Purchaser.

In general the testing voltage should not exceed 100 volts per mil of measured
coating thickness, unless otherwise stipulated by the coating manufacturer.

All holidays detected shall be repaired and retested.

6.7 Coating Repairs

The Supplier shall submit a coating repair procedure based on the coating
manufacture’s recommendations and using the appropriate grade of material.
(The repair material shall be supplied by the main coating manufacturer and be
suitable for repair procedures.)

For pinholes, holidays and small defect areas measuring less than 150mm in
diameter the repair areas may be roughened /prepared using carborundum cloth,
sandpaper, file or surface grinder.

For defect areas larger than 150 mm in diameter the repair area shall be
roughened/prepared using abrasive blasting.

The repair area shall overlap the surrounding good coating by at least 25 mm.
Overlap areas for larger repairs shall be feathered. All prepared surfaces shall be
completely clean and dry prior to applying the coating.

11775-SPC-PL-007 Rev 0 Page 8 of 8


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Appendix A: Table 1 Material Properties

1. General

This Appendix relates to the required properties of the coating liquid components and the
tests for the cured coating on test specimens prepared in laboratory.

2. Materials

2.1. Identification

All materials supplied for coating operations shall be marked with the following minimum
information:

a) The name of the Manufacturer.


b) Material name.
c) Batch number.
d) Date of manufacture.
e) Safety data sheets.
f) Maximum recommended storage temperature.

Each batch of material supplied to the Contractor shall be accompanied by a certificate


stating that all the tests required have been carried out on every batch and that the
results are in accordance with this Specification.

The Supplier shall issue the Purchaser with copies of all certificates prior to coating
application. Material for which no satisfactory test certificates have been received shall
not be used.

2.2. Approved Materials

The Supplier shall ensure that the material Manufacturer submits data sheets for the
approved paint material, together with recommendations for storage and coating
application procedures, which will ensure that the bends and other linepipe ancillary
items when coated will meet all the requirements of this specification.

Data sheets submitted by the Manufacturer shall include acceptable values for the
following properties of the liquid components,

a) Viscosity
b) Relative density
c) Mixing ratio
d) Pot life
e) Flash point

3. Basic Properties of the Cured Applied Coating

The Supplier shall ensure that the Manufacturer submits certified test results for the
cured applied coating in accordance with the requirements of DIN 30671.

Certified test results shall be for the following requirements,

a) Impact strength
b) Indentation resistance
c) Flexibility
d) Elongation at break
e) Coating resistivity
f) Heat reversion
g) Cathodic disbonding

11775-SPC-PL-007 Rev 0 Page 1 of 1


Design of New
Hydrant System
(Package #7)

Tie-In Schedule
Head Office:
Penspen Group Limited
3 Water Lane
Richmond upon Thames
Surrey
TW9 1TJ
United Kingdom

Kuwait Aviation Fuelling Co Regional Office:


Penspen International Limited
P.O. Box 46562
Abu Dhabi
United Arab Emirates

11775-SCH-ME-001 Rev 1
DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

1. TIE-IN SCHEDULE

Tie-In Documents Existing KAFCO Documents

Tie-In
Service From To Size Type P&ID Piping GA Existing P&ID Existing Piping GA
Number
Main Hydrant 24”-P-4060- Cut and 11775/PR/7/ 11775/ME/7/ 05062/PR/4/100 Rev 5 05062/ME/4/045 Rev 3
TP-01 24”-P-4060-1A2 24”
Network 1A2 Weld 02/102 10/003 Sheet 10 of 37 Sheet 2 of 5
Main Hydrant 24”-P-4060- 11775/PR/7/ 11775/ME/7/ 05062/PR/4/100 Rev 5 05062/ME/4/045 Rev 3
TP-02 24”-P-4060-1A2 24” Flanged
Network 1A2 02/102 10/003 Sheet 10 of 37 Sheet 3 of 5
3”-P-4585- Cut and 11775/PR/7/ 11775/ME/7/ 05062/PR/4/100 Rev 5 05062/ME/4/045 Rev 3
TP-03 Product Drain 3”-P-4585-1A1 3”
1A1 Weld 02/102 10/003 Sheet 10 of 37 Sheet 2 of 5
3”-P-4585- Cut and 11775/PR/7/ 11775/ME/7/ 05062/PR/4/100 Rev 5 05062/ME/4/045 Rev 3
TP-04 Product Drain 3”-P-4585-1A1 3”
1A1 Weld 02/102 10/003 Sheet 10 of 37 Sheet 2 of 5
Main Hydrant PIT-4014 24”-P-4060- 11775/PR/7/ 11775/ME/7/ 05062/PR/4/100 Rev 5 05062/ME/4/045 Rev 3
TP-05 2” Flanged
Network 2” Isolation Valves 1A2 02/102 10/003 Sheet 10 of 37 Sheet 3 of 5

11775-SCH-ME-001 Rev 1 Page 3 of 3


Design of New Hydrant System (Package #7)

Valve Schedule
Location/
Tag No. Size Type Body Material Ends Operator Service Data Sheet Line No. P&ID
Package
Lugged Type to Suit RF
V49909 24" Check Carbon Steel - JET-A1 11775-DAT-ME-003 24"-P-4060-1A2 11775/PR/7/02/102 SHT 2 Inside New Fuel Depot
150#

V49910 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-P-4060-1A2 11775/PR/7/02/102 SHT 2 Inside New Fuel Depot

V49911 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-P-4401-1A2 11775/PR/7/02/102 SHT 2 Inside New Fuel Depot

V49912 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-P-4401-1A2 11775/PR/7/02/102 SHT 2 Inside New Fuel Depot

V49913 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-P-4401-1A2 11775/PR/7/02/102 SHT 2 Inside New Fuel Depot

V49914 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-P-4402-1A2 11775/PR/7/02/102 SHT 2 Inside New Fuel Depot

V49915 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-P-4402-1A2 11775/PR/7/02/102 SHT 2 Inside New Fuel Depot

V49916 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-P-4402-1A2 11775/PR/7/02/102 SHT 2 Inside New Fuel Depot

V49917 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-P-4060-1A2 11775/PR/7/02/102 SHT 2 Inside New Fuel Depot

Lugged Type to Suit RF


V49918 24" Check Carbon Steel Lever JET-A1 11775-DAT-ME-003 24"-P-4403-1A2 11775/PR/7/02/102 SHT 2 Inside New Fuel Depot
150#
Lugged Type to Suit RF
V49919 24" Check Carbon Steel Lever JET-A1 11775-DAT-ME-003 24"-P-4060-1A2 11775/PR/7/02/102 SHT 2 Inside New Fuel Depot
150#
Lugged Type to Suit RF
V70001 12" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 12"-JET-7003-1A2 11775/PR/7/02/103 SVC 701
150#
Lugged Type to Suit RF
V70002 12" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 12"-JET-7003-1A2 11775/PR/7/02/103 SVC 701
150#

V70003 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 12"-JET-7003-1A2 11775/PR/7/02/103 SVC 701

V70004 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 12"-JET-7003-1A2 11775/PR/7/02/103 SVC 701

V70005 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 12"-JET-7003-1A2 11775/PR/7/02/103 SVC 701

V70006 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 12"-JET-7003-1A2 11775/PR/7/02/103 SVC 701

V70007 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 12"-JET-7003-1A2 11775/PR/7/02/103 SVC 701

V70008 3/4" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-002 12"-JET-7003-1A2 11775/PR/7/02/103 SVC 701

V70009 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 12"-JET-7003-1A2 11775/PR/7/02/103 SVC 701

Lugged Type to Suit RF


V70010 24" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 24"-JET-7005-1A2 11775/PR/7/02/103 SVC 702
150#
Lugged Type to Suit RF
V70011 16" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 24"-JET-7005-1A2 11775/PR/7/02/103 SVC 702
150#

11775-SCH-ME-002 Rev 0 Page 2 of 11


Design of New Hydrant System (Package #7)

Valve Schedule
Location/
Tag No. Size Type Body Material Ends Operator Service Data Sheet Line No. P&ID
Package
Lugged Type to Suit RF
V70012 20" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 20"-JET-7006-1A2 11775/PR/7/02/103 SVC 702
150#
Lugged Type to Suit RF
V70013 20" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 20"-JET-7006-1A2 11775/PR/7/02/103 SVC 702
150#
Lugged Type to Suit RF
V70014 20" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 20"-JET-7008-1A2 11775/PR/7/02/103 SVC 702
150#
Lugged Type to Suit RF
V70015 20" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 20"-JET-7008-1A2 11775/PR/7/02/103 SVC 702
150#
V70016 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7005-1A2 11775/PR/7/02/103 SVC 702

V70017 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7005-1A2 11775/PR/7/02/103 SVC 702

V70018 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7005-1A2 11775/PR/7/02/103 SVC 702

V70019 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7005-1A2 11775/PR/7/02/103 SVC 702

V70020 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7005-1A2 11775/PR/7/02/103 SVC 702

V70021 3/4" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-002 24"-JET-7005-1A2 11775/PR/7/02/103 SVC 702

V70022 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 24"-JET-7005-1A2 11775/PR/7/02/103 SVC 702

V70023 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7006-1A2 11775/PR/7/02/103 SVC 702

V70024 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7006-1A2 11775/PR/7/02/103 SVC 702

V70025 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7006-1A2 11775/PR/7/02/103 SVC 702

V70026 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7006-1A2 11775/PR/7/02/103 SVC 702

V70027 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7006-1A2 11775/PR/7/02/103 SVC 702

V70028 3/4" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-002 20"-JET-7006-1A2 11775/PR/7/02/103 SVC 702

V70029 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 20"-JET-7006-1A2 11775/PR/7/02/103 SVC 702

V70030 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7008-1A2 11775/PR/7/02/103 SVC 702

V70031 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7008-1A2 11775/PR/7/02/103 SVC 702

V70032 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7008-1A2 11775/PR/7/02/103 SVC 702

V70033 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7008-1A2 11775/PR/7/02/103 SVC 702

11775-SCH-ME-002 Rev 0 Page 3 of 11


Design of New Hydrant System (Package #7)

Valve Schedule
Location/
Tag No. Size Type Body Material Ends Operator Service Data Sheet Line No. P&ID
Package
V70034 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7008-1A2 11775/PR/7/02/103 SVC 702

V70035 3/4" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-002 20"-JET-7008-1A2 11775/PR/7/02/103 SVC 702

V70036 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 20"-JET-7008-1A2 11775/PR/7/02/103 SVC 702

Lugged Type to Suit RF


V70037 16" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 16"-JET-7011-1A2 11775/PR/7/02/103 SVC 703
150#
Lugged Type to Suit RF
V70038 12" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 16"-JET-7011-1A2 11775/PR/7/02/103 SVC 703
150#

V70039 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 16"-JET-7011-1A2 11775/PR/7/02/103 SVC 703

V70040 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 16"-JET-7011-1A2 11775/PR/7/02/103 SVC 703

V70041 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 16"-JET-7011-1A2 11775/PR/7/02/103 SVC 703

V70042 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 16"-JET-7011-1A2 11775/PR/7/02/103 SVC 703

V70043 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 16"-JET-7011-1A2 11775/PR/7/02/103 SVC 703

V70044 3/4" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-002 16"-JET-7011-1A2 11775/PR/7/02/103 SVC 703

V70045 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 16"-JET-7011-1A2 11775/PR/7/02/103 SVC 703

Lugged Type to Suit RF


V70046 20" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 20"-JET-7013-1A2 11775/PR/7/02/104 SVC 704
150#
Lugged Type to Suit RF
V70047 20" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 20"-JET-7013-1A2 11775/PR/7/02/104 SVC 704
150#
Lugged Type to Suit RF
V70048 20" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 20"-JET-7014-1A2 11775/PR/7/02/104 SVC 704
150#
Lugged Type to Suit RF
V70049 20" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 20"-JET-7014-1A2 11775/PR/7/02/104 SVC 704
150#

V70050 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7013-1A2 11775/PR/7/02/104 SVC 704

V70051 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7013-1A2 11775/PR/7/02/104 SVC 704

V70052 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7013-1A2 11775/PR/7/02/104 SVC 704

V70053 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7013-1A2 11775/PR/7/02/104 SVC 704

V70054 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7013-1A2 11775/PR/7/02/104 SVC 704

V70055 3/4" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-002 20"-JET-7013-1A2 11775/PR/7/02/104 SVC 704

11775-SCH-ME-002 Rev 0 Page 4 of 11


Design of New Hydrant System (Package #7)

Valve Schedule
Location/
Tag No. Size Type Body Material Ends Operator Service Data Sheet Line No. P&ID
Package
V70056 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 20"-JET-7013-1A2 11775/PR/7/02/104 SVC 704

V70057 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7014-1A2 11775/PR/7/02/104 SVC 704

V70058 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7014-1A2 11775/PR/7/02/104 SVC 704

Lugged Type to Suit RF


V70059 20" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 20"-JET-7016-1A2 11775/PR/7/02/104 SVC 705
150#
Lugged Type to Suit RF
V70060 20" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 20"-JET-7016-1A2 11775/PR/7/02/104 SVC 705
150#

V70061 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7016-1A2 11775/PR/7/02/104 SVC 705

V70062 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7016-1A2 11775/PR/7/02/104 SVC 705

V70063 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7016-1A2 11775/PR/7/02/104 SVC 705

V70064 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7016-1A2 11775/PR/7/02/104 SVC 705

V70065 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7016-1A2 11775/PR/7/02/104 SVC 705

V70066 3/4" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-002 20"-JET-7016-1A2 11775/PR/7/02/104 SVC 705

V70067 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 20"-JET-7016-1A2 11775/PR/7/02/104 SVC 705

Lugged Type to Suit RF


V70068 24" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 24"-JET-7020-1A2 11775/PR/7/02/105 SVC 711
150#
Lugged Type to Suit RF
V70069 24" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 24"-JET-7020-1A2 11775/PR/7/02/105 SVC 711
150#

V70070 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7020-1A2 11775/PR/7/02/105 SVC 711

V70071 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7020-1A2 11775/PR/7/02/105 SVC 711

V70072 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7020-1A2 11775/PR/7/02/105 SVC 711

V70073 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7020-1A2 11775/PR/7/02/105 SVC 711

V70074 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7020-1A2 11775/PR/7/02/105 SVC 711

V70075 3/4" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-002 24"-JET-7020-1A2 11775/PR/7/02/105 SVC 711

V70076 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 24"-JET-7020-1A2 11775/PR/7/02/105 SVC 711

Lugged Type to Suit RF


V70077 24" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 24"-JET-7022-1A2 11775/PR/7/02/105 SVC 712
150#

11775-SCH-ME-002 Rev 0 Page 5 of 11


Design of New Hydrant System (Package #7)

Valve Schedule
Location/
Tag No. Size Type Body Material Ends Operator Service Data Sheet Line No. P&ID
Package
Lugged Type to Suit RF
V70078 24" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 24"-JET-7022-1A2 11775/PR/7/02/105 SVC 712
150#

V70079 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7022-1A2 11775/PR/7/02/105 SVC 712

V70080 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7022-1A2 11775/PR/7/02/105 SVC 712

V70081 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7022-1A2 11775/PR/7/02/105 SVC 712

V70082 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7022-1A2 11775/PR/7/02/105 SVC 712

V70083 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7022-1A2 11775/PR/7/02/105 SVC 712

V70084 3/4" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-002 24"-JET-7022-1A2 11775/PR/7/02/105 SVC 712

V70085 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 24"-JET-7022-1A2 11775/PR/7/02/105 SVC 712

Lugged Type to Suit RF


V70086 12" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 12"-JET-7025-1A2 11775/PR/7/02/106 SVC 706
150#
Lugged Type to Suit RF
V70087 12" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 12"-JET-7025-1A2 11775/PR/7/02/106 SVC 706
150#

V70088 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 12"-JET-7025-1A2 11775/PR/7/02/106 SVC 706

V70089 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 12"-JET-7025-1A2 11775/PR/7/02/106 SVC 706

V70090 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 12"-JET-7025-1A2 11775/PR/7/02/106 SVC 706

V70091 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 12"-JET-7025-1A2 11775/PR/7/02/106 SVC 706

V70092 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 12"-JET-7025-1A2 11775/PR/7/02/106 SVC 706

V70093 3/4" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-002 12"-JET-7025-1A2 11775/PR/7/02/106 SVC 706

V70094 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 12"-JET-7025-1A2 11775/PR/7/02/106 SVC 706

Lugged Type to Suit RF


V70095 24" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 24"-JET-7027-1A2 11775/PR/7/02/106 SVC 707
150#
Lugged Type to Suit RF
V70096 16" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 24"-JET-7027-1A2 11775/PR/7/02/106 SVC 707
150#
Lugged Type to Suit RF
V70097 20" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 20"-JET-7028-1A2 11775/PR/7/02/106 SVC 707
150#
Lugged Type to Suit RF
V70098 20" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 20"-JET-7028-1A2 11775/PR/7/02/106 SVC 707
150#
Lugged Type to Suit RF
V70099 20" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 20"-JET-7030-1A2 11775/PR/7/02/106 SVC 707
150#

11775-SCH-ME-002 Rev 0 Page 6 of 11


Design of New Hydrant System (Package #7)

Valve Schedule
Location/
Tag No. Size Type Body Material Ends Operator Service Data Sheet Line No. P&ID
Package
Lugged Type to Suit RF
V70100 20" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 20"-JET-7030-1A2 11775/PR/7/02/106 SVC 707
150#

V70101 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7027-1A2 11775/PR/7/02/106 SVC 707

V70102 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7027-1A2 11775/PR/7/02/106 SVC 707

V70103 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7027-1A2 11775/PR/7/02/106 SVC 707

V70104 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7027-1A2 11775/PR/7/02/106 SVC 707

V70105 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7027-1A2 11775/PR/7/02/106 SVC 707

V70106 3/4" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-002 24"-JET-7027-1A2 11775/PR/7/02/106 SVC 707

V70107 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 24"-JET-7027-1A2 11775/PR/7/02/106 SVC 707

V70108 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7028-1A2 11775/PR/7/02/106 SVC 707

V70109 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7028-1A2 11775/PR/7/02/106 SVC 707

V70110 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7028-1A2 11775/PR/7/02/106 SVC 707

V70111 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7028-1A2 11775/PR/7/02/106 SVC 707

V70112 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7028-1A2 11775/PR/7/02/106 SVC 707

V70113 3/4" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-002 20"-JET-7028-1A2 11775/PR/7/02/106 SVC 707

V70114 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 20"-JET-7028-1A2 11775/PR/7/02/106 SVC 707

V70115 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7030-1A2 11775/PR/7/02/106 SVC 707

V70116 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7030-1A2 11775/PR/7/02/106 SVC 707

V70117 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7030-1A2 11775/PR/7/02/106 SVC 707

V70118 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7030-1A2 11775/PR/7/02/106 SVC 707

V70119 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7030-1A2 11775/PR/7/02/106 SVC 707

V70120 3/4" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-002 20"-JET-7030-1A2 11775/PR/7/02/106 SVC 707

V70121 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 20"-JET-7030-1A2 11775/PR/7/02/106 SVC 707

11775-SCH-ME-002 Rev 0 Page 7 of 11


Design of New Hydrant System (Package #7)

Valve Schedule
Location/
Tag No. Size Type Body Material Ends Operator Service Data Sheet Line No. P&ID
Package
Lugged Type to Suit RF
V70122 16" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 16"-JET-7033-1A2 11775/PR/7/02/106 SVC 708
150#
Lugged Type to Suit RF
V70123 12" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 16"-JET-7033-1A2 11775/PR/7/02/106 SVC 708
150#

V70124 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 16"-JET-7033-1A2 11775/PR/7/02/106 SVC 708

V70125 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 16"-JET-7033-1A2 11775/PR/7/02/106 SVC 708

V70126 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 16"-JET-7033-1A2 11775/PR/7/02/106 SVC 708

V70127 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 16"-JET-7033-1A2 11775/PR/7/02/106 SVC 708

V70128 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 16"-JET-7033-1A2 11775/PR/7/02/106 SVC 708

V70129 3/4" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-002 16"-JET-7033-1A2 11775/PR/7/02/106 SVC 708

V70130 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 16"-JET-7033-1A2 11775/PR/7/02/106 SVC 708

Lugged Type to Suit RF


V70131 20" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 20"-JET-7035-1A2 11775/PR/7/02/107 SVC 709
150#
Lugged Type to Suit RF
V70132 20" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 20"-JET-7035-1A2 11775/PR/7/02/107 SVC 709
150#
V70133 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7035-1A2 11775/PR/7/02/107 SVC 709

V70134 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7035-1A2 11775/PR/7/02/107 SVC 709

V70135 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7035-1A2 11775/PR/7/02/107 SVC 709

V70136 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7035-1A2 11775/PR/7/02/107 SVC 709

V70137 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7035-1A2 11775/PR/7/02/107 SVC 709

V70138 3/4" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-002 20"-JET-7035-1A2 11775/PR/7/02/107 SVC 709

V70139 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 20"-JET-7035-1A2 11775/PR/7/02/107 SVC 709

Lugged Type to Suit RF


V70140 20" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 20"-JET-7037-1A2 11775/PR/7/02/107 SVC 710
150#
Lugged Type to Suit RF
V70141 20" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 20"-JET-7037-1A2 11775/PR/7/02/107 SVC 710
150#
Lugged Type to Suit RF
V70142 20" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 20"-JET-7038-1A2 11775/PR/7/02/107 SVC 710
150#
Lugged Type to Suit RF
V70143 20" Butterfly Carbon Steel Handwheel / Gear JET-A1 11775-DAT-ME-005 20"-JET-7038-1A2 11775/PR/7/02/107 SVC 710
150#

11775-SCH-ME-002 Rev 0 Page 8 of 11


Design of New Hydrant System (Package #7)

Valve Schedule
Location/
Tag No. Size Type Body Material Ends Operator Service Data Sheet Line No. P&ID
Package
V70144 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7037-1A2 11775/PR/7/02/107 SVC 710

V70145 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7037-1A2 11775/PR/7/02/107 SVC 710

V70146 2" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7037-1A2 11775/PR/7/02/107 SVC 710

V70147 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7037-1A2 11775/PR/7/02/107 SVC 710

V70148 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7037-1A2 11775/PR/7/02/107 SVC 710

V70149 3/4" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-002 20"-JET-7037-1A2 11775/PR/7/02/107 SVC 710

V70150 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 20"-JET-7037-1A2 11775/PR/7/02/107 SVC 710

V70151 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7038-1A2 11775/PR/7/02/107 SVC 710

V70152 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7038-1A2 11775/PR/7/02/107 SVC 710

V49920 3/4" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-002 PSV-4098 Inlet 11775/PR/7/02/102 SHT 2 Inside New Fuel Depot

V49921 1" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-002 1"-P-4404-1A2 11775/PR/7/02/102 SHT 2 Inside New Fuel Depot

V49922 3/4" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-002 PSV-4097 Inlet 11775/PR/7/02/102 SHT 2 Inside New Fuel Depot

V49923 1" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-002 1"-P-4405-1A2 11775/PR/7/02/102 SHT 2 Inside New Fuel Depot

V49924 3/4" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-002 PSV-4096 Inlet 11775/PR/7/02/102 SHT 2 Inside New Fuel Depot

V49925 1" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-002 1"-P-4406-1A2 11775/PR/7/02/102 SHT 2 Inside New Fuel Depot

V49926 3/4" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-002 PSV-4099 Inlet 11775/PR/7/02/102 SHT 2 Inside New Fuel Depot

V49927 1" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-002 1"-P-4407-1A2 11775/PR/7/02/102 SHT 2 Inside New Fuel Depot

V49928 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-P-4060-1A2 11775/PR/7/02/102 SHT 2 Inside New Fuel Depot

V70153 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 12"-JET-7003-1A2 11775/PR/7/02/103 SVC 701

V70154 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 12"-JET-7003-1A2 11775/PR/7/02/103 SVC 701

V70155 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 12"-JET-7003-1A2 11775/PR/7/02/103 SVC 701

V70156 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7005-1A2 11775/PR/7/02/103 SVC 702

11775-SCH-ME-002 Rev 0 Page 9 of 11


Design of New Hydrant System (Package #7)

Valve Schedule
Location/
Tag No. Size Type Body Material Ends Operator Service Data Sheet Line No. P&ID
Package
V70157 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7005-1A2 11775/PR/7/02/103 SVC 702

V70158 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 24"-JET-7005-1A2 11775/PR/7/02/103 SVC 702

V70159 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7006-1A2 11775/PR/7/02/103 SVC 702

V70160 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7006-1A2 11775/PR/7/02/103 SVC 702

V70161 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 20"-JET-7006-1A2 11775/PR/7/02/103 SVC 702

V70162 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7008-1A2 11775/PR/7/02/103 SVC 702

V70163 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7008-1A2 11775/PR/7/02/103 SVC 702

V70164 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 20"-JET-7008-1A2 11775/PR/7/02/103 SVC 702

V70165 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 16"-JET-7011-1A2 11775/PR/7/02/103 SVC 703

V70166 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 16"-JET-7011-1A2 11775/PR/7/02/103 SVC 703

V70167 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 16"-JET-7011-1A2 11775/PR/7/02/103 SVC 703

V70168 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7013-1A2 11775/PR/7/02/104 SVC 704

V70169 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7013-1A2 11775/PR/7/02/104 SVC 704

V70170 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 20"-JET-7013-1A2 11775/PR/7/02/104 SVC 704

V70171 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7016-1A2 11775/PR/7/02/104 SVC 705

V70172 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7016-1A2 11775/PR/7/02/104 SVC 705

V70173 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 20"-JET-7016-1A2 11775/PR/7/02/104 SVC 705

V70174 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7020-1A2 11775/PR/7/02/105 SVC 711

V70175 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7020-1A2 11775/PR/7/02/105 SVC 711

V70176 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 24"-JET-7020-1A2 11775/PR/7/02/105 SVC 711

V70177 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7022-1A2 11775/PR/7/02/105 SVC 712

V70178 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7022-1A2 11775/PR/7/02/105 SVC 712

11775-SCH-ME-002 Rev 0 Page 10 of 11


Design of New Hydrant System (Package #7)

Valve Schedule
Location/
Tag No. Size Type Body Material Ends Operator Service Data Sheet Line No. P&ID
Package
V70179 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 24"-JET-7022-1A2 11775/PR/7/02/105 SVC 712

V70180 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 12"-JET-7025-1A2 11775/PR/7/02/106 SVC 706

V70181 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 12"-JET-7025-1A2 11775/PR/7/02/106 SVC 706

V70182 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 12"-JET-7025-1A2 11775/PR/7/02/106 SVC 706

V70183 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7027-1A2 11775/PR/7/02/106 SVC 707

V70184 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 24"-JET-7027-1A2 11775/PR/7/02/106 SVC 707

V70185 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 24"-JET-7027-1A2 11775/PR/7/02/106 SVC 707

V70186 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7028-1A2 11775/PR/7/02/106 SVC 707

V70187 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7028-1A2 11775/PR/7/02/106 SVC 707

V70188 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 20"-JET-7028-1A2 11775/PR/7/02/106 SVC 707

V70189 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7030-1A2 11775/PR/7/02/106 SVC 707

V70190 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7030-1A2 11775/PR/7/02/106 SVC 707

V70191 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 20"-JET-7030-1A2 11775/PR/7/02/106 SVC 707

V70192 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 16"-JET-7033-1A2 11775/PR/7/02/106 SVC 708

V70193 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 16"-JET-7033-1A2 11775/PR/7/02/106 SVC 708

V70194 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 16"-JET-7033-1A2 11775/PR/7/02/106 SVC 708

V70195 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7035-1A2 11775/PR/7/02/107 SVC 709

V70196 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7035-1A2 11775/PR/7/02/107 SVC 709

V70197 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 20"-JET-7035-1A2 11775/PR/7/02/107 SVC 709

V70198 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7037-1A2 11775/PR/7/02/107 SVC 710

V70199 3" Ball Carbon Steel RF 150# Lever JET-A1 11775-DAT-ME-001 20"-JET-7037-1A2 11775/PR/7/02/107 SVC 710

V70200 1/2" Ball Carbon Steel Screwed 800# Lever JET-A1 11775-DAT-ME-002 20"-JET-7037-1A2 11775/PR/7/02/107 SVC 710

11775-SCH-ME-002 Rev 0 Page 11 of 11


Design of New Hydrant System (Package #7)

Line List

Line Documents Design Test Medium


Line Number
From To Size Class Specification P&ID Isometric Prs Tmp Prs

24"-P-4401-1A2 24"-P-4060-1A2 24"-JET-7001-1A4 24" 1A2 ASME B31.3 11775/PR/7/02/102 SHT 2 TBA 16 barg 50 DegC 24 barg WATER

24"-P-4402-1A2 24"-P-4060-1A2 24"-JET-7019-1A4 24" 1A2 ASME B31.3 11775/PR/7/02/102 SHT 2 TBA 16 barg 50 DegC 24 barg WATER

Return Line
24"-P-4403-1A2 24"-P-4402-1A2 24" 1A2 ASME B31.3 11775/PR/7/02/102 SHT 2 TBA 16 barg 50 DegC 24 barg WATER
(Package 4)

24"-JET-7001-1A4 24"-P-4401-1A2 24"-JET-7005-1A2 24" 1A4 ASME B31.3 11775/PR/7/02/102 SHT 2 TBA 16 barg 50 DegC 24 barg WATER

24"-JET-7019-1A4 24"-P-4402-1A2 24"-JET-7020-1A2 24" 1A4 ASME B31.3 11775/PR/7/02/102 SHT 2 TBA 16 barg 50 DegC 24 barg WATER

12"-JET-7002-1A4 24"-JET-7001-1A4 12"-JET-7003-1A2 12" 1A4 ASME B31.3 11775/PR/7/02/103 TBA 16 barg 50 DegC 24 barg WATER

12"-JET-7003-1A2 12"-JET-7002-1A4 12"-JET-7004-1A4 12" 1A2 ASME B31.3 11775/PR/7/02/103 TBA 16 barg 50 DegC 24 barg WATER

12"-JET-7004-1A4 12"-JET-7003-1A2 End Cap 12" 1A4 ASME B31.3 11775/PR/7/02/103 TBA 16 barg 50 DegC 24 barg WATER

24"-JET-7005-1A2 24"-JET-7001-1A4 16"-JET-7010-1A4 24" 1A2 ASME B31.3 11775/PR/7/02/103 TBA 16 barg 50 DegC 24 barg WATER

20"-JET-7006-1A2 24"-JET-7005-1A2 20"-JET-7007-1A4 20" 1A2 ASME B31.3 11775/PR/7/02/103 TBA 16 barg 50 DegC 24 barg WATER

20"-JET-7007-1A4 20"-JET-7006-1A2 20"-JET-7016-1A2 20" 1A4 ASME B31.3 11775/PR/7/02/103 TBA 16 barg 50 DegC 24 barg WATER

20"-JET-7008-1A2 24"-JET-7005-1A2 20"-JET-7009-1A4 20" 1A2 ASME B31.3 11775/PR/7/02/103 TBA 16 barg 50 DegC 24 barg WATER

20"-JET-7009-1A4 20"-JET-7008-1A2 20"-JET-7013-1A2 20" 1A4 ASME B31.3 11775/PR/7/02/103 TBA 16 barg 50 DegC 24 barg WATER

16"-JET-7010-1A4 24"-JET-7005-1A2 16"-JET-7011-1A2 16" 1A4 ASME B31.3 11775/PR/7/02/103 TBA 16 barg 50 DegC 24 barg WATER

16"-JET-7011-1A2 16"-JET-7010-1A4 Future Connection 16" 1A2 ASME B31.3 11775/PR/7/02/103 TBA 16 barg 50 DegC 24 barg WATER

20"-JET-7013-1A2 20"-JET-7009-1A4 Future Connection 20" 1A2 ASME B31.3 11775/PR/7/02/104 TBA 16 barg 50 DegC 24 barg WATER

20"-JET-7014-1A2 20"-JET-7013-1A2 20"-JET-7015-1A4 20" 1A2 ASME B31.3 11775/PR/7/02/104 TBA 16 barg 50 DegC 24 barg WATER

20"-JET-7015-1A4 20"-JET-7014-1A2 20"-JET-7035-1A2 20" 1A4 ASME B31.3 11775/PR/7/02/104 TBA 16 barg 50 DegC 24 barg WATER

20"-JET-7016-1A2 20"-JET-7007-1A4 Future Connection 20" 1A2 ASME B31.3 11775/PR/7/02/104 TBA 16 barg 50 DegC 24 barg WATER

11775-LST-ME-001 Rev 0 Page 2 of 4


Design of New Hydrant System (Package #7)

Line List

Line Documents Design Test Medium


Line Number
From To Size Class Specification P&ID Isometric Prs Tmp Prs

24"-JET-7020-1A2 24"-JET-7019-1A4 24"-JET-7021-1A4 24" 1A2 ASME B31.3 11775/PR/7/02/105 TBA 16 barg 50 DegC 24 barg WATER

24"-JET-7021-1A4 24"-JET-7020-1A2 24"-JET-7022-1A2 24" 1A4 ASME B31.3 11775/PR/7/02/105 TBA 16 barg 50 DegC 24 barg WATER

24"-JET-7022-1A2 24"-JET-7021-1A4 24"-JET-7023-1A4 24" 1A2 ASME B31.3 11775/PR/7/02/105 TBA 16 barg 50 DegC 24 barg WATER

24"-JET-7023-1A4 24"-JET-7022-1A2 24"-JET-7027-1A2 24" 1A4 ASME B31.3 11775/PR/7/02/105 TBA 16 barg 50 DegC 24 barg WATER

12"-JET-7024-1A4 24"-JET-7023-1A4 12"-JET-7025-1A2 12" 1A4 ASME B31.3 11775/PR/7/02/106 TBA 16 barg 50 DegC 24 barg WATER

12"-JET-7025-1A2 12"-JET-7024-1A4 12"-JET-7026-1A4 12" 1A2 ASME B31.3 11775/PR/7/02/106 TBA 16 barg 50 DegC 24 barg WATER

12"-JET-7026-1A4 12"-JET-7025-1A2 End Cap 12" 1A4 ASME B31.3 11775/PR/7/02/106 TBA 16 barg 50 DegC 24 barg WATER

24"-JET-7027-1A2 24"-JET-7023-1A4 16"-JET-7032-1A4 24" 1A2 ASME B31.3 11775/PR/7/02/106 TBA 16 barg 50 DegC 24 barg WATER

20"-JET-7028-1A2 24"-JET-7027-1A2 20"-JET-7029-1A4 20" 1A2 ASME B31.3 11775/PR/7/02/106 TBA 16 barg 50 DegC 24 barg WATER

20"-JET-7029-1A4 20"-JET-7028-1A2 20"-JET-7035-1A2 20" 1A4 ASME B31.3 11775/PR/7/02/106 TBA 16 barg 50 DegC 24 barg WATER

20"-JET-7030-1A2 24"-JET-7027-1A2 20"-JET-7031-1A4 20" 1A2 ASME B31.3 11775/PR/7/02/106 TBA 16 barg 50 DegC 24 barg WATER

20"-JET-7031-1A4 20"-JET-7030-1A2 20"-JET-7037-1A2 20" 1A4 ASME B31.3 11775/PR/7/02/106 TBA 16 barg 50 DegC 24 barg WATER

16"-JET-7032-1A4 24"-JET-7027-1A2 16"-JET-7033-1A2 16" 1A4 ASME B31.3 11775/PR/7/02/106 TBA 16 barg 50 DegC 24 barg WATER

16"-JET-7033-1A2 16"-JET-7032-1A4 Future Connection 16" 1A2 ASME B31.3 11775/PR/7/02/106 TBA 16 barg 50 DegC 24 barg WATER

20"-JET-7035-1A2 20"-JET-7029-1A4 Future Connection 20" 1A2 ASME B31.3 11775/PR/7/02/107 TBA 16 barg 50 DegC 24 barg WATER

20"-JET-7037-1A2 20"-JET-7031-1A4 Future Connection 20" 1A2 ASME B31.3 11775/PR/7/02/107 TBA 16 barg 50 DegC 24 barg WATER

20"-JET-7038-1A2 20"-JET-7037-1A2 20"-JET-7018-1A4 20" 1A2 ASME B31.3 11775/PR/7/02/107 TBA 16 barg 50 DegC 24 barg WATER

20"-JET-7018-1A4 20"-JET-7038-1A2 20"-JET-7016-1A2 20" 1A4 ASME B31.3 11775/PR/7/02/107 TBA 16 barg 50 DegC 24 barg WATER

1"-P-4404-1A2 PSV-4098 Outlet 2"-P-4408-1A2 1" 1A2 ASME B31.3 11775/PR/7/02/102 SHT 2 TBA 16 barg 50 DegC 24 barg WATER

11775-LST-ME-001 Rev 0 Page 3 of 4


Design of New Hydrant System (Package #7)

Line List

Line Documents Design Test Medium


Line Number
From To Size Class Specification P&ID Isometric Prs Tmp Prs

1"-P-4405-1A2 PSV-4097 Outlet 2"-P-4408-1A2 1" 1A2 ASME B31.3 11775/PR/7/02/102 SHT 2 TBA 16 barg 50 DegC 24 barg WATER

1"-P-4406-1A2 PSV-4096 Outlet 2"-P-4408-1A2 1" 1A2 ASME B31.3 11775/PR/7/02/102 SHT 2 TBA 16 barg 50 DegC 24 barg WATER

1"-P-4407-1A2 PSV-4099 Outlet 2"-P-4408-1A2 1" 1A2 ASME B31.3 11775/PR/7/02/102 SHT 2 TBA 16 barg 50 DegC 24 barg WATER

2"-P-4408-1A2 End Cap 3"-P-4585-1A1 2" 1A2 ASME B31.3 11775/PR/7/02/102 SHT 2 TBA 16 barg 50 DegC 24 barg WATER

11775-LST-ME-001 Rev 0 Page 4 of 4


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

MTO FOR MECHANICAL MATERIALS


(Piping/Pipeline Bulk MTO)
Item and Type Coating Size (NPS) Rating / Sch Qty Unit

1.0 CS Fittings

90 LR ELL, SMLS, SW, ASTM A105, ASME B16.11 External: Painting ¾" 3000# 16 Nos

90 LR ELL, SMLS, SW, ASTM A105, ASME B16.11 External: Painting 1" 3000# 5 Nos
90 LR ELL, SMLS, BW, ASTM A234 WPB, ASME
External: Painting 2" Sch 40 2 Nos
B16.9
90 LR ELL, SMLS, BW, ASTM A234 WPB, ASME
External: Painting 3" Sch 40 116 Nos
B16.9
90 LR ELL, SMLS, BW, ASTM A234 WPB, ASME Internal: Two-pack epoxy resin
6" Sch 40 44 Nos
B16.9 External: Two-pack Liquid PU Coating
90 LR ELL, SMLS, BW, ASTM A234 WPB, ASME Internal: Two-pack epoxy resin
24" Sch 20 2 Nos
B16.9 External: Two-pack Liquid PU Coating
90 LR ELL, SMLS, BW, ASTM A234 WPB, ASME Internal: Two-pack epoxy resin
24" Sch 20 21 Nos
B16.9 External: Painting

