06 Technical Specification

TECHNICAL SPECIFICATION
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KUWAIT OIL COMPANY (K.S.C)

(Register of Commerce No. 21835)
-For-
INSTALLATION OF NEW LP GAS RING HEADER AND ASSOCIATED WORKS AT
SHUAIBA INDUSTRIAL AREA
1. INTRODUCTION
1.1 In this Technical Specification, the description of the works to be executed is not given by way
of limitation but in amplification of the Works shown in the drawings and specifications and
shall be without prejudice to the requirements of the General Conditions of Contract, the
information obtained in the site visit and the Contract Specification.
1.2 The works and services to be executed by the Contractor specified in this Technical
Specification comprises of the ‘Installation of LP Ring header and related works inside KNPC
Shuaiba Industrial Area” as per the specifications, drawings and contract requirements as
specified in this document.
1.3 The Works shall be carried out by the Contractor in KNPC Shuaiba Industrial Area and related
sites as shown in the drawings. The Contractor shall execute the works in such a manner that
all the installations are complete in all aspects to meet the overall project requirements.
1.4 The basic design for this project have been prepared by the Company and incorporated in this
document. It is responsibility of the Contractor to use this information as the basis and prepare
all necessary additional drawings, details, calculations, stress and surge analysis and
identifying needs for anchorage, guides and supports required to complete the work.
1.5 The Contractor shall make good, relocate and reinstate roads and access points disrupted by
the work to permit free access during and after construction, to the Company’s operating and
maintenance personnel. Any such work shall be carried out with prior approval of the
Superintendent’s Representative.
1.6 The Contractor shall investigate , survey and locate all services crossing the areas of work
other than those mentioned on the relevant drawings and shall be responsible for maintaining
clearances and protections between the new Works and the existing services in accordance
with the Company Standards.
1.7 All the equipment shall be procured from Company’s approved Vendor list (VEC) and
internationally reputed vendors with proven experience in similar installations with a prior
approval from Company or from KOC approved vendor list.
2.0 CONTRACTOR’S DESIGN AND ENGINEERING
2.1. The Contractor shall be responsible for the design and detailed engineering of the
Facilities to ensure compliance with the design requirements stated in the Technical
Specification and drawings included in the Contract.
2.2. The Contractor shall carryout technical studies; follow up, submission of documents and
drawings for Company’s prior approval and all the construction works in accordance
with the Contract requirements.
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INSTALLATION OF NEW LP GAS RING HEADER AND ASSOCIATED WORKS AT SHUAIBA INDUSTRIAL AREA
2.3. If the Contractor recommends to make modifications or additions to any part of the
works, to meet the overall objective of project and without negatively impacting the
contractual obligations, it shall promptly notify the Superintendent of these, along with
the technical and commercial justifications together with any impact such a modification
or addition might, in the Contractor’s opinion, have on the Contract Price or the
Scheduled Turnover Date.
2.4. Review of Drawings & Documents
The drawings/ sketches provided in this document are ‘basic’ and indicative of the works
to be executed. The Contractor shall review and update all the drawings and documents
to incorporate its engineering input, HAZOP and system verification recommendations,
‘as built’ status etc..
2.5. Site Surveys, Re-Routing and Update of Data and Drawings
Prior to the commencement of works, the contractor shall carryout detailed site checks,
verifications and surveys to base their detailed design on specific site conditions, ground
levels, piping & equipment elevations, existing lines & services, and shall update the
project drawings and develop the construction and detail engineering drawings
accordingly.
The contractor shall therefore consider the same basis and shall carryout the works with the
same understanding within the contract obligation and at no extra cost and time.
2.6. Piping Stress Analysis
The Contractor shall carry out detail piping stress analysis of all new pipe work and pipe
line as per ASME B31.3/ ASME B31.8 and submit a Summary Report together with
detailed computer print outs, for Company’s verification & comments.