45 LR ELL, SMLS, BW, ASTM A234 WPB, ASME Internal: Two-pack epoxy resin
24" Sch 20 6 Nos
B16.9 External: Painting
45 LR ELL, SMLS, BW, ASTM A234 WPB, ASME Internal: Two-pack epoxy resin
24" Sch 20 6 Nos
B16.9 External: Two-pack Liquid PU Coating
45 LR ELL, SMLS, BW, ASTM A234 WPB, ASME Internal: Two-pack epoxy resin
20" Sch 20 31 Nos
B16.9 External: Two-pack Liquid PU Coating
45 LR ELL, SMLS, BW, ASTM A234 WPB, ASME Internal: Two-pack epoxy resin
12" Sch STD 3 Nos
B16.9 External: Two-pack Liquid PU Coating

EQL Tee, SMLS, BW, ASTM A234 WPB, ASME


External: Painting 2" Sch 40 1 Nos
B16.9
EQL Tee, SMLS, BW, ASTM A234 WPB, ASME Internal: Two-pack epoxy resin
16" Sch 30 2 Nos
B16.9 External: Painting
EQL Tee, SMLS, BW, ASTM A234 WPB, ASME Internal: Two-pack epoxy resin
20" Sch 20 4 Nos
B16.9 External: Painting
EQL Tee, SMLS, BW, ASTM A234 WPB, ASME Internal: Two-pack epoxy resin
24" Sch 20 7 Nos
B16.9 External: Painting

RED Tee, SMLS, BW, ASTM A234 WPB, ASME


External: Painting 2" x 2" x 1" Sch 40 x Sch 40 x Sch 80 4 Nos
B16.9
RED Tee, SMLS, BW, ASTM A234 WPB, ASME Internal: Two-pack epoxy resin
12" x 12" x 6" STD x STD x Sch40 2 Nos
B16.9 External: Two-pack Liquid PU Coating
RED Tee, SMLS, BW, ASTM A234 WPB, ASME Internal: Two-pack epoxy resin
12" x 12" x 8" STD x STD x Sch30 1 Nos
B16.9 External: Painting
RED Tee, SMLS, BW, ASTM A234 WPB, ASME Internal: Two-pack epoxy resin
16" x 16" x 8" Sch 30 x Sch 30 x Sch 30 2 Nos
B16.9 External: Painting
RED Tee, SMLS, BW, ASTM A234 WPB, ASME Internal: Two-pack epoxy resin
20" x 20" x 8" Sch 20 x Sch 20 x Sch 30 4 Nos
B16.9 External: Painting
RED Tee, SMLS, BW, ASTM A234 WPB, ASME Internal: Two-pack epoxy resin
20" x 20" x 10" Sch 20 x Sch 20 x Sch STD 6 Nos
B16.9 External: Two-pack Liquid PU Coating
RED Tee, SMLS, BW, ASTM A234 WPB, ASME Internal: Two-pack epoxy resin
24" x 24" x 10" Sch 20 x Sch 20 x Sch STD 4 Nos
B16.9 External: Two-pack Liquid PU Coating
RED Tee, SMLS, BW, ASTM A234 WPB, ASME Internal: Two-pack epoxy resin
24" x 24" x 12" Sch 20 x Sch 20 x Sch STD 2 Nos
B16.9 External: Two-pack Liquid PU Coating
RED Tee, SMLS, BW, ASTM A234 WPB, ASME Internal: Two-pack epoxy resin
24" x 24" x 20" Sch 20 x Sch 20 x Sch 20 4 Nos
B16.9 External: Painting

ECC Reducer, SMLS, BW, ASTM A234 WPB, ASME Internal: Two-pack epoxy resin
16" x 12" Sch 30 x STD 2 Nos
B16.9 External: Painting
ECC Reducer, SMLS, BW, ASTM A234 WPB, ASME Internal: Two-pack epoxy resin
24" x 16" Sch 20 x Sch 30 2 Nos
B16.9 External: Painting

Cap, SMLS, BW, ASTM A234 WPB, ASME B16.9 External: Painting 2" Sch 40 1 Nos
Internal: Two-pack epoxy resin
Cap, SMLS, BW, ASTM A234 WPB, ASME B16.9 6" Sch 40 2 Nos
External: Two-pack Liquid PU Coating
Internal: Two-pack epoxy resin
Cap, SMLS, BW, ASTM A234 WPB, ASME B16.9 8" Sch 30 16 Nos
External: Painting
Internal: Two-pack epoxy resin
Cap, SMLS, BW, ASTM A234 WPB, ASME B16.9 10" Sch STD 10 Nos
External: Two-pack Liquid PU Coating
Internal: Two-pack epoxy resin
Cap, SMLS, BW, ASTM A234 WPB, ASME B16.9 12" Sch STD 2 Nos
External: Two-pack Liquid PU Coating

Sockolet, SMLS, SW, ASTM A105, MSS SP-97 External: Painting 3" x ¾" 3000# 16 Nos
Sockolet, SMLS, SW, ASTM A105, MSS SP-97 External: Painting 12" x 1 1/2" 3000# 4 Nos
Sockolet, SMLS, SW, ASTM A105, MSS SP-97 External: Painting 16" x 1 1/2" 3000# 2 Nos
Sockolet, SMLS, SW, ASTM A105, MSS SP-97 External: Painting 20" x 1 1/2" 3000# 8 Nos
Sockolet, SMLS, SW, ASTM A105, MSS SP-97 External: Painting 24" x ¾" 3000# 4 Nos
Sockolet, SMLS, SW, ASTM A105, MSS SP-97 External: Painting 24" x 1½" 3000# 4 Nos

Weldolet, SMLS, BW, ASTM A105, MSS SP-97 External: Painting 8" x 3" Sch 30 x Sch 40 16 Nos
Weldolet, SMLS, BW, ASTM A105, MSS SP-97 External: Painting 12" x 2" STD x Sch 40 8 Nos
Weldolet, SMLS, BW, ASTM A105, MSS SP-97 External: Painting 12" x 3" STD x Sch 40 4 Nos
Weldolet, SMLS, BW, ASTM A105, MSS SP-97 External: Cold Applied Tape 12" x 6" STD x Sch 40 14 Nos
Weldolet, SMLS, BW, ASTM A105, MSS SP-97 External: Painting 12" x 8" STD x Sch 30 4 Nos
Weldolet, SMLS, BW, ASTM A105, MSS SP-97 External: Painting 16" x 2" Sch 30 x Sch 40 4 Nos
Weldolet, SMLS, BW, ASTM A105, MSS SP-97 External: Painting 16" x 3" Sch 30 x Sch 40 5 Nos

11775-MTO-ME-001 Rev 2 Page 2 of 5


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

MTO FOR MECHANICAL MATERIALS


(Piping/Pipeline Bulk MTO)
Item and Type Coating Size (NPS) Rating / Sch Qty Unit
Weldolet, SMLS, BW, ASTM A105, MSS SP-97 External: Painting 16" x 8" Sch 30 x Sch 30 2 Nos
Weldolet, SMLS, BW, ASTM A105, MSS SP-97 External: Painting 20" x 2" Sch 20 x Sch 40 16 Nos
Weldolet, SMLS, BW, ASTM A105, MSS SP-97 External: Painting 20" x 3" Sch 20 x Sch 40 20 Nos
Weldolet, SMLS, BW, ASTM A105, MSS SP-97 External: Cold Applied Tape 20" x 6" Sch 20 x Sch 40 105 Nos
Weldolet, SMLS, BW, ASTM A105, MSS SP-97 External: Painting 20" x 8" Sch 20 x Sch 30 8 Nos
Weldolet, SMLS, BW, ASTM A105, MSS SP-97 External: Painting 24" x 2" Sch 20 x Sch 40 15 Nos
Weldolet, SMLS, BW, ASTM A105, MSS SP-97 External: Painting 24" x 3" Sch 20 x Sch 40 12 Nos
Weldolet, SMLS, BW, ASTM A105, MSS SP-97 External: Cold Applied Tape 24" x 6" Sch 20 x Sch 40 8 Nos
Weldolet, SMLS, BW, ASTM A105, MSS SP-97 External: Painting 24" x 8" Sch 20 x Sch 30 6 Nos

2.0 CS Flanges

SW Flange, RF, Stock Finish, ASTM A105, ASME


B16.5
External: Painting ¾" 150# 28 Nos
SW Flange, RF, Stock Finish, ASTM A105, ASME
External: Painting 1" 150# 12 Nos
B16.5
SW Flange, RF, Stock Finish, ASTM A105, ASME
External: Painting 1½" 150# 18 Nos
B16.5

WN Flange, RF, Stock Finish, ASTM A105, ASME


External: Painting 2" 150# 45 Nos
B16.5
WN Flange, RF, Stock Finish, ASTM A105, ASME
External: Painting 3" 150# 91 Nos
B16.5
WN Flange, RF, Stock Finish, ASTM A105, ASME
External: Painting 8" 150# 12 Nos
B16.5
WN Flange, RF, Stock Finish, ASTM A105, ASME
External: Painting 12" 150# 18 Nos
B16.5
WN Flange, RF, Stock Finish, ASTM A105, ASME
External: Painting 16" 150# 14 Nos
B16.5
WN Flange, RF, Stock Finish, ASTM A105, ASME
External: Painting 20" 150# 60 Nos
B16.5
WN Flange, RF, Stock Finish, ASTM A105, ASME
External: Painting 24" 150# 38 Nos
B16.5

WN Flange, FF, Stock Finish, ASTM A105, ASME


External: Painting 3" 150# 30 Nos
B16.5

Blind Flange, RF, Stock Finish, ASTM A105, ASME


External: Painting ¾" 150# 16 Nos
B16.5
Blind Flange, RF, Stock Finish, ASTM A105, ASME
External: Painting 1½" 150# 18 Nos
B16.5
Blind Flange, RF, Stock Finish, ASTM A105, ASME
External: Painting 2" 150# 42 Nos
B16.5
Blind Flange, RF, Stock Finish, ASTM A105, ASME
External: Painting 3" 150# 25 Nos
B16.5
Blind Flange, RF, Stock Finish, ASTM A105, ASME
External: Painting 8" 150# 12 Nos
B16.5
Blind Flange, RF, Stock Finish, ASTM A105, ASME
External: Painting 12" 150# 2 Nos
B16.5
Blind Flange, RF, Stock Finish, ASTM A105, ASME
External: Painting 16" 150# 2 Nos
B16.5
Blind Flange, RF, Stock Finish, ASTM A105, ASME
External: Painting 20" 150# 4 Nos
B16.5
Blind Flange, RF, Stock Finish, ASTM A105, ASME
External: Painting 24" 150# 3 Nos
B16.5

3.0 Gasket

Spiral Wound, RF, SS316L centering and outer SS


ring with flexible non-asbestos filler, 4.5mm thk., ¾" 150# 44 Nos
ASME B16.20
Spiral Wound, RF, SS316L centering and outer SS
ring with flexible non-asbestos filler, 4.5mm thk., 1" 150# 12 Nos
ASME B16.20
Spiral Wound, RF, SS316L centering and outer SS
ring with flexible non-asbestos filler, 4.5mm thk., 1½" 150# 18 Nos
ASME B16.20
Spiral Wound, RF, SS316L centering and outer SS
ring with flexible non-asbestos filler, 4.5mm thk., 2" 150# 86 Nos
ASME B16.20
Spiral Wound, RF, SS316L centering and outer SS
ring with flexible non-asbestos filler, 4.5mm thk., 3" 150# 178 Nos
ASME B16.20
Spiral Wound, RF, SS316L centering and outer SS
ring with flexible non-asbestos filler, 4.5mm thk., 8" 150# 12 Nos
ASME B16.20
Spiral Wound, RF, SS316L centering and outer SS
ring with flexible non-asbestos filler, 4.5mm thk., 12" 150# 20 Nos
ASME B16.20
Spiral Wound, RF, SS316L centering and outer SS
ring with flexible non-asbestos filler, 4.5mm thk., 16" 150# 14 Nos
ASME B16.20
Spiral Wound, RF, SS316L centering and outer SS
ring with flexible non-asbestos filler, 4.5mm thk., 20" 150# 60 Nos
ASME B16.20

11775-MTO-ME-001 Rev 2 Page 3 of 5


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

MTO FOR MECHANICAL MATERIALS


(Piping/Pipeline Bulk MTO)
Item and Type Coating Size (NPS) Rating / Sch Qty Unit
Spiral Wound, RF, SS316L centering and outer SS
ring with flexible non-asbestos filler, 4.5mm thk., 24" 150# 37 Nos
ASME B16.20

Spiral Wound, FF, SS316L centering and outer SS


ring with flexible non-asbestos filler, 4.5mm thk., 3" 150# 32 Nos
ASME B16.20

4.0 Small Fittings

Hex Head Plug, THRD, ASTM A105 ½" 3000# 32 Nos

5.0 Miscellaneous Fittings

Drip Ring, RF, API 590, 40mm thk., drilled with a ½"
3" 150# 32 Nos
NPT threaded.
Aircraft Adapter 2½" 32 Nos

Insulating Flange Kit 12" 150# 6 Nos


Insulating Flange Kit 16" 150# 4 Nos
Insulating Flange Kit 20" 150# 12 Nos
Insulating Flange Kit 24" 150# 8 Nos

6.0 Pipe Lengths/Nipples

Nipple, TBE, SMLS, ASTM A106 Gr. B (L=100mm ) ½" Sch 80 32 Nos

Nipple, PBE, SMLS, ASTM A106 Gr. B (L=100mm ) ¾" Sch 80 32 Nos

Nipple, PBE, SMLS, ASTM A106 Gr. B (L=100mm ) 1½" Sch 80 16 Nos

Pipe, PE, SMLS, ASTM A106 Gr. B, ASME B36.10 External: Painting 3/4" Sch 80 6 m

Pipe, PE, SMLS, ASTM A106 Gr. B, ASME B36.10 External: Painting 1" Sch 80 13 m
Pipe, BE, SMLS, API 5L Gr. B, ASME B36.10 External: Painting 2" Sch 40 16 m
Pipe, BE, SMLS, API 5L Gr. B, ASME B36.10 External: Painting 3" Sch 40 173 m
Internal: Two-pack epoxy resin
Pipe, BE, SMLS, API 5L Gr. B, ASME B36.10 6" Sch 40 336 m
External: 3LPE
Internal: Two-pack epoxy resin
Pipe, BE, SMLS, API 5L Gr. B, ASME B36.10 12" STD 612 m
External: 3LPE
Internal: Two-pack epoxy resin
Pipe, BE, SMLS, API 5L Gr. B, ASME B36.10 12" STD 12 m
External: Painting
Internal: Two-pack epoxy resin
Pipe, BE, SMLS, API 5L Gr. B, ASME B36.10 16" Sch 30 996 m
External: 3LPE
Internal: Two-pack epoxy resin
Pipe, BE, SMLS, API 5L Gr. B, ASME B36.10 16" Sch 30 12 m
External: Painting
Internal: Two-pack epoxy resin
Pipe, BE, SMLS, API 5L Gr. B, ASME B36.10 20" Sch 20 5496 m
External: 3LPE
Internal: Two-pack epoxy resin
Pipe, BE, SMLS, API 5L Gr. B, ASME B36.10 20" Sch 20 36 m
External: Painting
Internal: Two-pack epoxy resin
Pipe, BE, SMLS, API 5L Gr. B, ASME B36.10 24" Sch 20 3600 m
External: 3LPE
Internal: Two-pack epoxy resin
Pipe, BE, SMLS, API 5L Gr. B, ASME B36.10 24" Sch 20 168 m
External: Painting

7.0 Bolt and Nut

Studbolt, ASTM A193 Gr. B7 w/ 2 ASTM A194 Gr. 2H


1/2" x 65mm 200 Nos
Heavy Hex. CS nuts + washers
Studbolt, ASTM A193 Gr. B7 w/ 2 ASTM A194 Gr. 2H
1/2" x 70mm 72 Nos
Heavy Hex. CS nuts + washers
Studbolt, ASTM A193 Gr. B7 w/ 2 ASTM A194 Gr. 2H
1/2" x 85mm 12 Nos
Heavy Hex. CS nuts + washers
Studbolt, ASTM A193 Gr. B7 w/ 2 ASTM A194 Gr. 2H
5/8" x 85mm 344 Nos
Heavy Hex. CS nuts + washers
Studbolt, ASTM A193 Gr. B7 w/ 2 ASTM A194 Gr. 2H
5/8" x 90mm 584 Nos
Heavy Hex. CS nuts + washers
Studbolt, ASTM A193 Gr. B7 w/ 2 ASTM A194 Gr. 2H
5/8" x 135mm 128 Nos
Heavy Hex. CS nuts + washers
Studbolt, ASTM A193 Gr. B7 w/ 2 ASTM A194 Gr. 2H
3/4" x 110mm 96 Nos
Heavy Hex. CS nuts + washers
Studbolt, ASTM A193 Gr. B7 w/ 2 ASTM A194 Gr. 2H
7/8" x 120mm 96 Nos
Heavy Hex. CS nuts + washers
Studbolt, ASTM A193 Gr. B7 w/ 2 ASTM A194 Gr. 2H
7/8" x 210mm 72 Nos
Heavy Hex. CS nuts + washers
Studbolt, ASTM A193 Gr. B7 w/ 2 ASTM A194 Gr. 2H
1" x 135mm 96 Nos
Heavy Hex. CS nuts + washers
Studbolt, ASTM A193 Gr. B7 w/ 2 ASTM A194 Gr. 2H
1" x 245mm 64 Nos
Heavy Hex. CS nuts + washers
Studbolt, ASTM A193 Gr. B7 w/ 2 ASTM A194 Gr. 2H
1 1/8" x 160mm 440 Nos
Heavy Hex. CS nuts + washers
Studbolt, ASTM A193 Gr. B7 w/ 2 ASTM A194 Gr. 2H
1 1/8" x 295mm 400 Nos
Heavy Hex. CS nuts + washers

11775-MTO-ME-001 Rev 2 Page 4 of 5


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

MTO FOR MECHANICAL MATERIALS


(Piping/Pipeline Bulk MTO)
Item and Type Coating Size (NPS) Rating / Sch Qty Unit
Studbolt, ASTM A193 Gr. B7 w/ 2 ASTM A194 Gr. 2H
1 1/4" x 170mm 380 Nos
Heavy Hex. CS nuts + washers
Studbolt, ASTM A193 Gr. B7 w/ 2 ASTM A194 Gr. 2H
1 1/4" x 330mm 120 Nos
Heavy Hex. CS nuts + washers
Studbolt, ASTM A193 Gr. B7 w/ 2 ASTM A194 Gr. 2H
1 1/4" x 400mm 60 Nos
Heavy Hex. CS nuts + washers

8.0 Heat Shrinkable Sleeves

Polyethylene Heat Shrinkable Sleeves 6" 34 Nos


Polyethylene Heat Shrinkable Sleeves 12" 62 Nos
Polyethylene Heat Shrinkable Sleeves 16" 100 Nos
Polyethylene Heat Shrinkable Sleeves 20" 525 Nos
Polyethylene Heat Shrinkable Sleeves 24" 344 Nos

9.0 Hydrant Refueling Pit

Hydrant Refueling Pit Assembly 6" 103 Nos

10.0 Vent/Drain Assembly

Vent Assembly 6" 17 Nos


Drain assembly 6" 18 Nos

11775-MTO-ME-001 Rev 2 Page 5 of 5


Design of New
Hydrant System
(Package #7)

Specification for
Piping Materials
Head Office:
Penspen Group Limited
3 Water Lane
Richmond upon Thames
Surrey
TW9 1TJ
United Kingdom
Kuwait Aviation Fuelling Co
Regional Office:
Penspen International Limited
P.O. Box 46562
Abu Dhabi
United Arab Emirates

11775-SPC-ME-001 Rev 0
DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

1. Scope

1.1 General

This specification covers the requirements for piping materials for the extension of
the existing fuel hydrant system at Kuwait International Airport relating to the New
Cargo Area.

2. Precedence

Any case of apparent conflict between the requirements of this Specification and
any other relevant documents shall be notified to the Company. Unless otherwise
agreed the following descending order of precedence shall apply:-

1st This Specification


2nd Other Project Specifications
3rd The Codes and Standards listed in this specification
4th Other API, ASME, ANSI, BS Codes or Standards as appropriate

3. References

The following project documentation shall be read with and form part of this
specification:

11775-CLC-ME-001 Wall Thickness Calculations


11775-SPC-PL-003 Specification for Factory Applied Polyethylene Coating
of Linepipe
11775-SPC-PL-004 Specification for Cold Applied Tape / Multi-component
liquid Coating
11775-SPC-PL-005 Specification for Factory Applied Internal Lining
11775-SPC-ME-011 Specification for Paint Works

4. Definitions

The ‘Company’ is KAFCO (Kuwait Aviation Fuel Company) or their appointed agent
or representative.

The ‘Supplier’ is the vendor, manufacturer or supplier of the equipment defined in


this specification.

Throughout this document the following terminology is used:

“must” signifies a legal or statutory requirement


“shall” signifies a requirement made mandatory by this Specification
“may” signifies a feature which is discretionary in the context in which it is
applied
“will” signifies a feature which the Supplier may assume to be already
present

11775-SPC-ME-001 Rev 0 Page 3 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

4.1 Flange Facing

FF Flat Face
RF Raised Face
Ra Roughness Average (ASME B46.1)
RTJ Ring Type Joints

4.2 Fittings

LEB Large End Bevel


LEP Large End Plain
LET Large End Threaded
PBE Plain Both Ends
POE Plain One End
SEP Small End Plain
SEB Small End Bevel
SET Small End Threaded
TBE Threaded Both Ends (Nipples)
TOE Threaded One End
LR Long Radius (Elbow)
SR Short Radius (Elbow)
BW Butt Weld
PE Plain End

4.3 Connections

BW or WELD Butt-Weld
FLGD Flanged
SCRD Screwed
SO Slip-On
SW Socket Weld
THD'D Threaded
WN Welding Neck

4.4 Wall Thickness

SCH Schedule in accordance with ASME B36.10 or B36.19


STD Standard Weight Wall Thickness
XS Extra Strong Wall Thickness
XXS Double Extra Strong Wall Thickness
CALC Calculated Wall Thickness

11775-SPC-ME-001 Rev 0 Page 4 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

4.5 Valve Description

BC Bolted Cap
BB Bolted Bonnet
ES Extension Stem
FB Full Bore
GO Gear Operated
NRS Non-Rising Stem (with inside screw)
OS & Y Outside Screw and Yoke
RB Reduced Bore
RS Rising Stem
SC Screwed Cap
UB Union Bonnet
UC Union Cap
WB Welded Bonnet

4.6 Pipes Description

BE Bevelled End
CS Carbon Steel
ERW Electric Resistance Welded
EFW Electric Fusion Welded
FS Forged Steel
HFI High Frequency Induction
KCS Killed Carbon Steel
KFS Killed Forged Steel
OH Open Hearth
SAW Submerged Arc Welded
SMLS Seamless

5. Codes and Standards

The latest revisions of the following codes and standards shall be considered part
of this specification.

ASME B16.11 Forged Steel Fittings, Socket Welding and Threaded


ASME B16.20 Metallic Gaskets for Pipe Flanges
ASME B16.21 Non-metallic Flat Gaskets for Pipe Flanges
ASME B16.47 Large Diameter Steel Flanges: NPS 26 Through NPS 60
ASME B16.48 Steel Line Blanks
ASME B16.5 Steel Pipe Flanges and Flange Fittings
ASME B16.9 Factory-Made Wrought Steel Buttwelding Fittings
ASME B31.3 Process Piping

11775-SPC-ME-001 Rev 0 Page 5 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

ASME B36.10M Welded and Seamless Wrought Steel Pipe


ASME B46.1 Surface Texture
API 5L Line Pipe
API 598 Valve Inspection & Testing
API 6D Specification for Pipeline Valves
API 600 Steel Gate Valves Flanged and Buttwelding Ends
API 608 Metal Ball Valves-Flanged and Butt-Welding Ends
MSS SP 44 Steel Pipeline Flanges
MSS SP 75 Specification for High Test Wrought Butt Welding Fittings
ASTM A105 Forgings, Carbon Steel, for Piping Components
ASTM A193 Alloy Steel and Stainless Steel Bolting Materials for High
Temperature Service
ASTM A194 Carbon and Alloy Steel Nuts for Bolts for High Pressure and
High Temperature Service
ASTM A216 Steel Castings, Carbon, Suitable for Fusion Welding, for High-
Temperature Service
ASTM A234 Piping Fittings of Wrought Carbon Steel and Alloy Steel for
Moderate and Elevated Temperatures
ASTM A285 Pressure Vessel Plates, Carbon Steel, Low and Intermediate
Tensile Strength.
ASTM A694 Forgings, Carbon and Alloy Steel, for Pipe Flanges, Fittings,
Valves and Parts for High Pressure Transmission Service
ASTM A333 Seamless and Welded Steel Pipe for Low Temperature
Service
ASTM A350 Forged Carbon and Low Allow Steel requiring Notch
Toughness Testing for Piping Components
ASTM A420 Piping Fittings of Wrought Carbon Steel and Alley Steel for
Low Temperature Service.

6. Piping Classes

6.1 General

Piping Classes assigned for the project are based on the following system.

First Digit: Numerical, denoting the basic system rating or flange class.
Note: Systems are always defined at the rating immediately
above the specific design pressure

i.e., 1 = ASME CL 150


3 = ASME CL 300
6 = ASME CL 600

Second Digit: Alphabetical, denoting the material of construction

i.e., A = Carbon Steel.


B = Stainless Steel.

11775-SPC-ME-001 Rev 0 Page 6 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Third Digit: A sequential number used to differentiate two different piping


classes which are defined to the same ASME class rating and
material type but need to be differentiated due to other
characteristics.

i.e., 2 = Station | SVC Piping,


4 = Buried Hydrant Piping.

6.2 Design Philosophy

Pipework will be designed in accordance with the following philosophy;

Utilities Systems ASME B31.3

ASME B31.3 requires post weld heat treatment for piping above 19.05 mm wall
thickness

6.3 Pressure and Temperature rating

The maximum pressure and temperature rating in accordance with ASME B16.5
and B16.47 is listed at the top of each piping material specification.

6.4 Service

The following table outlines the material, rating, corrosion allowance and service of
the piping class.

Corrosion
Piping
Material Rating Allowance Service Location
Class
(mm)
Aviation
Carbon Station | SVC
1A2 150 1.5 Fuel - Jet
Steel Piping
A1
Aviation
Carbon Buried
1A4 150 1.5 Fuel - Jet
Steel Hydrant Piping
A1
Aviation
Stainless Station | SVC
1B1 150 0 Fuel - Jet
Steel Piping
A1

The piping class specifications are Penspen standard documents, which will be
developed during the detailed design stage.

6.5 Specific Requirements

6.5.1 General

All standard grade forgings shall be normalized, and all high strength (F grades)
forgings shall be normalized, quench and tempered. All stainless steel shall be in
the solution treated condition.

6.5.2 Steel Materials

API 5L high strength linepipe (X grade) shall be manufactured and tested to


product specification level 2 (PSL2) and fracture toughness tested in acceptance
with API 5L SR5 and SR6. The carbon equivalent (IIW) for welded pipe shall not
exceed 0.38%.

11775-SPC-ME-001 Rev 0 Page 7 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

High strength fittings shall be Charpy impact tested, as a minimum, to the same
requirements as the API 5L high strength (X grade) (PSL2) linepipe.

When size limitations preclude the availability of seamless pipe, substitution of


double submerged arc welded (DSAW) pipe made from plate with 100%
radiography shall be permitted, subject to Company approval.

6.5.3 Post Weld Heat Treatment (PWHT)

ASME B31.3 calls for PWHT when the wall thickness exceeds 19mm.

High strength pipe (X grades) and high strength fittings (Y grades) can suffer loss
of strength and toughness when they are post weld heat treated.

Material selected should avoid the need for PWHT of high strength pipe and fittings
unless approved by the Company.

11775-SPC-ME-001 Rev 0 Page 8 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Appendix A: Material Specifications (B31.3)

Piping Class: 150 Material: Carbon Steel


Design Code: ASME B31.3 Corrosion Allowance: 1.5mm
Maximum Pressure / Temperature Rating (ASME B16.5 and B16.47) Specification
Barg 19.65 17.68 15.82 13.8
o
C -29 / +37.8 100 150 200 1A2
SIZE MATERIAL
ITEM
RANGE
DESCRIPTION SPECIFICATION
NOTE

PIPE: ½″ – 1½″ Seamless Sch 80 plain ends to ASME B36.10 ASTM A106 Grade B 1
2″ – 6″ Seamless Sch 40 bevelled ends to ASME B36.10 API 5L Grade B 1
8″ Seamless Sch 30 bevelled ends to ASME B36.10 API 5L Grade B 1
12” Seamless Sch STD bevelled ends to ASME B36.10 API 5L Grade B 1
16” Seamless or SAW Sch 30 bevelled ends to ASME B36.10 API 5L Grade B 1
20″ Seamless or SAW Sch 20 bevelled ends to ASME B36.10 API 5L Grade B 1
24″ Seamless or SAW Sch 20 bevelled ends to ASME B36.10 API 5L Grade B 1
PIPE NIPPLES: ½″ – 1½″ Seamless Sch 80 100mm long. Ends plain, threaded one end ASTM A106 Grade B 1
(TOE), or threaded both ends (TBE) as required.
FITTINGS: ½″ – 1½″ Forged steel Class 3000 ASME B16.11 socket weld or screwed ASTM A105 2
ASME B1.20.1 fittings as listed:
Socket weld – Couplings equal and reducing, Elbows 45o and 2
90o, Tees equal and reducing or MSS SP-97 Sockolets as
appropriate see branch schedule.
Screwed – Couplings equal and reducing, female Unions, pipe 2
Caps and hex. head Plugs.
Note: Screwed fittings are only to be used after the first isolation 2
valve.
2″ – 24″ Wrought steel ASME B16.9 butt weld fittings wall thickness as ASTM A234 Grade 2&5
pipe:
Long radius Elbows 45o and 90o, Reducers concentric and WPB 2&5
eccentric, pipe Caps, Tees equal and reducing see branch
schedule.
2″ – 24″ Forged steel MSS SP-97 butt weld reducing outlet Weldolet ASTM A105 2
fittings see branch schedule.

BRANCH SCHEDULE
Branch

Size 1" 1 1/2" 2" 2 1/2" 3" 4" 6" 8" 10" 12" 14" 16" 18" 20" 24"

24" SOL SOL WOL WOL WOL WOL WOL WOL WTR WTR WTR WTR WTR WTR WTE

20" SOL SOL WOL WOL WOL WOL WOL WTR WTR WTR WTR WTR WTR WTE

18" SOL SOL WOL WOL WOL WOL WOL WTR WTR WTR WTR WTR WTE

16" SOL SOL WOL WOL WOL WOL WTR WTR WTR WTR WTR WTE

Run 14" SOL SOL WOL WOL WOL WOL WTR WTR WTR WTR WTE

12" SOL SOL WOL WOL WOL WOL WTR WTR WTR WTE

10" SOL SOL WOL WOL WOL WTR WTR WTR WTE

8" SOL SOL WOL WOL WOL WTR WTR WTE Note:

6" SOL SOL WOL WTR WTR WTR WTE Minimum branch size 1"

4" SOL SOL WTR WTR WTR WTE STE = Socket Weld Tee - Equal

3" SOL SOL WTR WTR WTE STR = Socket Weld Tee - Reducing

2 1/2" SOL SOL WTR WTE SOL = Sockolet

2" STR STR WTE WTE = Weld Tee - Equal

1 1/2" STR STE WTR = Weld Tee - Reducing

1" STE WOL = Weldolet

11775-SPC-ME-001 Rev 0 Page 9 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Piping Class: 150 Material: Carbon Steel


Design Code: ASME B31.3 Corrosion Allowance: 1.5mm
Maximum Pressure / Temperature Rating (ASME B16.5 and B16.47) Specification
Barg 19.65 17.68 15.82 13.8
o
C -29 / +37.8 100 150 200 1A2
SIZE MATERIAL
ITEM
RANGE
DESCRIPTION SPECIFICATION
NOTE
FLANGES: ½″ – 1½″ Forged steel ASME B16.5 Class 150 socket weld to ASME B16.11 or blind, ASTM A105 2&3
raised face stock finish, bore to suit pipe.
2″ – 24″ Forged steel ASME B16.5 Class 150 weld neck or blind, raised face stock ASTM A105 2, 3 & 4
finish bore to suit pipe.
LINE BLINDS & 1″ – 12″ Steel plate API 590 Figure 8 spade and ring spacer Class 150 raised face ASTM A516 Grade 70 2&3
SPACERS: stock finish.
14” – 24” Steel plate API 590 paddle flange and ring spacer Class 150 raised face ASTM A516 Grade 70 2&3
stock finish.
DRIP RINGS: 1” – 3” Steel plate API 590 ring spacer, 40mm thick drilled and tapped from outer to ASTM A516 Grade 70 2&3
inner diameter with a ¾” NPT thread
GASKETS: ½″ – 24″ Spiral wound SS316L centering and outer SS rings with flexible non-asbestos
filler 4.5 mm thick ASME B16.20
BOLTING: ½″ – 24″ Galvanised alloy steel stud bolts sizes in accordance with ASME B16.5, or ASTM A193 Grade B7
ASME B16.47 as applicable see bolt schedule, threaded full length with 2 No. and ASTM A194 Grade
heavy hexagonal carbon steel nuts with washers. 2H
VALVES
BALL VALVE ½” – 1 ½” Single piece or split body, reduced bore, floating ball, renewable seat rings, Body: ASTM A105
fire safe and anti-static design, anti-blowout stem, raised face flanged ends or Trim: 13% Chrome
screwed ends. Stainless Steel
2” – 12” Single piece or split body, end entry, floating ball, renewable seat rings, fire Body: ASTM A105/
safe and anti-static design, raised face flanged ends ASTM A216 Gr.WCC
Trim: Stainless Steel
DOUBLE BLOCK 2- 24” Reduced port, trunnion mounted, double block and bleed valve, dual Body: ASTM A216 WCC
AND BLEED expanding seals, high integrity, positive shut-off, retractable slips, AQAD Trim: Materials to be
VALVE approved, raised face flanged ends compatible for Jet A-1
service.
WAFER CHECK 2” – 24” Dual plate, retainerless wafer, lugged (through bolt holes) spring assisted, for Body: ASTM A105 /ASTM
VALVE installation between ASME B16.5 raised face flanges A216 Gr.WCC
Trim: 316 SS / inconel
BUTTERFLY 3” – 24” Lugged pattern, bi-directional, offset seat type construction, tight shut-off, Body: ASTM A105 /ASTM
VALVE coated disc, fire safe and anti-static design, suitable for installation between A216 Gr.WCC
two ASME B16.5 flanges Trim: 13% chrome.
BOLTING SHEDULE
Nominal Nominal Bolt Standard Bolt Length for Number of
Pipe Size Diameter Bolt Length Line Blind Bolts / Joint
½″ ½″ 60mm 65mm 4
¾″ ½″ 65mm 70mm 4
1″ ½″ 65mm 75mm 4
1½″ ½″ 70mm 80mm 4
2″ ⅝″ 85mm 95mm 4
2½″ ⅝″ 90mm 100mm 4
3″ ⅝″ 90mm 100mm 4
4″ ⅝″ 90mm 105mm 8
6″ ¾″ 105mm 120mm 8
8″ ¾″ 110mm 125mm 8
10″ ⅞″ 115mm 135mm 12
12″ ⅞″ 120mm 140mm 12
14″ 1″ 135mm 160mm 12
16″ 1″ 135mm 165mm 16
18″ 1⅛″ 150mm 180mm 16
20″ 1⅛″ 160mm 190mm 20
24” 1 ¼” 170mm 200mm 20

Note:
The stud bolt length does not include the height of the points
(part beyond the thread)
*An increase in bolt length may need to be considered if the use of hydraulic tensioning
equipment is to be employed for bolt diameters 1¼″ and larger.

11775-SPC-ME-001 Rev 0 Page 10 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

GENERAL

1 All pipe, fittings, bends, elbows, tees, reducers, flanges etc. of diameter 4” and above shall be Internally coated
and Externally painted in accordance with Project Specifications 11775-SPC-PL-005/11775-SPC-ME-011
respectively. In addition to the specified codes, pipe shall have the following limits on product analysis: Carbon
0.23% max, Carbon Equivalent (long formula) 0.43% max and Sulphur 0.015% max. Unless otherwise approved
by the Purchaser pipe shall be supplied in the normalised or quenched and tempered condition. Final hardness
shall not exceed 248 HV10.

2 In addition to the specified codes, fittings and flanges shall have the following limits on product analysis:
Carbon 0.23% max, Carbon Equivalent (long formula) 0.43% max and Sulphur 0.015% max. Fittings and flanges
shall be supplied in the normalised or quenched and tempered condition. Final hardness shall not exceed 248
HV10.

3 Flange making surface finishes shall be as per ASME B46.1 – Surface texture (Surface roughness, waviness and
lay). “Stock Finish” shall mean: The gasket contact surface shall be formed by a continuous spiral groove
generated by a 1.6mm radius round-nosed tool at a feed rate between 0.7 and 0.9mm per revolution. This will
result in a roughness between Ra 6.3 and 12.5 microns.

4 Flat faced flanges shall be supplied where specified on the MTO/Order.

5 All fittings, elbows, tees etc. with diameters 12” and below shall be seamless.

6 Deleted.

7 Piping design meets full vacuum at ambient condition.

11775-SPC-ME-001 Rev 0 Page 11 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Piping Class: 150 Material: Carbon Steel


Design Code: ASME B31.3 Corrosion Allowance: 1.5mm
Maximum Pressure / Temperature Rating (ASME B16.5 and B16.47) Specification
Barg 19.65 17.68 15.82 13.8
o
C -29 / +37.8 100 150 200 1A4
SIZE MATERIAL
ITEM
RANGE
DESCRIPTION SPECIFICATION
NOTE

PIPE: ½″ – 1½″ Seamless Sch 80 plain ends to ASME B36.10 ASTM A106 Grade B 1
2″ – 6″ Seamless Sch 40 bevelled ends to ASME B36.10 API 5L Grade B 1
8″ Seamless Sch 30 bevelled ends to ASME B36.10 API 5L Grade B 1
12” Seamless Sch STD bevelled ends to ASME B36.10 API 5L Grade B 1
16” Seamless or SAW Sch 30 bevelled ends to ASME B36.10 API 5L Grade B 1
20″ Seamless or SAW Sch 20 bevelled ends to ASME B36.10 API 5L Grade B 1
24″ Seamless or SAW Sch 20 bevelled ends to ASME B36.10 API 5L Grade B 1
PIPE NIPPLES: ½″ – 1½″ Seamless Sch 80 100mm long. Ends plain, threaded one end ASTM A106 Grade B 1
(TOE), or threaded both ends (TBE) as required.
FITTINGS: ½″ – 1½″ Forged steel Class 3000 ASME B16.11 socket weld or screwed ASTM A105 2
ASME B1.20.1 fittings as listed:
Socket weld – Couplings equal and reducing, Elbows 45o and 2
90o, Tees equal and reducing or MSS SP-97 Sockolets as
appropriate see branch schedule.
Screwed – Couplings equal and reducing, female Unions, pipe 2
Caps and hex. head Plugs.
Note: Screwed fittings are only to be used after the first isolation 2
valve.
2″ – 24″ Wrought steel ASME B16.9 butt weld fittings wall thickness as ASTM A234 Grade 2&5
pipe:
Long radius Elbows 45o and 90o, Reducers concentric and WPB 2&5
eccentric, pipe Caps, Tees equal and reducing see branch
schedule.
2″ – 24″ Forged steel MSS SP-97 butt weld reducing outlet Weldolet ASTM A105 2
fittings see branch schedule.