The Contractor shall finalize the locations, types, details of pipe supports, racks, guides
& anchor points and shall supply & fabricate all rolled steel structural (structures?)
required to ensure that the exerted forces, moments & stresses, are within specified
limits. Contractor to note that the pipe supports, their locations & numbers shown in the
Company Drawings are preliminary only for guidance.
2.7. Gas Analysis and Process Simulation:

In the drawings and data sheets certain basic information regarding gas mixture and its
composition is provided. However, the Contractor based on their engineering shall
obtain and site verify all the requisite information to ensure overall suitability of the new
facilities installed by them.
3.0 Deleted
4.0 HSE STUDIES:
The Contractor’s scope shall also include the following HSE studies, verifications and analysis
works to fully ensure safe, operable and well-designed modifications to the existing system.
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4.1. The Contractor shall submit HSE Plan addressing potential hazards, safety deliverables
and HSE issues associated with various phases of the Project. A set of Company document
is attached herewith for the Contractor’s guidance and implementation.
4.2. The Contractor’s submitted HSE Plan shall be subject to prior approval by the Company.
4.3. The Contractor shall during design, detail engineering, construction, installation and
execution works shall take corrective measures and evaluate/explore to incorporate all
associated health, safety and environment aspects to minimise hazards and risks at no extra
cost and time to the Company.
4.4. HAZOP study:
a) The Contractor shall perform a process system HAZOP analysis of the completed design
of the new facilities, including all significant vendor equipment information. The analysis
shall be performed by a team of knowledgeable personnel in process design, mechanical
design, engineering, operations, instrumentation and control system, maintenance and
other specialties as deemed appropriate. The HAZOP Study shall be in compliance to the
KOC Document No. KOC-L-017.
b) The HAZOP team leader shall be a third party independent of the Contractor’s
organization. Representatives of the Company, the Contractor’s project team and where
necessary, Vendor representatives shall be required to participate in the HAZOP Studies.
c) CVs of the HAZOP team leader and Contractor’s key personnel who will be participating
in the HAZOP review shall be submitted to the Company to make necessary
arrangements.
d) The HAZOP report shall contain the list of members, an overview of the techniques,
HAZOP work sheets, all relevant P&IDs with nodes marked up and final
recommendations. Draft report of study shall be submitted to the Company for review
and approval. The final report shall be completed before of ‘Approved for construction’
issue of the drawings. The Contractor shall, at no cost or schedule impact to the
Company, implement all HAZOP report’s final recommendations, which have arisen as
a result of non-compliance with the Works or due to the Contractor’s negligence.
e) For the purpose of the HAZOP study, the Contractor shall submit the proposed Plan &
Procedure for Company’s prior approval.
f) The Contractor shall during design, detail engineering and construction execution shall
take corrective measures and evaluate/explore to incorporate all associated health, safety
and environment aspect to minimize hazards and risks at no extra cost and time to the
Company.
4.5.Environmental and Social Impact Assessment (ESIA)
a. The Contractor shall not later than 30 days prior to commencements of Site construction
activities, provide to the Company and environmental impact assessment regarding the
proposed construction/commissioning activities for the Company’s approval. This must
assess the environmental risks inherent in the construction /commissioning phase and
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recommended measures to be taken to minimize them. It shall demonstrate that all

environmental issues have been identified and resolved regarding construction/
commissioning activities, including those identified at earlier phases. The assessment
shall include:
i) A register of significant environmental sensitivities.
ii) A register of the sources and amount of significant wastes and emissions, which will
be produced during construction/commissioning of the facilities.
iii) A description of the means by which the project HSE plans minimizes the amounts
of waste and emissions generated during construction/ commissioning activities.
iv) An assessment of any significant environmental impacts, which may be caused to

land, water or air during construction /commissioning. These impacts may occur
locally at the Site or at remote locations e.g. waste disposal sites, aquifers, and the
like.
v) Recommendations regarding the manner how the facilities shall be constructed

and/or commissioned and operated to minimize adverse environmental impacts.
vi) Assurance that construction and commissioning activities will result in compliance
with applicable environmental protection regulation that can reasonably be foreseen.
b) The Environmental and Social Impact Assessment Study (ESIA) should be carried out
during preliminary design phase of the project by the Contractor and must assess the
environmental risks inherent in the construction, pre- commissioning, commissioning
and operation of the project and demonstrate that, all environmental issues have been
identified and resolved.
c) The PEIA should be carried out through an independent third party selected from the list
of National Consultancy Firms approved by the Kuwait Environmental Public Authority
(KEPA), through tendering procedure (List of Consultancy National Firms will be
provided to the Contractor during execution of the Contract), and shall include the work
specified in this document.
d) In order to prepare the ESIA study and to obtain timely approval of project
Environmental Impact Statements (EIS) from the KEPA, HSE Group through the
HSEMS Implementation Committee has established ESIA procedure for KOC’s projects
and has placed on the KOC website with other approved HSE procedures for easy access
by project teams.
e) Based on the ESIA Procedure, project’s HSE Coordinator (Assigned by the

Superintendent) will be accountable for determining the need for application of the
Environmental Impact Assessment Process on a specific project.
f) The Contractor along with the HSE Co-ordinator shall be responsible of ensuring
development of ESIA documentation as defined by this procedure and in charge of
serving as the point of contact with in the Group or Team proposing project development.
Moreover, he / she is accountable for communication with the Environmental
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Public Authority on project-specific issues, including submission and approval of

documents related to the ‘Environmental and Social Impact Assessment Process’
4.6.Other HSE Studies as per approved HSE Plan according to KOC HSEMS Procedures.
5.0 WORKS TO BE EXECUTED
5.1 General & Mechanical
5.1.1. Unless otherwise specified hereunder and in the appendices, the Mechanical and Piping
works shall be performed in accordance with ASME B31.3, ASME B31.8, NACE-MR-
0175/ISO 15156 and other relevant standards referred in this Contract.
5.1.2. The Mechanical, Piping and Pipeline Works shall comprise Design, Procurement, Supply,
Installation, Construction, Inspection, Testing, Pre-commissioning, Commissioning and
Hand-over of new facilities along with all the piping , equipment and the associated works
in accordance with the specifications and drawings provided in this Contract and as
specified here to.
5.1.3. Scope of pipeline work are summarized hereunder at Table-1:
Table -1
New New
Pipeline No. of
S. Pipeline Pipeline
Line No Service From To Material/ new Pig
No. Diameter distance
Schedule Traps
(Inches) (Meters)
MAA API 5L Gr.B 2 No’s
MF-F7
1 FG-73A LP Gas Battery 52” 14.27 mm 3250 52” x
Limit 56”
Near Al- API 5L Gr.B
2 FG-XX LP Gas MF- Ahliya 10” 9.27 mm 3250 NA
SH01
Near Note XX
3 BD-XX LP Gas MF- MF-F7 Note XX 1500 NA
SH01
Notes:
a Pipeline Lengths as mentioned above are tentative; Final lengths shall be as per layout drawings
developed by the Contractor based on its own site survey & detail engineering. Same shall be finalized
after review & approval by the Company.
b The mentioned pipeline lengths include only the portion of FG pipelines designed as per ASME B31.8
respectively and therefore any section/non-piggable portion designed as per ASME B31.3 should not
be considered in the same.
c Pipe wall thicknesses specified in the above table are minimum requirements. However, it is
mandatory for the Contractor to calculate and determine the actual pipe wall thicknesses required for
the tie-in points on the existing pipelines and submit the same to Company for review and approval.
Accordingly, Contractor shall obtain Company’s approval on the wall thicknesses of the new line
pipes before taking up any action on procurement.