BRANCH SCHEDULE

Branch

Size 1" 1 1/2" 2" 2 1/2" 3" 4" 6" 8" 10" 12" 14" 16" 18" 20" 24"

24" SOL SOL W OL WOL W OL WOL W OL W OL WTR W TR WTR W TR WTR W TR W TE

20" SOL SOL W OL WOL W OL WOL W OL W TR WTR W TR WTR W TR WTR W TE

18" SOL SOL W OL WOL W OL WOL W OL W TR WTR W TR WTR W TR WTE

16" SOL SOL W OL WOL W OL WOL W OL W TR WTR W TR WTR W TE

Run 14" SOL SOL W OL WOL W OL WOL W OL W TR WTR W TR WTE

12" SOL SOL W OL WOL W OL WOL W OL W TR WTR W TE

10" SOL SOL W OL WOL W OL WTR W TR W TR WTE

8" SOL SOL W OL WOL W OL WTR W TR W TE Note:

6" SOL SOL W OL WTR W TR WTR W TE Minimum branch size 1"

4" SOL SOL W TR WTR W TR WTE STE = Socket W eld Tee - Equal

3" SOL SOL W TR WTR W TE STR = Socket W eld Tee - Reducing

2 1/2" SOL SOL W TR WTE SOL = Sockolet

2" STR STR W TE W TE = W eld Tee - Equal

1 1/2" STR STE W TR = W eld Tee - Reducing

1" STE W OL = W eldolet

11775-SPC-ME-001 Rev 0 Page 12 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Piping Class: 150 Material: Carbon Steel


Design Code: ASME B31.3 Corrosion Allowance: 1.5mm
Maximum Pressure / Temperature Rating (ASME B16.5 and B16.47) Specification
Barg 19.65 17.68 15.82 13.8
o
C -29 / +37.8 100 150 200 1A4
SIZE MATERIAL
ITEM
RANGE
DESCRIPTION SPECIFICATION
NOTE
FLANGES: ½″ – 1½″ Forged steel ASME B16.5 Class 150 socket weld to ASME B16.11 or blind, ASTM A105 2&3
raised face stock finish, bore to suit pipe.
2″ – 24″ Forged steel ASME B16.5 Class 150 weld neck or blind, raised face stock ASTM A105 2, 3 & 4
finish bore to suit pipe.
LINE BLINDS & 1″ – 12″ Steel plate API 590 Figure 8 spade and ring spacer Class 150 raised face ASTM A516 Grade 70 2&3
SPACERS: stock finish.
14” – 24” Steel plate API 590 paddle flange and ring spacer Class 150 raised face ASTM A516 Grade 70 2&3
stock finish.
DRIP RINGS: 1” – 3” Steel plate API 590 ring spacer, 40mm thick drilled and tapped from outer to ASTM A516 Grade 70 2&3
inner diameter with a ¾” NPT thread
GASKETS: ½″ – 24″ Spiral wound SS316L centering and outering SS rings with flexible non-
asbestos filler, 4.5 mm thick, ASME B16.20
BOLTING: ½″ – 24″ Galvanised alloy steel stud bolts sizes in accordance with ASME B16.5, or ASTM A193 Grade B7
ASME B16.47 as applicable see bolt schedule, threaded full length with 2 No. and ASTM A194 Grade
heavy hexagonal carbon steel nuts with washers. 2H
VALVES
BALL VALVE ½” – 1 ½” Single piece or split body, reduced bore, floating ball, renewable seat rings, Body: ASTM A105
fire safe and anti-static design, anti-blowout stem, raised face flanged ends or Trim: 13% Chrome
screwed ends. Stainless Steel
2” – 12” Single piece or split body, end entry, floating ball, renewable seat rings, fire Body: ASTM A105/
safe and anti-static design, raised face flanged ends ASTM A216 Gr.WCC
Trim: Stainless Steel
DOUBLE BLOCK 2- 24” Reduced port, trunnion mounted, double block and bleed valve, dual Body: ASTM A216 WCC
AND BLEED expanding seals, high integrity, positive shut-off, retractable slips, AQAD Trim: Materials to be
VALVE approved, raised face flanged ends compatible for Jet A-1
service.
WAFER CHECK 2” – 24” Dual plate, retainerless wafer, lugged (through bolt holes) spring assisted, for Body: ASTM A105 /ASTM
VALVE installation between ASME B16.5 raised face flanges A216 Gr.WCC
Trim: 316 SS / inconel
BUTTERFLY 3” – 24” Lugged pattern, bi-directional, offset seat type construction, tight shut-off, Body: ASTM A105 /ASTM
VALVE coated disc, fire safe and anti-static design, suitable for installation between A216 Gr.WCC
two ASME B16.5 flanges Trim: 13% chrome.
BOLTING SHEDULE
Nominal Nominal Bolt Standard Bolt Length for Number of
Pipe Size Diameter Bolt Length Line Blind Bolts / Joint
½″ ½″ 60mm 65mm 4
¾″ ½″ 65mm 70mm 4
1″ ½″ 65mm 75mm 4
1½″ ½″ 70mm 80mm 4
2″ ⅝″ 85mm 95mm 4
2½″ ⅝″ 90mm 100mm 4
3″ ⅝″ 90mm 100mm 4
4″ ⅝″ 90mm 105mm 8
6″ ¾″ 105mm 120mm 8
8″ ¾″ 110mm 125mm 8
10″ ⅞″ 115mm 135mm 12
12″ ⅞″ 120mm 140mm 12
14″ 1″ 135mm 160mm 12
16″ 1″ 135mm 165mm 16
18″ 1⅛″ 150mm 180mm 16
20″ 1⅛″ 160mm 190mm 20
24” 1¼” 170 m 200 mm 20

Note:
The stud bolt length does not include the height of the points
(part beyond the thread)
*An increase in bolt length may need to be considered if the use of hydraulic tensioning
equipment is to be employed for bolt diameters 1¼″ and larger.

11775-SPC-ME-001 Rev 0 Page 13 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

NOTES
GENERAL

1. All pipe, fittings, bends, elbows, tees, reducers, flanges etc. of diameter 4” and above shall be Internally and
Externally coated in accordance with Project Specifications 11775-SPC-PL-005 and 11775-SPC-PL-
003/004/006/007 respectively. In addition to the specified codes, pipe shall have the following limits on product
analysis: Carbon 0.23% max, Carbon Equivalent (long formula) 0.43% max and Sulphur 0.015% max. Unless
otherwise approved by the Purchaser pipe shall be supplied in the normalised or quenched and tempered
condition. Final hardness shall not exceed 248 HV10.

2 In addition to the specified codes, fittings and flanges shall have the following limits on product analysis:
Carbon 0.23% max, Carbon Equivalent (long formula) 0.43% max and Sulphur 0.015% max. Fittings and flanges
shall be supplied in the normalised or quenched and tempered condition. Final hardness shall not exceed 248
HV10.

3 Flange making surface finishes shall be as per ASME B46.1 – Surface texture (Surface roughness, waviness and
lay). “Stock Finish” shall mean: The gasket contact surface shall be formed by a continuous spiral groove
generated by a 1.6mm radius round-nosed tool at a feed rate between 0.7 and 0.9mm per revolution. This will
result in a roughness between Ra 6.3 and 12.5 microns.

4 Flat faced flanges shall be supplied where specified on the MTO/Order.

5 All fittings, elbows, tees etc. with diameters 12” and below shall be seamless.

6 Deleted.

7 Piping design meets full vacuum at ambient condition.

11775-SPC-ME-001 Rev 0 Page 14 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Piping Class: 150 Material: Stainless Steel


Design Code: ASME B31.3 Corrosion Allowance: 0mm
Maximum Pressure / Temperature Rating (ASME B16.5 and B16.47) Specification
Barg 15.9 31.3 12.0
o
C -29 / +37.8 100 150 1B1
SIZE MATERIAL
ITEM DESCRIPTION NOTE
RANGE SPECIFICATION
PIPE: ½″ – 1½″ Seamless Sch 80S plain ends to ASME B36.19 ASTM A312 Grade
TP316L
2″ – 2½″ Seamless Sch 40S bevelled ends to ASME B36.19 ASTM A312 Grade
TP316L
3″ – 8″ Seamless Sch 40S bevelled ends to ASME B36.19 ASTM A312 Grade 1
TP316L
PIPE NIPPLES: ½″ – 1½″ Seamless Sch 80S 100mm long. Ends plain, threaded one end ASTM A312 Grade
(TOE), or threaded both ends (TBE) as required. TP316L
FITTINGS: ½″ – 1½″ Forged stainless steel Class 3000 ASME B16.11 socket weld or ASTM A182 Grade
screwed ASME B1.20.1 fittings as listed: F316L
Socket weld – Couplings equal and reducing, Elbows 45o and 90o,
Tees equal and reducing or MSS SP-97 Sockolets as appropriate
see branch schedule.
Screwed – Couplings equal and reducing, female Unions, pipe Caps
and hex. head Plugs.
Note: Screwed fittings are only to be used after the first isolation
valve.
2″ – 8″ Wrought stainless steel ASME B16.9 butt weld fittings wall thickness ASTM A403 Grade
as pipe: WP316L
Long radius Elbows 45o and 90o, Reducers concentric and
eccentric, pipe Caps, Tees equal and reducing see branch
schedule.
2″ – 8″ Forged stainless steel MSS SP-97 butt weld reducing outlet ASTM A182 Grade
Weldolet fittings see branch schedule. F316L

BRANCH SCHEDULE

Branch

Size 1" 1 1/2" 2" 2 1/2" 3" 4" 6" 8" Note:

8" SOL SOL W OL WOL WOL W TR W TR W TE Minimum branch size 1"

6" SOL SOL W OL WTR WTR W TR W TE STE = Socket W eld Tee - Equal

4" SOL SOL W TR WTR WTR W TE STR = Socket W eld Tee - Reducing

Run 3" SOL SOL W TR WTR WTE SOL = Sockolet

2 1/2" SOL SOL W TR WTE W TE = Weld Tee - Equal

2" W TER W TER W TE W TR = Weld Tee - Reducing

1 1/2" STR STE W OL = Weldolet

1" STE W TER = Equal Weld Tee and Swage Nipple

11775-SPC-ME-001 Rev 0 Page 15 of 16


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Piping Class: 150 Material: Stainless Steel


Design Code: ASME B31.3 Corrosion Allowance: 0mm
Maximum Pressure / Temperature Rating (ASME B16.5 and B16.47) Specification
Barg 15.9 13.3 12.0
o
C -29 / +37.8 100 150 1B1
SIZE MATERIAL
ITEM DESCRIPTION NOTE
RANGE SPECIFICATION
FLANGES: ½″ – 1½″ Forged alloy steel ASME B16.5 Class 150 socket weld to ASME ASTM A182 Grade 2
B16.11 or blind, raised face stock finish, bore to suit pipe F316
2″ – 8″ Forged alloy steel ASME B16.5 Class 150 weld neck or blind, raised ASTM A182 Grade 2
face stock finish bore to suit pipe F316
LINE BLINDS: 1″ – 8″ Stainless steel plate API 590 Figure 8 or spectacle, spade and ASTM A240 Grade 2
spacer Class 150 raised face stock finish 316
GASKETS: ½″ – 8″ Spiral wound SS316L centering and outering SS rings with flexible
non-asbestos filler, 4.5 mm thick,ASME B16.20
BOLTING: ½″ – 8″ Stainless steel stud bolts sizes in accordance with ASME B16.5, or Bolts to ASTM
ASME B16.47 as applicable see bolt schedule, threaded full length A193 Grade B8M
with 2No. heavy hexagonal stainless steel nuts and stainless steel Class 2, Nuts to
washers. A194 Grade 8M
(Strain Hardened)
and Washers to
SS316.

BOLTING SCHEDULE

Bolt Length
Nominal Nominal Bolt Standard Number of
for
Pipe Size Diameter Bolt Length Bolts / Joint
Line Blind
½″ ½″ 60mm 65mm 4
¾″ ½″ 65mm 70mm 4
1″ ½″ 65mm 75mm 4
1½″ ½″ 70mm 80mm 4
2″ ⅝″ 85mm 95mm 4
2½″ ⅝″ 90mm 100mm 4
3″ ⅝″ 90mm 100mm 4
4″ ⅝″ 90mm 105mm 8
6″ ¾″ 105mm 120mm 8
8″ ¾″ 110mm 125mm 8

Note:
The stud bolt length does not include the height of the points (part beyond the
thread)
*An increase in bolt length may need to be considered if the use of hydraulic
tensioning equipment is to be employed for bolt diameters 1¼″ and larger.

NOTES
1. Schedule 10S wall thickness is not suitable for threading.
2. The gasket contact surface shall be “Stock” finish i.e. Having a roughness between Ra 6.3 and 12.5 microns.

11775-SPC-ME-001 Rev 0 Page 16 of 16


Design of New
Hydrant System
(Package #7)

Specification for
General Valves

Head Office:
Penspen Group Limited
3 Water Lane
Richmond upon Thames
Surrey
TW9 1TJ
United Kingdom

Regional Office:
Kuwait Aviation Fuelling Co Penspen International Limited
P.O. Box 46562
Abu Dhabi
United Arab Emirates

11775-SPC-ME-002 Rev 1
DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

1. Scope

This specification covers the general requirements for the design, manufacture
and testing of ball, gate, butterfly and check valves for the Kuwait International
Airport.

2. Precedence

Any case of apparent conflict between the requirements of this Specification and
any other relevant documents shall be notified to the Company. Unless otherwise
agreed the following descending order of precedence shall apply:-

1st This Specification


2nd Other Project Specifications
3rd The Codes and Standards listed in this specification
4th Other API, ASME, ANSI, BS Codes or Standards as appropriate

3. References

The following documentation shall be read in conjunction with and form part of this
specification.

11775-DAT-ME-004 Data Sheet for Double Block and Bleed Valve – CL150
11775-DAT-ME-001 Data Sheet for Reduced Bore Floating Ball Valve – CL150
11775-DAT-ME-002 Data Sheet for Ball Valves ½” to 1½” – CL150 and CL800
11775-DAT-ME-003 Data Sheet for Wafer Check Valve – CL150
11775-DAT-ME-005 Data Sheet for Lugged Pattern Butterfly Valve – CL150
11775-LST-EN-001 Codes and Standards List
11775-SCH-ME-002 Valve Schedule
11775-SPC-ME-010 Specification for Double Block and Bleed Valves
11775-SPC-PL-004 Specification for Cold Applied Tape / Multi-Component
Liquid Coating
11775-SPC-ME-011 Specification for Paint Works
11775-SPC-ME-001 Specification for Piping Materials
11775-SPC-IN-006 Specification for MOV Actuators

4. Definitions

The ‘Company’ is KAFCO (Kuwait Aviation Fueling Company) or their appointed


agent or representative.

The ‘Supplier’ is the vendor, manufacturer or supplier of equipment and/or


materials defined in this specification.

11775-SPC-ME-002 Rev 1 Page 3 of 8


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Throughout this document the following terminology is used:

“must” signifies a legal or statutory requirement


“shall” signifies a requirement mage mandatory by this Specification
“may” signifies a feature which is discretionary in the context in which it is
applied
“will” signifies a feature which the Supplier may assume to be already
present

5. Codes and Standards

This Specification makes reference to the latest edition of the following documents
which shall be applicable as referenced.

The latest revision of the following Codes and Standards shall be considered part
of this specification:

ASME B16.5 Pipe Flanges and Flanged Fittings


ASME B16.34 Valves, Flanged, Threaded and Welded End
ASME B31.3 Process Piping
API 6D Specification for Pipeline Valves
API 598 Valve Inspection and Testing
API 6FA Specification for Fire Test for Valves
API 600 Steel Gate Valves – Flanged and Butt Welding Ends,
Bolted Bonnets
API 607 Fire Test for Soft-Seated Quarter-Turn Ball Valves
API 609 Butterfly Valves: Double Flanged, Lug and Wafer Type
BS EN 12266 Testing of Valves
ISO 10474 Steel and Steel Products - Inspection Documents
ISO 17292 Metal ball valves for petroleum, petrochemical and allied
industries
ISO 9001 Quality management systems — Requirements

For the complete list of applicable codes and standards, refer to Codes and
Standards List (Document No: 11775-LST-EN-001)

6. Technical Requirements

6.1 Service

All valves shall be compatible with the service conditions detailed on the project
valve data sheets.

11775-SPC-ME-002 Rev 1 Page 4 of 8


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

6.2 Valves - General

Valves shall comply with the Valve Schedule, document no. 11775-SCH-ME-002,
and the relevant project data sheets. Where specified, flanged ends shall be in
accordance with ASME B16.5, ‘stock finish’ as defined in the Specification for
Piping Materials, document no. 11775-SPC-ME-001. Screwed ends shall be
threaded NPT.

6” and smaller valves shall be equipped with manual lever operators. 8” and larger
valves shall be equipped with gearboxes and hand wheels. All valves shall be
fitted with provision for locking in either the open or closed position. Valves shall
have robust limit stops to ensure correct alignment of components in the open or
closed position.

Valve bodies shall be manufactured from either forged or cast carbon steel. Both
forged and cast steels shall have a maximum carbon content of 0.23% with a
carbon equivalent (CE) not exceeding 0.43% based on the long formula.

The pressure and temperature rating of valves shall be in accordance with ASME
B16.34.

6.3 Ball Valves

Ball valves shall conform to API 6D or ISO 17292 (supersedes BS 5351), as


specified on the data sheets, and shall be anti-static and 'fire safe' to API 6FA or
API 607.

If specified on data sheets, ball valves shall incorporate a means of automatic


body cavity pressure relief, in the upstream direction, to prevent body cavity
overpressure.

6.4 Plug Valves – Double Block and Bleed

For double block and bleed valve requirements, refer to the Specification for
Double Block and Bleed Valves, document no. 11775-SPC-ME-010.

6.5 Gate Valves

Gate valves shall be wedge type and shall conform to API 600 or API 6D. Gate
valves shall be metal to metal seated with seating components made from low
wear material or materials with hard facings.

6.6 Butterfly Valves

Butterfly valves shall be bi-directional, lugged body, offset seat design and metal to
metal seating (with secondary resilient seals), providing tight shut-off. The valves
shall conform to API 609 and MSS SP-68.

6.7 Check Valves

Check valves shall be either dual plate wafer or swing type, as specified on data
sheets. Check valves shall comply with API 6D or API 594.

Dual plate wafer type check valves shall be a retainerless, lugged (through bolt
hole) design. Swing check valves shall be bolted cover type and the disc shaft
shall not penetrate the valve body.

11775-SPC-ME-002 Rev 1 Page 5 of 8


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

6.8 Marking

Body marking and identification plates shall be in accordance with the applicable
design code.

For valves 1½” and above, an additional plate shall be provided in stainless steel,
and be secured or wired to the valve body. This plate is to be stamped with the valve
tag number as listed in Valve Schedule, document no. 11775-SCH-ME-002.

6.9 Material Certification

Full certification to ISO 10474 type 3.1B or equivalent shall be furnished with all
valves supplied.

6.10 Non-Destructive Examination (NDE)

All NDE procedures shall be submitted to the Company’s Representative for


approval prior to commencement.

All welds joining pressure containing parts, including attachment of pups, shall be
subjected to visual and 100 % X-Ray radiographic and magnetic particle
inspection in accordance with API 6D (Annex A).

Welds joining non-pressure containing parts of valves, stems, gear boxes, etc.,
shall be subject to random 10% magnetic particle inspection in accordance with
API 6D (Annex A).

Lifting lugs and valve supports, welded to the valve bodies shall be subjected to
100% MPI. No indications will be acceptable.

Weld end surface and volume for both ends of each pup, where provided, shall be
tested to API 6D (Annex A.22) for laminations and defects.

6.11 Impact Testing

All carbon, alloy steels and non-austenitic stainless steel for pressure-containing
parts in valves shall meet the toughness test requirements of the project piping
design code, ASME B31.3, and the applicable valve design standard.

6.12 Visual Inspection

Visual inspection / dimensional checks shall be carried out in accordance with the
applicable design code.

6.13 Pressure Testing

Hydrostatic shell, seat and stem tests, and functionality tests, shall be carried out in
accordance with the applicable design code.

At least six (6) working days notice shall be given of tests to permit witnessing by the
Company’s Representative if he so wishes.

All testing shall be carried out after any pup welding has been completed

Test certificates shall be provided stating:

- Type of Test
- Recorded Pressures

11775-SPC-ME-002 Rev 1 Page 6 of 8


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

- Test Supervisor
- Other relevant information

6.14 Fire Testing

All valve assemblies shall be fire type-tested in accordance with API 6FA and/or API
607. Certification shall be provided.

6.15 Inspection

The Supplier shall operate an effective Quality System which, as a minimum, shall
comply with the requirements of ISO 9001 and will control its work and the work of
any of its sub-contractors.

Prior to any production activity the Supplier shall advise the Company of the
production schedule. The Company’s Representative reserves the right to inspect
any manufacturing operation related to the valves on the Supplier’s site. The
Company shall receive six (6) working days advance notice to schedule
inspections.

6.16 Coating

6.16.1 Internal

Valve’s carbon steel internal surfaces shall be coated with an anti-corrosion


system compatible with JET-A1, as per supplier’s standards with Company’s
approval.

6.16.2 External - Above Ground Valves

The external coatings shall be applied according to the Specification for Paint Works
(11775-SPC-ME-011).

Alternative coating systems may only be used following Company approval.

6.16.3 External – Below Ground Valves

All below ground valves shall be installed inside the valve chamber (SVC).

The external coatings shall be applied according to the Specification for Paint Works
(11775-SPC-ME-011).

Alternative coating systems may only be used following Company approval.

7. Documentation

The following drawings, documents and certificates shall be submitted by the


Supplier to the Company for acceptance. This list is not exhaustive and shall be
supplemented by the documentation requirements of the applicable valve design
code and any other documentation required to assess the compliance of the
equipment, or as directed by the Company.

11775-SPC-ME-002 Rev 1 Page 7 of 8


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

7.1 Initial Documentation

The following ‘Initial’ Supplier Documentation is required for acceptance, prior to


commencement of manufacture:

• Manufacturer’s Quality Plan


• Production Programme
• Completed Data Sheets
• Manufacturer’s Catalogues and Brochures
• Manufacturing Procedures
• General Arrangement Drawings
• Cross-sectional Drawings, Parts and Materials Lists
• Welding and NDT Procedures
• Welder certificates
• Test and Acceptance Procedures
• Shipping Instructions/Procedures
• Installation Instructions/Procedures
• Commissioning Instructions/Procedures
• Operating and Maintenance Procedures
• Spares Lists (Commissioning and Operating)
• Calculations

3 no. copies of the Initial Documentation shall be provided under each submission.
All Initial Documentation shall be provided within 28 days of receipt of the Purchase
Order.

7.2 Final Documentation

The following ‘Final’ Supplier Documentation is required:

• Test and Inspection Reports


• Manufacturing Record Book
• Material Certification
• Data Sheets / GA Drawings

5 no. copies of the Final Documentation shall be provided at time of shipment.

8. Packaging and Protection

All valves shall be provided with adequate protection against corrosion,


mechanical damage and deterioration until they are unpacked at site. The Supplier
shall ensure that all packing and protection supplied for the valves are adequate to
maintain the material guarantees. The Supplier shall advise the Company of the
proposed packing controls prior to release for shipment.

11775-SPC-ME-002 Rev 1 Page 8 of 8


Design of New
Hydrant System
(Package #7)

Specification for
Field Welding
Head Office:
Penspen Group Limited
3 Water Lane
Richmond upon Thames
Surrey
TW9 1TJ
United Kingdom

Kuwait Aviation Fuelling Co Regional Office:


Penspen International Limited
P.O. Box 46562
Abu Dhabi
United Arab Emirates

11775-SPC-ME-003 Rev 0
DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

9. Production Welding
9.1 Site Welding Preparation
9.2 Alignment and Fit-Up Tolerances
9.3 Edge Inspection
9.4 Tack Welds
9.5 Welding Technique
9.6 Preheating and Interpass Temperatures
9.7 Post Weld Heat Treatment (PWHT)
9.8 Finishing of Surfaces
9.9 Weld Repairs

10. Inspection and Testing


10.1 General
10.2 Mandatory Stages of Inspection
10.3 Visual Inspection
10.4 Magnetic Particle Inspection and Dye Penetrant Inspection
10.5 Radiographic Examination
10.6 Ultrasonic Examination
10.7 Additional Non-Destructive Testing

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DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

1. Scope

This specification covers the welding of piping within the new hydrant system at
Kuwait International Airport (KIA).

All welding procedures, welder qualifications, inspection and testing shall be in


accordance with the latest edition of ASME B31.3 and ASME IX supplemented,
where applicable, by this Specification.

2. Precedence

Any case of apparent conflict between the requirements of this Specification and
any other relevant documents shall be brought to the Company's notice, by the
Contractor. Unless otherwise agreed, the following descending order of
precedence shall apply:

1st This Specification.

2nd ASME IX.

3rd Other Codes, Standards and Recommendations, as appropriate.

3. Definitions

The “Company” is KAFCO (Kuwait Aviation Fuelling Company) or their appointed


agent or representative.

The “Contractor” is the organization employed by the Company or their appointed


agent or representative in order to carry out the Work..

The “Work” is the extension of the new hydrant system at Kuwait International
Airport (KIA).

Throughout this document the following terminology is used:

“must” signifies a legal or statutory requirement

“shall” signifies a requirement made mandatory by this Specification

“may” signifies a feature which is discretionary in the context in which it is


applied

“will” signifies a feature which the Contractor may assume to be already


present.

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DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

4. References

The following documentation shall be read in conjunction with this specification:

11775-LST-EN-001 Codes and Standards List

11775-SPC-PL-001 Specification for Linepipe

11775-SPC-PL-002 Specification for Pipeline Forged Bends

5. Applicable Codes and Standards

This Specification makes reference to the latest edition of the following documents
which shall be applicable as referenced.

ASME B31.3 Process Piping


BS 4515 Welding of steel pipelines on land and offshore.
BS EN 499 Welding Consumables. Covered Electrodes for Manual Metal
Arc Welding of Non Alloy and Fine Grain Steels.
ASME V Boiler and Pressure Vessel Code: Nondestructive
Examination
ASME VIII Boiler and Pressure Vessel Code: Pressure Vessels
ASME IX Boiler and Pressure Vessel Code: Welding and Brazing
Qualifications
ASTM E94 Guide for Radiographic Testing.
ASTM E1316 Terminology for Non-Destructive Examinations.

For the complete list of applicable codes and standards, refer to Codes and
Standards List (Document No: 11775-LST-EN-001).

6. Documentation

Prior to commencement of any part of the fabrication, the Contractor shall submit
to the Company the following documentation for approval.

a) Welding procedures and repair welding procedures qualified to the


requirements of this Specification.

b) Certificates of welders and welding operators qualified in accordance with


this Specification, complete with list of welder identification numbers and
photographs of welders.

Note that all welders shall be specifically re-qualified for this


Contract unless approved otherwise by the Company.

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DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

c) Listing of proposed welding consumables and their areas of application,


manufacturer's test certificates for all welding consumables. Detailed
working procedures for consumable storage, issue and baking of
electrodes.

d) Procedures and detailed report sheets for non-destructive testing and


inspection. This shall include separate sheets and procedures for Visual,
Radiography, Ultrasonics, Dye Penetrant, and Magnetic Particle
Inspection.

e) Identification and control procedures for materials inclusive of paint


marking scheme.

f) Certificates (originals) for all inspection personnel qualifications.

Following completion of any part of the Works the Contractor shall submit 3 copies
of the following documentation for approval by the Company.

g) Plans marked to relate certificate references for all material to its final
position in the pipework system. Each Plan shall have the relevant
material certification attached.

h) NDT test reports and isometrics marked showing final identification


numbering, test report numbers and the results.

i) Post Weld Heat Treatment (PWHT) charts and hydrostatic test reports and
charts for all items tested.

j) As-built drawings and specifications.

The format of the above documentation shall be submitted to the Company for
approval prior to the commencement of the Works.

7. Welding Procedures

7.1 General

All piping butt joints shall be full penetration buttwelds. All butt and fillet welds shall
be made by the shielded metal arc process, (SMAW) or the gas tungsten arc
process, (GTAW). The GTAW process shall be used for all root passes.

The use of the gas metal arc process is prohibited. The gas tungsten arc process
shall incorporate a high frequency starting unit, a crater eliminating device and
delayed gas cut-off. In general, the welding shall be to ASME B31.3 and the
Approved Drawings, but the restrictions listed below shall also apply.

a) All welding consumables shall be approved by the Company.

b) The downhill mode of welding progression using cellulosic electrodes shall


not be used. There shall be no internal welding of any kind.

c) Backing rings, copper backing strips and mitres at welded joints are
prohibited.

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DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

d) Peening of the weld is prohibited.

e) Flame gouging, arc-air gouging and chipping shall not be used.

f) When back purging stainless or carbon steel, it is essential that all air is
removed by the admission of a volume of purging gas of at least six times
the volume of air being displaced.

g) Should the tungsten electrode accidentally strike the work, the area shall
be ground clean and the electrode re-pointed before further welding takes
place. Arc strikes onto the pipe are unacceptable and must be carefully
removed by grinding followed by wall thickness checks.

h) Fillet welds shall only be used with the approval of the Company. Fillet
welds shall be completed using low hydrogen Electrodes or GTAW.
Single run fillet welds shall not be permitted.

i) The hardness of the weld and heat affected zone in the as welded or post
weld heat treated condition shall not exceed 248HV10.

j) The root pass shall be undertaken using GTAW and the vertical up
technique. The remaining passes shall be undertaken using low-hydrogen
electrodes employing an uphill technique. The root pass for stainless steel
shall be by GTAW with a gas backing. The technique used for gas
backing shall be approved by the Company.

k) Notwithstanding j) above the GTAW process shall be used for all weld
passes, all materials, when the pipe diameter is 3 inch Nominal Diameter
or smaller and is in gas service.

Welding Conditions

For all welding the following conditions shall apply:

a) The maximum time delay between completion of the root and the start of
the second pass shall be five minutes.

b) External line up clamps shall be used to achieve fit-up (i.e. root gap)
required by the welding procedure specification. All tack welding shall be
performed by qualified welders, and shall form part of the completed joint.
The clamp shall not be removed until all tacking has been completed.
Such tacks shall be equally spaced around the circumference, and a
minimum of four tacks shall be used. The ends of all tack welds
incorporated into joints shall be feather ground.

c) Weld beads shall not start at the same point unless the area is dressed
clean and sound before the second bead is started.

d) Intermediate cooling, after at least three weld passes are complete, shall
be slow and under insulation. The welding of repairs, fittings, fillet welds
and tie-ins shall be completed in one heat cycle.

e) The pipe shall not be hammered or heated to remove welding slag, assist
fit-up etc.

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DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

f) Earth clamps approved by the Company shall be used. No temporary


attachment of any kind shall be welded to the piping.

g) Unless approved otherwise by the Company, the toe of one weld must be
at least 150mm from the toe of any other weld.

h) Root runs in stainless steel welds must be made by the GTAW process.

i) For socket joints the pipe shall be inserted fully into the socket and then
withdrawn 1.5mm + 0.5mm – 0mm.

7.2 Weather Protection

The Contractor shall establish sufficient shielding to protect each welding site from
rain and wind and to prevent water from running into the weld joint. Complete
wind protection is particularly important when gas shielded welding is being used.
Welding shall not be carried out when the weld surfaces are damp. The welding
operation shall be stopped when weather conditions are unsuitable for welding.
On these matters, the Company's decision shall be final.

7.3 Welding Materials and Equipment

The electrodes, wires and fluxes used shall be chosen to produce welds with
mechanical properties not less than, and chemical properties equal to those
required for the base material or, that for the higher strength, parent material, in
the case of joints between dissimilar materials. They shall be subjected to
additional inspection and approval at the discretion of the Company. All tools and
equipment used in the welding operations shall be in acceptable operating
condition and shall be of a capacity suited to the work for which they are
employed, in accordance with the manufacturer's recommendations.

Welding generators, cables, electrode holders, earth return clamps and all other
ancillary equipment, including cutting equipment shall be supplied by the
Contractor. This equipment shall be of modern design and maintained in first
class working condition throughout the duration of the contract.

The continuous rated capacity of all equipment shall be at least 30% greater than
the duty required for any welding or cutting procedure used in the contract.

A plainly visible means of adjusting and measuring the welding current and voltage
shall be provided for each welding set and the accuracy of the ammeter and
voltmeter readings shall be checked on a regular basis.

Earth return clamps shall be used and maintained so that no stray arcing occurs.

Line up clamps shall be provided to ensure alignment of the weld components to


within the requirements of the specification and the qualified welding procedure.
Pipe clamps shall be suitable for establishing concentricity of pipe bores without
scoring or otherwise damaging the pipe surfaces.

7.4 Storage and Issue of Welding Consumables

All welding consumables shall be stored and handled in accordance with the
manufacturer's recommendations. Any consumable, which is unmarked or
showing signs of damage or deterioration, shall be discarded. Different grades of
electrodes shall be stored separately. All consumables shall be batch certified.

11775-SPC-ME-003 Rev 0 Page 8 of 18


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

All welding electrodes shall be supplied in clearly identifiable hermetically sealed


packets and stored in a dry location at a temperature of not less than 20ºC. The
Contractor shall have heating ovens with automatic heat control and each welder
shall be supplied with a heated quiver.

Prior to use, low-hydrogen electrodes shall be baked at a temperature of 300ºC for


a minimum period of one hour at this temperature or in accordance with the
manufacturer's instructions to provide a weld metal deposit with a hydrogen
content not exceeding 10 mls per 100 grams, to BS EN 499.

Following baking, the electrodes shall be transferred to a heated storage cabinet at


o
150 C for later use. Hydrogen controlled shielded metal arc electrodes shall be
withdrawn as required for immediate use and held in a heated quiver at a minimum
o
temperature of 75 C. All hydrogen controlled electrodes unused after a period of
8 hours shall be returned and re-baked as specified above before being re-issued
for welding.

Gas tungsten arc welding consumables shall be clearly identified and stored in a
o
dry location at a temperature of not less than 20 C. Identification shall state
manufacturer's grade and batch number.

Gas tungsten arc welding consumables shall be withdrawn from the store as
required for immediate use. Unused consumables shall be returned to the store
on completion of the welding operation.

The Contractor shall prepare a detailed welding consumable quality control


procedure for the approval of the Company.

7.5 Identification of Electrodes Wire and Flux

All SMAW electrodes shall be fully identified up to the time of usage. Each
electrode shall be distinguished by a code marking. If the code is destroyed by
baking, handling or other causes, the electrodes shall be replaced with identifiable
electrodes. Each batch of wire shall be labelled with the information from the
supply container.

7.6 Qualification of Welding Procedures

All welding procedures, including those for repair, shall be in accordance with
ASME IX, and this Specification. Separate procedures shall be submitted to the
Company for approval and shall be established and qualified before starting
welding. The qualification tests shall not be performed until the procedure has
been approved by the Company. Qualification of a welding procedure shall be
witnessed by the Company.

Procedure test welds shall be made under site conditions or simulated site
conditions. The welding procedure site specification shall be submitted for
approval on a welding procedure sheet drawn up in accordance with the format
shown in ASME IX. The following information shall be recorded.

a) Welding process used.

b) Material types, specification, thickness and diameter used for the


procedure qualification.

11775-SPC-ME-003 Rev 0 Page 9 of 18


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

c) Sketch of joint showing edge preparation, joint fit-up and tolerances.


Shape and size of fillet welds.

d) Welding position and welding direction.

e) The make, trade name, classification to ASME/AWS and diameter of all


electrodes and wires to be used.

f) Shielding gas by name and type, including the rate of flow and purity. This
applies also to the gas backing required for stainless steel.

g) Sketch showing number of beads and welding sequences.

h) For each run, the current type, polarity, arc current, voltage and welding
speed.

i) Method of weld cleaning.

j) Preheat and interpass temperature, method of application and method of


checking.

k) Post-weld heat treatment if applicable.

l) Treatment of consumables which forms part of the procedure, e.g. baking


temperature and time, use of heated quivers.

m) Tack welding procedure, stating minimum number and minimum length of


tacks, type of line-up clamp that will be used, and the stage at which this
clamp will be removed.

n) Copies of the Welding Procedures shall be readily available for reference


by the welders, welding operators, foremen and the Company and shall be
displayed in the working area.

7.7 Mechanical Tests for Welding Procedure Qualification

In general, qualification of the welding procedures shall be to ASME B31.3 and


ASME IX. To qualify a welding procedure the following tests are necessary.

a) 100 percent visual examination to ASME B31.3 and ASME IX and to this
specification.

b) 100 percent radiography examination using X-ray to this specification.

c) Mechanical testing requirements as per ASME IX.

d) Macro and hardness surveys of weld metal and heat affected zones.
Macro samples shall be taken from the approximate 3, 6, 9 and 12 o'clock
positions, prepared to a 600 grit paper finish, etched and examined at x 10
magnification. Planar defects will be cause for rejection. A hardness
survey in accordance with BS 4515 shall be carried out on each of the
macro samples. For carbon steel an individual hardness value shall not
exceed 248 HV10 unless approved otherwise by the Company.

11775-SPC-ME-003 Rev 0 Page 10 of 18


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

The Company's will be present during all welding and the completed test shall be
subject to the Company's approval prior to any of the above mentioned tests. The
tests shall be carried out in an independent laboratory, which shall be mutually
agreeable to the Contractor and the Company. All mechanical testing shall be
witnessed by the Company. A minimum time delay of 12 hours shall elapse
following welding before testing is started (including non-destructive testing). The
results of the welding procedure qualification tests shall be submitted for the
Company's approval and shall be signed by all parties.

The Contractor shall provide all the equipment for the weld procedure qualification
tests and shall bear all costs.

Should a test weld fail any of the required tests, the cause of the failure shall be
established, rectified and the complete procedure test shall be repeated unless
agreed otherwise with the Company. No production welding shall commence until
the appropriate procedure tests have been approved by the Company. Should a
qualified welding procedure show poor production performance, the causes of the
poor performance shall be assessed, and a modified welding procedure shall be
qualified and submitted to the Company for approval.

The Company reserves the right to halt production when the number of defective
joints welded in any day exceeds 5% of the total for that day.

Re-qualification of a welding procedure is required when changes are made to any


of the essential variables of ASME B31.3 and ASME IX or a change in the
classification, trade name and manufacturer of any of the welding consumables.
Changes in one or more of the non-essential variables shall call for a new weld
procedure specification to be documented, and submitted to the Company for
approval.

8. Qualification of Welders and Welding Operators

8.1 General

The purpose of a welder qualification test is to verify that the welder can use a
qualified welding procedure to produce welds of satisfactory quality.

The Company shall require site qualification/re-qualification of each welder before


fabrication is started.

Welders shall be qualified in accordance with the requirements of ASME B31.3


and ASME IX and this Specification. The essential variables of ASME IX shall
apply. Welders shall be qualified for all welding positions. Qualification tests shall
be conducted using either the 2G and 5G positions or the 6G position, as defined
in ASME IX. A number of welders shall be qualified for repairs.

All welder qualification tests shall be witnessed and approved by the Company
before the welder is permitted to weld on the Work. The decision taken by the
Company regarding the qualification of any welder shall be final.

The Contractor shall provide all the equipment for the welder qualification tests
and shall bear all costs.

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DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

8.2 Welder Identification System

An identification system shall be established during welder testing. This shall be


established and agreed with the Company.