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Table -1
New New
Pipeline No. of
S. Pipeline Pipeline
Line No Service From To Material/ new Pig
No. Diameter distance
Schedule Traps
(Inches) (Meters)
d The Contractor shall ensure consistent inside diameter for line pipes , flanges, valves and fittings,
bends and elbows over and above ensuring the above wall thickness requirements.
e The approximate lengths indicated do not include miscellaneous piping at the pig traps viz. drain lines,
vent lines, kicker and bypass lines, PSV lines, Tie-in piping and fittings, Auxiliary piping for utility
streams.
f All lines and materials shall be suitable for ‘sour service’ and shall comply with NACE
MR0175/ISO15156. Piping classes and associated fittings and valves shall be as per KOC-MP-010.
g The new pig traps complete with associated piping, valves and accessories up to the insulation flanges
shall be installed in Manifold, as indicated in the Project drawings.
h For all piggable pipelines caliper pigging shall be performed.
i All the pipeline works listed in Table-1 shall be read in conjunction with the Technical Specification
and its annexures.
5.1.4. The following works shall be included in , but not limited to, in the scope:
a A detailed site survey shall be carried out to identity any obstacle in the proposed pipe
route.
b Installation of a new underground 52” (150 #) LP Lean Gas Pipeline from MAA battery
limit to MF F-7, in place of demolished 42” (FG069) pipeline and connect it to existing
52” Fuel Gas pipeline (FG073) seamlessly, to make the new line piggable from MAA
Battery limit to MF F-7.
c The new 52” pipeline shall tie-in from the existing 42” pipeline (FG 068) in a manner to
enable the future demolishing of the FG-068 pipeline and isolation, without interruption
to the LP gas consumers.
d Tie –in with existing 42” FG-068, 52” FG-73 and 10”-FG- Al Ahliya pipeline tie in shall
be performed by Hot Tap stoppling and by pass method for uninterrupted supply of Fuel
Gas to existing consumers, getting feed by FG-068 pipeline.
e Installation of a PIG Launcher/Receiver (S-1001) on new 52” LP Lean Gas pipeline near
MAA Battery limit and another PIG Launcher/Receiver at MF F-7 (S-1002) to make the
new 52” pipeline piggable from MAA battery limit up to MF F-7.
f Installation of a fiscal quality metering skid near MAA B/L (FMS-Z-001) to measure
the incoming LP lean gas flow rate. The metering skid shall have flow computers for
each run and associated instruments.
g Installation of a Gas Chromatograph (GC) with PLC at the Metering skid near MAA B/L
(FMS-Z-001).
h Installation of three barred Tee connections with remote operated valves and blind
flanges for future connections near Shuaiba Manifold SH-01. The sizes of the barred Tee
connections shall be one of 42” and two of 30” size.
i There shall be a branch-off near Shuaiba Manifold SH-01 for a new 10” pipeline to
supply LP gas to Al-Ahlia. This new 10” pipeline shall tie-in to the existing 10” Al-Ahlia
line near Al-Ahlia Battery Limit.
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j Installation of a 1.3 km (approx.) depressurization line, originating from downstream of

the 10” remote operated valve (ROV 1005) on the 10” pipeline to Al-Ahlia and
connecting up to existing burn of pit at MF-F-7 via the depressurization line for the new
52” LP gas pipeline. Size of Depressurization line shall be calculated by Contractor based
on depressurization calculation to be done at detail design stage.
k Installation of a fiscal quality metering skid (FMS-Z-002) with flow computers near Al-
Ahlia tie-in point. The Gas Chromatograph located at Metering skid near MAA B/L
(FMS-Z-001) shall be utilized for the metering skid (FMS-Z-002).
l Control station for metering skids near MAA B/L (FMS-Z-001) and near Al-Ahlia B/L
(FMS-Z-002) shall be provided.
m Drain pit with Vacuum tanker connection shall be provided near MAA PIG
Launcher/Receiver area.
n Drain pit with Vacuum tanker connection shall be provided near the metering skid at Al-
Ahlia B/L (FMS-Z-002).
o A flow meter with pressure and temperature transmitters with required upstream and
downstream lengths to be provided downstream of the Launcher/Receiver in MF F-7
area.