Each qualified welder shall be supplied with an identifying marker, and shall mark
each of his production welds. All welds not clearly marked may be rejected by the
Company. Die stamping is not permitted.

The Contractor shall ensure that only qualified welders are employed, and only on
the type of weld for which their qualification tests applies. At the discretion of the
Company, a welder shall be re-qualified, if inspection during fabrication reveals
that extensive repairs are necessary due to unacceptable defects.

8.3 Base Material

Welders shall be qualified using materials of the same ASME IX grouping used for
fabrication.

8.4 Retests

At the Company's discretion, a welder failing the qualification test may carry out
two further test joints of the same type. If both these test joints meet the
specification requirements, the welder shall be accepted as qualified.

8.5 Welder Qualification Record

A record of welder’s qualification tests, including a reference to the corresponding


welding procedure specification, and the test results, shall be issued for each
welder for each test they pass.

8.6 Welding Procedures

The welder qualification tests shall be carried out to an approved welding


procedure specification.

Backwelding or backing strips are not acceptable.

8.7 Tests to be Applied and Acceptance Criteria

Each test piece shall be inspected as follows:

a) Visual examination to ASME B31.3 and ASME IX

b) 100 percent radiographic examination by X-ray to this Specification.

8.8 Validity of Certificates

Renewal of a certificate is required whenever a welder has not used the


appropriate welding procedure for a period of more than 6 months, whenever there
is a reason to question the performance of welding, there is a change in the code
number or trade name of any of the welding consumables, or a change in any of
the essential variables of ASME B31.3 and ASME IX. A certificate is maintained
valid when acceptable welding performance is documented by regular non-
destructive testing during fabrication, and the Contractor keeps records of periods

11775-SPC-ME-003 Rev 0 Page 12 of 18


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

and type of work for each certified welder. The validity of a certificate shall be
endorsed at regular intervals by a system of quality control approved by the
Company.

9. Production Welding

9.1 Site Welding Preparation

The site preparation of the fusion faces shall be by mechanical machining, or by


thermal cutting, plasma arc cutting followed by careful grinding. Mechanical
guided cutting shall be used. After cutting back a mill bevel, the new bevel, and
100 mm back into the pipe, shall be ultrasonic tested for presence of laminations.
Lamination detected shall be investigated and the affected area removed to the
satisfaction of the Company.

Fusion faces and 25 mm beyond shall be rotary wire brushed free of slag, rust, oil,
moisture and primer on external/internal surfaces. For stainless steel the fusion
faces shall be meticulously cleaned using stainless steel wire brushes and shall be
degreased just before welding.

9.2 Alignment and Fit-Up Tolerances

For pipe of the same nominal wall thickness, the maximum offset or misalignment
of the abutting pipe ends shall not exceed 1.5mm. If pipe ends are damaged or
dented beyond these acceptance limits they shall be cut and rebevelled.

When joints of unequal thickness but of the same grade of material are to be
joined, the external and internal offset shall not exceed the limits of ASME B31.3
or 1.5 mm, whichever is the least.

If this value is exceeded, the excess thickness of the heavier end shall be
machined back from the bevel on a "one in four taper" in accordance with ASME
B31.3. Alternatively, a machined transition piece shall be inserted that satisfies
the ASME B31.3 requirements and is approved by the Company.

An approved type of line-up clamp shall be used. The use of temporary weld-on
attachments of any kind is prohibited. The piping shall be supported to provide
adequate working clearance around the pipe while the welding operations are in
progress.

9.3 Edge Inspection

Fusion faces shall be fully visually inspected. Any defect shall be explored by
grinding and where appropriate by wet magnetic particle and ultrasonic
techniques. Defects to a maximum depth of 1 mm shall be removed by grinding to
an even profile. Defects greater than this depth shall be removed by cutting off an
appropriate length and re-establishing the weld preparation. The final preparation
shall be by grinding and wire brushing. Welding is not permitted.

9.4 Tack Welds

Tack welds shall be a minimum length of 25 mm and shall be carried out to an


approved welding procedure by a qualified welder. Where preheat is required this
shall be applied prior to tack welding and maintained until the joint is complete.

11775-SPC-ME-003 Rev 0 Page 13 of 18


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Tack welds shall form part of the completed weld and shall be ground to a feather
edge and completely fused with the root run. Cracked tack welds shall be
completely removed and shall not be incorporated into the finished weld.

Arc-burns are unacceptable and the Contractor shall take care to eliminate this
defect by the provision of effective earthing and competent supervisors.

9.5 Welding Technique

Welding shall use a small bead multi-pass technique. The weave width for SMAW
shall not exceed two and one half times the core wire diameter or 12mm,
whichever is less. The maximum size of electrode allowed shall be 5mm for the
1G, 2G, 1F and 2F positions. For all other positions, the maximum size shall be
4mm.

9.6 Preheating and Interpass Temperatures

The preheat temperature for carbon steel shall be in accordance with the
established welding procedure, shall be effective over an area of 100 mm each
side of the weld groove and shall be maintained over the full length of the joint.
The preheat requirements also apply to the tack welding.

It is the responsibility of the Contractor to review the following levels of preheat


and to specify additional preheat where necessary.

A minimum preheat of 50ºC shall be used when the ambient temperature is below
o
0ºC or when the weld surfaces are damp. A minimum preheat of 100 C shall be
applied to the welding of fittings regardless of ambient temperature unless agreed
otherwise with the Company. At all joints, where preheating is required the
temperature shall be checked on the reverse side, if feasible, prior to any welding.
The heated material shall be held at the required temperature until the weld is
completed. The temperature shall be checked by means of thermosticks. The
weld area shall be protected from draughts and lagging shall be provided to
maintain the required temperature.

If notwithstanding the above preheating requirements, hydrogen induced cracking


is found, the whole of the weld procedure as well as the level of preheat employed
shall be reviewed and re-assessed. The interpass temperature during welding
o
shall be checked by thermosticks and shall never exceed 250 C for carbon steel
o
and 100 C for stainless steel.

Weld end valves, of butt weld or socket weld type, shall be welded using a low
interpass temperature procedure in accordance with the valve manufacturer's
recommendations.

Welding requirements for these valves shall be covered in a Method Statement


issued for the Company's approval prior to the commencement of these Works.

9.7 Post Weld Heat Treatment (PWHT)

The requirements for PWHT shall be in accordance with ASME B31.3. Exposed
machined and threaded surfaces shall be protected from oxidation during PWHT.
No welding shall be performed after heat treatment is completed.

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DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

9.8 Finishing of Surfaces

Prior to inspection the Contractor shall mechanically clean welds and shall remove
all burrs, spatter and arc strikes. When this reduces the wall below of the specified
minimum wall thickness, the damaged portion shall be cut out as a cylinder and
replaced to the requirements of this Specification. Arc strikes onto the surface of
the material shall be ground and proved free of defects by MPI or shall be cut out
as a cylinder of pipe, at the discretion of the Company. The Company shall
require an ultrasonic thickness test to prove that wall thickness has not been
reduced below the minimum.

9.9 Weld Repairs

No rectification, repair or modification shall be made without the approval of the


Company. Prior to commencing fabrication the Contractor shall qualify and obtain
approval from the Company for sufficient number of repair procedures and welders
to cover all anticipated repair welding situations, including the repair of accidental
arc strikes.

Unacceptable defects shall be rejected and the welds affected shall be repaired at
the Contractor's cost. Repairs shall be completed one day maximum after the
initial radiography. If a weld containing unacceptable flaws has been rendered
inaccessible, the Contractor shall remove welds or members to permit inspection
or repair to the satisfaction of the Company. The removal of weld metal may be
undertaken by machining or grinding. Repairs shall be inspected 100% by the
method prescribed for the original weld. Welds containing cracks shall be cut out.
An area may only be repaired once, thereafter the weld shall be cut out. Repairs
are limited to 30% of the weld length. A daily report of all repairs shall be prepared
by the Contractor.

10. Inspection and Testing

10.1 General

The ASME B31.3 and ASME IX codes shall be the authority for welding and
welding inspection with the exceptions noted herein. The Contractor shall submit
radiographic, ultrasonic, magnetic particle and dye penetrant procedures for
approval. The radiographic procedure shall be qualified by site tests taken during
welding/welder procedure testing. All procedure radiographs shall be retained by
the Company for future reference.

The Contractor shall supply all staff, labour and materials to carry out all welding
inspection, non-destructive testing and interpretation of radiographs to ensure that
each weld meets the standard of acceptability. All non-destructive testing
operators shall be qualified in accordance with the requirements of the American
Society of Non-destructive Testing.

The Contractor shall provide on site facilities for radiographic and ultrasonic
inspection of welds, including equipment for development and viewing of films and
the full-time services of qualified technicians and inspectors conversant with
radiographic and ultrasonic inspection techniques to operate the equipment. All
technicians and inspectors shall be approved by the Company.

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DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

The recommendations of the International Commission on Radiological Protection


shall be observed. Radiographic Protection is the responsibility of the Contractor.
All testing of welds or repair welds shall be carried out as soon as possible after
the completed welds have cooled to ambient temperature. As soon as the
radiographs have been taken by the Contractor they shall be developed and
evaluated by him and then submitted to the Company for his examination. The
radiograph shall be submitted in a separate folder for each weld, clearly marked on
the outside with the weld identification number, the date on which the radiograph
was taken, the name of the radiographer and the name of the welder(s) who made
the weld and any other information that the Company may require. A report of the
Contractor's interpretation shall accompany the radiograph. Final acceptance
testing of PWHT joints shall be done after PWHT.

The Company shall be the final judge of the acceptability of all welds and the
Company's decision will be final.

The Company shall be advised at least two working days prior to the Contractor
starting any work, such as assembling or fabrication of any section. The Company
shall be notified before any repairs are made to welds where defects are found.
Whenever any piece is to be assembled that will prevent inspection of the area,
the Company shall be notified, the area inspected and any defects corrected
before proceeding with the assembly. If a weld subject to inspection has been
rendered inaccessible, the Contractor shall remove welds and/or members to
permit inspection at no additional cost to the Company.

The Company shall have the right to inspect, at any time, tools or equipment to be
used in any part of the Work, and shall have the right to reject any equipment or
Work which does not comply with the requirements of the Specification or the
Drawings.

The Company will approve all phases of the testing operations, repair of defects
and replacement of materials and equipment found to be defective during testing.

The Company shall have the right to request any additional inspection to ensure
that the Work conforms to the Specification.

The Contractor shall furnish, install and maintain in a safe operating condition all
scaffolding, ladders, walkways, adequate lighting, etc., necessary for safe and
thorough inspection by the Company.

The Contractor shall establish, before starting the job, a numbering system to
identify each area, isometric, joint, etc. uniquely. Detailed records of all welds and
pipe numbers including repairs shall be maintained. The records shall include
identification serial numbers, the position of each weld, date of production,
qualified procedure, reference number, welder identification number and shall also
include cross reference to all inspection sheets and technical records. The
numbering system shall be used for identification purposes on all drawings, shall
be clearly marked on each section and member using paint and stencil and shall
be carried forward and incorporated into the "As-built" drawings.

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DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

10.2 Mandatory Stages of Inspection

As a minimum the inspection stages employed by the Contractor for welded joints
shall be as follows:

a) All preparations and pipe ends inside and outside for damage prior to
welding. All incoming materials are subject to visual inspection for surface
defects, lamination and dimensional tolerances etc. The Contractor shall
report all defects/discrepancies found immediately, satisfy himself of the
suitability of each component in all aspects and accept all related
responsibilities therefore.

b) Fit up prior to root pass welding. This shall include a dimensional check of
the pipework.

c) Following any back grinding operation.

d) Following completion of the weld.

Stages a) and b) above shall generally be visual, stage c) shall be by M.P.I., stage
d) shall be by visual and magnetic particle for socket and fillet welds, and by visual
and radiographic methods for butt welds. Dye penetrant shall be used in place of
MPI for stainless steel.

10.3 Visual Inspection

All welds shall be visually inspected to ASME B31.3 and ASME V and shall meet
the requirements of that standard and those listed below.

a) The offset on weld preparation shall be in accordance with this


Specification.

b) The maximum height of external and internal weld reinforcement shall be


1.6 mm. As a minimum the weld shall be flush.

c) All welds shall be free from undercut, cracks, lack of fusion and surface
porosity.

d) Arc strikes are not acceptable. The Company may approve the repair of
one arc strike per pipe to an approved procedure. Otherwise the weld shall
be removed at the Contractor's expense.

10.4 Magnetic Particle Inspection and Dye Penetrant Inspection

All carbon steel fillet welds, socket welds and background profiles shall be MPI
tested. The Contractor's procedure shall be in accordance with ASME V using wet
particles and yoke methods. Acceptance levels shall be in accordance with ASME
VIII. Local surface grinding of the weld to enable examination to be carried out
shall be at the discretion of the Company. All stainless steel fillet welds and socket
welds shall be dye penetrant tested. The Contractor's procedure shall be in
accordance with ASME B31.3 and ASME V. Acceptance levels shall be in
accordance with ASME B31.3.

11775-SPC-ME-003 Rev 0 Page 17 of 18


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

10.5 Radiographic Examination

All butt welds shall be subject to 100% radiography. The radiographic procedure
and acceptance standard shall be per ASME V for severe cyclic conditions. The
use of X-radiographic methods is preferred. Gamma radiography will only be
permitted if the Contractor can demonstrate that the requirements of this
Specification concerning sensitivity and density can be achieved in radiographic
procedure tests. The technique shall utilise ultra fine grain film (Agfa Gevaert D4
or equivalent) and lead screens.

Wire type penetrameters shall be used and shall be placed at the ends of the
diagnostic length of the film, as determined from the radiographic procedure
qualification. The sensitivity shall be better than 2.0% and the H and D film density
shall be between 1.8 and 2.5 according to ASTM E94 and ASTM E1316.

Since radiography gives two-dimensional results only, welds may be rejected even
though they appear to meet the standards of acceptability, if there are reasonable
grounds to anticipate that the depth of a defect might in any way prejudice the
integrity of the weld.

Acceptance criteria for welds shall be as defined in ASME VIII.

10.6 Ultrasonic Examination

As a minimum, the procedure shall comply with ASME B31.3 and ASME V. The
acceptance standard shall be to ASME B31.3 and ASME VIII. Ultrasonic
examination shall be used for defect verification, for areas where radiography is
impractical, thickness testing and when directed by the Company.

10.7 Additional Non-Destructive Testing

If defects are discovered which in the opinion of the Company are detrimental to
the integrity of the facilities then all such welds shall be repaired at no cost to the
Company. If the Company believes that a defect exists in any weld or pass,
including a tack weld, the Contractor shall perform all inspection and testing
required by the Company. If the weld is deemed defective it shall be repaired or
replaced to the complete satisfaction of the Company and at the Contractor’s cost.

11775-SPC-ME-003 Rev 0 Page 18 of 18


Design of New
Hydrant System
(Package #7)

Specification for
Cleaning, Testing
and Drying of Head Office:
Hydrant Pipework Penspen Group Limited
3 Water Lane
Richmond upon Thames
Surrey
TW9 1TJ
United Kingdom

Regional Office:
Penspen International Limited
Kuwait Aviation Fuelling Co P.O. Box 46562
Abu Dhabi
United Arab Emirates

11775-SPC-ME-005 Rev 0
DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

7. Cleaning and Gauging


7.1 General
7.2 Contractor’s Procedure
7.3 Cleaning
7.4 Gauging
7.5 Acceptance Criteria

8. Hydrostatic Pressure Strength Testing (‘Hydro-testing’)


8.1 General
8.2 Contractor's Procedures
8.3 Hydrostatic Test
8.4 Safety during Hydro-testing
8.5 Test Documentation and Certification
8.6 Pre-test of Pipe/Fabrications

9. De-watering & Drying


9.1 General
9.2 Contractor's Procedures
9.3 De-watering
9.4 Drying
9.5 Storage and Monitoring
9.6 Acceptance Criteria

10. Nitrogen Inhibiting


10.1 General
10.2 Contractor’s Procedure
10.3 Nitrogen Purge
10.4 Storage and Monitoring
10.5 Removal of Nitrogen (Air Purge)
10.6 Acceptance
10.7 Documentation

11. Pneumatic Integrity Test


11.1 General
11.2 Contractor’s Procedure
11.3 Testing
11.4 Assessment of Integrity Test
11.5 Documentation

12. Tests During Commissioning


12.1 General
Appendix A: Test Data

11775-SPC-ME-005 Rev 0 Page 3 of 23


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

1. Scope and Introduction

This Specification details the requirements for cleaning, gauging, hydrostatic


pressure strength testing (‘hydro-testing’) drying and pneumatic integrity testing of
buried pipelines, installed as part of the new hydrant system at Kuwait
International Airport (KIA).

The buried pipelines may be required to be ‘preserved’ for a period of time,


pending installation of the interconnecting Sectioning Valve Chamber (SVC)
pipework and introduction of fuel. Therefore, this specification also covers the
nitrogen inhibiting requirements for this interim preservation period.

In addition, this specification also includes requirements for pre-testing of pipe


fabrications for installation at crossings of taxi ways/service roads.

Cleaning and pre-testing of piping for installation within sectioning valve chambers
(SVC) is covered by Specification No. 11775-SPC-ME-004: Specification for
Mechanical and Piping Installation.

Routine tightness control system testing with jet fuel as the test liquid is not
covered by this document. Annex E of API/IP 1540 describes how a relevant
method statement should be prepared if deemed necessary.

2. Precedence

Any case of apparent conflict between the requirements of this Specification and
any other relevant documents shall be notified to the Company. Unless otherwise
agreed the following descending order of precedence shall apply:-

1st This Specification


2nd Other Project Specifications
3rd The Codes and Standards listed in this specification
4th Other API, ASME, ASME, BS Codes or Standards as appropriate

3. References

The following documentation shall be read in conjunction with and form part of this
specification.

11775-LST-EN-001 Codes and Standards List

11775-SPC-PL-001 Specification for Linepipe

11775-SPC-ME-004 Specification for Mechanical and Piping Installation

11775-SPC-ME-006 Specification for the Installation of Buried Hydrant


Pipelines

11775-SPC-ME-005 Rev 0 Page 4 of 23


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

4. Definitions

The ‘Company’ is KAFCO (Kuwait Aviation Fuelling Company) or their appointed


agent or representative.

The ‘Contractor’ is the organization employed by the Company or their appointed


agent or representative in order to carry out the Work.

The ‘Work’ is the extension of the new hydrant system at Kuwait International
Airport (KIA).

Throughout this document the following terminology is used:

“must” signifies a legal or statutory requirement


“shall” signifies a requirement made mandatory by this Specification
“may” signifies a feature which is discretionary in the context in which it is
applied
“will” signifies a feature which the Contractor may assume to be already
present.

5. Codes and Standards

This Specification makes reference to the latest edition of the following documents
which shall be applicable as referenced.

ASME B31.3 Process Piping


API/IP 1540 Design, construction, operation and maintenance of aviation
fuelling facilities
API/EI 1585 Guidance in the Cleaning of Airport Hydrant Systems
API/EI 1594 Initial Pressure Strength Testing of Airport Fuel Hydrant
Systems with Water

For the complete list of applicable codes and standards, refer to Codes and
Standards List (Document No: 11775-LST-EN-001).

6. General Requirements

6.1 General

The hydrant pipeline network comprises a number of pipeline sections terminating


at flanged connections within sectioning valve chambers (SVCs). The piping
assemblies within SVCs will generally be installed after installation and testing of
the hydrant pipeline sections.

Following installation, the hydrant pipelines shall be cleaned, gauged, hydro-tested


and dried, ready for the introduction of fuel and commissioning of the hydrant
system.

11775-SPC-ME-005 Rev 0 Page 5 of 23


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

If any hydrant section is to be stored for more than 30 days, prior to


commissioning, it shall be purged with nitrogen to inhibit any potential corrosion or
micro-biological growth.

6.2 Test Fluid

Hydrostatic pressure testing of hydrant pipeline sections shall be performed using


clean, filtered, potable water, with a solids contamination level less than 1mg/litre.

Fire main or other non-potable water sources shall not be acceptable unless
suitably filtered and/or treated to reduce solids contamination to the required level
and to fully remove micro-biological contaminants.

Proposed water source and any required filtration or treatment shall be subject to
the Company’s approval.

6.3 Test Sections

Cleaning, gauging, hydro-testing and drying shall be carried out section by section
as construction proceeds.

Test sections will generally comprise individual pipeline sections. Alternatively,


pipeline sections may be interconnected for the purposes of hydro-testing and/or
drying by means of temporary piping, provided the requirements of this
specification are met in every respect.

The Contractor shall detail, as part of his procedures, proposals for configuration
of the test sections. These shall be subject to the Company’s approval.

6.4 Exposure of Girth Welds

In accordance with API/IP 1540 and Company practice, all girth welds shall be left
exposed until such time as hydro-testing has been successfully completed.

Depending on prevailing weather conditions at time of test, Contractor shall


provide covers/shades for exposed girth welds to mitigate temperature variances
at the exposed joints.

6.5 Extension to Existing Hydrant Section

If the section to be hydro-tested is an extension to an existing, live hydrant system,


it is must be physically separated from the live system. If necessary, a pipe spool
or valve shall be omitted or removed and blind flange installed to achieve this
separation.

Line or spectacle blind shall not be sufficient separation between test section and
live system.

6.6 SVC Piping

Cleaning and pre-testing of piping for installation within sectioning valve chambers
(SVC) is covered by Specification No. 11775-SPC-ME-004: Specification for
Mechanical and Piping Installation.

Inclusion of SVC piping in the pipelines hydro-test is not recommended due to


difficulties in pigging and de-watering of the SVC piping and valves.

11775-SPC-ME-005 Rev 0 Page 6 of 23


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

If the Contractor proposes to include SVC piping in the hydro-test section, he shall
include specific provisions in his procedures, which shall be subject to Company
approval.

6.7 Hydrant Pit Valves

Hydrant Pit Valves shall be installed only after hydro-testing and drying has been
successfully completed, immediately prior to the pneumatic integrity test and
commissioning of the hydrant system.

Where under-valve isolation valves are specified, these shall be installed at the
same time as the Hydrant Pit Valves.

Temporary blind flanges shall be fitted to hydrant risers during cleaning, hydro-
testing and nitrogen inhibiting, incorporating a bleed facility for hydro-test venting.

6.8 Sample, Vent and Drain Points

Sample, vent and drain points located in hydrant sections shall generally be fitted
with temporary blind flanges or threaded caps during hydro-testing. A bleed facility
for hydro-test venting shall be incorporated.

6.9 Pre-Test Pipeline Sections

Where pipelines cross constructed taxi ways or service roads, pre-testing of the
pipe section/fabrication for installation at that location shall generally be required.

Pre-test sections shall extend a minimum of 5 metres from either side of the
structure to be crossed. Pre-testing shall be carried out as detailed in Section 8.6.

6.10 Programme

Cleaning, gauging and hydro-testing shall commence as early as practicable within


the construction of the Work.

The Contractor shall produce, as part of his procedures, a detailed programme


giving proposed dates and durations of cleaning, gauging, hydro-testing and drying
for each test section. This shall be subject to the Company’s approval.

6.11 Testing Personnel

Cleaning, gauging, hydro-testing, drying and related operations shall be carried out
by experienced specialists either from the Contractor’s own organisation or a
specialist sub-contractor. The Contractor shall nominate his Test Engineer for
approval by the Company. The Test Engineer, who shall be suitably qualified and
experienced, shall be responsible for, and be present on site during, all cleaning,
gauging, hydro-testing, drying and associated Works.

6.12 Procedures

The Contractor shall prepare detailed procedures covering all cleaning, gauging,
testing, drying and associated Works. These shall be submitted to the Company
for approval, a minimum of twenty-one (21) days prior to commencement of the
related Works. The Contractor shall not commence any cleaning, gauging, hydro-
testing, drying or associated Works until written approval of the relevant procedure
has been obtained from the Company.

11775-SPC-ME-005 Rev 0 Page 7 of 23


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

The procedures shall include, but not be limited to:

i) Fully detailed programme giving proposed dates and durations of


cleaning, testing and associated Works for each test section.
ii) List of Contractor’s nominated Test Engineer and other supervising
personnel, identifying individual responsibilities.
iii) Safety provisions and procedures to be followed.
iv) Details of all equipment, materials, instrumentation and spares to be used
during cleaning, gauging, testing, and lay-up operations, including current
certification for all test instrumentation.
v) Proposed test sections including details of any temporary piping.
vi) For each test section, a schematic drawing indicating the locations of all
equipment, fittings, valves, instrumentation and temporary connections,
including temporary pig trap locations.
vii) Detailed procedures and checklists for each stage of the cleaning, testing
and associated Works.
viii) Sample test sheets and certificates.

6.13 Contractor Supplied Materials

6.13.1 General

The Contractor shall provide all equipment, facilities and power required for the
safe and efficient completion of all cleaning, gauging, hydro-testing, drying and
associated Works.

Suitable temporary pig traps for use in cleaning, gauging and de-watering activities
shall be provided by the Contractor.

6.13.2 Materials for Temporary Works

Where piping is adjusted, isolated, interconnected or extended to enable cleaning,


testing or associated operations, the Contractor shall provide all temporary piping,
spades, blanks, full bore spacer rings, blind flanges, gaskets, padlocks, etc.
required to do so. The Contractor shall remove and dispose of all temporary
materials and reinstate the piping upon completion of the operation.

The Contractor shall supply replacement gaskets, seals and the like, all in
accordance with the appropriate specification, to replace any such items damaged
or otherwise rendered unfit for further use or re-use as a result of the cleaning,
testing and associated Works.

6.13.3 Pigs

The Contractor shall provide pigs and carry out all pigging operations as required
by this Specification. The following types of pigs shall be required:

i) For Cleaning:
• Bi-directional disc light cleaning/displacement pigs
• Bi-directional disc magnetic pigs
• Polyurethane Foam pigs

11775-SPC-ME-005 Rev 0 Page 8 of 23


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

ii) For Gauging:


• Disc/cup gauging pigs

iii) For De-watering:


• High seal Bi-directional pigs
• Foam pigs

Cup and/or disc material shall be flexible polyurethane. Pigs shall not be fitted
with any form of brush or blade cleaning devices.

All pigs shall be capable of negotiating a minimum bend radius of 1½ pipe


diameters and satisfactorily negotiating tees, branches, low-point sumps and
valves as necessary.

All pigs, cups and materials shall be new and of recent manufacture and shall be
of a proven design. The materials of construction shall be such as not to cause
damage to the pipeline or internal epoxy lining.

Magnetic Pigs:

For magnetic pigs the magnets shall be securely fixed to the body of a 2-disc
displacement pig and shall not interfere with the ability of the pig to negotiate the
minimum bend radius. The preferred method of positively securing the magnets is
by wiring the bolts so that they cannot turn. Alternatively, spot welding, ‘nylock’
nuts or thread locking fluid may be used.

Magnetic pigs shall be suitable for the attraction and transportation of steel/ferrous
metallic debris from the line.

Gauging Pigs:

Gauging pigs shall comprise a slit aluminium gauging plate secured to the body of
a standard 2-disc pig. The gauging plate diameter shall be 95% of the minimum
internal diameter of the pipeline section. The gauging plate shall be slit radially and
the running edges shall be chamfered to avoid damage to the internal epoxy lining
of the pipelines.

6.14 Contractor Supplied Test Equipment

6.14.1 General

The Contractor shall provide all necessary equipment, labour, materials, spare
parts, consumables, services, supervision and supplies necessary for carrying out
all cleaning, testing and associated works

6.14.2 Instrumentation Accuracies

All instrumentation shall have valid calibration certificates and historic utilisation
records. Calibration certificates shall not be more than 2 months old. A verified
copy of the calibration certificate shall be available for inspection by the Company.

The accuracies for measurement of specific parameters are listed below. All other
parameters not specified below are to be measured to normal Industry standards.

• Pressure (dead weight) to ± 0.1%


• Pressure (dial gauge) to ± 1.0%

11775-SPC-ME-005 Rev 0 Page 9 of 23


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

• Barometric Pressure to ± 1 millibar


• Chart Recorders to ± 1.0% of range
• Temperature to ± 0.1°C
• Dewpoint to better than 2% variation on repeatability as
compared with the calibration certificate

6.14.3 Temperature Measurement

Pipewall temperature shall be measured by means of a magnetic thermocouple


sealed onto the pipewall and thermally insulated from ambient conditions.

Ground temperature shall be measured by means of temperature probes installed


at the average centreline depth of the test section. Ground temperature probes
shall be installed adjacent to each end of the test section.

The Contractor shall ensure that all temperature measurement equipment has
been in place for 24 hours, is recording properly and has stabilised prior to its use.

24 hours rotary or continuous strip type chart recorders shall be used to record
temperatures.

For pre-testing of pipe/fabrications prior to installation, the temperature of the pipe


contents shall be measured by probes in the test ends.

Ambient air temperature shall be recorded at hourly intervals, on suitable charts.

6.14.4 Barometric Pressure Measurement

Barometric pressure shall be measured by aneroid barometer and recorded on a


strip chart recorder.

6.14.5 Dewpoint Measurement

For dewpoint measuring equipment, calibration shall be checked repeatedly on


site during the Work and results compared with calibration charts covering the full
pressure range; a drift greater than 2% is not acceptable.

Dewpoint shall be recorded on a multi-speed strip chart recorder. Dewpoint


measurement shall be performed by suitable dewpoint sensor connected to a meter
that shall have remote read-out in the test cabin. The equipment shall be capable of
measuring dewpoints in the range (minus) - 50°C to +20°C. The dewpoint
transducer shall protrude inside the monitoring spool so as to ensure a true
representation of the flow dewpoint in the pipeline section.

6.15 Pigging

Pigging operations forming part of the cleaning, gauging, hydro-testing and drying
works shall comply with the following requirements:

• Pigs shall be launched and received in suitable temporary traps. The traps
shall be designed fabricated and hydro-statically tested in accordance
with the requirements of Specification No. 11775-SPC-ME-004
(Specification for Mechanical and Piping Installation). Design pressure
shall be as per the system design pressure, unless the traps are to be
removed during hydro-test in which case a lower design pressure of 7
barg may be applied.

11775-SPC-ME-005 Rev 0 Page 10 of 23


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

The traps shall be either fitted with ASME Class 150 Raised Face Flanges
at each end, or alternatively one end may be fitted with a proprietary pig
trap end closure for pig access. The traps shall be fitted with an
injection/vent valved connection with a minimum diameter of 2”. An ASME
Class 150 ball valve shall be fitted to the connection. The length of the
trap shall be sized in order to accommodate the type of pigs proposed to
be used by the Contractor.
• Pigs shall generally be compressed air-driven and shall be run against an
appropriate back-pressure to achieve a controlled velocity as specified.
• During the running of pigs, the Contractor shall fit and monitor pressure
indicating devices to the pipeline section.
• Removal of pigs from traps shall not be undertaken until the pressure has
been reduced to atmospheric in all parts of the test section.
• All pigs shall be loaded into and unloaded from the temporary traps in the
presence of the Contractor’s Test Engineer.
• The Contractor shall notify the Company at least one working day in
advance of any pigging operation being carried out.

6.16 Safety during Cleaning, Testing and Associated Works

The Contractor shall take all necessary safety precautions during cleaning, testing
and associated Works including, but not limited to the following:

i) Notification and updating of all third parties of the proposed programme.


ii) Awareness of all involved persons with associated hazards.
iii) Cordoning of hazardous areas and erection of warning notices.
iv) Provision of adequate access.
v) Fencing of open excavations (eg at exposed girth welds)
vi) Restrictions on work during pressure testing.
vii) Precautions to avoid build-up of nitrogen in valve chambers.
viii) Use of oxygen depletion meters in valve chambers during nitrogen filling
and purging.

6.17 Documentation and Certification

Within fourteen (14) days of completion of cleaning, gauging and hydro-testing, the
Contractor shall submit to the Company record documentation, including:

• Summary report.
• Test certificates and documentation.
• Test logs.
• Records of any failures and subsequent rectification.

Documentation requirements specific to hydrostatic pressure testing shall be as


detailed in Section 10.

11775-SPC-ME-005 Rev 0 Page 11 of 23


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

7. Cleaning and Gauging

7.1 General

The Contractor shall exercise rigorous controls during construction and installation
of the pipelines to maintain the internal cleanliness of the pipelines and shall
institute progressive checks on the condition of the pipelines to prevent
contamination with waste materials, debris and water ingress during construction
activities as per API/EI 1585.

Following installation, the Contractor shall conduct a programme of cleaning to


demonstrate to the Company’s satisfaction the internal cleanliness of the pipeline
sections. This shall be supplemented by drying of the pipeline sections.

7.2 Contractor’s Procedure

In addition to the general requirements of Section 6.6, the Contractor's cleaning


and gauging procedures shall address the following:

i) Details of all equipment, materials, instrumentation and spares to be used


during cleaning and gauging operations.
ii) Details of the pigs to be used.
iii) Method of controlling flow pressure and pig travel.
iv) Criteria for assessment of cleanliness.
v) Method of disposal of debris during cleaning and gauging.
vi) Method of measuring dewpoint during drying

7.3 Cleaning

Cleaning of each pipeline section shall be carried out as soon as possible after the
section has been backfilled.
The cleaning sequence shall comprise the following stages:

i) Polyurethane foam pigging


Foam pigs shall be driven through the pipeline section to remove light
construction debris. Successive pigs shall be run until no further debris is
displaced. Pigs shall be polyurethane foam pigs driven by compressed air.

ii) Scraper Cleaning


Scraper type cleaning pigs shall be driven through the pipeline section, in
order to remove residual construction debris.
Cleaning pigs shall be bi-directional urethane disc pigs, driven by
compressed air.

iii) Magnetic Pigging


Magnetic pigs shall be driven through the pipeline section to extract any
steel residues.

Cleaning pigs shall be run at a controlled velocity of between 0.6 and 1.0
metres/second.

11775-SPC-ME-005 Rev 0 Page 12 of 23


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

If cleaning operations need to be undertaken after the hydrant system has become
operational, relevant procedures within API/EI 1585 should be applied.

7.4 Gauging

Gauging shall be carried out by means of a pig fitted with an aluminium gauging
plate having a diameter 95% of the minimum internal diameter of the pipeline
section.

The gauging plates shall be slit radially and the running edges shall be chamfered
to avoid damage to the internal epoxy lining of the pipelines.

The Contractor shall offer the gauging plate for inspection by the Company before
insertion into the pipeline.

The gauging pig shall be run at a controlled velocity of between 0.3 and 0.5
metres/second.

The removal of all gauging pigs from pipeline sections shall be witnessed by the
Company.

Should the gauging plate display deformation or other damage after passing
through the pipeline section, the section shall be rejected. The Contractor shall
determine and rectify the cause and the gauging run shall be repeated.

The gauging plates shall be indelibly marked with the pipeline section identification
and date and shall be retained by the Company.

7.5 Acceptance Criteria

7.5.1 Cleaning

A pipeline section shall be considered clean when there is no longer a significant


discharge of debris at the end of the section when pigs are received

7.5.2 Gauging

Acceptance of the gauging runs shall be based on the requirements of API 5L and
the Specification. Dents greater than 6% of the nominal pipe diameter shall not be
acceptable in any pipeline section.

8. Hydrostatic Pressure Strength Testing (‘Hydro-testing’)

8.1 General

This section defines the minimum requirements for hydrostatic pressure testing of
the hydrant pipelines.

Hydrostatic testing shall be carried out using potable water as the test medium.

8.2 Contractor's Procedures

The Contractor shall submit his Hydrostatic Testing Procedure for approval by the
Company. In addition to the general requirements of Section 6 above, the
Contractor's procedure shall address the following:

11775-SPC-ME-005 Rev 0 Page 13 of 23


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

i) Test procedure and checklists.


ii) Method of monitoring pressure and temperature in the test section.
iii) Method of pressurisation, including pump and temporary piping details.
iv) Method of depressurisation.
v) Details of safety measures to be adopted during testing.
vi) Method of determining the volume of residual air.
vii) Theoretical pressure/volume curves and pressure/temperature curves.
viii) Criteria for assessment of tests.

8.3 Hydrostatic Test

The hydrostatic pressure test shall be executed as a holding test at a minimum


pressure of 150% of the design pressure, as detailed in Appendix A.

In the event of any leaks, the Contractor shall determine their location, effect repair
and re-test the test section until the acceptance criteria have been met.

Pressure testing shall not be carried out against closed valves.

8.3.1 Vents & Drains

In order to achieve a successful test, the Contractor shall ensure that all air has
been displaced from the system. Where required provision for venting of air from
high-points within the test section is not included in the permanent facilities, the
Contractor shall design and install such temporary or additional facilities as may be
required for this purpose.

Similarly, the Contractor is responsible for the design and installation of any
additional drain facilities required for removal of the test water following testing.

Such vent and drain facilities shall be designed in accordance with the relevant
specification and shall be subject to the Company’s approval.

8.3.2 Preparatory Checks

The temperature of the water shall be monitored and if the difference between the
water and ground temperatures may affect the test results, a period of temperature
stabilisation shall be allowed before the test commences.

The Contractor shall carry out a valve status check ensuring all valves are in the
correct position. The valve status check shall be carried out in accordance with
the Contractor's checklist.

Before the pressure is raised, the Contractor shall demonstrate that all safety
precautions have been met and that he has sufficient staff available for the
duration of the test to meet all contingencies. All connections, branches, fittings,
etc. that are not in use, shall be blanked or plugged.

8.3.3 Testing Cycle

The pressure at the test point at the commencement of pressurisation shall be that
which gives zero gauge pressure at the highest point in the test section.

11775-SPC-ME-005 Rev 0 Page 14 of 23


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

The pressure shall first be raised to 50% of the hydrostatic test pressure (as
detailed in Appendix A) and allowed to stabilise. The pressure/volume (p/v)
relationship curve shall be plotted, at 1 bar intervals, during pressurisation.

The rate of pressurisation shall not exceed 1 bar per minute. The air content shall
be determined from the p/v curve using the initial pressure at the test point as the
origin. The maximum air content shall not exceed 0.2% of the calculated capacity
of the pipeline network. If the air content exceeds this, the test section shall be
depressurised and the fuel filling procedure repeated.

If the air content is satisfactory, the pressure shall be held at 50% test pressure
and all connections and fittings on the pipe and test equipment checked for leaks.

The test shall not continue whilst there are observable leaks. The measuring of
observable leaks and the offsetting of the calculated pressure loss so caused
against the fall in test pressure shall not be permitted.

On completion of this leak check, the pressurisation shall be recommenced and


the p/v plot resumed, again at 1 bar intervals until the full hydrostatic test pressure
is reached.

The pressure at the test point shall be such that the hydrostatic test pressure
specified in Appendix A is attained at the highest point in the section under test.

The p/v relationship shall be monitored continuously to ensure that it does not
deviate from that predicted.

100% test pressure shall be held for a period of twenty-four (24) hours.

During the hold period, the pressure as indicated by Dead Weight Tester shall be
recorded at 30 minute intervals. If, owing to temperature effect, the pressure falls
1 bar or rises 0.3 bar, the test pressure shall be restored by pumping in or bleeding
off jet fuel as necessary. The quantity of water pumped in or bled off shall be
measured and recorded.

Ground and ambient parameters shall be recorded continuously throughout the


duration of the test.

Following successful completion of the hydro-test, pressure in the test section shall
be reduced to 1 barg, at a depressurisation rate not exceeding 5 bar per minute.