p Pig traps (numbers and sizes as per P&ID’s) shall be procured from Company’s approved
manufacturers. The Pig traps shall be as per KOC Standard KOC-MP-005. The
Contractor shall prepare the data sheet for pig launcher and obtain Company’s approval,
supply prior to procurement action.
q The Contractor shall be responsible for procurement, supply, fabricate, testing and
inspection of all other piping items necessary to perform the Works, including, but not
limited to, the following items:
 Coating materials for underground piping
 All welding consumables
 Insulation kits for insulated joints
 Repair material for buried pipe coating/ wrapping
 Any rolled steel section, structural steel, plate or pipe material, bolts, clamps,
washers and nuts required for fabricating miscellaneous pipe supports, guides and
anchors.
 Primer and painting material, including solvents and wire brushes for above ground
piping, valves and fittings, in accordance with KOC Standard for Painting and
Coating of Metal Surfaces-New Construction (KOC-P-001).
 All piping and fittings for the bypass lines, including valve/piping supports and
saddle pads.
 Miscellaneous pipes, fittings and valves required for pipe filling, hydro-testing and
pre-commissioning.
 Non sparking tools, balloons/blinds for safe isolations and light fittings suitable to
hazardous location.
 Supply pigs for hydro-test
 Gas plugs
5.1.5. Demolition Works
5.1.5.1. The Contractor shall obtain prior approval of Superintendent for the demolition
procedure, schedule and the demolition programme shall need specific prior approval
of the Superintendent. The same shall be executed as shown in the drawings and
specified elsewhere in the Contract.
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5.1.5.2. The demolition works shall include :
a. Demolition of existing 42” HP Fuel Gas pipeline (FG069) from MAA Battery limit
up to the MF-SH 01 42” (EF/1877) isolation valve point location (Approx. 2 KM).
b. Demolition of existing pipeline, equipment and installed items/services being

replaced by new works. The demolition and removal works shall, as a minimum,
include pipes, fence and redundant items.
c. Demolition of all the redundant and unwanted pipes and items pursuant to installation
of new works. All the materials and items made redundant by new works and
demolished will be transported and properly stored by the Contractor at a location in
Ahmadi as per the directives of the Superintendent.
5.1.6. Firefighting System
Firefighting system comprising fire extinguishers shall be installed at the Pig Trap
Stations. The Contractor shall review the firefighting system and Fire handling philosophy
of Shuaiba Manifold 01. Same shall be enhanced for new trap area and metering skid
inside Shuaiba Industrial Area.
5.1.7 General Technical Requirements
5.1.7.1 Procurement and Materials
a The Contractor’s scope of procurement shall include design, obtaining approval of the
Company, supply of material, inspection, testing and delivery to Company Stores. The
suitability, adequacy including redundancy, as needed, and operability of the material and
equipment supplied shall be Contractor’s responsibility. All material to be used in the
Works shall be new and Company reserves the right to reject Contractor’s or manufacturer’s
material which may have suffered undue deterioration due to storage, transit etc.
b All material required for the same shall be supplied by the Contractor. All supplied
materials shall be as per the relevant International and KOC Standards and shall comply
with NACE MR0175 / ISO 15156 for sour service, HIC tested as per NACE TM0284.
c All piping, valves, fittings shall be as per KOC Standard Specifications KOC-MS-001
(KOC Material Specification: Line Pipe for Sour Service) & KOC-Q-014 (KOC Standard
for Project QA/QC Requirements). The piping material shall conform to the following KOC
standards:
 Pipes, SMLS, API 5l KOC-MP-018
 Pipes, SAW, API 5l KOC-MP-019
 Line pipe for sour service KOC-MS-001 Pt.1
 Ball Valves KOC-M-033 Pt.1
 Globe Valves KOC-M-014
 Gate Valves KOC-MP-013
 Check Valves KOC-MP-015
 Induction Bends KOC-MS-002
 Pipe Fittings KOC-MP-010
 Pig Traps KOC-MP-005
d Carbon Steel Pipes for sour service shall be manufactured as per KOC-MS-001. Double
seam submerged arc welded pipes shall not be acceptable.
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e Lines pipes inside fence shall be SAML or Seamless as per the standards.
f Bevel Protectors of line pipes shall be hookable type to facilitate hooking with removing
during pipe handling.
g Carbon steel shall be fully killed. Material grades and mechanical properties of pipe fitting
and pipes shall match and their weldability shall be ensured. HIC Testing and Impact
Testing requirements shall be complied.
h Induction bends shall be used for the pipelines to ensure piggability. Spiral SAW pipes shall
not be used for the manufacture of induction bends. Contractor shall submit datasheet for
the Hot Induction Bends for Company prior approval.
i Contractor shall submit datasheets for the line pipes, piping material, pipefittings, valves
and all the materials for Company prior approval.
j Fittings shall be as per ASME B 16.9 and the relevant KOC Standards.
k Ball Valves shall be fire-safe, tight shut-off, as per API 6D and the related KOC
Standard.
l Spectacle blinds shall be as per the standard drawing (material to be specified by design
engineer). Steel line blanks shall be in accordance with ASME B16.48/ ASME B 31.3.
Spectacle Blinds shall be used up to a maximum weight of 50 Kgs. Blinds and spacers to
be used if weight exceeds 50 Kgs. Pipe flanges at line blanks (spade, spectacle blind) shall
be fitted with jack screws. At all tie-in locations where spectacle blinds are not to be
provided, the Contractor shall install a spacer ring to facilitate future isolation by blinding.
The flanges shall be provided with jack screws.
m Pipeline tees shall be barred type for branch opening size above 30% of pipeline dia. and
shall be as per standard drawing, as specified in the document.
n The Contractor shall supply all new valves as shown in the P&ID and piping layout
Drawings. The valve pressure ratings shall be as indicated in the P&ID. All new valves,
shall conform to the relevant KOC standards as specified at Exhibit II and shall be suitable
for sour service.
o The Contractor shall submit completed valve data sheets available in relevant KOC
standards and valve manufacturer’s Drawings for the Company’s review and approval
prior to submission of enquiry specifications. The Contractor shall submit valve data sheet
for all valves, duly filled, for Company approval prior to placement of purchase order with
valve manufacturer. The format for valve data sheet shall be as per the data sheet in the
relevant KOC standard.
p After receipt of new valves from manufacturer, all new valves 100% should be transported
by Contractor for inspection at Company Central Workshop and testing shall be carried out
under the Contractor and Company witness inspection. In the event of failure of any of the
selected new valves during the hydro test, the rejected valves shall be returned back to
manufacturer and the valves shall be replaced at no extra cost to the Company. After testing
and servicing, the Contractor shall transport the valves to the Site for installation.
q All ball valves shall be of bolted construction, as per attached project data sheet. For all
valves on piggable lines bore shall match internal diameter (ID) of pipe.
r The Contractor shall procure , supply , provide storage and install for all material/ items
required for the Works, in accordance with the specifications, codes and standards given
in Contract and based on its own material take off to be prepared after Site survey and
verification of all Company supplied Drawings. The Company shall not be responsible for
any short fall in the quantities of such material/ items. The Contractor is also fully
responsible for any delays caused due to its procurement of material/ items.
s The Contractor shall be responsible for all the pipe delivery and storage activities including
transporting the line pipe and stacking them in an area to be designated by the
Superintendent’s Representative. Random checking of pipe external coating shall be done
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by the Contractor using its holiday detection equipment and under the supervision of
Company’s personnel. Damage, which may occur to pipe coating during
transportation/handling, shall be repaired by the Contractor at its own expense as per the
requirements of KOC-P-004 Part 6, Rev.2 and KOC-P-004 Part 4, as applicable. Repaired
portions of the external coating shall be checked as above.
t Studs and Fasteners when electro-zinc plated shall comply with ASTM 633 SC4 Type I.