8.4 Safety during Hydro-testing

The following particular precautions shall be taken during hydro-testing:

i) Notices reading: “DANGER PIPELINE UNDER TEST” in both English and


Arabic languages, shall be placed and maintained at points of danger.
ii) No work shall be permitted on sections under test, or the associated
connections, until the pressure is reduced to a safe, positive pressure of 1
barg maximum.
iii) The Contractor shall obtain the Company’s approval prior to
commencement of pressurisation of each test section.
iv) Hydro-testing against closed valves shall not be permitted.

11775-SPC-ME-005 Rev 0 Page 15 of 23


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

8.5 Test Documentation and Certification

Within fourteen (14) days of completion of the hydro-test, the Contractor shall
submit to the Company the hydro-test report which shall include:

• Summary test report.


• Test certificates for all test sections.
• P/V curves, theoretical and plotted.
• All calculations: residual air content, etc.
• All recorder charts and strips.
• All test logs.
• Records of any failures and subsequent rectification.

The original and 1 No. copy of all documentation shall be provided.

8.6 Pre-test of Pipe/Fabrications

Sections of pipe crossing existing taxiways or service roads shall be subjected to a


full pressure test prior to installation, at a pressure exceeding that of the main
hydrant hydro-static pressure test.

8.6.1 Contractor's Procedure

The Contractor shall submit his Pre-test procedure for approval by the Company.
The procedure shall address the following particular items:

i) Method of containment of pressure in the pre-test section.


ii) Method of monitoring pressure and temperature in the pre-test section.
iii) Method of pressurisation.
iv) Method of depressurisation.
v) Details of safety measures to be adopted during pre-testing
vi) Criteria for assessment of pre-testing.

8.6.2 Pre-testing

The pre-test shall be conducted in water. The Contractor should demonstrate to


the Company’s satisfaction suitable procedures for dewatering and drying of the
pre-test sections prior to installation in accordance with API/EI 1594.

Prior to pre-testing, the pipe/fabrication shall be cleaned by flushing or blowing


through with dry air and in accordance with API/EI 1585.

The test pressure shall be 105% of the main hydrostatic test pressure given in
Appendix A.

The test hold duration shall be four (4) hours

The pre-test section shall be pressurised initially to 50% of the test pressure and
allowed to stabilise. During this period the fabrication shall be checked for
leakages and rectified as necessary and all external surfaces carefully dried. All
details of pressurising shall be recorded.

11775-SPC-ME-005 Rev 0 Page 16 of 23


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

The pressure shall then be raised to 105% of the test pressure and held for a
minimum 4-hour holding period. During the "Hold" period the test pump,
compressor or supply shall be disconnected and the connection plugged or
capped.

Containment shall be effected by suitably rated blind flanges or welded-on dome


end caps. On no account shall closed valves be utilised for pressure containment
in the fabrication under test.

8.6.3 Safety during Pre-testing

The following particular precautions shall be taken during hydrotesting:

i) Notices reading: “DANGER PIPELINE UNDER TEST” in both English and


Arabic languages, shall be placed and maintained at points of danger.
ii) No work shall be permitted on sections under test, or the associated
connections, until the pressure is reduced to a safe, positive pressure of 1
barg maximum.
iii) The Contractor shall obtain the Company’s approval prior to
commencement of pressurisation of each test section.
iv) Hydro-testing against closed valves shall not be permitted.

8.6.4 Assessment of Tests

The criteria for acceptance shall be an absence of visible leaks and no loss of
pressure that cannot be satisfactorily accounted for by changes in ambient
temperature. The Contractor's Test Engineer shall provide calculations to
reconcile any such changes in pressure, and shall extend the hold period until a
satisfactory correspondence has been demonstrated and accepted by the
Company. Due consideration shall be given to pressure change lag relative to
temperature change. Adequate provision for measuring the ambient, pipe wall and
fluid temperatures shall be made to ensure adequate data is available to support
such calculations.

Pipes and fabrications that have successfully passed the pressure test shall be
marked with a continuous red band along the length of the pipe/fabrication. The
Test Pressure shall be marked on the pipe at 3.0 metre intervals.

8.6.5 Documentation

On successful completion of each pre-test, the Contractor shall prepare a test


report and forward to the Company for approval.

9. De-watering & Drying

9.1 General

Following hydro-testing, the pipeline sections shall be de-watered and dried to


achieve a stable dry atmosphere for the introduction of fuel, or nitrogen inhibiting if
required.

De-watering and Drying shall be carried out in accordance with API/EI 1594.

11775-SPC-ME-005 Rev 0 Page 17 of 23


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

9.2 Contractor's Procedures

The Contractor shall submit his De-watering and Drying Procedure for approval by
the Company. In addition to the general requirements of Section 6 above, the
Contractor's procedure shall address the following:

i) Procedures and checklists for De-watering and Drying


ii) Method of De-watering including pump and temporary piping details.
iii) Method of water disposal.
iv) Details and designs of any additional or temporary connections required for
de-watering process
v) Method for measurement of Dewpoint
vi) Criteria for assessment of drying.

9.3 De-watering

De-watering shall remove as much free water as practical from the pipeline
section. De-watering shall be carried out in two stages:

• Displacement (Initial De-watering)


• Absorption

9.3.1 Displacement

Initial de-watering to remove the bulk of the free water. Test water may be
removed by one or more methods as applicable to the test section, such as:
• Draining at test-ends
• Draw off from permanent ‘drain points’ (using suitable pump)
• Draw off from temporary low-point drains (using suitable pump)
• Air-propelled pig to displace water to temporary discharge points

9.3.2 Absorption

Running air-propelled foam pigs through the hydrant pipeline section to absorb
remaining free water from the section.

Foam pigs shall be run in pig trains between tight-fitting cupped pigs at controlled
speeds to maximize water absorption.

During the pig runs, the low point drains shall be checked and any accumulation of
free water removed.

Pig trains shall be run repeatedly until foam pigs emerge dry. In addition, foam
pigs shall be weighed before and after the pig runs to quantify the amount of water
absorbed

The objective of the absorption process is to remove as much free water as


practically possible to minimize residual water and hence evaporation time during
subsequent drying process.

11775-SPC-ME-005 Rev 0 Page 18 of 23


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

9.3.3 Additional Drain/Discharge facilities

Any additional or temporary facilities necessary for de-watering purposes,


including drain points or temporary discharge facilities, shall be designed, supplied
and installed by the Contractor. All such facilities shall be subject to the
Company’s prior approval.

9.4 Drying

Following completion of the de-watering, the hydrant sections shall be dried to the
dewpoint specified in Appendix A.

Drying of pipeline sections shall be conducted in two stages:

i) Evaporation
ii) Soak Test

Further drying shall be carried out as necessary following installation of the SVC
piping, prior to introduction of fuel into the hydrant. This shall be conducted
section-by-section using the installed sectioning valves for isolation.

9.4.1 Evaporation

The pipeline sections shall be dried to the dewpoint specified in Appendix A by


blowing through with dry, oil-free air, at atmospheric pressure. Suitable desiccant
driers shall be fitted to the air-compressor outlet to achieve the required dewpoint.

For larger volume sections, it is recommended to carry out the drying process
progressively from vent point to vent point. This will identify if any particular sub-
section contains residual free water requiring removal for drying to proceed
efficiently.

Vacuum drying may be proposed by the Contractor as an alternative, subject to


approval by the Company.

9.4.2 Soak Test

When a dewpoint at or below that specified in Appendix A has been achieved, the
hydrant section shall be isolated and left on soak test. All dewpoint and
temperature measuring instruments shall be left installed and operating for the
soak test.

The soak test period shall be of sufficient time to determine that the dewpoint is
stable. Should an increasing dewpoint trend be detected with no signs of
stabilisation, the Contractor shall resume the evaporation stage.

9.5 Storage and Monitoring

Following completion of the drying process, the section shall be sealed and
pressurized to between 0.7 and 1.0 barg.

Injection and venting connections on the hydrant section shall be closed, capped
and blind flanged as appropriate and left in place during storage.

Each hydrant section or interconnected section shall be fitted with a temporary,


valved, 0 to 1 barg, dial pressure gauge for monitoring of internal pressure during
storage.

11775-SPC-ME-005 Rev 0 Page 19 of 23


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

The section pressure shall be monitored weekly and the pressure maintained at a
minimum 0.7 barg.

9.6 Acceptance Criteria

The criteria for the acceptance of the soak test and the termination of the drying
operation shall be as follows:

• Stable dewpoint equal to or lower than the specified value in Appendix A


in the hydrant section.
• Stable pressure of 0.5 to 0.7 barg in the hydrant section

10. Nitrogen Inhibiting

10.1 General

If any hydrant section is to be ‘stored’, following completion of hydro-testing and


drying, for more than 30 days, before introduction of fuel, it shall be purged with
nitrogen to inhibit any potential corrosion or micro-biological growth.

Nitrogen inhibiting shall comprise the purging of the section with high purity
nitrogen, sealing and storage at a pressure of 0.5 to 0.7 barg.

Nitrogen inhibition shall be carried out in compliance with the approved


procedures.

Appropriate safety procedures shall be established and observed when dealing


with nitrogen.

10.2 Contractor’s Procedure

In addition to the general requirements of Section 6.6, the Contractor's Nitrogen


Inhibition procedure shall address the following:

i) Particular precautions to be taken to remove the risk of asphyxiation


associated with nitrogen purging operations.
ii) Proposed facilities for monitoring of nitrogen pressure and purity during lay-
up.

10.3 Nitrogen Purge

The section shall be depressurised and purged with dry, high purity nitrogen,
closed, sealed and stored at a pressure of between 0.5 and 0.7 barg.

Flanged ends of all dead legs, hydrant risers, laterals and spurs shall be verified
for nitrogen concentration.

The pipeline section shall be closely monitored for the first 72 hours to ensure that
the nitrogen pressure is maintained. Should the pressure drop, the Contractor
shall establish and rectify the leak.

11775-SPC-ME-005 Rev 0 Page 20 of 23


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

10.4 Storage and Monitoring

Purging injection and venting connections on the pipeline section shall be closed,
capped and blind flanged as appropriate and left in place during storage.

Each hydrant section or interconnected section shall be fitted with a temporary,


valved, 0 to 1 barg, dial pressure gauge for monitoring of internal pressure.

The nitrogen pressure shall be monitored weekly. A minimum pressure of 0.5 barg
shall be maintained at all times. The Contractor shall supply and inject high purity
nitrogen as necessary to maintain the minimum pressure.

10.5 Removal of Nitrogen (Air Purge)

Prior to the introduction of fuel and commissioning of the hydrant system, all
nitrogen shall be purged from the system using clean, dry, oil-free air, with a
dewpoint equal to or lower than the dewpoint specified in Appendix A.

This ‘air purge’ shall be carried out no more than 30 days prior to the introduction
of fuel to the system.

The section shall be sealed and pressurized to 0.7 to 1.0 barg pending
commencement of filling operations.

10.6 Acceptance

The acceptance criteria for the nitrogen inhibition operation shall be as follows:

• The dewpoint of the system shall not be greater than the value stipulated
in Appendix A
• The pipeline section shall contain high purity nitrogen at a stable pressure
of 0.5 to 0.7 barg.
• The residual oxygen content in the system shall be not more than 0.2% at
any point.

10.7 Documentation

For each pipeline section or interconnected section, the Contractor shall submit
records of the nitrogen inhibition operation to substantiate that the section has
been purged to the specified criteria, for the Company’s approval.

11. Pneumatic Integrity Test

11.1 General

Following installation and hook up of the SVC piping and Hydrant Pit Valves, and
prior to the introduction of fuel to the system, a pneumatic ‘integrity’ test shall be
performed on the completed system, to verify the integrity of the untested flanged
and threaded connections.

11.2 Contractor’s Procedure

In addition to the general requirements of Section. 6.6 above, the Contractor's


pneumatic integrity testing procedure shall address the following:

11775-SPC-ME-005 Rev 0 Page 21 of 23


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

i) Method of monitoring pressure in the pipeline section.


ii) Method of pressurisation and depressurisation.

11.3 Testing

The pneumatic integrity test shall be executed as short duration holding test
conducted using dry air.

The test pressure shall be 1.0 barg and the hold duration one hour.

Prior to testing, all connections, branches, fittings, etc. that are not in use, shall be
blanked or plugged.

The air pressure in the section under test shall be raised to the test pressure and
all connections bubble tested for leaks. Following satisfactory bubble testing, the
pressure shall be held at the test pressure and monitored for the hold duration.

In the event of any leaks, the Contractor shall determine the cause, effect repair
and re-test the test section until the acceptance criteria have been met.

Prior to leak testing of any section, the Contractor shall give sufficient notice to
allow the Company to witness the test.

11.4 Assessment of Integrity Test

The test shall be judged successful if there is, over the hold period, no change in
pressure.

11.5 Documentation

On successful completion of the leak test for each test section, the Contractor shall
prepare a test report and forward to the Company for approval.

12. Tests During Commissioning

12.1 General

Following filling of the hydrant system with fuel, a leak test shall be carried out to a
pressure of 110% Normal Operating Pressure.

This shall be followed by a 7-day soak test and system flushing to verify its
cleanliness and ‘saturation’ of the internal lining.

These operations are fully detailed in the specification for commissioning.

11775-SPC-ME-005 Rev 0 Page 22 of 23


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Appendix A: Test Data

Pipeline System Flange Design Piping Design Hydrostatic Dry to Diameter


Rating Code Class Pressure Test stable
Pressure Dewpoint
(@ Atm.)
of:
(barg) (barg) (°C)
(° (inches)

Hydrant Pipelines ASME


#150 1A1 19.26 28.89 - 20 All sizes
(Buried) B31.3

Note:
1. 6” Riser Flanges are #300 to suit mating flanges.

11775-SPC-ME-005 Rev 0 Page 23 of 23


Design of New
Hydrant System
(Package #7)

Specification for
the Installation of
Buried Hydrant
Head Office:
Pipelines Penspen Group Limited
3 Water Lane
Richmond upon Thames
Surrey
TW9 1TJ
United Kingdom

Kuwait Aviation Fuelling Co Regional Office:


Penspen International Limited
P.O. Box 46562
Abu Dhabi
United Arab Emirates

11775-SPC-ME-006 Rev 0
10. Trenching
10.1 Trial Excavations
10.2 General Excavation
10.3 Trench Dimensions and Pipe Cover
10.4 Limitation of Open Trench
10.5 Earth Spoil Bank
10.6 Timbering and Supports
10.7 Protective Measures for Open Trenches
10.8 Water Removal and Disposal
10.9 Access
10.10 Existing Services
10.11 Bedding Material
10.12 Pipeline Surround Material

11. Pipeline Fittings, Field Bending and Cutting of Pipe


11.1 Elbows
11.2 Flanges and Flanged Joints
11.3 Butt Welding Fittings
11.4 Field Bends and Equipment
11.5 Cutting and Bevelling of Pipe
11.6 Pup Sizes

12. Welding and Non Destructive Testing


12.1 Alignment and Welding Operations
12.2 Non Destructive Testing (NDT) Operations

13. Coating of Weld Joints


13.1 General
13.2 Specification

14. Pipe Laying and Back-filling


14.1 Trench Preparation
14.2 Pipe Laying
14.3 Construction of Hydrant Risers
14.4 Pipeline Construction Tolerances
14.5 Back-filling

15. Cleaning and Testing


15.1 Cleaning, Gauging, etc
15.2 Pressure Testing

16. Crossings
16.1 Crossing of Existing Services
16.2 Crossings of Existing Taxi Ways and Service Roads

17. Reinstatement
17.1 General
17.2 Access to Working area after Testing and/or Reinstatement
17.3 Pipeline Markers
17.4 Parking Areas, Storage Areas, Working Areas and Accesses
Appendix A: DELETED
Appendix B: Pipeline Construction Tolerances

11775-SPC-ME-006 Rev 0 Page 3 of 23


1. Scope and Introduction

This Specification details the construction requirements for buried hydrant


pipelines to be installed as part of the new hydrant system at Kuwait International
Airport (KIA).

The scope of this specification is limited to feeder lines, hydrant mains, risers and
laterals.

2. Precedence

Any case of apparent conflict between the requirements of this Specification and
any other relevant documents shall be notified to the Company. Unless otherwise
agreed the following descending order of precedence shall apply:-

1st This Specification


2nd Other Project Specifications
3rd The Codes and Standards listed in this specification
4th Other API, ASME, ANSI, BS Codes or Standards as appropriate

3. References

The following documentation shall be read in conjunction with and form part of this
specification.

11775-SPC-PL-003 Specification for Factory Applied Polyethylene Coating of


Line Pipe

11775-SPC-PL-005 Specification for Factory Applied Internal Lining

11775-SPC-PL-006 Specification for Heat Shrink Sleeves

11775-LST-EN-001 Codes and Standards List

11775-SPC-PL-002 Specification for Pipeline Forged Bends

11775-SPC-ME-001 Specification for Piping Materials

11775-SPC-ME-009 Specification for Storage, Handling and Transport of Line


Pipe and Fittings

11775-SPC-ME-003 Specification for Field Welding

11775-SPC-ME-004 Specification for Mechanical and Piping Installation

11775-SPC-ME-005 Specification for Cleaning, Testing and Drying of Hydrant


Pipework

11775-SPC-PL-007 Specification for Factory Applied Liquid Coating of


Fittings.

4. Definitions

The ‘Company’ is KAFCO (Kuwait Aviation Fuelling Company) or their appointed


agent or representative.

11775-SPC-ME-006 Rev 0 Page 4 of 23


The ‘Contractor’ is the organization employed by the Company or their appointed
agent or representative in order to carry out the Work.

The ‘Relevant Authority’ is any statutory authority, company, agency, contractor or


other party who may be affected by the Work.

The ‘Work’ is the extension of the new hydrant system at Kuwait International
Airport (KIA).

Throughout this document the following terminology is used:

“must” signifies a legal or statutory requirement


“shall” signifies a requirement made mandatory by this Specification
“may” signifies a feature which is discretionary in the context in which it is
applied
“will” signifies a feature which the Contractor may assume to be already
present.

5. Codes and Standards

This Specification makes reference to the latest edition of the following documents
which shall be applicable as referenced.

API 5L Specification for Linepipe

API RP 1540 Design, Construction, Operation and Maintenance of Aviation


Fuelling Facilities/IP Model Code of Safe Practice Part 7

ASME B31.3 Process Piping

BS 6031 Code of Practice for Earthworks

NFPA 407 Standard for Aircraft Fuel Servicing

For the complete list of applicable codes and standards, refer to Codes and
Standards List (Document No: 11775-LST-EN-001)

11775-SPC-ME-006 Rev 0 Page 5 of 23


6. General

6.1 Routing

For detailed pipeline routing, refer to pipeline drawings.

6.2 Access to the Site

The new hydrant system works lie within the boundary fence of Kuwait
International Airport with access limited to those locations designated by the
Relevant Authority.

6.3 Construction Sequence

The Contractor shall program his pipeline construction activities to take account of
other construction within the new hydrant system development area and minimise
disruption to other Contractors as applicable.

In the existing airport facilities, no more than 100 metres of trench shall be open at
anytime without prior permission of the Company.

7. Surveying and Setting Out

7.1 Survey Control System

7.1.1 Horizontal Control Stations

Horizontal survey control stations shall be established around the site, consisting
of a number of permanent ground markers (PGM). PGMs shall be coordinated on
the airport grid by established surveying techniques, using DGPS electronic total
stations and levels as appropriate absolute relative to height. The positional
accuracy of the PGMs shall be:

Horizontal Vertical
± 10mm absolute ± 3mm absolute
± 3mm relative to neighboring stations ± 1.5mm relative to height

The Contractor shall propose a suitable construction arrangement of the PGMs for
the Company’s approval. All survey works shall be tied to the PGM network.

7.1.2 Location and Protection of Control Stations

The Contractor shall co-ordinate the location of PGMs and Bench Marks with the
Company and other involved parties to ensure that the locations selected will not
be in conflict with other temporary and permanent works being constructed by
others on the site. In the event that conflict arises necessitating relocation of any
of the PGMs, relocation shall be carried out by the Contractor at his own cost and
the new PGM shall be coordinated and levelled into the control system and the
reference drawings shall be updated accordingly and re-issued.

Reference drawings of the survey control system shall be prepared by the


Contractor and issued to the Company.

PGMs shall be protected throughout the duration of the works and shall be subject
to checks for co-ordinate and level accuracy at intervals to be agreed with the
Company. The Contractor shall be held responsible for any errors detected in co-
ordinates and levels and for any corrective measures required to line and level of
the hydrant pipelines resulting there from.

11775-SPC-ME-006 Rev 0 Page 6 of 23


PGMs are expected to remain in position after completion; however this will be
subject to the Company’s agreement. In the event that any or all PGMs are
required to be removed, the Contractor shall do so at no additional cost.

7.2 Setting Out of the Pipeline Routes

The Contractor shall set out the routes of the pipelines in accordance with the
Drawings.

Using the survey control system, the pipelines shall be set out to accuracies of:

Horizontal: ± 10mm

Vertical: ± 3mm

The Contractor shall allow 2 working days for the Company to check the setting
out before the routes are fixed. Minor adjustments and realignment may be
required to facilitate construction and shall, if required, be made at the Contractor’s
cost.

7.3 Working Area and Additional Working Areas

The Contractor shall define his working area and extra working area requirements
and submit his proposal to the Company for approval.

8. Preparation of the Working Area

8.1 Availability of the Land

Subject to other constraints detailed in this specification, and in the Contract, the
working area and additional working areas will be made available to the Contractor
for the duration of the Works. However it may be necessary to restrict access in
particular areas at certain times in order to enable works by others. The
Contractor shall accommodate such working within his programme at no additional
cost.

8.2 Clearing, Grading and Filling

The Contractor shall clear the working area of the pipeline route commensurate
with the programme agreed by the Company. Any grading activities required shall
be undertaken by the Contractor.

The working area shall be prepared by the Contractor to suit pipelining operations.
The Contractor shall import suitable batch fill where required to improve ground
conditions and shall dispose of surplus imported fill material upon completion of
reinstatement of the working area.

8.3 Refuse and Debris

All refuse and debris shall be collected from the working area and hauled away
from the Site to tipping areas to be provided by the Contractor.

The Contractor needs to review and comply with relevant standards and foreign
regulation in response to Foreign Object Debris (FOD).

11775-SPC-ME-006 Rev 0 Page 7 of 23


8.4 Location and Protection of Other Services

The Contractor shall familiarise himself with all statutory authorities, companies,
agencies contractors or other parties (Relevant Authority) who may own or be
responsible for the operation of temporary or permanent services within or close to
the working area or additional working areas.

Prior to clearing the working area the Contractor shall contact the Relevant
Authorities and shall be responsible for the location of any services (of a temporary
or permanent nature) within the working area or which might be affected by the
Works.

The Contractor shall locate the precise position of all existing underground
services and apparatus utilising the latest underground detection equipment and
confirm the location by means of trial excavations which shall be hand dug well
ahead of any work which could cause damage. Services located shall be clearly
indicated by warning signs which shall be maintained throughout the construction
period indicating the type, size and depth. The location shall be recorded on
drawings (plans and sections) to be prepared by the Contractor.

Without prejudice to this obligation, the Company may issue the Contractor with
Drawings showing locations of existing underground services. Such information
shall be for guidance only and no guarantee is offered or implied as to its
completeness or accuracy.

The Contractor shall prepare drawings showing his proposals for the support and
protection of existing underground services during construction for approval if
required by the Company and Relevant Authority.

Where telephone, power or other overhead utility lines or structures interfere with
the Contractor's access along or to the working area, the Contractor shall if
required submit proposals for approval of the Company and Relevant Authority for
protecting and maintaining continuous use of such telephone, power or other
overhead lines or structures during the Works.

The Contractor shall be responsible for, and shall bear the cost of, any damage
caused to existing services, apparatus, overhead lines or structures when locating
their position or at any time during the performance of the Contract.

8.5 Drainage Ditches and Culverts

All existing drainage ditches and culverts crossing the working area shall be
reinstated to their original condition during pipeline back-fill operations.

8.6 Temporary Fencing and Gates

Temporary fencing shall be provided by the Contractor to all sides of the working
area throughout pipelining operations. Gates shall be provided where the working
area crosses designated site access roads.

8.7 Access Roads and Tracks

8.7.1 Existing Roads and Tracks

The Contractor shall, prior to use for access of any road or track, obtain written
permission from the Relevant Authority and shall make due allowance for
restrictions placed by the authority on movement of vehicles on such accesses.

11775-SPC-ME-006 Rev 0 Page 8 of 23


The Contractor shall prepare a record of the condition of all such accesses prior to
their use. Such records shall take the form of a written report supplemented by
photographs to be submitted to the Company.

The Contractor shall be responsible for any damage to the accesses caused by
the passage of his plant materials and equipment. The Contractor shall correct
such damage as soon as it is identified.

8.7.2 Temporary Access Roads

The Contractor shall assess the requirement for any temporary access roads, in
addition to those shown on the Drawings, to be built along or to the pipeline route.
These temporary roads shall take the form of hardcore or other approved material
laid over geo-textile or lightweight recoverable tracking or timber machine mats.

The temporary roads shall be maintained throughout the duration of their use in a
clean and serviceable condition. Should the road deteriorate at any time to the
point where contamination or damage to the underlying soil occurs, the Contractor
shall cease all trafficking across the damage part of the road until adequate steps
have been taken to repair and restore the road to an acceptable condition.

Unless otherwise instructed by the Company, the Contractor shall remove and
dispose of the temporary access roads upon the completion of the Contract.

9. Storage, Handling and Transportation of Linepipe and Fittings

9.1 General

Pipe storage, handling and transportation shall be carried out in accordance with
Specification No. 11775-SPC-ME-009: Specification for Storage, Handling and
Transport of Line Pipe and Fittings

9.2 Stringing and Intermediate Stacking

The Contractor shall string pipe in a manner designed to prevent rolling.

The pipes shall not be placed on the ground, but raised on timbers not less than
150mm x 150mm in cross section and with approved padding and wedges. The
padding shall overhang the width of the timber by not less than 25mm each side,
and have a minimum thickness of 50mm before compression.

The Contractor shall remove from pipes, collect and dispose off site to a licenced
tip, all bevel protectors and protective rubber bands supplied by the pipe
manufacturer. This operation shall be carried out daily, directly after the pipe has
been strung and prior to any subsequent operation. Protective rubber bands shall
not be used as a substitute for packing between timbers and pipe.

When stringing the pipe, the Contractor shall leave gaps at intervals to permit third
party access as instructed by the Company. The pipes shall be strung so that
existing access routes are not restricted.

All sidebooms used on the pipeline shall have their jibs wrapped with rubber
belting or other approved materials to alleviate damage to the coating of the pipe.

When stacking is necessary, the height of the stack shall not exceed three pipe
diameters. Padding between layers of pipes shall be as described in Specification
No. 11775-SPC-ME-009.

11775-SPC-ME-006 Rev 0 Page 9 of 23


The Contractor shall, during the stringing operation, and the subsequent bending
operation, plan the location of the longitudinal seams of alternate pipes so that the
requirements for the placing and spacing of seams, as stated in Specification No.
11775-SPC-ME-003: Specification for Field Welding, are met.

10. Trenching

10.1 Trial Excavations

The Contractor shall excavate trial holes L-shaped slit trenches along the
centerline of the pipelines to a depth equal to the invert of the pipe plus 250mm, at
a distance not exceeding 100m between slit trenches.

From the information gathered from the trial holes, the Contractor shall assess his
requirements for excavation of the trench and the extent of dewatering and special
precautions.

The Contractor shall give the Company a minimum of four hours notice before a
trial hole is back-filled in order that the Company may inspect the excavation. No
trial holes shall be left open overnight.

10.2 General Excavation

The pipe trench shall be carefully excavated to a depth of 200mm deeper than the
invert levels specified in the Drawings. The trench bottom contour shall be such
as to obtain a smooth profile for the pipeline and to obviate field bending.

All excavation shall be by hand or mechanical equipment subject to proximity of


other services.

The pipe trench shall be excavated along the staked alignment but where there is
a change in direction, the trench shall be cut so as to accommodate the specified
radius of pipe bend. A clearance shall be maintained between the bend and the
trench walls to conform to the trench dimension requirements.

The finished trench shall be free from stones, rocks or other hard objects which
may damage the pipe or pipe coating. Provision shall be made for dewatering if
required.

Where the trench has been over-excavated to a depth greater than that specified
above, the Contractor shall refill the trench to the specified depth with suitable
excavated material and consolidate.

10.3 Trench Dimensions and Pipe Cover

The pipe trench shall be excavated as specified above. The trench width shall be
at least 300mm greater than the outside diameter of the coated pipe. At locations
where work on the installed pipe is to be performed later, such as at tie-ins,
sufficient extra excavation shall be made so that welding and other work can be
performed satisfactorily around the pipe in the trench. The depth of cover shall be
1.5m or otherwise advised on the Drawings.

10.4 Limitation of Open Trench

In order to reduce the hazard of long lengths of open trench excavation and to
avoid the risk of problems and additional work caused by earth slips and falls in
rainy weather, the Contractor shall plan his construction programme and
excavating operations so that the trench remains open for as short a period as

11775-SPC-ME-006 Rev 0 Page 10 of 23


practicable. Protective measures to be adopted at open trenches shall be as
detailed in Section 10.7 below.

The maximum length of trench permitted to be open at any one time is 300 metres.

Note – Intermediate tie-in welds to be left exposed until hydrotest satisfactory


completed with suitable fencing barriers in place.

10.5 Earth Spoil Bank

The bank of earth spoil produced by pipe trench excavation shall not be
contaminated by organic and other foreign materials that would produce an
unsatisfactory back-fill. The Contractor shall make gaps in the spoil bank so that
rainfall will not cause water to accumulate and flood adjacent areas.

Where insufficient land is available to accommodate the excavated material, it


shall be removed from site for temporary storage and if suitable, returned for the
back-filling operation.

10.6 Timbering and Supports

When ground conditions are such that the sides of the trench are unstable or
where the depth of the excavation exceeds 1.5 metres, the Contractor shall
provide timbering, sheet piling and supports to retain the trench side walls to the
satisfaction of the Company

Trench supports shall be fixed in accordance with Section 13 of BS 6031. This


specification provides details and sketches of various types of support systems.
The Contractor shall be responsible for selecting the most suitable type of support
system based on prevailing ground conditions.

10.7 Protective Measures for Open Trenches

The Contractor shall install temporary warning signs and lights at all open trenches
and excavations. Warning signs shall read “DANGER DEEP EXCAVATION –
KEEP OUT” or similar approved wording, in both English and Arabic languages
and shall be placed at intervals along the trench of no more than 20 metres.

10.8 Water Removal and Disposal

Open trenches shall be kept free from water at all times.

The Contractor shall submit to the Company his proposed methods for trench
dewatering, including equipment to be used. Inlet filters shall be fitted and used on
all pumps used for dewatering.

Water shall not be pumped onto adjacent land, but shall be disposed of by means
of hoses or pipes to a suitable water course or drain. The means of disposal and
choice of water course shall be subject to the approval of the Company.

The deposition of silt in ditches, water courses or drains due to disposal of water
from the Works shall as far as possible be avoided, but if so caused, shall be
cleared out by the Contractor.

10.9 Access

Where access is to be provided across the pipeline route, the Contractor shall
provide safe access across the trench. Such access shall be provided at
reasonable intervals for third parties where directed by the Company.

11775-SPC-ME-006 Rev 0 Page 11 of 23


10.10 Existing Services

The Contractor shall follow the approved proposals for support and protection of
existing underground services.

Excavation around existing services shall be carried out by hand with such care as
is necessary to avoid damage to the services.

10.11 Bedding Material

Where required the Contractor shall import and lay bedding to the invert of the
trench, after excavation of the trench. Should the Contractor not have excavated the
trench to sufficient depth to accept imported bedding, which would result in the laid
pipe not having sufficient cover, then the Contractor shall re-excavate or lower the
bottom of the trench by an approved method.

Imported material used for bedding shall be sand and shall be clean and salt free
and shall not contain clay, roots, stones or other material which is likely to cause
damage to the pipe coating. The Contractor shall, prior to any imported material
being used for pipe bedding, submit samples of the proposed materials for the
approval of the Company’s representative, and shall satisfy the that sufficient
quantities of suitable materials are readily available for use in the pipeline trench.
The Contractor shall arrange for the Company’s representative to visit the source of
the proposed material.

10.12 Pipeline Surround Material

Where suitable material free from sharp stones or flints, perishable matter or other
materials likely to cause damage to the pipe coating, other than the surface top soil
material, can be selected / obtained from the excavated material adjacent to the
point of backfilling, same shall be used to provide intimate backfill for the pipeline.
The material shall be carefully placed over and around the pipe and shall not be
dropped directly onto the pipe from a height above the pipe exceeding 500mm. The
material shall be worked around and under the pipe by either mechanical or hand
held machines or tools, to fill any voids which exist. Within the constraints of safe
working practices, the material shall be rammed around the pipe in layers not
exceeding 150mm using suitable tools ensuring that no damage is caused to the
pipeline coating.

Such suitable material shall be used up to a level of at least 150mm above the
crown of the pipe.

Where the whole of the excavated material is unsuitable for pipe surround or where
the excavated material is inconsistent over a section of pipeline trench, making
selection difficult, the Contractor shall import suitable material with which to surround
and cover the pipeline to a depth of at least 150mm.

The imported material shall be that described for sand bedding and shall be placed
and compacted around the pipe in the manner described above.

11. Pipeline Fittings, Field Bending and Cutting of Pipe

11.1 Elbows

Factory made forged 1½D elbows in accordance with Specification 11775-SPC-


PL-002: Specification for Pipeline Forged Bends, shall be used whenever a
change of direction is required, as shown on the Drawings.

11775-SPC-ME-006 Rev 0 Page 12 of 23


Elbows shall be externally coated and internally lined in accordance with project
Specification No’s 11775-SPC-PL-007 and 11775-SPC-PL-005 respectively.

11.2 Flanges and Flanged Joints

Flanges, blank flanges, bolts and gaskets shall comply in all respects with ASME
B16.5.

Flanges shall be set square to the end of the pipes. Flanges of adjoining
fabrications shall be aligned so that the mating faces are parallel.

11.3 Butt Welding Fittings

Butt welding fittings shall comply with 11775-SPC-ME-001: Specification for Piping
Materials and shall be coated and lined in accordance with Specification No’s
11775-SPC-PL-007 and 11775-SPC-PL-005 respectively.

11.4 Field Bends and Equipment

The need for introducing field bends shall be avoided wherever possible.

Field bends shall only be permitted with the approval of the Company in every
instance.

Where approval is given for a field bend, it shall be formed in accordance with the
following requirements:

• Field bends shall be cold formed on an approved bending machine of the


correct size with an internal mandrel. The pipe shall be bent to a radius
not less than 40D. All bends shall have a tangential straight not less than
5 times the nominal pipe diameter on each end. On seam welded pipe
the seam shall be aligned along the neutral axis prior to bending.

• Wherever possible a field bend shall not be made through a


circumferential weld, or within a distance of 5 times the pipe nominal
diameter from a circumferential weld. Where it is necessary to bend
through a circumferential weld, the weld shall be subject to radiographic
inspection.

• All field bends shall be of constant radius, uniformly circular in section and
free from buckling, wrinkling, flattening, cracking or any other defect or
damage. The pipe diameter shall not be reduced at any point by more
than 2.5 per cent.

• Before they are incorporated in the pipeline, all bends shall be proved with
a gauging device fitted with two sizing plates 95% of the pipe internal
diameter held apart by a distance of approximately 1 pipe diameter.

• Where bends have been formed from coated pipe, the coating shall be
inspected. Where damage has occurred, the coating shall be repaired or
replaced in accordance with the specification and method statement
agreed.

11.5 Cutting and Bevelling of Pipe

All pipe cutting shall be done by an approved pipe cutter or thermal cutting and
bevelling machine. Manual cutting shall not be permitted.

End preparation for butt-welding shall be in accordance with ASME B31.3.

11775-SPC-ME-006 Rev 0 Page 13 of 23


A minimum of 150mm longitudinal length of coating shall be removed from either
side of each joint to permit cutting of pipes and their subsequent welding.

11.6 Pup Sizes

The minimum length of "pup" shall be 1.5 times the outside diameter of the pipe or
0.6 metre, whichever is the greater.

12. Welding and Non Destructive Testing

12.1 Alignment and Welding Operations

The pipelines shall be constructed by aligning and welding each joint of each pipe
to the proceeding joint of pipe to form the maximum continuous length of pipeline
allowable within physical constraints. Alignment and welding shall be carried out
in accordance with Specification No. 11775-SPC-ME-003: Specification for Field
Welding

The continuous lengths shall be supported on padding and skids with wedges to
prevent rolling, at least 400 mm above ground during all welding operations.

Skid supports shall be constructed such that the pipeline is supported


longitudinally and restrained laterally.

The continuous lengths of pipeline above or below ground shall have temporary
end caps fitted to prevent the ingress of extraneous matter when no work is in
progress. The caps shall be of a type approved by the Company.

12.2 Non Destructive Testing (NDT) Operations

NDT shall be carried out in accordance with project 11775-SPC-ME-003:


Specification for Field Welding

All butt welds fabricated shall be subjected to 100% radiography.

All fillet welds shall be subjected to 100% magnetic particle inspection.

All radiographs shall be submitted for sentencing no more than thirty six (36) hours
after the weld to which the radiograph relates has cooled to ambient temperature.

All cut ends shall be checked for laminations using ultrasonics.

Final Tie-in welds (Golden Welds) shall be subjected to 100% radiography, 100%
ultrasonics and 100% Magnetic Particle Inspection

Any pipe used to make final tie-ins shall have been pressure tested to the same
test pressure and for the same duration as the most onerous of the adjacent test
sections.

13. Coating of Weld Joints

13.1 General

Weld joints shall only be coated following the successful completion of the NDT
Operations.

11775-SPC-ME-006 Rev 0 Page 14 of 23


13.2 Specification

Buried girth joints shall be painted in accordance with project specification No.
11775-SPC-PL-006.

For external coating of hydrant riser joints such as Mastic for weldolet area then
cold wrapping of PE and PVC tape.

14. Pipe Laying and Back-filling

14.1 Trench Preparation

The pipe shall be laid on prepared trench padding in accordance with Section
10.11 above.

14.2 Pipe Laying

The equipment used to lift and lower the sections of pipeline into the trench shall
be suitable for the purpose and certified as lifting appliances.

Sidebooms shall have the boom sticks ("A" frames) covered with suitable impact
softening material such as rubber belting. Excavators when used as lifting
appliances shall have purpose made and tested lifting eyes attached to the bucket,
under no circumstances are belts to be attached to the bucket teeth.

Lowering in belts shall be purpose designed wide flat belts and shall be in new or
good condition. Lowering-in shall take place as soon as possible after the trench
has been excavated, all welds accepted, all field joint coating completed and all
coating repairs carried out. Welds which have not been previously accepted shall
not be lowered into the trench without prior permission of the Company. Care
should be taken to ensure that the pipe coating sustains no damage from the
lowering operation. The pipe shall be "holiday" detected after it is lifted from the
skids but prior to being lowered into the trench. All "holiday" indications shall be
repaired prior to being lowered into the trench.

Should the Contractor propose to use rollers to lay any sections of the pipelines,
the rollers shall be properly sized for the pipe to be laid, used in sufficient numbers
to safely lower in and be made of a material which will not damage the pipe
coating.