5.1.7.2 Fabrication and Welding
a For pipelines to design code ASME B31.8, the welding and NDE shall be in accordance
to API 1104, supplemented by the project specifications, Appendix M-7 and KOC 015
Specification 015-LH-1001 and its addendum.
b For piping to design code ASME B31.3, the welding and NDE shall be in accordance
to ASME IX, supplemented by the project specifications, Appendix M-1 and KOC 015
Specification 015-WH-1001 , 015-WH-1002 and their addendums.
c All piping Fabrication and Installation works shall be carried out in accordance with
ASME B 31.3, ASME B31.8 , Appendix M-1, Appendix M-2 and Appendix M-3 as per
the related works.
d The welding Procedures and welders and welding operators qualification shall be as
per A p p e n d i x M - 1 , ASME Sec. IX and API 1104. Welding procedures and welders
and welding operators shall be qualified and approved by the Company prior to
commencement of welding work.
e For piping as per ASME B31.3, the NDE shall be in accordance with KOC Standard
KOC-MP-010.
f Any form of hot work, including welding, shall be minimized inside the GCs and MFs
and shall be carried out with the permission of Company’s Fire and HSE Teams.
Therefore, the Contractor shall maximize the use of pre-fabricated pipe spools, which
include piping, valves and fittings, requiring only shop fabrication of spools and cold
work for field assembly and installation at Site.
g The Contractor shall submit for Company’s approval, its procedure for shop - fabrication
and installation of pipework and piping route, together with the shop/working Drawings
considering the above criteria.
5.1.7.3 Installation
a Piping and pipeline installation shall be as per ASME B31.3 & ASME B31.8
respectively and Company Specification 015-IH-1001 and SPC-ME-03: Spec for Piping
Fabrication & Erection.
b Piping and piping spools at all the locations shall be installed, as per Company approved
procedure and working Drawings. The Contractor shall submit its proposed procedure
and sequence for pipeline assembly and erection for Company’s review and approval.
c Right of way (R.O.W) shall be constructed by the Contractor as specified at Civil and
Structural Works and shall be regularly maintained in order to keep the working area
accessible at all times.
d The Contractor shall be responsible for de-watering of ditches for pipeline installation due
to high water table areas along the pipeline route, if required. The Contractor shall also
remove, pump out and dispose of water that might seep and accumulate inside ditches.
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e For piping/pipeline to be installed in/or crossing existing pipe racks, the modifications
required to existing structures including supply and installation of fabricated steel items,
brackets, U bolts, clamps, nuts and necessary drilling shall be carried out by the
Contractor.
f Pipeline installed underground shall be buried such that the minimum cover is 1000 mm
measured from the top of the pipe to the normal ground level in the area; however, the
depth of burial is to be increased locally as required to eliminate minor vertical changes
in the piping route.
g The minimum cover or buried depth of the pipeline shall be increased gradually in the
vicinity of other buried piping or services so that it passes under the existing obstruction
with a minimum clearance as specified in KOC standard KOC-L-002.
h Electrical isolation of pipelines and pipings shall be done using insulation flanges as per
KOC Standard KOC-L-015 Cl.7.11 and KOC-L-012 Cl. 7.8.
i Minimum Corrosion Allowance foar carbon steel vessels, pig traps and pipes shall 3.2
mm in line with KOC-MP-005 Cl.7.9 and 015-CH-1002 Cl.5.0 as applicable.
j Clearances between new and existing pipe/structures shall be as per KOC Standard KOC-
L-002. Clearance between services shall also be in accordance to applicable Codes /
Standards as approved by the Company.
k Line markers for underground pipeline shall be installed every 200 meters and at all pipe
bends, either side of road crossing and at the start and end of the pipeline along the route
of the new pipelines as per KOC standard drawing 55-04-67.