Lowering the pipe into the trench shall be undertaken using sufficient sidebooms
or other authorised pieces of plant in accordance with an approved procedure
which shall ensure that any bending stresses are minimised and in any event do
not exceed 85% of the specified minimum yield stress of the linepipe material.
Once lowered into the trench the pipes shall be in an unstressed state.

Lowering in shall not be undertaken when the bed of the trench is not visible due
to the presence of water.

The pipe shall be laid so that each side of the pipe has a minimum clearance of
150mm from each side of the pipeline trench to allow back-fill to flow around and
under the pipe.

All open pipe ends shall be closed to prevent the ingress of any material into the
pipeline section. The end closures shall remain in place until the sections are tied
in. In particular, vertical risers shall be closed by securely fixed (strapped) cap or
seal welded plate.

11775-SPC-ME-006 Rev 0 Page 15 of 23


14.3 Construction of Hydrant Risers

The Contractor shall propose his method for construction of the vertical hydrant
risers and installation within the specified tolerances.

Where over-length risers are welded into the mains, subsequent cutting and
preparation for welding shall only be permitted using a mechanically guided,
automatic cutting tool, with suitable precautions taken to prevent swarf from
entering the riser or main. During welding operations, every effort shall be made
to prevent weld splatter, etc. entering the riser pipe and damaging the internal
lining, with suitable protective devices employed where appropriate.

Where weldolets are specified for connection to the hydrant main, this connection
shall be pre-fabricated, inspected and coating repaired prior to installation in the
main, to the satisfaction of the Company.

Requirements for installation of the hydrant pit boxes are given in 11775-SPC-ME-
004: Specification for Mechanical and Piping Installation
14.4 Pipeline Construction Tolerances

The pipelines shall be laid to the levels and coordinates shown on the Drawings,
within the allowable tolerances detailed in Appendix B.

The specified minimum falls must be maintained at all locations and this shall be
the governing criterion.

The alignment of each laid pipeline section shall be checked before any back-filling
of the section.

The Contractor shall allow for the Company to check the alignment of a pipeline
section. Back-filling of a section shall only commence with the approval of the
Company.

14.5 Back-filling

The requirements for back-filling below shall be read in conjunction with the
Drawings.

All circumferential weld joints in the existing airport facilities shall be left exposed
until the successful completion of the hydraulic test.

14.5.1 Intimate Back-fill

Pipeline intimate back-fill shall be sand of an equal specification to that of trench


padding. The material shall be carefully placed over and around the pipe and shall
not be dropped directly onto the pipe from a height above the pipe exceeding
500mm. The material shall be worked around the pipe to fill any voids which exist.
Within the constraints of safe working practices, the material shall be hand
rammed around the pipe in layers not exceeding 150mm thick using wooden
tampers or other tools ensuring that no damage is caused to the pipeline coating.

Such sand back-fill shall be used up to a level of 300mm above the crown of the
pipe.

14.5.2 General Back-filling and Compacting

The remaining excavated material shall be returned to the trench in layers not
exceeding 300mm and compacted. Compaction shall be undertaken in
accordance with an approved procedure using mechanical equipment. The
procedure shall state a method and degree of compaction adequate to preclude
any further settlement.

11775-SPC-ME-006 Rev 0 Page 16 of 23


The Contractor shall establish by field tests the type of compacting plant and
number of passes to be used taking into account the cohesiveness and the
moisture content of the back-fill. Such a procedure shall be reviewed whenever
the soil type and conditions show significant variation. The Contractor shall
consider reducing the excavated material to a suitable size and texture, and
supplying and adding water to obtain an optimum moisture content.

The Contractor shall commission an approved testing house to carry out regular
compaction tests at various levels of the compacted back-fill material to verify the
degree of compaction achieved. The tests shall be Nuclear Density testing, the
results of which shall be forwarded to the Company on the same day that they are
received by the Contractor.
The density of the compacted back-fill shall not be less than 95% of the adjacent
undisturbed soil at the same depth.

14.5.3 Imported General Back-fill

Should the Company consider that the excavated material cannot be used for
general back-fill material for whatever reason he will instruct the Contractor to
remove the unsuitable material from the site and dispose of it at a licensed tip.

Under such circumstances the Contractor will be instructed to import suitable


general back-fill material from an approved source. The material shall be either
granular or cohesive and be free from any material or chemicals which may be
detrimental to the integrity of the pipeline or incompatible with the native soil
conditions. The Contractor shall submit samples of materials he proposes to use
for this purpose for approval by the Company. The imported materials shall be
back-filled and compacted as described for general back-fill.

14.5.4 Back-filling Future Apron, Taxiway and Road Areas

Where the trench is in any area designated for development of airport aprons,
taxiways or roads, foam concrete shall be used as the backfilling material up to a
level of 700mm below the planned future finished ground level. The foam concrete
shall be laid strictly in accordance with the manufacturer’s instructions.

The level above the foam concrete shall be reinstated in accordance with the
relevant Directorate General of Civil Aviation (DGCA) specifications.

14.5.5 Back-filling of Vertical Pipe

Risers and any other vertical sections of hydrant piping shall be surrounded by a
minimum 150mm layer of intimate backfill in accordance with Section 14.5.1.

During back-filling, the riser shall be laterally supported by temporary timber or


other approved restraints.

14.5.6 Removal of Surplus Excavated Material

Surplus excavated material displaced by the pipelines and the presence of


imported material shall be removed from the site and disposed of by the
Contractor.

The Contractor shall ensure that the material actually removed from site is the
material from the part of the trench excavation which has been replaced by the
pipe and imported material.

11775-SPC-ME-006 Rev 0 Page 17 of 23


14.5.7 Pipeline Warning Tape

During back-filling of the trench pipeline warning tape shall be introduced above
the pipeline on top of the intimate backfill, refer to Section 14.5.1.

Pipeline warning tape shall be high strength metallic/polyethylene material, yellow


in colour, carrying the repeated wording “FUEL PIPELINE BELOW” in English and
Arabic languages alternately. The tape shall be detectable by industry standard
cable locating devices. The width of the tape shall be 150mm minimum. Samples
of the proposed tape shall be submitted for the Company’s approval. The tape
shall be run in continuous parallel lengths above the width of the pipeline diameter.
14.5.8 Tie-ins

The Contractor shall ensure that sufficient lengths of pipe are left exposed to allow
for any tie-in work to proceed without stressing the pipe and that excavation and
bell holes are suitably aligned to ensure vertical and lateral line up without the use
of force.

15. Cleaning and Testing

15.1 Cleaning, Gauging, etc

Immediately following installation, the pipelines shall be subjected to a programme


of internal cleaning, gauging, drying and testing as detailed in Specification No.
11775-SPC-ME-005: Specification for Cleaning, Testing and Drying. The
programme shall comprise the following:

a) Hydrotest using clean potable water to 150% design pressure


b) Internal cleaning and de-watering - compressed air-driven pig runs.
c) Gauging - compressed air-driven 95% gauging plate run through all
pipeline sections in order to verify the geometrical integrity of the pipelines.
d) Drying – vacuum drying or dry air or nitrogen blowing (desiccant and
drying).
e) Leak test - sealed pipeline sections in air or nitrogen at 7.0 barg.

Following successful completion of this programme, the pipeline sections shall be


laid-up under nitrogen blanket until such time as the interconnecting piping within
sectioning valve chambers is installed.

The Contractor shall make all preparations necessary for carrying out the cleaning,
gauging, drying and leak testing, including provision of temporary pig traps, valves,
connections, etc. and their removal following completion.

15.2 Pressure Testing

Following installation of SVC piping and equipment, the hydrant network shall be
subjected to the following tests:

a) Integrity test: Leak test of the hydrant network in air or nitrogen at 3.5
barg.
b) Functional Pressure Test. Following successful completion of the integrity
test, the hydrant network shall be filled with jet fuel and subjected to a
pressure test at 110% of the hydrant design pressure. The functional
pressure test shall be carried out in jet-fuel, as part of commissioning
activities. Filling the hydrant with jet fuel will be undertaken by the

11775-SPC-ME-006 Rev 0 Page 18 of 23


Company. The Contractor shall provide all necessary assistance to the
Company during this operation.

The above tests shall be carried out in accordance with Specification No. 11775-
SPC-ME-005.

16. Crossings

16.1 Crossing of Existing Services

16.1.1 General

In the event that the Relevant Authority should identify the presence of existing
services within the hydrant working area, the Contractor shall, following location of
the service(s) at site, liaise with the Relevant Authority to identify any additional
construction requirements or working restrictions and shall reach agreement on
the construction details and working methods to be adopted in the existing
services crossing.

Before commencing work on any crossing, the Contractor shall obtain written
approval of his methods from the Relevant Authority, and shall give sufficient
notice to allow their representative to be present during construction of the
crossing.

16.1.2 Particular Requirements

The Contractor shall, where appropriate, comply with the following particular
requirements:

a) Excavation in the close vicinity of underground services shall be by hand.

b) The pipeline shall where practicable be installed beneath any underground


services. The clearance between the pipeline and other services shall not
be less than 0.6m. In the event that such clearance cannot be achieved
the Contractor shall notify the Company accordingly and request the
Company’s instruction.

c) Special precautions shall be taken in respect of Contractor’s equipment


and other vehicles and machinery which must operate or travel near
existing services.

d) The Contractor shall comply with any statutory requirements and


regulations.

e) Plant with restricted working heights may be required for working in close
proximity to overhead lines and structures.

f) Temporary fencing in close proximity to high voltage lines shall be


adequately earthed because of the risk of the induced currents.

g) Welding shall be not be carried out within 1 metre of any existing service
unless specifically agreed by the Company.

h) Where existing underground services are covered with slabs, tiles or


tapes, these shall be removed by the Contractor and replaced on the
completion of the Work.

11775-SPC-ME-006 Rev 0 Page 19 of 23


i) Where required by these specifications or the Relevant Authority, the
Contractor shall provide and install reinforced concrete slabs immediately
above the existing underground service or between the existing service
and the pipeline.

16.2 Crossings of Existing Taxi Ways and Service Roads

16.2.1 General

Crossing of existing taxiways shall be constructed in accordance with the


Drawings.

16.2.2 Pressure Testing

Pipe or fabrications for installation at main crossings shall be pre-tested. Pipe/


fabrications shall be tested in a safe location and then brought to the crossing for
welding in.

Test pressure and test procedures shall be in accordance with Specification No.
11775-SPC-ME-005: Specification for Cleaning, Testing and Drying.

17. Reinstatement

17.1 General

Unless otherwise directed, the Contractor shall permanently reinstate all areas
disturbed by the Work, or as a result of the construction of the Work, including
surfaces, structures and features to a condition equivalent to that existing before
the commencement of the Work and shall provide all materials required. All such
reinstatement shall be to the approval and satisfaction of the Company and the
Relevant Authority.

The Contractor shall maintain the reinstatement, and make good the surface of the
trench, all sinkages, scouring, erosion or other defects until the Final Acceptance
of the Work.

Reinstatement shall be carried out as soon as practicable after completion of back-


filling.

The material used in soil reinstatement shall be the excavated material from the
upper levels of the pipe trench and shall match the soil in the surrounding area.
The Contractor shall remove all surplus excavated material.

17.2 Access to Working area after Testing and/or Reinstatement

Upon commencement of hydrostatic testing of a pipeline section, all further access


required by the Contractor to that section shall be subject to work permit
procedures and may require the full-time presence of an inspector allocated by the
Company.

The Contractor shall give the Company at least two working days notice of his
intention to work or to move vehicles within such a restricted access location.

Such restrictions to access by the Contractor shall also apply up to the completion
of reinstatement.

After completion and acceptance of reinstatement, restrictions on access to and


across the working area may be eased, however any excavation work within 5
metres of the pipelines will be subject to work permit.

11775-SPC-ME-006 Rev 0 Page 20 of 23


17.3 Pipeline Markers

Temporary and permanent pipeline markers shall be installed as follows.

17.3.1 Temporary Markers

Temporary pipeline markers shall be installed at exposed hydrant risers following


construction of pipeline sections where risk of third party interference from other
construction activities is deemed to be increased.

Temporary markers shall be of a design approved by the Company and shall be


left in place until such time as all construction has been completed.

17.3.2 Permanent Markers

Permanent pipeline markers shall be installed where indicated on the Drawings.


Pipeline markers design and inscription shall be agreed by the Company.

17.4 Parking Areas, Storage Areas, Working Areas and Accesses

The Contractor shall reinstate the surface of all parking areas, storage areas,
working areas and access routes on or adjacent to the Site and the Construction
Base and Pipe Storage Compound(s) to a condition not less than equal to that
existing before the commencement of the Work and to the satisfaction of the
Company.

11775-SPC-ME-006 Rev 0 Page 21 of 23


Appendix A: DELETED

11775-SPC-ME-006 Rev 0 Page 22 of 23


Appendix B: Pipeline Construction Tolerances

Location Construction Tolerances (mm) Minimum Fall (mm)

Horizontal Vertical [Notes 2, 3]

Feeder Lines ± 100 ± 20 ± 20

Hydrant Laterals ± 25 ± 10 N/A

Hydrant Pits [Note 1] ± 10 ±5 N/A

SVC Entries ± 10 ±5 N/A

Notes:
1. Measured at the Hydrant Riser Flange.
2. Shallowest permissible slope, at any point, in the direction shown on the relevant Drawing(s).
3. Minimum Fall is the governing criterion.

11775-SPC-ME-006 Rev 0 Page 23 of 23


Design of New
Hydrant System
(Package #7)

Specification for
Adaptors
Head Office:
Penspen Group Limited
3 Water Lane
Richmond upon Thames
Surrey
TW9 1TJ
United Kingdom

Regional Office:
Kuwait Aviation Fuelling Co Penspen International Limited
P.O. Box 46562
Abu Dhabi
United Arab Emirates

11775-SPC-ME-007 Rev 0
DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

1. Scope and Introduction

This Specification details the requirements for Adaptors to be installed as part of


the new hydrant system at Kuwait International Airport (KIA).

2. Precedence

Any case of apparent conflict between the requirements of this Specification and
any other relevant documents shall be notified to the Company. Unless otherwise
agreed the following descending order of precedence shall apply:-

1st This Specification


2nd Other Project Specifications
3rd The Codes and Standards listed in this specification
4th Other API, ASME, ANSI, BS Codes or Standards as appropriate

3. References

The following documentation shall be read in conjunction with this specification.

11775-LST-EN-001 Codes and Standards List

4. Definitions

The ‘Company’ is KAFCO (Kuwait Aviation Fueling Company) or their appointed


agent or representative.

The ‘Supplier’ is the vendor, manufacturer or supplier of equipment and/or


materials defined in this specification.

Throughout this document the following terminology is used:

“must” signifies a legal or statutory requirement

“shall” signifies a requirement made mandatory by this Specification

“may” signifies a feature which is discretionary in the context in which it is


applied

“will” signifies a feature which the Supplier may assume to be already


present

11775-SPC-ME-007 Rev 0 Page 3 of 5


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

5. Codes and Standards

Latest revisions of the following Codes and Standards shall be considered part of
this specification:

ISO 10474 Steel and Steel Products - Inspection Requirements

ASME B 16.5 Pipe Flanges and Flanged Fittings NPS 1/2 to NPS 24

For the complete list of applicable codes and standards, refer to Codes and
Standards List (Document No: 11775-LST-EN-001)

6. General Technical Requirements

6.1 General

Adaptors shall have a male 3 lug type connector (2 ½”) with positive action locking
mechanism to facilitate coupling and uncoupling of pressurised hoses under no-
flow conditions.

Adaptors shall have 3” flat faced ASME class 150 flanges.

Each unit shall contain a fail-safe spring-loaded/poppet valve, seating on a tapered


seat, controlled by the action of coupling and uncoupling the mating hose unit.

Each adaptor shall have bosses which are suitable for mounting pressure gauges
or sampling ports.

Each adaptor shall be fitted with a metal military style pressure cap, suitably
tethered to the body of the adaptor.

Adaptor shall be Carter Model No. 64373CEF

6.2 Design Conditions

All adaptors shall satisfy the following design conditions:

Design Temperature: -5°C Minimum:


50°C Maximum:

6.3 Materials of Construction and Coating

Materials of construction for all components shall be suitable for and compatible
with all grades of aviation fuel.

All materials and coatings proposed shall be subject to approval by the Company.

Materials certification shall be in accordance with ISO 10474 type 3.1B.

11775-SPC-ME-007 Rev 0 Page 4 of 5


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

7. Specific Technical Requirements

7.1 Design Conditions

Design Pressure: 16 barg Minimum


Test Pressure 24 barg Minimum

7.2 Materials

Body/flange: Carbon steel


Dust cap: Gunmetal or similar approved by the Company

8. Documentation

Documentation to be submitted to the Company for approval shall include the


following:

i) Prior to commencement of manufacturing:


Data sheets/General Arrangement Drawings
Manufacturing Quality Plan

ii) Final Documentation:


Data sheets/General Arrangement Drawings
Manufacturing Record Book
Installation Instructions
Operation and Maintenance Instructions

3 No. copies of all submissions shall be provided.

11775-SPC-ME-007 Rev 0 Page 5 of 5


Design of New
Hydrant System
(Package #7)

Specification for
Hydrant Pit
Assemblies
Head Office:
Penspen Group Limited
3 Water Lane
Richmond upon Thames
Surrey
TW9 1TJ
United Kingdom

Kuwait Aviation Fuelling Co Regional Office:


Penspen International Limited
P.O. Box 46562
Abu Dhabi
United Arab Emirates

11775-SPC-ME-008 Rev 0
DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

1. Scope and Introduction

This Specification details the requirements for Hydrant Pit Valve Assemblies to be
installed as part of the new hydrant system at Kuwait International Airport (KIA).

2. Precedence

Any case of apparent conflict between the requirements of this Specification and
any other relevant documents shall be notified to the Company. Unless otherwise
agreed the following descending order of precedence shall apply:-

1st This Specification


2nd Other Project Specifications
3rd The Codes and Standards listed in this specification
4th Other API, ASME, ANSI, BS Codes or Standards as appropriate

3. References

The specification for the Warner Lewis Hydrant Pit Box, Model No. WL 5917, shall
be read in conjunction with this specification.

4. Definitions

The ‘Company’ is KAFCO (Kuwait Aviation Fueling Company) or their appointed


agent or representative.

The ‘Supplier’ is the vendor, manufacturer or supplier of equipment and/or


materials defined in this specification.

Throughout this document the following terminology is used:

“must” signifies a legal or statutory requirement


“shall” signifies a requirement made mandatory by this Specification
“may” signifies a feature which is discretionary in the context in which it is
applied
“will” signifies a feature which the Supplier may assume to be already
present

5. Codes and Standards

This Specification makes reference to the latest edition of the following documents
which shall be applicable as referenced.

11775-SPC-ME-008 Rev 0 Page 3 of 6


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

rd
EI 1584 3 Edition 4” Hydrant System Components and Arrangements

ISO 10474 Steel and Steel Products - Inspection Requirements

For the complete list of applicable codes and standards, refer to Codes and
Standards List (Document No: 11775-LST-EN-001)

6. General Technical Requirements

6.1 General
rd
Hydrant pit valve assemblies shall conform to API Standard EI 1584 3 Edition ‘4”
Hydrant Systems Components and Arrangements’ as supplemented and modified
herein.

Hydrant pit valve assemblies shall be supplied as assembled and tested units
complete with all interconnecting bolting and gaskets. Each assembly shall
comprise the following components:

i) A 4” (100mm) API profile self-sealing tank-unit fuelling adaptor.

ii) A pilotless operated, slow-opening/slow-closing hydrant pit valve located


upstream of (i) which shall permit maintenance of the API adaptor under
no-flow conditions without depressurisation or draining of the hydrant line,
Carter Model No. 60554Y.

Closure under flow conditions shall be by means of release of a ‘deadman’


device or by pulling a lanyard. Opening shall be accomplished by
activating the ‘deadman’ air feed.

iii) A manually operable under-hydrant isolation valve, located upstream of


(iii) to facilitate service/maintenance of the hydrant pit valve, Warner Lewis
Model No. WL5759.

6.2 Dimensions

The hydrant pit valve assembly shall be suitable for installation and operation
within the Warner Lewis Hydrant Pit Box, Model No. WL 5917.

6.3 Design Conditions

All components shall satisfy the following design conditions:

Design Pressure: 19.27 barg

Design Temperature: -5°C Min


50°C Max

6.4 Materials of Construction and Coating

Materials of construction for all components shall be suitable for and compatible
with Jet-A1.

All proposed materials, internal and external coatings shall be subject to approval
by the Company.

11775-SPC-ME-008 Rev 0 Page 4 of 6


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Materials certification shall be in accordance with ISO 10474 type 3.1B.

6.5 Testing

6.5.1 Type Approval Testing

The Supplier shall demonstrate that type approval tests in accordance with EI
rd
1584 3 Edition requirements have been successfully carried out on equipment
representative of that to be supplied.

6.5.2 Hydrostatic Testing

All assemblies shall be subjected to a factory hydrostatic test to 150% of the


design pressure. The test shall be conducted with the hydrant valve and isolation
valve set in the open position.

7. Specific Technical Requirements

7.1 Pit Adaptor

The hydrant pit adaptor shall be a 4” (100mm) self-sealing tank unit fuelling adaptor,
in accordance with API Standard 1584, Fig 1.

The pit adaptor shall be fully compatible with other manufacturers' 4” couplers.

The pit adaptor shall be supplied with a tough plastic dust-cap, suitably tethered to
the body of the hydrant valve.

7.2 Hydrant Valve

7.2.1 Construction

The hydrant valve shall have a 4” (100mm) inlet flange, to match ASME Class 150.

The hydrant valve shall have positive closure, effected by means of ceasing air
supply and a detachable lanyard. Valve closure shall be possible under both flow
and no-flow conditions.

Valve opening shall be effected by air supply means, independent of the lanyard,
in order to ensure differentiation between opening and closing operations.

Valve opening and closing shall be even and progressive. Opening and closing
times shall be as specified below.

Maintenance requirements of the valve shall be minimal and the design shall be
such that the actuator mechanism and external seals can be serviced/replaced
without the necessity for removal of the valve from the hydrant pit, or for
depressurisation of the hydrant line.

7.2.2 Operating Parameters

The hydrant valve shall satisfy the following operating parameters:

11775-SPC-ME-008 Rev 0 Page 5 of 6


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Opening Time (0-90% rated flow): 5 seconds Min


10 seconds Max

Closing Time: 2 seconds Min


5 seconds Max

Rated Flow: 4,500 litres/minute

Overshoot Volume: 225 litres Max

Pressure Loss (at 4,500 l/min): 1.35 bar Max

Pressure loss shall be measured across entire assembly (including spacer and
under-hydrant valve) mating hose unit and swivel. Test fluid shall be Jet A-1 fuel.

7.3 Under Hydrant Isolation Valve

The under hydrant isolation valve shall comprise a durable leak tight ball valve,
fire safe with stainless steel ball, fitted with a simple, safe, manual operating
mechanism.

The valve shall be carbon steel epoxy coated internally and externally.

The valve shall be suitably flanged to mate with the 4" hydrant valve (downstream)
and 6" ASME Class 300 riser flange (upstream).

7.4 Gaskets, Bolting etc.

All gaskets, nuts, bolts, washers, retaining clips etc shall be suitable for exposure
to aviation fuel.

Riser flange studs shall be stainless steel with steel plated nuts and washers.

8. Documentation

Documentation to be submitted to the Company for approval shall include the


following:

i) Prior to commencement of manufacturing:


Data sheets/General Arrangement Drawings
Manufacturing Quality Plan

ii) Final Documentation:


Data sheets/General Arrangement Drawings
Manufacturing Record Book
Installation Instructions
Operation and Maintenance Instructions

3 No. copies of all submissions shall be provided.

11775-SPC-ME-008 Rev 0 Page 6 of 6


Design of New
Hydrant System
(Package #7)

Specification for
Storage, Handling
and Transportation
of Linepipe and
Fittings Head Office:
Penspen Group Limited
3 Water Lane
Richmond upon Thames
Surrey
TW9 1TJ
United Kingdom

Regional Office:
Kuwait Aviation Fuelling Co Penspen International Limited
P.O. Box 46562
Abu Dhabi
United Arab Emirates

11775-SPC-ME-009 Rev 0
DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

1. Scope

This specification covers the storage, handling and transportation of linepipe and
fittings from manufacturing completion, lining and coating, through to delivery to
the designated by the Company storage compound(s) for the new hydrant system
at Kuwait International Airport (KIA).

The Contractor shall be responsible for all aspects of the above inclusive of all
interstage activities between pipemill(s), coating yard(s) and storage compound(s).

2. Precedence

Any case of apparent conflict between the requirements of this Specification and
any other relevant documents shall be brought to the notice of the Company.
Unless otherwise agreed, the following descending order of precedence shall
apply:

1st Local Authority or Statutory Regulations


2nd This Specification
3rd Other Project Specifications
4th The Codes and Standards listed in Section 5
5th Other Internationally Recognized Codes and Standards, as appropriate

3. References

The following documentation shall be read in conjunction with and form part of this
specification.

11775-LST-EN-001 Codes and Standards List

11775-SPC-PL-003 Specification for Factory Applied Polyethylene Coating of


Linepipe

11775-SPC-PL-005 Specification for Factory Applied Internal Lining

11775-SPC-PL-001 Specification for Linepipe

11775-SPC-PL-002 Specification for Pipeline Forged Bends

11775-SPC-PL-007 Specification for Factory Applied Liquid Coating of


Fittings.

11775-SPC-ME-009 Rev 0 Page 3 of 8


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

4. Definitions

The ‘Company’ is KAFCO (Kuwait Aviation Fuelling Company) or their appointed


agent or representative.

The ‘Contractor’ is the organization employed by the Company or their appointed


agent or representative in order to carry out the Work.

The ‘Supplier’ is the vendor, manufacturer or supplier of equipment and/or


materials defined in this specification.

The ‘Work’ is the extension of the new hydrant system at Kuwait International
Airport (KIA).

Throughout this document the following terminology is used:

“must” signifies a legal or statutory requirement


“shall” signifies a requirement made mandatory by this Specification
“may” signifies a feature which is discretionary in the context in which it is
applied
“will” signifies a feature which the Supplier/Contractor may assume to be
already present

5. Codes and Standards

This Specification makes reference to the latest edition of the following documents
which shall be applicable as referenced.
API 5L Specification for Linepipe.

API 5L8 Recommended Parctise for Field Inspection of New Line


Pipe.

API RP 1 Railway Transportation of Coated Pipe Line

API RP5LW Recommended Parctise for Transportaion of Linepipe on


Barges and Maritime Vessels.

ASME B16.9 Factory-Made Wrought Steel Butt-welding Fittings.

ASME B31.3 Process Piping.

ISO 9001 Quality Managemnt System – Requirments.

ISO18001 Occupational Health & Safety management System.

For the complete list of applicable codes and standards, refer to Codes and
Standards List (Document No: 11775-LST-EN-001)

11775-SPC-ME-009 Rev 0 Page 4 of 8


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

6. General Requirements

6.1 General

Storage, handling and transportation of uncoated linepipe and fittings shall be


carried out in accordance with ASME B31.3, in such a manner as to avoid distortion,
denting, gouging, grooving, flattening, damage to the beveled ends, or any other
type of damage to the pipe/fittings.

Storage, handling and transportation of externally coated and/or internally lined


linepipe and fittings shall additionally avoid any damage to the coating or lining.

Damaged linepipe, fittings, their coating or lining shall be repaired, recoated or


replaced, as appropriate, at the Contractor’s expense, to the satisfaction of the
Company.

6.2 Handling

At all times coated linepipe and fittings shall be handled and stored in such a
manner as to prevent damage to the coating. Particular care shall be taken
immediately after coating to avoid damage while the coating is above ambient
temperature. No stacking or loading shall be undertaken until the coating has
cooled sufficiently to avoid marking.

All reasonable precautions shall be taken to avoid damage to the internal lining of
pipe and fittings during coating operations.

The Contractor shall ensure that the end caps are in position to avoid ingress of
debris. Caps shall be replaced immediatelly after having been removed for any
specific purpose.

6.3 Transportation

In the transport of coated linepipe and fittings, the Contractor shall take all
reasonable precautions to avoid damage to the linepipe / fittings or coating from
such transportation. All trucks, wagons, supports, cradles, separators, lifting and
other devices shall be proposed by the Contractor and approved prior to use by the
Company. This approval in no way relieves the Contractor of his responsibilities
under the Purchase Order.

The Contractor shall deliver the finished (coated and lined) linepipe and fittings to
one or more storage compounds adjacent to the site, as nominated by the
Company.

6.4 Storage

During storage on the Supplier’s premises, at the site storage compound and at
any other time under his control, the Contractor shall be responsible for the
linepipe and fittings.

11775-SPC-ME-009 Rev 0 Page 5 of 8


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

6.5 Inspection on Delivery

All linepipe and fittings to be offloaded and stored at the storage compound by the
Contractor will be inspected by the Company and any damage to pipe/fitting,
coating or lining will be notified to the Contractor and may be cause for rejection
and replacement.

6.6 Repair/Replacement of Damaged Items

If any linepipe, fitting, its coating or lining is shown to have sustained damage
through the transportation, off-loading and stacking activities, it shall be stacked
separately and the Company will decide whether the damage can be repaired or
the linepipe is to be rejected and must be replaced.

The Contractor shall be responsible for all additional handling and storage of
defective items including loading, unloading, transport and storage. Damage to, or
loss of unique pipe/identity number shall be cause for rejection.

Where damage is judged by the Company as repairable, the Supplier shall


undertake the repair in accordance with ASME B31.3 and the project
Specifications, to the satisfaction of the Company.

Replacement linepipe and fittings to be provided by the Contractor in lieu of


rejected items, shall be subject to the same specification requirements as the
original rejected items.

7. Specific Requirements

7.1 Pipe

7.1.1 General

The pipe to be supplied to site shall be manufactured in accordance with API 5L


supplemented by project Specification 11775-SPC-PL-001: Specification for
Linepipe.

All linepipe with a nominal bore greater than 100mm shall be internally lined in
accordance with project Specification 11775-SPC-PL-005. The linepipe shall be
externally coated in accordance with project Specification 11775-SPC-PL-003,
unless otherwise specified by the Company.

7.1.2 Handling

Strict supervision shall be maintained by the Contractor at all stages during the
loading and unloading of coated and uncoated pipes. Only slings and equipment
of a type previously approved by the Company shall be used when loading,
unloading and handling of pipes is being carried out.

Pipe shall not be allowed to drop or strike objects which may injure the linepipe or
coating but shall be lifted or lowered from one level to another by suitable
approved equipment.

11775-SPC-ME-009 Rev 0 Page 6 of 8


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Uncoated pipes being loaded or unloaded from transportation shall be lifted by


equipment to be approved by the Company. Coated linepipe shall be handled
using approved blocked linepipe end hooks, which shall be sufficiently padded with
nylon inserts or any other material and which shall be subject to approval by the
Company. The use of vacuum lifts for lifting pipes shall also be permitted.

The Contractor may with the specific approval of the Company to use front loaders
with padded forks to handle bare pipe. If the Company does not consider this
method acceptable, the Contractor shall then use approved blocked linepipe and
hooks or vacuum lifting equipment.

Proper protection shall be given to the linepipe against the dangers of corrosion
and erosion due to exposure to the environment. Stacking on bare sand rows
shall not be allowed.

7.1.3 Transportation

When transporting coated linepipe, the bottom layer shall be carried in shaped
cradles lined with protective rubber or an approved similar sheeting and having a
300mm minimum support width and chocked to avoid movement. Subsequent
layers of linepipe shall be suitably protected and shall rest on a minimum of four
lengths of approved packing over the entire length of the previously loaded layer of
pipe. On completion of loading, the pipes shall be adequately secured in such a
manner as to prevent damage to the linepipe coating during transportation through
movement or point compression or wearing. Suitable straps and protective
padding shall be used.

7.1.4 Storage

The Contractor shall store linepipe in a manner designed to avoid damage to the
linepipe and coating and to prevent accidental rolling.

In order to prevent damage to the linepipe and protective coating, pipes shall not
be placed on the ground but raised on timbers not less than 230mm wide and
100mm thick, and with approved padding and wedges. The padding shall
overhang the 230mm width of timber by not less than 25mm each side, and have a
minimum thickness of 50mm before load compression. The timbers, padding and
wedges shall be provided and placed by the Contractor. When stacking is
necessary three strips of approved padding shall be placed between the stacks at
4.5m centers. When stacking on timbers the maximum spacing between each
timber shall be 4.50 meters.

To facilitate ease of monitoring and handling, each individual linepipe stack shall
be made up of pipes of the same diameter and wall thickness.

Before stacking linepipe the Contractor shall ensure that the timber supports on
which they are to be placed are adequate to support the stack having given
consideration to the ground conditions. Should the stack at any time become
unsafe or unstable due to failure of the ground support, or for any other reason,
the Contractor shall carry out restacking to the satisfaction of the Company.

11775-SPC-ME-009 Rev 0 Page 7 of 8


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

7.2 Fittings

7.2.1 General

The fittings covered by this specification shall be butt-welding tees and elbows
manufactured in accordance with ASME B16.9. All fittings with a nominal bore
greater than 100mm shall be internally lined in accordance with project
Specification 11775-SPC-PL-005. Fittings shall be externally coated in accordance
with project Specification 11775-SPC-PL-007, unless otherwise specified by the
Company.

7.2.2 Handling

Only slings and equipment of a type previously approved by the Company shall be
used when loading, unloading and handling of fittings is being carried out.

7.2.3 Storage

Fittings shall not be placed directly on the ground but raised on padded/wedged
timbers, as described in 7.1.4, or pallets.

During storage, fittings shall be orientated such as to avoid internal accumulation


of water or other deposits.

11775-SPC-ME-009 Rev 0 Page 8 of 8


Design of New
Hydrant System
(Package #7)

Specification for
Paint Works
Head Office:
Penspen Group Limited
3 Water Lane
Richmond upon Thames
Surrey
TW9 1TJ
United Kingdom
Kuwait Aviation Fuelling Co Regional Office:
Penspen International Limited
P.O. Box 46562
Abu Dhabi
United Arab Emirates

11775-SPC-ME-011 Rev 0
DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

1. Scope

This specification covers the requirements for the painting of above ground plant
including tanks, process installations, pipework and associated equipment for the
new hydrant system at Kuwait International Airport (KIA).

This specification is intended for use on new or previously painted structures and
covers paint systems for coastal areas, jetties, marine piling, together with
protective and decorative paints for plaster and wood substrates.

2. Precedence

Any case of apparent conflict between the requirements of this Specification and
any other relevant documents shall be notified to the Purchaser. Unless otherwise
agreed the following descending order of precedence shall apply:-

1st This Specification


2nd Other Project Specifications
3rd The Codes and Standards listed in this specification
4th Other API, ASME, ANSI, BS Codes or Standards as appropriate

3. References

The following documentation shall be read in conjunction with and form part of this
specification.

None referenced.

4. Definitions

The ‘Company’ is KAFCO (Kuwait Aviation Fuelling Company) or their appointed


agent or representative.

The ‘Consultant’ is Penspen Limited or their appointed agent or representative.

The ‘Relevant Authority’ is any statutory authority, company, agency, contractor or


other party who may be affected by the Work.

The ‘Contractor’ is the organization employed by the Company or their appointed


agent or representative in order to carry out the Work.

The ‘Supplier’ is the vendor, manufacturer or supplier of equipment and/or


materials defined in this specification.

The “Work” is the extension of the new hydrant system at Kuwait International
Airport (KIA).

Throughout this document the following terminology is used:

11775-SPC-ME-011 Rev 0 Page 3 of 24


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

“must” signifies a legal or statutory requirement


“shall” signifies a requirement made mandatory by this Specification
“may” signifies a feature which is discretionary in the context in which it is
applied
“will” signifies a feature which the Contractor may assume to be already
present.

5. Codes and Standards

This Specification makes reference to the latest edition of the following documents
which shall be applicable as referenced.

ASTM 4940 Standard Test method for Conductimetric Analysis of


Water Soluble Contamination of Blasting Abrasives.
EN 13823 Reaction to Fire tests of building products
EN ISO 11925 Ignitability of building products
EN 23270 Specification for temperature and humidities for
conditioning and testing paints, varnishes and their
raw materials
EN ISO 2431 Paints and varnishes. Determination of flow time by
use of flow cups.
EN ISO 2808 Paints and varnishes. Determination of film thickness.
EN ISO 4624 Paints and varnishes. Pull-off test for adhesion.
EN ISO 2811-All parts Paints and varnishes. Determination of density.
EN ISO 8501-All parts Preparation of Steel Substrates before Application of
Paints and Related Products - Visual assessment of
surface cleanliness
EN ISO 8502-2 Preparation of Steel Substrates before Application of
Paints and Related Products – Test for the
assessment of surface cleanliness. Laboratory
determination of chlorides on cleaned surfaces.
EN ISO 8502-3 Preparation of Steel Substrates before Application of
Paints and Related Products - Test for the
assessment of surface cleanliness. Assessment of
dust on steel surfaces prepared for painting
(pressure-sensitive tape method).
EN ISO 8502-9 Preparation of Steel Substrates before Application of
Paints and Related Products – Test for the
assessment of surface cleanliness. Field method for
the conductometric determination of water soluble
salts.
EN ISO 8503-All parts Preparation of Steel Substrates before Application of
Paints and Related Products - Surface roughness
characteristics of blast cleaned steel substrates

11775-SPC-ME-011 Rev 0 Page 4 of 24


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

EN ISO 8504-All parts Preparation of Steel Substrates before Application of


Paints and Related Products - Surface preparation
methods.
EN ISO 9001 Quality management systems. Requirements.
EN ISO 11124-All parts Specification for metallic blast-cleaning abrasives.
EN ISO 12944-All parts Paints and Varnishes. Corrosion protection of steel
structures by protective paint systems.
EN ISO 14713 Protection against corrosion of iron and steel in
structures. Zinc and aluminium coatings.

6. Special Technical Requirements

6.1 Quality Assurance and Inspection Requirements

6.1.1 Quality System

The Contractor shall operate a Quality System in accordance with ISO 9001.

6.1.2 Quality Plan

When specified in the Purchase Order and prior to commencement of work, the
Contractor shall supply a quality plan, which shall be subject to approval by the
Company.

The Plan shall include:

• Control of raw materials.


• Contractor's own inspection system and procedures.
• Contractor's inspection equipment.
• Calibration of equipment.
• Blending and painting controls.
• Record keeping and procedures.

6.1.3 Inspection

Contractor shall allow the Company access to all aspects of the work.

6.2 Procurement and Storage of Materials

6.2.1 Approval

All paints and coatings shall be approved by the Company.

6.2.2 Uniformity of Sourcing

All the materials applied to a particular item or group of surfaces shall be products
of the same Supplier unless otherwise approved by the Company. Seven working

11775-SPC-ME-011 Rev 0 Page 5 of 24


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

days notice of any proposal to deviate from this requirement shall be given.
Satisfactory compatibility shall be demonstrated by providing the results of
approved testing.

6.2.3 Delivery and Shelf Life

Coatings shall be obtained in original, undamaged, Supplier's containers with


product reference, batch numbers and expiry date of shelf life clearly marked and
shall remain unopened until required for use. Labeling on each container shall
comply with the guidelines given within this Specification. Coatings with an expired
shelf life shall not be used.

6.2.4 Condition of Coatings

Coatings which have deteriorated during storage shall not be used. This includes,
but is not limited to, coatings which have gelled (except those which are intended
to be thixotropic), formed a sediment which cannot be reconstituted, or formed a
skin more than 1mm thick.

6.2.5 Storage Conditions

Coatings shall be stored in a safe building, out of sunlight, and in a position where
they do not pose a fire risk to other areas.

6.2.6 Manufacturer's Requirements

The Contractor shall conform to all the Supplier's requirements. Before


commencing work the Contractor must be in possession of all of the Supplier's
application sheets and health and safety sheets. The requirements of the
Supplier's data sheets shall be observed in conjunction with the requirements of
this Specification.

6.2.7 Standard Labeling

Every drum or tin supplied under the Contract must possess its own label securely
attached to the side of the container. Each label must include the following
information stated clearly and legibly in English.

• Coating name
• Coating description
• Product (container contents) name and identification code
• Product description (including brushing or spraying grade)
• Mixing instructions
• Batch identification code
• Batch manufacture date
• Supplier's name
• Manufacturer name (if different)
• Basic information and instructions:
- flammability
- ventilation/breathing equipment
- skin contact
- spillage

11775-SPC-ME-011 Rev 0 Page 6 of 24


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

• Clear reference to additional information sheets to:


- coating data sheet
- application instruction sheet
- health and safety sheet

Each delivery of paint products must be accompanied by four complete sets of all
relevant Supplier's data sheets, application sheets and health and safety sheets.

6.3 Health and Safety

6.3.1 General

The Contractor shall work in a safe manner at all times.

6.3.2 Abrasive Blasting

Operators using abrasive blasting equipment shall be adequately protected with


fresh air helmets, boots, leather aprons and gloves.

Blasting equipment should include a dead man's handle to stop the abrasive flow
as soon as the operator releases the nozzle.

6.3.3 Painting and Coating Operations

Contractor shall be in possession of the Supplier's Health and Safety Data Sheets
and shall work to the stated requirements.

Care shall be taken to reduce fire risks with flammable paints.

Adequate ventilation shall be provided to ensure that fire, explosion and toxicity
risks from fumes are minimised.

Face masks and goggles shall be worn for paint spraying.

6.3.4 Special Requirements for Enclosed Spaces

For the coating of tanks, vessels, pits and all enclosed spaces, special precautions
such as forced draught ventilation or suction shall be employed to ensure that
vapour concentration is kept below the Lower Explosive Limit (LEL) value and also
below the toxic Threshold Limit Value (TLV).

If the TLV value cannot be maintained, full fresh air hoods shall be worn.

Precautions shall be taken to eliminate fire and spark risk in confined spaces. Anti-
static equipment shall be used and rubber soled shoes must be worn.

Where Suppliers use the terms, Occupational Exposure Limit (OEL) or Maximum
Exposure Limit (MEL) instead of Threshold Limiting Value (TLV) for control of safe
working concentrations, these limits are acceptable and should be adhered to by
Contractor

6.3.5 Skin Irritants

Precautions must be taken to prevent skin irritation or dermatitis due to contact


with aromatic solvents, epoxy resins and other known irritants.

11775-SPC-ME-011 Rev 0 Page 7 of 24


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

6.4 Surface Preparation

6.4.1 Preliminary Inspection

Before starting any surface preparation of steel, the surface shall be inspected for
defects including but not limited to sharp edges (min. radius 2mm), surface
laminations, weld spatter, porous welds, weld undercuts, weld scars and any other
surface irregularity likely to hinder correct surface preparation or the application of
a satisfactory coating. Any defects discovered shall be remedied before work on
the item begins.

6.4.2 Preliminary Decontamination

Prior to surface preparation by abrasive blasting, power or hand tools, all traces of
hydrocarbon (oil, grease, etc.) contamination shall be removed. Mineral
contaminants such as mud, welding residues, salts (including zinc salts), etc. shall
be removed.

Hydrocarbon deposits shall be removed by solvent cleaning in accordance with


ISO 8502 followed by washing and rinsing.

Mineral deposits shall be removed by high pressure jetting following the application
of a biodegradable industrial detergent and/or scrubbing with stiff bristle brushes
using a solution of 2% of the detergent in fresh water. The cleaned surface shall
be rinsed with fresh, potable water and allowed to dry. Rags shall not be used for
drying.

6.4.3 Testing for Presence of Corrosive Salts

Steel items that have either been exposed to a salt laden atmosphere, stored in
contact with the ground, become pitted or are selected for testing by the Engineer,
shall be tested for the presence of corrosion-promoting salts. This shall be carried
out prior to abrasive blast cleaning or power or hand tool cleaning. Testing shall be
in accordance with ISO 8502. Any salts discovered shall be removed by washing,
the surface retested and the process repeated until no salts remain to the
satisfaction of the Company.

6.4.4 Edges, Corners and Welds

Edges prepared for welding shall be abrasive blast cleaned and masked to a
distance of 100mm from the weld before priming. Subsequent coats applied
before welding shall terminate 60mm from the termination of the primer coat.

All sharp edges, corners and welds shall be rounded to a minimum radius of 2mm
and/or smoothed by grinding. Any major defects, particularly surface laminations
or scabs, likely to be detrimental to the protective coating systems shall be
removed by suitable dressing. Defects revealed during blast cleaning and subject
to dressing shall be reblasted.

All boltholes shall be drilled and de-burred before blast cleaning.

6.4.5 Surfaces Primed with Holding Primer

Surfaces primed with holding primer shall be inspected prior to preparation for
overcoating. Any areas of damage, misses, corrosion breakthrough, etc. shall be

11775-SPC-ME-011 Rev 0 Page 8 of 24


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

corrected by the use of abrasive disc or spot blast cleaning, in accordance with this
Specification before applying the principal primer of the specification.

6.4.6 Fabrication Welds

Fabrication welds on structural members, blast cleaned and primed before


fabrication shall be prepared in accordance with this Section.

6.4.7 Ambient Conditions

Final surface preparation shall not be carried out when,

• the relative humidity is more than 85%


• the temperature of the surface is less than 3°C above the dew point of the
surrounding air or outside the limits set by the Manufacturer.
• the wind is raising dust.
• during rain.
• or when any of these conditions is imminent.

6.4.8 Power Tool Cleaning

Power tool cleaning shall only be performed as and when approved by the
Engineer on a case-by-case basis. The following tools shall be used:

a) electric or air powered needle guns followed by hand or electric powered wire
brushes.

b) electric or air powered disc sanders followed by needle guns if necessary to


produce the required surface profile.

Needles for needle gunning shall have chisel tips or pointed tips as appropriate to
the item being prepared.

Brushes for electric powered wire brushing shall be in accordance with ISO 8504.

6.4.9 Abrasive Blast Cleaning

All open blast cleaning nozzles shall be provided with remote control of the blast
stream. The remote control mechanism shall be kept in good working order and
without exception only be kept in the ON position by the operator's hand when blast
cleaning is in progress.

Blast cleaning on plate and sections prior to fabrication or assembly may be


performed in installations such as wheelabrators or manual blast cubicles in which
the abrasive is recovered and reused.

Abrasive for blast cleaning shall be clean, dry and of the correct particle size to
produce the profile specified for the coating to be applied and shall not leave any
residue embedded in the profile of the blast cleaned surface.

Non-expendable abrasives such as chilled iron or steel grit and steel shot shall be
mixed and graded to produce the required surface profile. The abrasive mixture
shall be replenished using new and worn abrasive so as to produce a consistent

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DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

profile height and standard of surface cleanliness. The abrasive mixture shall be
kept free of dust (including metallic particles) and debris.

Expendable abrasive used for blast cleaning shall be free of contaminants such as
chlorides and other soluble salts and shall not contain metallic copper, nor more
than 2% by weight of copper oxide.

Expendable abrasives shall not be recycled. Sand shall not be used for blast
cleaning.

The amplitude of the profile of the blast cleaned surface shall be as stated in the
relevant coating schedules.

Isolated spot blasting on coated surfaces shall be carried out by means of vacuum
recovery equipment.

Any contamination of blast cleaned surfaces by oil or grease shall be removed by


swabbing with xylol or similar approved solvent and the surface reblasted to the
required standard.

All dust, abrasive and other debris shall be removed from the surface by vacuum
cleaning, blowing with clean dry compressed air or with clean soft bristle brushes
before coating work begins.

6.4.10 Air Quality

Compressed air supplied for surface preparation shall be free of oil and condensed
water as determined by a daily blotter test. If necessary, after-coolers shall be
provided to reduce the water content of the compressed air.

6.4.11 Air Pressure

The supply of compressed air for blast cleaning shall provide a pressure of 7 bar at
each blast nozzle. Compressors and hoses shall be sized to enable this pressure
to be maintained with the nozzle size(s) selected and making allowance for nozzle
wear.

6.4.12 Defects Revealed by Blast Cleaning

Defects in the steel surface revealed by blast cleaning shall be remedied as


required by the Engineer. Thereafter, the area affected by remedial action shall be
reblasted prior to coating.

6.4.13 Priming Delay of Prepared Surfaces

All prepared steel surfaces shall be coated within four hours of the start of surface
preparation and while the surface is still at the specified standard, unless
expressed permission is given by the Engineer.

6.4.14 Preparation of Coated Surfaces for Overcoating

Coated surfaces which have been exposed to a marine or industrial atmosphere


shall be cleaned of air-borne contaminants by washing with fresh potable water
and shall be allowed to dry before overcoating.

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DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

All deposits, whether organic or mineral, shall be removed in accordance with the
requirements of this specification.

All defective coating on the surface shall be removed by scraping, abrasive discing
or sweep blasting as detailed in this specification until a sound surface is obtained.

All glossy surfaces shall be rendered matt (i.e. the gloss removed) by sanding with
abrasive paper, light abrasive discing or sweep blasting in accordance with the
requirements of this specification.

At areas of patch repair a 50mm margin of the existing coating shall be prepared.
In addition, this margin shall be feathered to a fine edge by sanding or discing
taking care not to damage the base coat on the repair area.

The requirements for decontamination shall particularly apply to surfaces around


welds, points of damage by burning etc. Contamination shall be removed from all
such surfaces which may be overcoated during the repair of coatings at these
points. This shall be done before surface preparation on the welds, burns, etc.
begins. Overspray from earlier coating operations shall be completely removed so
as to expose any contamination beneath.

6.4.15 Sweep Blasting

Sweep blasting of existing coatings for the purpose of overcoating shall only be
carried out when approved by the Engineer on a case-by-case basis.

On surfaces subject to patch repair, sweep blasting of coatings to be retained shall


not be conducted at the same time as abrasive blast cleaning of the exposed steel
but as a separate activity after preparation of the steel is complete.

6.4.16 Galvanised Surfaces

Galvanised surfaces shall be thoroughly degreased by solvent cleaning in


accordance with ISO8502 or by high pressure water jetting after applying an
approved bio-degradable industrial detergent and rinsed before any other surface
preparation takes place.

Zinc salts if present on the galvanised surface shall be removed by high pressure
water jetting with fresh potable water, scrubbing with fresh potable water stiff bristle
brushes or by sand papering, or by any combination of all three needed to achieve
complete removal of the salts.

Galvanised items welded permanently to supporting members before or after the


latter are primed shall, except for the weld and galvanised steel within 50mm of the
weld, be effectively protected from abrasive blast. Galvanised surfaces exposed to
the blast shall be primed at the same time as the supporting structure.

Galvanised surfaces not required to be coated shall be effectively masked to


protect them from overspray.

6.4.17 Stainless Steel and Aluminum Surfaces

The surface shall be thoroughly degreased by solvent cleaning in accordance with


ISO 8502 or by high pressure water jetting after applying an approved
biodegradable non-caustic detergent and rinsed.

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DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

The surface shall be scrubbed with fresh water and stiff bristle brushes or washed
by high pressure water jetting to remove soluble contaminants and allowed to dry.

Fresh potable water only shall be used in hand or power washing and rinsing.

The surface shall be lightly but thoroughly abraded to a uniformly matt appearance
by sand papering or abrasive blasting with non-metallic abrasive. Metal brushes
and needles shall not be used.

6.4.18 Passive Fire Protection Surfaces

a) Cementitious Surfaces

Surfaces of Pyrocrete, Mandolite and cement-bound finishing of fibrous


protection such as ceramic fibre shall be sand papered to remove nibs and
sharp edges. Cavities and cracks shall be filled with two-pack epoxy
knifing compound.

b) Surfaces of Intumescent Fire-Protection

Surfaces of Chartek and similar epoxy based materials shall be lightly


abraded to enable adhesion by the finish coating system and to remove
nibs and sharp edges. Any pronounced ripples shall be filled with a two-
pack epoxy knifing compound.

6.4.19 Wood Surfaces

Wood surfaces shall not be painted when the moisture content of the timber
measured with an electric moisture meter exceeds 12% for interior surfaces and
18% for exterior surfaces.

Hardwoods or softwoods for which a clear finish is specified shall be rubbed down
with abrasive paper to give a smooth surface which shall be free from
contaminating substances, scratches and other imperfections.

Surfaces which are to be painted shall be rubbed down to remove all contaminating
substances and imperfections which would be visible in the finished paint film.

The surfaces of knots and resinous streaks shall then be painted with two coats of
knotting, the first allowed to dry before the second is applied.

Where the surfaces are suspected of being infected with mould they shall be
thoroughly treated with a fungicide.

6.5 Special Requirements

6.5.1 Surfaces not to be Painted

Unless otherwise stated the following surfaces shall not be coated except for fluid
identification purposes:

• Aluminum and aluminum alloys exposed to a controlled atmosphere.

• Uninsulated duplex and superaustenitic stainless steels, with an operating


surface temperature less than 120°C.

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DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

• Uninsulated 18/8 type stainless steel items, with a surface operating


temperature below 50°C.

• Copper and copper alloys.

• Nickel and nickel plated materials.

• Zinc coated surfaces (electroplated or galvanised) exposed to a controlled


atmosphere.

• Brass, lead, glass, plastic and other materials resistant to atmospheric


corrosion.

• Acoustic or architectural textured finishes.

• Equipment finish painted to the requirements of this Specification.

• Threaded surfaces or surfaces in sliding contact which are intended to move


in normal operation such as valve stem threads, actuators, linkages. These
surfaces shall be protected with a temporary rust preventing material.

• Mating faces of flanges.

• Other surfaces as advised by the Engineer.

6.5.2 Flange Faces

Flange faces and bolt holes of carbon steel pipework and vessel flanges shall be
blast cleaned and coated.

The ring groove on ring type joint flanges, raised faces and pipe or nozzle bore
surfaces shall be protected from blasting and coating.

The appropriate coating system shall be applied to all other surfaces of flanges
(including bolt holes) from the outside edge of the flange to the outer
edge of the ring groove or raised face.

6.5.3 Internal Coating Work

In addition to the general requirements of this specification the following conditions


shall apply wherever internal coating work is being carried out:

• The work shall be illuminated to the satisfaction of the Engineer.

• Forced draught ventilation to the approval of the Engineer shall be used


wherever required for the needs of personnel or for drying out surfaces.

• Operatives shall work in pairs.

The Contractor shall demonstrate all his methods, equipment and materials before
any work commences. Sample areas of substrate shall be prepared and coated as
required by the Company and for his approval.

There shall be strict control of surface cleanliness between paint coats. Vacuum
removal of dust and sand shall be employed and contamination shall be removed
as specified in appropriate preparation clauses herein. Where dirt or dust has
become trapped in the painted surface it shall be removed with suitable abrasive

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DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

paper. The surface being painted shall be free of visible moisture throughout these
operations.

6.6 Preparation of Coating Materials

All coating materials shall be prepared in strict accordance with Supplier's


instructions.

Single pack coatings supplied in containers of 5 litres or less may be stirred by


hand. A power stirrer shall be used to prepare larger units.

Two-pack coatings shall be stirred by mechanical means only. Before mixing, the
individual components shall be thoroughly stirred in their original containers until a
uniform consistency is obtained.

The Supplier's stated mixing ratio for two-pack coatings shall be strictly complied
with. Standard units of two-pack coatings shall not be broken down to provide
smaller quantities unless approved by the Engineer.

Particular attention shall be paid to mixing coatings with heavy pigments such as
zinc to ensure that the pigment is thoroughly dispersed in the medium prior to
application. Such coatings shall be stirred continuously during application.

Coatings being prepared in their original containers shall not be transferred until all
settled pigment is incorporated into the vehicle. Part of the material may be poured
off temporarily to assist in this process, but the whole shall finally be blended to a
uniform consistency.

Coatings shall not be mixed or maintained in dispersion by means of an air stream


introduced into the material through a hose.

The contents of containers which have been opened shall be protected from
contamination from whatever source.

6.7 Application of Coatings

6.7.1 General

Coating application shall be in accordance with the paint Manufacturer's data


sheets.

6.7.2 Application Methods

Coatings shall generally be applied by airless or air atomizing spray as appropriate.


Hopper guns or special two component guns may be used for certain solvent-free
high viscosity coatings.

Brushes may be used for touch-in repairs, stripe coating and the coating of small
diameter pipework. Brushes may also be used for woodwork and decorative
coating.

Coatings shall be applied in a uniform layer, with each pass of the spray pattern
overlapping by 50% onto the previous pass. The spray pattern shall be such that
the coating is deposited in a solid, uniform, wet film, free of runs, sags, misses, dry
spray, pores and bubbles.

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DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Spray nozzles and tips shall be of the correct size for the coating being applied, in
accordance with the Manufacturer's recommendations. Variable spraying tips shall
not be used.

The maximum width of spray fan shall be 300mm. Fan widths generally shall be
suitable for the dimensions of the surfaces to be coated.

Spray fans shall be maintained at right angles to the surface being coated (45° at
corners and internal angles) and at a maximum distance of 300mm from the
surface.

Edges, corners, welds and all areas difficult to coat adequately by spraying shall
receive an extra coat by brush immediately before the overall spray coat. This
does not apply to zinc silicate primers.

Any runs, sags or bubbles that may form shall immediately be brushed out, or the
coating shall be removed and reinstated in accordance with Approved procedures.

6.7.3 Ambient Conditions

Unless permitted by the Supplier's data sheets, coatings shall not be applied when
the relative humidity of the air exceeds 85% or to surfaces with a temperature,

• below 10°C
• above 40°C
• less than 3°C above the dew point of the surrounding air

Additionally, unless the work is being performed in facility approved by the


Company, it shall not proceed when wind is raising dust, during mist or rain or
when any of these conditions is imminent.

6.7.4 Overcoating

The Supplier's published over-coating delay times, both minimum and maximum,
shall be strictly complied with.

6.7.5 Drying

Coatings shall not be applied to previously coated surfaces unless the preceding
coat has dried. The preceding coat shall be considered dry for overcoating when
the next coat can be applied without the development of any film defects, including
wrinkling, lifting, or loss of adhesion in previous coat(s), in the event of such
developments application of the new coat shall cease immediately.

6.7.6 Overspray

Overspray or drips shall not be allowed to fall onto surfaces that have already been
prepared or coated. If this occurs all of the coating on the affected area should be
removed and reinstated.

Particular attention must be paid to ensure that zinc containing products do not
overspray or fall onto stainless steel. If this occurs the zinc must be removed
immediately by a process that does not require heat.

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DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

6.7.7 Requirements for Zinc-Rich Primers

Zinc silicates shall be sprayed with extreme care so as to avoid defects in the film
and excessive thickness. Brushes shall only be used on small areas to correct
variations in the wet film thickness.

Welds on sections, plate, tubulars, etc., previously prepared and primed with zinc
silicate and points of damage requiring repair of zinc silicate primer shall be blast
cleaned in accordance with the requirements of the specification and primed with a
two-pack zinc-rich epoxy primer containing at least 90% by weight of zinc in the dry
film.

All necessary steps shall be taken to prevent damage (e.g. by overblast) to


surfaces coated with zinc silicate primer with the aim that surfaces (where
specified) shall be uniformly primed with zinc silicate and not zinc silicate
extensively repaired with zinc-rich epoxy. Any surface coated with zinc silicate
which is subjected to excessive repair shall be reblasted and recoated.

Any films of zinc silicate affected by mud-cracking shall be removed by blast


cleaning and the surface reprimed in accordance with the requirements of this
Specification.

Zinc silicate primers shall be overcoated within seven days of application and/or
before zinc salts have begun to form.

Zinc rich epoxy primers shall be overcoated before zinc salts have begun to form.

Zinc rich primers shall not be applied to hand cleaned or mechanically cleaned
surfaces.

6.7.8 Dry Film Thickness (DFT) of Coatings

Generally, dry film thicknesses specified are nominal thicknesses and the average
of readings taken over any square metre of the scheduled area shall be equal to or
exceed the nominal thickness. No one reading shall be less than 75% or greater
than 50% of the nominal thickness.

For surfaces beneath passive fire protection total coating thickness shall be within
-20% + 0% of the sum of the specified thicknesses of the individual coatings.

For systems intended for elevated temperature service, the thickness of silicate
(where present) and/or the thickness of the combined coats of silicone or modified
silicone shall be within - 20% + 0% of sum of the specified thicknesses of the
individual coatings.

6.7.9 Cleaning of Painting Equipment

Fluid hoses and paint guns should be flushed out with clean solvent wherever a
coating material change is made. Solvents used shall be compatible with both
coatings involved in the change.

Cleaning solvent shall be discharged from hoses and guns before spraying begins.
Brushes shall be kept clean, dry and flexible.

Coatings shall not be left in the equipment overnight or for long enough for two
component mixtures to solidify.

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DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

6.7.10 Handling

Coated items shall not be handled or lifted before the coatings are fully cured.
Special precautions shall be taken to avoid any damage to the coating system
during handling.

6.8 Test Equipment

Unless otherwise agreed with the Company the following approved test equipment
shall be provided and maintained at the site of the works by the Contractor.

a) Standard ISO 8501-1.

b) Surface profile gauge or 'press-on' films and micrometer.

c) Coating thickness meter.

d) Wet film thickness combs.

e) Hygrometer.

f) Maximum and minimum thermometer.

g) Magnetic steel thermometer.

h) Flow cup type B No. 4 (to BS 3900) and stop watch.

i) Adhesion tester (0-280 kg/cm2).

j) Holiday detector.

6.9 Repair of Coatings

6.9.1 Damaged and Defective Coatings

Defective or damaged coatings shall be removed by scraping, abrasive discing or


sweep blasting until a surface suitable for overcoating is obtained and the repair
coatings applied in accordance with the Coating Schedules of this Specification.

6.9.2 Damage Exposing Substrate

Areas of damage to the primer or damage exposing the substrate, shall be


prepared by spot blast cleaning.

Surfaces which cannot be blast cleaned because of lack of space for blast nozzles
or proximity of sensitive equipment may be prepared by hand or power tool
cleaning.

6.9.3 Margin of Sound Coating

Sound existing coatings at the periphery of areas of damaged or defective coatings


shall be prepared for overcoating in accordance with all relevant requirements of
the Specification. Additionally, a 50mm margin of the surrounding coating shall be
feathered to a fine edge by sanding or discing taking care not to damage
underlying coatings.

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DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

6.9.4 Glossy Surfaces

Glossy surfaces and coatings which have exceeded the overcoating delay time
shall be treated as a coated surface and then in accordance with the requirements
of the specification prior to overcoating.

6.9.5 Repair of Galvanising

Points of damage to galvanising shall be repaired by abrasive blast cleaning to ISO


8501-1 Sa2½, or abrasive discing to an equivalent quality, followed by the
application of two coats of an approved two-pack zinc-rich epoxy primer in
accordance with all the relevant requirements of this Specification. The dry film
thickness of zinc-rich primer shall not be less than 75 microns in at least two coats.

7. Control, Inspection and Reporting Procedures

7.1.1 General

The Contractor shall submit procedures for Approval before commencement of the
work.

7.1.2 Pre-Start Meeting

At the request of the Company a pre-start meeting shall be held at least one week
before the start of the work. Attendees should include the Company, Contractor
and Supplier.

7.1.3 Technical Service

The Supplier will be expected to provide a response to any application problems


and visit the site if required.

7.1.4 Engineer Inspection and Witness

The Company shall have the right to witness and inspect all stages from quality
control of raw materials to completion of the job. Contractor shall provide the
Company with adequate notification of each stage of the contract work to facilitate
Company witness.

7.1.5 Contractor Inspection

All aspects of the work should be subject to inspection by the Contractor to ensure
that the requirements of this Specification are maintained.

7.1.6 Reporting

The Contractor shall produce the following report records for all site work.

Daily Reports

a) Coatings used, areas and locations treated.


b) Types of work performed (blasting, etc.)
c) Weather or ambient conditions.

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DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

d) Problems delaying work.

Weekly or Monthly Reports

a) Percentage of work completed.


e) Target percentage of work.
f) Problem highlights.

Final Report

a) Coatings used and where used.


g) Coating reports.
h) Acceptance certificates.

7.2 Maintenance Coating

7.2.1 General

Surface preparation and application of maintenance coatings shall be treated as for


repair systems with the provision that the areas involved for maintenance may be
much larger and the original coating type may be unknown.

7.2.2 Coating Compatibility

Contractor shall ensure that the maintenance coatings used are compatible with
the existing paint system being overcoated. Solvents and resins in the
maintenance coating shall not cause any cissing, blistering, lifting or dissolving of
the existing system.

Contractor shall carry out such tests on small sample areas, and on small flakes
taken for laboratory study as are necessary to ensure compatibility if adequate
background data is not available.

7.2.3 Existing Coating Condition

The condition of the existing coating shall be assessed and the maintenance
procedure selected in accordance with damage to the undercoat top-coat systems.

a) Undercoat Sound, Top Coat Sound With Loss of Gloss

Treat as coated surface to be overcoated.

b) Undercoat Sound, Top Coat Damaged

Top coat shall be completely removed by sanding or light sweep blasting.


Undercoat shall be checked for satisfactory adhesion and thickness and
satisfactory undercoat cleaned and overcoated.

c) Undercoat Damage Less Than 3% of Surface Area

Local repairs shall be undertaken by spot blasting, spray or brush


application of coating system in accordance with the Coating Schedules.

d) Undercoat Damage More Than 3% but Less Than 20% of Surface Area

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DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Repairs shall be undertaken by abrasive blast cleaning of affected areas


and spray application of coating system in accordance with the Coating
Schedules.

e) Undercoat Damage More Than 20% of Surface Area

Complete structure shall be abrasive blast cleaned and re-coated as new


work.

7.2.4 Overcoating Existing Systems

Overcoating may be applied to increase the number of coats, renew the gloss and
appearance or change the colour. In all applications the original coating should be
identified and the following procedures used.

a) Overcoating Alkyds or Chlor-Rubbers

Remove all dirt, oil and grease by washing with detergent, rinsing will fresh
water and solvent cleaning as necessary with white spirit, methyl alcohol or
an approved solvent that will not damage the old coating. After drying, any
areas that still retain a gloss should be lightly sanded. Weathered areas
need no further treatment.

A compatible overcoat shall then be applied directly to the old system as


per the appropriate Schedule.

b) Overcoating Epoxies, Polyurethanes and Epoxy Mastic

Remove all dirt, oil and grease as per the overall requirements of this
specification (Note: stronger solvents may be used.) Sweep blast or
abrade the entire area to be overcoated, brush or blow off loose dust and
overcoat as per the appropriate Schedule.

c) Overcoating Zinc Silicates

Aged zinc silicate should be checked for soundness and freedom from
mud cracking. It should then be thoroughly wire brushed and washed with
fresh water to remove zinc corrosion salts, before drying and overcoating
as per the appropriate Schedule.

7.2.5 Upgrading of Overcoating

The maintenance programme may require that the protective performance of a


coating to be upgraded. Provided that the existing coating is sound, it shall usually
be accomplished by cleaning the old coating, and overcoating with an epoxy mastic
coating.

7.3 Temporary Protection of Items

7.3.1 General

The temporary protection of items is required where components or items are


manufactured on site for future use or where items are ordered from overseas and
require protection during transportation and/or subsequent storage. It is essential
that the protection system utilized can easily be removed when necessary, using

11775-SPC-ME-011 Rev 0 Page 20 of 24


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

techniques that are available at the location where the equipment is to begin its
'working life'.

Items for general storage or transit should be protected from mechanical damage.
Items for storage in coastal areas or involving ocean shipment shall be protected
from exposure to sea water and stored off the ground and at an incline to promote
water run-off by the use of racks or pallets. Adequate ventilation must be allowed
within all storage containers and packages. Items for storage or transit in desert
environments should be protected from direct sunlight and dust.

In addition to the above requirements for storage and transit, temporary protective
finishes will be applied as detailed below. These protective finishes are not
mandatory in a controlled environment.

7.3.2 Temporary Protection of Large Items

Tanks and Vessels on Site

If finish coating cannot proceed immediately then large on-site tanks and vessels
shall be internally and externally blast cleaned and coated overall with a holding
primer. Tank internals should be dry and ports sealed.

Holding of on-site tanks and vessels in the part painted or unpainted condition for
periods in excess of ten weeks shall not be permitted. Finish coating must be
completed within this time.

Small Tanks and Containers

Small tanks and containers for storage in sheltered conditions shall be treated as
per standard size tanks or shall be internally/externally coated with a wax based
temporary protective and sealed.

Skid Mounted Equipment

These items shall be finish painted and stored in open shed conditions protected
from extreme weather conditions. All openings should be sealed and machined
surfaces shall be protected with anti-corrosive grease.

Mechanical, Electrical and Vendor Supplied Equipment

These items should normally be stored or transported in the finish painted


condition. Exposed moving parts, nozzles, intakes exhausts and sensitive areas
should be masked to prevent ingress of dust or moisture. Machined surfaces
should be coated with a suitable grease or temporary protective.

Electrical equipment and controls shall be finish painted by the Manufacturer and
stored in controlled environmental conditions.

Pipework

Pipework shall not be coated for storage, it should be subject to the general
requirements as per the beginning of this section.

Stainless steel pipe and tube should be stored in sheltered conditions. Instrument
piping should be stored in a controlled (air-conditioned) environment and should
have sealed ends.

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DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Structural Steel and Ferrous Components

Structural steel if not galvanised shall be abrasive blast cleaned to ISO8501-1


Sa2½ standard and coated with a holding primer for storage or transit.

Forgings or castings should be subject to the general requirements, temporary


protective coatings are not normally required.

Fasteners

Fasteners, nuts, bolts, and screws shall be coated with a wax based, temporary
protective and stored in sheltered conditions.

Aluminum

Aluminum should be etch primed or treated with an approved temporary protective


for storage or transport.

7.3.3 Temporary Protection of Smaller Items

Table 1 Summary Guide - Selection of Temporary Protectives

Type of
Characteristics of Article Temporary Protective Options
Article
Simple Parts Small articles packed in quantity (where 1. Oil film type (TP 6a) supplemented by
individual wrapping is impracticable), e.g. nuts, outer wrapping
bolts, etc.
2. Volatile corrosion inhibitors (TP 9)
Parts of simple geometric shape TP 1, TP 2, TP 3, TP 4a, TP 5, TP 6a, TP 7, TP 8,
TP 9, TP 10
TP 10 contact inhibitor is for special application for
certain ferrous metal and zinc items
Articles water-wet after cleaning or Water-displacing, solvent deposited types (TP 1c,
manufacture TP 2b)
Metal parts with rubber attached Castor oil grease (TP 4b)
Articles without any of the characteristics given 1. Hard film, solvent deposited type (TP 1a, 1b)
above, e.g. simple hand tools, gear wheels, 2. Soft film, solvent deposited type (TP 2a)
crankshafts, etc
3. Grease type if a drying time is unacceptable
(TP 4a or TP 5)
4. Strippable coating hot or cold applied types
(TP 7 or TP 8)
5. Volatile corrosion inhibitor (Type TP 9)
Assemblies Articles of low degree of complexity with large Grease (TP 4a) on working surfaces and in
proportion of simple surface crevices, then whole article coated with solvent
deposited protective (TP 1a, 1b, TP 2 or TP 8)
Articles with internal surfaces difficult of Oil film type (TP 6a) supplemented by water-
access. Lubricating oil systems vapour resistant barrier
Delicate mechanisms 1. Oil film type (TP 6a) supplemented by
water-vapour resistant barrier
2. No temporary protective, water-vapour-resistant
package with desiccant

11775-SPC-ME-011 Rev 0 Page 22 of 24


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Type of
Characteristics of Article Temporary Protective Options
Article
Oily or greasy material not tolerable 1. No temporary protective, water-vapour resistant
package with desiccant
2. Volatile corrosion inhibitor (TP 9) with sealed
package
Metal parts with rubber attached Castor oil grease (TP 4b)
Articles without any of the characteristics given 1. Soft, thick film type (TP 3) where hot
above dipping is appropriate
2. Grease type (TP 4a) where hand application is
economical or no heat is available
3. Soft film semi-fluid type (TP 5) where free
application is required on large articles
4. No temporary protective; water-vapour resistant
package with desiccant
Especially valuable simple parts or assemblies, particularly Strippable coating (hot applied) (TP 7)
having precision external surfaces
Notes to Table 1
The types of temporary protective indicated in Table 1 are described briefly below.
Type TP 1 Hard film, solvent-deposited, consisting of solutions of protectives such as suitably plasticized resins
in volatile solvent and generally applied by dipping or spraying. On evaporation of the solvent a thin
hard film of protective remains. There are three grades:
TP 1a, quick drying
TP 1b, slow drying
TP 1c, slow drying, water displacing

Grade TP 1c is a variety of TP 1b having water displacing properties. It can therefore be used to


protect wet articles without previous drying by more conventional means.
Type TP 2 Soft film, solvent deposited, consisting of solutions of protectives such as lanolin in volatile solvent
and applied by dipping or spraying. On evaporation of the solvent a thin soft film of protective
remains. There are two grades:
TP 2a, ordinary grade
TP 2b, water displacing grade

Type TP 2b has water displacing properties similar to those referred to in TP 1c above.


Type TP 3 Soft film, hot dipping, giving a thick soft film of protective usually based on Petrolatum (sometimes
called petroleum jelly or mineral jelly).
Type TP 4 Soft film grease, normally applied by brushing or smearing to give a thick soft film. There are two
grades:
TP 4a, metallic soap mineral oil base grease
TP 4b, castor oil base grease
Type TP 4a is a conventional type grease used as a protective while TP 4b is a grease of special
composition for application to metal parts to which rubber is attached.
Type TP 5 Soft film, semi-fluid, applied by brushing or swabbing to give films of medium thickness. They are
usually based on solutions of suitable corrosion inhibitors (e.g. wool fat derivatives) in mineral oils or
in mixtures of mineral oils and petrolatum.
Type TP 6 Oil film type consisting of lubricating oils containing soluble corrosion inhibitors, and generally
applied by dipping, spraying or circulation and generally serving as lubricants as well as temporary
protectives.

11775-SPC-ME-011 Rev 0 Page 23 of 24


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

There are two grades:


TP 6a, oil type, general purpose protective
TP 6b, oil type, engine protective
Type TP 7 Strippable hot dip coating consisting of ethyl cellulose and small amounts of mineral oil together with
plasticizers, resins and stabilizers. It is applied by hot dip application to form tough impermeable
films which can readily be stripped from the protected article.
Type TP 8 Strippable coating, cold applied, consisting of solutions of protectives such as vinyl copolymer
resins, plasticizers and stabilizers in flammable or non-flammable solvents. They are usually applied
by spraying, brushing, or dipping to form tough impermeable films which can readily be stripped from
the protected article.
Type TP 9 Volatile corrosion inhibitors consisting of substances, the vapour from which will inhibit corrosion of
ferrous metals.
Type TP 10 Contact inhibitors consisting of substances which when in contact with metallic surfaces will inhibit
corrosion.

7.4 Painting Colour Codes

The finish colour for all items shall be as advised by the Company and when
required by the Company the Contractor shall apply colour banding, warning
marks, direction of flow arrows etc.

11775-SPC-ME-011 Rev 0 Page 24 of 24


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Appendix A: Coating Schedule

Note : This Schedule shall always be read in conjunction with the appropriate Paint Specification.

Total
Surface
Applicable Surface Coating System Nominal
No. Designated Use Preparation
Structures Thickness
Always In accordance with
Primer Intermediate Finish Microns
acengineering specification

1 External coating for above ground Tanks, vessels, separators, Blast-cleaned to Sa 2.5 Type : Epoxy zinc phosphate Type : Polyamide cured Type : Recoatable
steel structures with service pipework, valves (uninsulated) and epoxy (high build) Polyurethane
temperatures of less than 100C general equipment / ducting in Surface Profile : App Meth : Airless spray
240
carbon or low alloy steel. 50 - 75 microns App Meth : Airless spray App Meth : Airless Spray
DFT : 50 microns
DFT : 140 microns DFT : 50 microns

2 External coating for steel structures Tanks, vessels, pipework, valves Blast-cleaned to Sa 2.5 Type : Epoxy zinc phosphate Type : Polyamide cured Type : Polyamide cured epoxy
in below ground cavities i.e. pits, (uninsulated) supports and epoxy with micaceous (high build)
tunnels service temps of less than structures in carbon and low alloy Surface Profile : App Meth : Airless spray iron oxide
100C steel 50 - 75 microns App Meth : Airless Spray 290
DFT : 50 microns App Meth : Airless spray
DFT : 120 microns
DFT : 120 microns

3 External coating for steel structures Tanks, vessels , pipework and valves Blast-cleaned to Sa 2.5 Type : Ethyl zinc silicate Type : Temperature resistant Type : Temperature resistant
for above or below ground with (insulated or uninsulated), flare silicone resin with silicone resin with
service temps. of 100 C - 450 C components and furnaces in carbon Surface Profile : App Meth : Air Atomised spray aluminium pigment aluminium pigment
or low alloy steel. 50 - 75 microns 100 - 120
DFT : 50-70 microns App Meth : Airless spray / atomiser App Meth : Airless spray / atomiser

DFT : 25 microns DFT : 25 microns

4 External coating for steel structures Tanks, vessels pipework valves and Blast-cleaned to Sa 2.5 Type : Coal tar epoxy (brown) Type : Coal tar epoxy (black)
buried in direct soil contact at support structures in carbon or low
service temps. of less than 80C alloy steel. Surface Profile : App Meth : Airless spray App Meth : Airless spray Not Required 300
50 - 75 microns
DFT : 150 microns DFT : 150 microns

5 External coating for steel structures Coating of tanks, plant pipework, Blast-cleaned to Sa 2.5 Type : Epoxy phenolic Type : Epoxy phenolic Type : Epoxy phenolic
buried in direct soil contact at valves and support structures in
service temps. of between 80C - carbon or low alloy steel. Surface Profile : App Meth : Brush, Air assisted, or App Meth : Airless spray App Meth : Airless spray
275
140C 50 - 75 microns Airless spray
DFT : 125 microns DFT : 125 microns
DFT : 25 microns

6+ Solvent based internal coating for Tanks and vessels for water service Blast-cleaned to Sa 2.5 Type : Epoxy Type : Amine cured epoxy Type : Amine cured epoxy
steel structures at service temps. of and hydrocarbon storage. (high build) (high build)
less than 70C Surface Profile : App Meth : Airless spray
275
50 - 75 microns App Meth : Airless spray App Meth : Airless spray
DFT : 25 microns
DFT : 125 microns DFT : 125 microns

11775-SPC-ME-011 Rev 0 Appendix A Page 1 of 4


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Total
Surface
Applicable Surface Coating System Nominal
No. Designated Use Preparation
Structures Thickness
Always In accordance with
Primer Intermediate Finish Microns
acengineering specification

6A Solvent based internal coating for Tanks and vessels for storage of jet Blast-cleaned to Sa 2.5 Type : Epoxy Type : Epoxy
steel structures at service temps. of fuel.
less than 70C Surface Profile : App Meth : Airless spray Not Required App Meth : Airless spray 250
The epoxy coating shall be certified 50 - 75 microns
as suitable for use with aviation fuel. DFT : 125 microns DFT : 125 microns

7 Solvent free internal coatings for Tanks and vessels for water service Blast-cleaned to Sa 2.5 Type : Solvent free epoxy
steel structures at service temps. of and hydrocarbon storage. flake pigment
greater than 70C Surface Profile :
Not Required Not Required 250
50 - 75 microns App Meth : Airless spray

DFT : 250 microns

8 Internal coatings for steel structures Tanks and vessels for hot water Blast-cleaned to Sa 2.5 Type : Vinyl ester with glass
at service temps. of greater than 70C services; separators and traps for flake pigment
sweet or sour service at greater than Surface Profile :
Not Required Not Required 700
70C 30 microns App Meth : Airless spray

DFT : 700 microns

9 Coatings for small diameter steel Junction and switch boxes, bolt on Blast-cleaned to Sa 2.5 Type : Epoxy-mastic, Type : Epoxy-mastic, Type : Recoatable urethane
pipework, controls, electrical and instruments, small motors and aluminium pigmented aluminium pigmented
mechanical accessory items and controls, hydraulic and pneumatic Surface Profile : App Meth : Brush or Airless spray
approved power or manual tool App Meth : Brush or Airless spray App Meth : Brush or Airless spray 260
fittings at service temps. less than control systems, small diameter
70C pipework, retrofitted pipework and clean to St3 DFT : 60 microns
equipment. DFT : 100 microns DFT : 100 microns

10 Coating for Aluminium All structural aluminium, aluminium Surface to be thoroughly Type : Polyvinyl butyral / Type : Polyamide cured epoxy Type : Recoatable
piping, control lines, ducting and degreased as per specification phosphoric acid polyurethane
containers NOT applicable to App Meth : Brush or Air assisted
insulation cladding which is normally App Meth : Brush or Air assisted spray App Meth : Brush or Air ass. spray 160
uncoated spray
DFT : 100 microns DFT : 40 microns
DFT : 20 microns

11 Coating for galvanised steel Galvanised steel, handrails, ducting, Surface to be thoroughly Type : Mordant Wash Type : Polyamide cured Type : Recoatable urethane
derricks, coastal items. degreased and freed from zinc (uniform blackened epoxy with micaceous
salts as per specification surface) iron oxide pigment App Meth : Brush or Airless spray
160
DFT : 60 microns min (recommended)
App Meth : Brush swab or spray App Meth : Brush or Airless spray

DFT : N/A DFT : 85 microns min

12* Coating for stainless steel pipework, All austentitic and duplex stainless Blast-cleaned to Sa 2.5 Type : Polyamide cured epoxy Type : Recoatable urethane
vessels and equipment at services steel pipework, vessels and containing<100ppm
temps. between 50C - 120C equipment and fabrications Surface Profile : chloride and free of App Meth : Brush or Airless spray
operations in the chloride stress 25 - 50 microns metallic pigments 100 - 140 uninsulated
Not Required DFT : 40 microns
corrosion temp. range (50C to 121C) 60 -100 insulated
and exposed to high chloride App Meth : Brush or Airless spray
environments such as the coast,
offshore or under insulation DFT : 60 - 100 microns

11775-SPC-ME-011 Rev 0 Appendix A Page 2 of 4


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Total
Surface
Applicable Surface Coating System Nominal
No. Designated Use Preparation
Structures Thickness
Always In accordance with
Primer Intermediate Finish Microns
acengineering specification

13* Coating for stainless steel pipework, All austentitic and duplex stainless Blast-cleaned to Sa 2.5 Type : High temp. resistant Type : High temp. resistant
vessels and equipment at services steel pipework, vessels and silicate with low silicate with low
temps. between 121C - 400C equipment and fabrications Surface Profile : chloride content and chloride content and
operations in the chloride stress 25 - 50 microns free of metallic free of metallic
corrosion temp. range (121C to pigments Not Required pigments 80
400C) and exposed to high chloride
environments such as the coast, App Meth : Brush or Airless spray App Meth : Brush or Airless spray
offshore or under insulation
DFT : 40 microns DFT : 40 microns

14 Coatings for marine structures and Pier supports, structures, piling and Blast-cleaned to Sa 2.5 Type : Coal tar epoxy (brown) Type : Coal tar epoxy (black)
pilling pipework in subsea, splash zone or
tidal zone services. Surface Profile : App Meth : Airless spray or brush Not Required App Meth : Airless spray or brush 300
75 - 100 microns
DFT : 150 microns DFT : 150 microns

15 Coating for plaster, plasterboard and Surfaces with plaster, plasterboard Brush off any efflorescence. Type : Vinyl Emulsion cut by Type : Vinyl emulsion
gypsum based surfaces. and gypsum. New plaster or gypsum The surface must be kept dry at 20% clean water
must have dried out. all times. Any areas soiled with App Meth : Brush or spray
oil or grease have to be App Meth : Brush or spray Not Required N/A
abraded or cut out and remade. DFT : Minimum 2 xcoats, and
DFT : N/A sufficient to provide a
uniform colour

16 Paint coating for protection and Exterior and interior timber, plywood Ensure surfaces are dry, clean Type : Alkyd wood primer Type : Alkyd wood undercoat Type : Alkyd wood finish
decorative appearance on timber and hardboard. and free from grease and dust.
and hardboard App Meth : Brush App Meth : Brush App Meth : Brush
N/A
DFT : N/A DFT : Sufficient to hide DFT : Sufficient to cover
previous coat intermediate coat
completely

17 Fire retardant coatings for timber Interior timber, plywood and Ensure surfaces are dry, clean Type : Alkyd wood primer Type : Fire retardant, alkyd Type : Fire retardant, finish
and hardwood hardwood to meet BS 476: Part 7: and free from grease and dust. wood undercoat alkyd, to meet BS 476:
Class 2. App Meth : Brush Part 7: Class 2
App Meth : Brush
DFT : N/A N/A
App Meth : Brush
DFT : Sufficient to hide
previous primer. DFT : Sufficient to cover
intermediate coat.

18 Coating for internal timber and Interior timber, plywood and Ensure surfaces are dry, clean Type : Alkyd wood primer Type : Alkyd wood undercoat Type : Alkyd wood finish
hardboard. hardboard and free from grease and dust.
App Meth : Brush App Meth : Brush App Meth : Brush
N/A
DFT : N/A DFT : Sufficient to hide DFT : Sufficient to cover
previous coat intermediate coat
completely

11775-SPC-ME-011 Rev 0 Appendix A Page 3 of 4


DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Total
Surface
Applicable Surface Coating System Nominal
No. Designated Use Preparation
Structures Thickness
Always In accordance with
Primer Intermediate Finish Microns
acengineering specification

19^ Varnish coatings for timber and Exterior and interior timber, plywood Ensure surfaces are dry, clean Type : Spirit base stain Type : Clear polyurethane Type : Clear polyurethane
hardwood and hardboard where protection and and free from grease and dust. compatible with
decorative 'natural' appearance is polyurethane varnish App Meth : Brush App Meth : Brush
required. N/A
App Meth : Brush or cloth DFT : Uniform DFT : Uniform

DFT : N/A

20 Coatings for storage and transit Structural steelwork, pipework Blast-cleaned to Sa 2.5 Type : Epoxy zinc phosphate Note : only one coating
aluminium, for transit or long term holding/blasting required.
storage Surface Profile : primer Coating not necessary
50 - 75 microns for Pipework (black), N/A 50
App Meth : Airless or air atomising Ferrous components
spray and Aluminium items.

DFT : 50 microns

11775-SPC-ME-011 Rev 0 Appendix A Page 4 of 4


Design of New
Hydrant System
(Package #7)

Lugged Pattern
Butterfly Valve -
Class 150 Head Office:
Penspen Group Limited
3 Water Lane
Richmond upon Thames
Surrey
TW9 1TJ
United Kingdom

Regional Office:
Penspen International Limited
P.O. Box 46562
Kuwait Aviation Fuelling Co Abu Dhabi
United Arab Emirates

11775-DAT-ME-005 Rev 1
DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Valve Data Sheet


Lugged Pattern Butterfly Valve - Class 150 Data Sheet 11775-DAT-ME-005
Valve Description
Lugged pattern, bi-direction flow, triple offset, tight shut-off, coated disc,
fire safe and anti-static design, suitable for installation between two ASME B16.5 flanges.

1 VALVE SIZE RANGE 3" - 24"


GENERAL

2 VALVE ASME CLASS 150


DATA

3 VALVE TYPE Butterfly - Lugged Pattern NOTE 1


4 VALVE END CONFIGURATION Install between ASME B16.5 Raised Face Flanges
5 VALVE SERVICE Jet A-1 (Aviation Fuel - Kerosene)
6 VALVE BORE (FULL/REDUCED) Standard
7 PRESSURE - DESIGN BAR.G MINIMUM: Full Vacuum MAXIMUM: 19.6
8 TEMPERATURE - DESIGN °C MINIMUM: -5 MAXIMUM: 85
9 VALVE OPERATION - MOTORISED SEE VALVE SCHEDULE
10 VALVE OPERATION - MANUAL 3"-6" Lever Operated; 8" and above Handwheel and Gearbox NOTE 2
11 VENT CONNECTION None
DESIGN

12 DRAIN CONNECTION None


13 PRESSURE RELIEF CONNECTION None
14 SEALANT INJECT. CONNECTION None
15 SUPPORT LEGS/FEET None
16 LIFTING EYES None
17 LOCKING FACILITY Required
18 SURFACE TREATMENT Refer to Project Valve Specification
20 BODY ASTMA105 / ASTM A216 Gr.WCC
21 COVER/BONNET N/A
22 GATE N/A
23 BALL N/A
24 DISC ASTM A182 F6 or similar with low friction coating
MATERIALS

25 TRIM 13% Chrome


26 SEALS Metal to Metal with secondary Resilient seals
27 GASKETS N/A
28 STEM ASTM A182 F6 or similar
29 TRUNNION (See Stem)
30 SEAT/RINGS ASTM A182 F6 or similar
31 GLAND PACKING Manufacturer's Standard - Non Asbestos
32 BOLTING N/A
33 DESIGN API 609 and MSS SP-68
34 DIMENSIONS API 609 and MSS SP-68
STANDARDS

35 FLANGE DIMENSIONS ASME B16.5 Gasket Contact Surface Ra 6.3 to 12.5 microns (Stock)
CODES
&

36 WELD END DIMENSIONS N/A


37 CERTIFICATION Refer to Project Specification
38 FIRE TEST API 607
39 HYDROSTATIC TEST API 598
40 NOTES
41 1. Bolt holes in the body lugs shall be drilled through to accommodate appropriately sized stud bolts.
42 2. Lever to have mechanism to hold the valve in the fully open, fully closed and minimum five intermediate positions.
43
44
45
46
47
48

11775-DAT-ME-005 Rev 1 Page 3 of 3


Design of New
Hydrant System
(Package #7)

Ball Valves - 1/2"


to 1 1/2" -
Class 150 & 800 Head Office:
Penspen Group Limited
3 Water Lane
Richmond upon Thames
Surrey
TW9 1TJ
United Kingdom

Regional Office:
Penspen International Limited
P.O. Box 46562
Kuwait Aviation Fuelling Co Abu Dhabi
United Arab Emirates

11775-DAT-ME-002 Rev 0
DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Valve Data Sheet


Ball Valves - 1/2" to 1 1/2" - Class 150 & 800 Data Sheet 11775-DAT-ME-002
Valve Description
Single piece or split body, reduced bore, floating ball, renewable seat rings, fire safe and anti-static design,
anti-blow-out stem.

1 VALVE SIZE RANGE 1/2" - 1 1/2"


GENERAL

2 VALVE ASME CLASS 150 for flanged or 800 for screwed (as specifed on TRN)
DATA

3 VALVE TYPE Ball


4 VALVE END CONFIGURATION Raised Face Flanged Ends or Screwed NPT (as specified on TRN)
5 VALVE SERVICE JET-A1
6 VALVE BORE (FULL/REDUCED) Reduced - Cylindrical Port
7 PRESSURE - DESIGN BAR.G MINIMUM: Full Vacuum MAXIMUM: 19.6
8 TEMPERATURE - DESIGN °C MINIMUM: -5 MAXIMUM: 85
9 VALVE OPERATION - MOTORISED N/A
10 VALVE OPERATION - MANUAL Lever
11 VENT CONNECTION N/A
12 DRAIN CONNECTION N/A
13
DESIGN

PRESSURE RELIEF CONNECTION N/A


14 SEALANT INJECT. CONNECTION N/A
15 SUPPORT LEGS/FEET N/A
16 LIFTING EYES N/A
17 LOCKING FACILITY Required
18 SURFACE TREATMENT External paint system to be in accordance with 11775-SPC-ME-011,
'Specification for Paint Works"
Finish coat shall be white. Carbon steel internal surfaces shall be coated
19 with a anti-corrosion system compatible with JET-A1, manufacturer to propose.
20 BODY ASTM A105- NB Welded on flanges are not acceptable for flanged valves
21 COVER/BONNET N/A
22 GATE N/A
23 BALL 13% Chrome Stainless Steel - Solid Type
24 DISC N/A
MATERIALS

25 TRIM 13% Chrome Stainless Steel


26 SEALS Resilient
27 GASKETS Manufacturer's Standard - Non Asbestos
28 STEM 13% Chrome Stainless Steel
29 TRUNNION N/A
30 SEAT/RINGS 13% Chrome Stainless Steel - Resilient Inserts
31 GLAND PACKING N/A
32 BOLTING Manufacturer's Standard
33 DESIGN BS EN ISO 17292
34 DIMENSIONS BS EN ISO 17292 - Screwed valves to have internally tapered threads
STANDARDS

35 FLANGE DIMENSIONS ASME B16.5 Gasket Contact Surface Ra 6.3 to 12.5 microns (Stock)
CODES
&

36 WELD END DIMENSIONS N/A


37 CERTIFICATION Refer to Project Specification
38 FIRE TEST BS EN ISO 10497
39 HYDROSTATIC TEST BS EN 12266 Plus Hydrostatic Seat tests at full class rating. (ie WP + 10%)
40 NOTES
41 All materials to be compatible for Jet A-1 service.
42
43
44
45
46
47
48

11775-DAT-ME-002 Rev 0 Page 3 of 3


Design of New
Hydrant System
(Package #7)

Wafer Check Valve -


Class 150 Head Office:
Penspen Group Limited
3 Water Lane
Richmond upon Thames
Surrey
TW9 1TJ
United Kingdom

Regional Office:
Penspen International Limited
P.O. Box 46562
Kuwait Aviation Fuelling Co Abu Dhabi
United Arab Emirates

11775-DAT-ME-003 Rev 0
DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Valve Data Sheet


Wafer Check Valve - Class 150 Data Sheet 11775-DAT-ME-003
Valve Description
Dual Plate, Retainerless Wafer, Lugged (Through Bolt Holes), Spring Assisted,
For installation between 2 ASME B16.5 raised face flanges.

1 VALVE SIZE RANGE 2" - 24"


2 VALVE ASME PRESSURE RATING Class 150
GENERAL

3 VALVE TYPE Wafer Check, Dual Plate, Retainerless Wafer, Lugged (Through Bolt Holes), Spring
DATA

4 Assisted NOTE 1

5 VALVE END CONFIGURATION To fit between two ASME B16.5 Raised Face Flanges
6 VALVE SERVICE Jet A-1 (Aviation Fuel - Kerosene)
7 VALVE BORE (FULL/REDUCED) N/A
8 PRESSURE - DESIGN BAR.G MINIMUM: Full Vacuum MAXIMUM: 19.6
9 TEMPERATURE - DESIGN °C MINIMUM: -5 MAXIMUM: 85
10 VALVE OPERATION - MOTORISED N/A
11 VALVE OPERATION - MANUAL N/A
12 VENT CONNECTION None
DESIGN

13 DRAIN CONNECTION None


14 PRESSURE RELIEF CONNECTION None
15 SEALANT INJECT. CONNECTION None
16 SUPPORT LEGS/FEET None
17 LIFTING EYES Required for valves size 10" and larger
18 LOCKING FACILITY N/A
19 SURFACE TREATMENT Refer to Project Valve Specification
20 BODY ASTM A105/ASTM A216 Gr.WCC
21 COVER/BONNET N/A
22 GATE N/A
23 BALL N/A
24 PLATES Carbon Steel ( Manufacturer to propose ) NOTE 2
MATERIALS

25 TRIM (WETTED PARTS) 316 Stainless Steel / Inconel


26 SEALS Resilient (Manufacturer to propose)
27 GASKETS N/A
28 STEM N/A
29 TRUNNION N/A
30 SEAT/RINGS N/A
31 GLAND PACKING N/A
32 BOLTING N/A
33 DESIGN API 594 or API 6D
34 DIMENSIONS API 594 or API 6D
STANDARDS

35 END FACINGS Gasket Contact Surface Roughness Ra 6.3 to 12.5 microns ( Stock Finish )
CODES
&

36 WELD END DIMENSIONS N/A


37 CERTIFICATION / DOCUMENTATION Refer to Project Valve Specification
38 NON DESTRUCTIVE EXAMINATION Refer to Project Valve Specification
39 BODY AND SEAT TESTING API 598 or API 6D
40 NOTES
41 1. Scalloped lug design preferred to minimise weight
42 2. Materials shall be suitable for the service and design
43 3. Refer to the Project Valve Specification for valve marking requirements
44
45
46
47
48

11775-DAT-ME-003 Rev 0 Page 3 of 3


Design of New
Hydrant System
(Package #7)

Reduced Bore
'Floating Ball'
Ball Valve - Head Office:
Penspen Group Limited

Class 150 RF 3 Water Lane


Richmond upon Thames
Surrey
TW9 1TJ
United Kingdom

Regional Office:
Penspen International Limited
P.O. Box 46562
Kuwait Aviation Fuelling Co Abu Dhabi
United Arab Emirates

11775-DAT-ME-001 Rev 0
DESIGN OF NEW HYDRANT SYSTEM (PACKAGE #7)

Valve Data Sheet


Reduced Bore 'Floating Ball' Ball Valve - Class 150 RF Data Sheet 11775-DAT-ME-001
Valve Description
Single piece or split body, end entry, floating ball, renewable seat rings, fire safe and anti-static design.
This Data Sheet is applicable only for above ground station service.

1 VALVE SIZE RANGE 2" - 12" NOTE 1


GENERAL

2 VALVE ASME CLASS 150


DATA

3 VALVE TYPE Ball


4 VALVE END CONFIGURATION Raised Face Flanged Ends
5 VALVE SERVICE JET-A1
6 VALVE BORE (FULL/REDUCED) Reduced ( 1 size smaller than line size )
7 PRESSURE - DESIGN BAR.G MINIMUM: Full Vacuum MAXIMUM: 19.6
8 TEMPERATURE - DESIGN °C MINIMUM: -5 MAXIMUM: 85
9 VALVE OPERATION - MOTORISED No
10 VALVE OPERATION - MANUAL 2" - 6" Lever Operated; 8" and above Handwheel and Gearbox
11 VENT CONNECTION None
12 DRAIN CONNECTION Plugged
13 Any excess pressure in the body cavity shall be relieved upstream.
DESIGN

PRESSURE RELIEF CONNECTION


14 SEALANT INJECT. CONNECTION None
15 SUPPORT LEGS/FEET None
16 LIFTING EYES Required for valves weighing more than 150Kg. Unless otherwise agreed.
17 LOCKING FACILITY Required
18 SURFACE TREATMENT External paint system to be in accordance with 11775-SPC-ME-011,
'Specification for Paint Works"
Finish coat shall be white. Carbon steel internal surfaces shall be coated
19 with a anti-corrosion system compatible with JET-A1, manufacturer to propose.
20 BODY ASTM A105/ASTM A216 Gr.WCC
21 COVER/BONNET N/A
22 GATE N/A
23 BALL Stainless Steel
24 DISC N/A
MATERIALS

25 TRIM Stainless Steel


26 SEALS Resilient - Manufacturer to propose
27 GASKETS Manufacturer's Standard - Non Asbestos
28 STEM Stainless Steel
29 TRUNNION N/A
30 SEAT/RINGS Reinforced PTFE
31 GLAND PACKING N/A
32 BOLTING Manufacturer's Standard
33 DESIGN API 6D / BS EN ISO 17292
34 DIMENSIONS API 6D
STANDARDS

35 FLANGE DIMENSIONS ASME B16.5 Gasket Contact Surface Ra 6.3 to 12.5 microns (Stock)
CODES
&

36 WELD END DIMENSIONS N/A


37 CERTIFICATION Refer to Project Specification
38 FIRE TEST API 6FA or API 607
39 HYDROSTATIC TEST API 6D
40 NOTES
41 1. Valves 6" and above shall be of the 'Short Pattern' design.
42 2. All materials to be compatible for Jet A-1 service.
43
44
45
46
47
48

11775-DAT-ME-001 Rev 0 Page 3 of 3


Design of New
Hydrant System
(Package #7)

Specification for
Field Instruments
Head Office:
Penspen Group Limited
3 Water Lane
Richmond upon Thames
Surrey
TW9 1TJ
United Kingdom

Kuwait Aviation Fuelling Co Regional Office:


Penspen International Limited
P.O. Box 46562
Abu Dhabi
United Arab Emirates

11775-SPC-IN-001 Rev 0
1. GENERAL

1.1 Introduction

This Specification covers the minimum project requirements for design, manufacture,
supply, testing, installation and commissioning of Field Instruments for the New Aviation
Fuel Hydrant System at Kuwait International Airport (KIA).

1.2 Precedence

Any case of apparent conflict between the requirements of this specification and any other
relevant documents shall be notified to KAFCO. Unless otherwise agreed, the following
descending order of precedence shall apply:
st
1 Local Authority or Statutory Regulations
nd
2 This Specification
rd
3 Other Project Specifications as referenced herein
th
4 The Codes and Standards listed below
th
5 Other Internationally recognised Codes or Standards as appropriate

1.3 References

The following project documents shall be read in conjunction with and form part of this
specification.

11775-DAT-IN-001 Data Sheets for Field instruments

11775-DAT-IN-004 Data Sheets for MOV & ESD Valves

1.4 Definitions and Abbreviations

The ‘Company’ is KAFCO (Kuwait Aviation Fuel Company) or their appointed agent or
representative.

The ‘Supplier’ is the vendor, manufacturer or supplier of the equipment defined in this
specification.

Throughout this document the following terminology is used:

"must" signifies a legal or statutory requirement

"shall" signifies a requirement made mandatory by this specification.

"may" signifies a feature, which is discretionary in the context in which it is applied.

"will" signifies a feature, which the Suppliers may assume to be already present.

1.5 Codes and standards

1.5.1 International Design Codes and Engineering Standards

The latest editions of the International Design Codes and Engineering Standards as
below:

11775-SPC-IN-001 Rev 0 Page 3 of 13


American Petroleum Institute (API)

API RP 554 Process Instrumentation & Control


API RP 551 Process Measurement Instrumentation

American Society of Mechanical Engineers (ASME)

ASME B 4.01 Gauges & Pressure Indicating Dial Type, Elastic Element
ASME B16.5 Pipe Flanges & Flanged Fittings
ASME B 31.3 Process Piping
ASME B 40.100 Pressure Gauges & Gauge Attachments
ASME MC 96.1 Temperature Measurement Thermocouples

Atmospheres Explosibles (ATEX)

ATEX 100A Directive - Safety Of Apparatus

British Standards Institute (BSI)

BS 1041 Code For Temperature Measurement

BS 2765 Specification For Dimensions Of Temperature Detecting


Elements And Corresponding Pockets
BS 1780 Bourdon Tube Pressure And Vacuum Gauges

BS 5501 Electrical Apparatus For Potentially Explosive Atmospheres


BS 6134 Specification For Pressure And Vacuum Switches
BS 6739 Code Of Practice For Instrumentation In Process Control
Systems: Installation Design And Practice
BS EN 837-1 Pressure gauges. Bourdon tube pressure gauges. Dimensions,
metrology, requirements and testing
BS EN 13190 Dial Thermometers
BS EN 60079 Explosive atmospheres

Electronic Industries Alliance/Telecommunications Industry Association (EIA/TIA)

EIA/TIA Standard Test Procedures For Fiber Optic Fibers, Cables,


Transducers, Sensors Connecting And Terminating Devices, And
Other Fiber Optic Components

International Electro-technical Commission (IEC)

IEC 60079 Explosive Atmospheres


IEC 60079-0 Explosive Atmospheres - Part 0: Equipment - General
Requirements
IEC 60079-1 Explosive Atmospheres - Part 1: Equipment Protection By
Flameproof Enclosures "d"
IEC 60079-7 Explosive Atmospheres - Part 7: Equipment Protection By
Increased Safety "e"
IEC 60079-10-1 Explosive Atmospheres - Part 10-1: Classification Of Areas -
Explosive Gas Atmospheres
IEC 60079-11 Explosive Atmospheres - Part 11: Equipment Protection By

11775-SPC-IN-001 Rev 0 Page 4 of 13


Intrinsic Safety "i"
IEC 60079-15 Explosive Atmospheres - Part 15: Equipment Protection By
Type Of Protection "n"
IEC 60529 Degrees Of Protection Provided By Enclosures (IP Code)
IEC 60584-1 Thermocouples - Part 1: Reference Tables
IEC 60584-2 Thermocouples. Part 2: Tolerances
IEC 60584-3 Thermocouples - Part 3: Extension And Compensating Cables -
Tolerances And Identification System
IEC 60751 Industrial Platinum Resistance Thermometers And Platinum
Temperature Sensors
IEC 61000-4 Electromagnetic compatibility (EMC)

Institute of Petroleum (IP)

IP Model Code Of Safe Practice


Part 15: Area Classification Code for Petroleum Installations

The International Society of Automation (ISA)

ISA S5.1 Instrumentation Symbols And Identification


ISA-TR84.00.02 Safety Instrumented Function(SIF) –
Safety Integrity Level (SIL) Evaluation Techniques

International Organization for Standardization (ISO)

ISO 9000 Quality Management System


ISO 9001 Quality System - Model For Quality Assurance & Design,
Development, Production, Installation & Service

1.6 Environmental Conditions

Temperature:

Ambient : -3°C to +50°C


Shade (Maximum) : 50°C
Direct Sunlight (Maximum) : 85°C (black body)
Direct Sunlight (Maximum) : 63°C (white body)

Rainfall:

Annual (Maximum) : 200mm


Rate (Maximum) : 25mm in 30 minutes

Wind:

Design Velocity (Maximum) : 45 m/s


Continuous : 30 m/s
Humidity : 100% max

Climate – tropical, dense sand and fine dust storms, corrosive salt laden atmosphere

Condensation – corrosive fog and dew possible over winter months

11775-SPC-IN-001 Rev 0 Page 5 of 13


2. PRODUCTS

2.1 Design Life, Availability and Reliability

The overall availability and reliability of the complete package shall be demonstrated by the
Manufacturer. Unless otherwise stated, the package design life shall be 30 years, with an
uninterrupted period of operation of 3 years.

The Manufacturer shall identify any aspects of its standard components or packages that
do not meet this requirement and submit descriptions to the Purchaser for consideration
during the tendering process.

2.2 Service Conditions

2.2.1 Product

Equipment supplied under this specification shall be suitable for use on Jet A-1 (Aviation
fuel) having a specific Gravity and Viscosity of 0.8 and 1.3 cSt @32 °C.

2.2.2 Electrical Design Codes, Standards and Specifications

Electrical equipment will be designed, manufactured and tested to British Standards (BS)
and International Electrotechnical Commission (IEC) Codes, or approved equivalents.

The electrical system design shall be based upon the following Codes and Standards:

Supply voltage: 240V AC ± 10% 50Hz ± 1% single phase


Signal: 24V DC ± 1%

Ingress protection shall be afforded to a minimum of IP 65.

2.3 Location

All electronic transmitters supplied shall be suitable for serial interface based on HART.

The instruments/ MOVs shall be permanently marked with the following information as a
minimum:

- Manufacturer’s name
- Model, type and serial No.
- Range & Calibration (Including unit of measurement)
- Date of manufacture
- Instrument Tag number
- Body rating
- Electrical safety / Type of protection
- Ingress Protection

2.4 Area Classification

Area classification will be in accordance with IP Model Code of Safe Practice Part 15 –
Area Classification Code for Petroleum Installations.

Electrical equipment will be certified suitable for the hazardous areas, and the contract
specification will list acceptable alternative equivalent area classifications to facilitate
equipment selection.

Within Zone 0; where an explosive gas atmosphere is present continuously or is present


for long periods, electrical Equipment shall be:

• Intrinsically safe EEx “ia”.

Within Zone 1; where an explosive gas atmosphere is likely to occur in normal operation,
electrical Equipment shall be:

11775-SPC-IN-001 Rev 0 Page 6 of 13


• Flame proof EEx “d”.
• Increased safety EEx “e”.
• Intrinsically safe EEx “ia”.

Within Zone 2; where an explosive gas atmosphere is not likely to occur in normal
operation and if it occurs will exist only for a short period, electrical equipment shall be:

Same as required for Zone 1 for EEx “d” equipment.

For this Project application an area classification of Class 1 & Division 1 shall be followed.

3. FIELD INSTRUMENTATION

3.1 Pressure Instruments

3.1.1 General Pressure Requirements

Pressure elements measuring a steady normal operating pressure shall be manufactured


from stainless steel and shall not exceed 75% of its maximum range. Pressure elements
measuring fluctuating pressure should not normally operate beyond 60% of their maximum
range. Pressure instruments on pulsating pressure service shall be equipped with
pulsation dampeners.

For measured ranges less than the process design pressure, over-range protection shall
be provided up to 130% of range. All instruments shall have a body pressure rating to the
line or vessel design pressure.

Process impulse lines for pressure instruments shall be compatible with the piping
specifications for the service. Transmitters shall be supplied with a conventional instrument
Manifold as an integral assembly to each transmitter. 5 valve manifolds shall be supplied
for DP type transmitters & 2 valve manifold for pressure transmitters. The arrangement of
valves shall be such that the instrument can be calibrated and tested at site.

Where there is a possibility of high temperature vapour entering the measuring chamber of
an instrument then siphon shall be provided.

3.1.2 Pressure Transmitters

Pressure and differential pressure transmitters shall be RFI immune, analogue 4-20mA
with “smart” capabilities suitable for communication (HART) from a remote location. The
transmitter will normally be used in the analogue mode (4-20mA, 2-wire transmission)
between 30% and 60% of the maximum range.

Transmitters shall have built-in local span, zero, Integral damping adjustment and local
LCD indicator in engineering unit.

Transmitters shall have traditional side flanges or coplanar (bottom) flanges. The flanges,
adapters, bolts, drain/vent valves and isolating diaphragms shall be in 316 Stainless Steel,
with silicone oil fill for diaphragm type transmitters. The pressure transmitter assembly
shall be manufactured from compatible corrosion resistant materials, suitable for the
required service conditions.

Accuracy of transmitters shall be ±0.075% of span, within a rangeability of 1:30.The


accuracy is defined for the combined effect of repeatability, linearity and hysteresis.

The stability of the transmitters shall be 0.1% of span for a period of minimum 36 months.
Transmitter shall update the output at least 4 times a second unless otherwise specified.

For HART protocol, the following features must be ensured to be operational. It shall allow
multi masters (two for example, primary and secondary) for configuration, calibration,
diagnosis and maintenance. The primary could be the Control System or Host computer

11775-SPC-IN-001 Rev 0 Page 7 of 13


and the secondary could be the hand-held Communicator or a maintenance computer. It
shall be capable of implementing universal commands.

The transmitters shall be suitable for 2” pipe mount type with ½” NPT (F) process and
M20x1.5 electrical connection.

3.1.3 Pressure Gauge

Pressure gauge element shall be 316 stainless steel as a minimum required and of a type
suitable for the service required, i.e. Bourdon, diaphragm, etc.

All local pressure gauges shall have 100mm diameter dial. For pressure greater than
1000psig, safety front guards shall be used. Pressure gauges shall be bottom entry, direct
mount type, with nominal accuracy of ± 1 % of span. The process connection shall be ½”
NPT.

Gauge cases shall be manufactured from stainless steel. The cases shall have a back
plate and be supplied with distance spacers for cases with blow out backs. Gauges shall
be of the solid form safety pattern type, with blow out backs and shatterproof glass.

3.1.4 Pressure Safety Valve

Relief and safety valves shall comply with ASME Code Sections I and VIII, API RP 520 and
API RP 521. Vendor shall submit the valve sizing calculations and submit for review and
approval.

All fuel lines shall be protected against overpressure by relief valves sized to relieve the
maximum of the following conditions:

a) The maximum vapour quantity generated by net input of heat on failure or closure
of normal outlets.
b) For closed valves in outlet lines: the quantity of fluids normally leaving the vessels.
c) The quantity of vapour generated in case of fire. Heat input per square foot of
wetted un-insulated surfaces shall be calculated in accordance with latest edition
of API Standard RP 520.

In process or other congested areas, the surface area of pressure vessels that may be
exposed to fire shall include all wetted areas to a height of 15 meters above the level at
which burning fuel can occur.

3.1.4.1 Types and Materials

All relief valves shall be manufacturer's standard type and material conforming to the
manufacturer's recommendations. However, as a minimum requirement, relief valve body
shall be carbon steel with stainless steel trim.

For other than liquid service, relief valves one inch and larger shall be of the type having a
nozzle bushing which extends through and beyond the base of the inlet bolting flange, and
which forms the gasket bearing surface for the inlet flange.

Flanged relief valves for process piping, excluding steam and air pressure piping, shall be
either the enclosed spring type or pilot operated type. Spring type relief valves shall have a
packed lifting lever on steam and air pressure piping systems. Balanced relief valves shall
be used if the total back pressure is more than 10% of valve set pressure.

Balanced relief valves may also be used where appreciable savings in the
discharge/disposal system piping can be affected by virtue of the increased allowable back
pressure. Rupture disc pressure relief devices shall not be used as primary relief devices.
Pilot operated valves shall have a field test connection and back flow preventer.

Spring valves shall use a bleed ring between the inlet and the inlet block valve to allow for
field testing.

11775-SPC-IN-001 Rev 0 Page 8 of 13


3.1.5 Connections

All process relief valves shall have flanged inlet and outlet connections. The outlet flange of
relief valves discharging into closed systems shall be at least equal to the rating of the
system.

3.2 Temperature Measurement

3.2.1 General Temperature Requirements

All temperature measurement devices shall have selectable upscale or downscale burnout
capability. Direction of burnout will be selected to provide the safest action of the system
utilizing the temperature signal

3.2.2 Temperature Elements

Temperature elements shall include the following IEC reference as dictated for a given
platinum Pt100 resistance thermometer sensor:

• Three wire single temperature detector to IEC 60751 class B


• Three wire dual temperature detector to IEC 60751 class B

Temperature elements shall be of the suitable RTD type unless measurements range
requirements dictate otherwise. Other specific requirements for temperature elements are
detailed below:

Temperature element heads shall be weatherproof, as per NEC requirement, and shall
have ½” NPT connections for wells and M20x1.5 connections for cable entries. Duplex
elements, where specified, shall have two M20x1.5 cable connections.

RTD’s shall be Platinum 100 type with characteristics in accordance with DIN 43760 and
resistance 100 ohms at 32°F. The resistance element will closely fit into the standard
thermowell. Platinum Resistance Temperature element shall fully comply with IEC 60751.

For RTD applications a three-wire system will be applied to compensate for change in the
resistance extension cable.

3.2.3 Thermowells

Threaded Thermowells shall not be used. In general, Thermowells shall be of 1 1/2” pipe
size flanged of minimum 150#, or to the same pressure rating of the line if higher, as
detailed in the P&IDs. The stem type of the thermowell shall be taper with a ½” NPT
instrument connection thread. Standard material for Thermowells shall be ANSI 316
stainless steel.

The connection head shall be in aluminium alloy, painted with two coats of epoxy, suitable
for degree of protection to IP 65 or better to IEC 60529. In addition this alloy head shall
include for the RTD/4-20 mA transmitter.

The Supplier shall submit calculations to show that all thermowells are suitable for stress
due to stream velocity conditions. The maximum wake frequency shall not exceed 80% of
the resonant frequency of the thermowell. A suitable calculation method is as per ASME
Power Test Code 19.3 Part 3 Instruments and Apparatus - Temperature. The calculation
submission is to include all equations, assumptions etc.

All Thermowell intended for critical services (High temperature and high pressure) shall be
100% radiographed.

The stainless steel extension piece shall be correctly sized to provide the correct insertion
length (Dim ‘U’) to accommodate the temperature element. The insertion length shall be
determined so as the sensitive part of the thermowell, plus one inch intrudes into the
process pipe, or as per vendor recommendations. Thermowells provided for test purposes
shall be equipped with a plug secured to the thermowell.

11775-SPC-IN-001 Rev 0 Page 9 of 13


3.2.4 Temperature Transmitters

Where applicable the transmitter shall be suitable for accepting inputs from all of the types
of temperature elements listed above.

Temperature transmitters shall be RFI immune, analogue 4-20mA with “smart” capabilities
suitable for communication (HART) from a remote location. The transmitter will normally
be used in the analogue mode (4-20mA, 2-wire transmission) between 30% and 60% of
the maximum range.

Transmitters shall have built-in local span, zero, adjustment and local LCD indicator in
engineering unit and inbuilt compensation for the thermocouple extension cable / cold
junction compensation.

Sensor Burnout Indication high scale / low scale: User selectable and shall be capable of
taking single sensor and dual sensor inputs. For those applications with dual temperature
detectors, the transmitter shall also be capable of accepting both inputs in a hot standby
configuration whereby the transmitter automatically switches to the second element if the
primary element fails.

The temperature transmitter housing shall be manufactured from compatible corrosion


resistant materials, suitable for the required service conditions.

The transmitter shall have an accuracy to IEC 60751 class B or better for Pt – 100
resistance thermometer detectors (RTD). The transmitters shall be suitable for 2” pipe
mount type with M20 x 1.5 electrical connection.

3.3 ESD Buttons

ESD Buttons shall be Break Glass Unit, self-resetting type with lift up flap guard to avoid
accidental operation. The make and model shall be as per the existing ESD buttons.

The ESD buttons shall have SS316 body, UV stabilized against sun radiation. Lettering
shall be raised and painted white. Lettering shall be in English. The ESD Buttons shall
mechanically latch upon operation and remain so until manually reset by opening with a
key common to all ESD Push Buttons.

The ESD Buttons shall incorporate SPDT switch, for voltage and current at which it
operates and shall operate on 24VDC.

The ESD Buttons shall be certified as EEx “d” suitable for hazardous area installation
where the device will be installed in accordance with IEC/ATEX or other approved standard
and shall be rated for IP 65 ingress protection as a minimum. All cable entries shall be IS0
M20x1.5 and fitted with blanking plugs to suit the hazardous area certification.

The exterior of the hand switch shall be identified with its hazardous area classification and
function. The external stainless steel labels shall be permanently attached to the hand
switch with a manufacturer's approved method.

3.4 Field Communicator

It shall be possible to perform routine configuration, calibration, display process variable,


diagnostics etc. from a hand held portable calibrator which can be connected at any
location in the transmitter loop. It shall be possible to perform all the above functions on-
line. The loop function shall remain unaffected while communication is going on between
transmitter and the field communicator.

In addition, there should be no interruption on the output while communicating with the
transmitter.

Field communicator shall meet the follow