l At road crossings, carrier pipes shall be sleeved as per KOC Standard Drawing No.55-04-
77A. All materials for road crossing shall be supplied by the Contractor. Sleeve pipes for
road crossing should be as per Section 7.8 of KOC Standard KOC-L-015 and shall be
externally coated and wrapped in accordance with KOC-P-004 Part-6 and internally
coated with phenolic epoxy to 300 microns as per KOC-P-005 - KOC Standard for
Internal Coating of Pipelines. For road crossings the enclosed SPC-C-01 Spec. for
Pipeline Crossings for Roads & Highways
m Pipe stringing, stacking and Right Of Way (ROW) shall be in accordance with KOC
Specification 015-IH-1001 - Pipeline Construction and relevant Company Standards.
n Piping and valve supports shall be in accordance with KOC and other approved relevant
standards. The Contractor shall check and verify by doing stress analysis on all loads for
all aboveground piping, Valves and pigging stations to find out the suitable supports
which shall be reviewed and approved by the Company before installation.
o All hot taps required for the Works shall be carried out by the Contractor in
compliance with KOC Standard KOC-MP-038 (KOC Recommended Practice for Hot-
Tapping and Plugging) using his own hot tap machine, labour and consumables.
Procedure for carrying out hot tapping Works shall be submitted for the Company’s
review and approval.
p The Contractor shall restore any temporarily removed items, which was removed to
facilitate construction activities. It shall also make good any damages inflicted to
Company's existing installation during its execution of the Works, all to the satisfaction
of the Superintendent.
q Color coding of above ground piping shall be in accordance with Company Standard
KOC-P-017.
r The Contractor shall insert gas plug after cold cutting the line, for welding flange, fittings
or the like. The Contractor shall provide all gas plugs, which shall be approved by the
Company.
Page 12 of 66
s The Contractor shall not use oxy-acetylene cutting gear or welding equipment on the
Works unless prior permission in writing is obtained from the Superintendent's
Representative. Before cold cutting of the line, the Contractor shall complete the isolation
and draining/venting of the line.
t All coated pipes shall be subjected to successful holiday detection tests at site immediately
prior to lowering of the pipes in the excavated trenches .Holiday test shall be carried out
by the Contractor under the supervision of Superintendent’s Representative.
u The piggable pipelines shall meet the requirements of the SPC-ME-05 Requirements for
a Pipeline to be ‘Piggable’ enclosed in this Contract. For pigging operations the SPC-ME
04 Calliper Pigging with GPS Mapping shall be referenced and followed.
5.1.7.5 Tie-ins and Shutdown
a) The Contractor shall prepare a tie-in schedule and procedure for carrying out the tie-in
Works, specifying the duration of Works required at each tie-in location for
Superintendent’s approval. This schedule shall show the period of shutdown required, if
any. Such shutdown work should be based on 24 hours basis in order to minimize the
shutdown period. The Contractor shall give fourteen (14) days advance information for the
shutdown requirement or thirty (30) days for complete line shutdown. Company approval
for a shutdown will be contingent upon the Contractor having completed and staged all
work required for the shutdown.
b) The Contractor shall give fourteen (14) days prior written notice to the Superintendent’s
Representative for the shutdown requirement or thirty (30) days for complete line shutdown.
No planned shutdown shall be permitted on Fridays, Saturdays and other national holidays,
unless absolutely necessary, and at the sole discretion of the Superintendent’s
Representative. The Contractor shall submit a detailed shutdown procedure and program
indicating duration to the Superintendent for review and approval. Only one shutdown of
the GC and MF shall be permitted.
c) Shutdown may be required for some tie-in Works. The Contractor shall ensure that all the
necessary preparatory Works are completed before taking shutdown. It is essential that the
shutdown must be minimized to the shortest possible period.
d) The Superintendent has the right to specify the duration of the shutdown and, if required,
the Contractor shall increase his manpower and equipment accordingly to complete the
Works in accordance with the Contract, within the specified time at no extra cost to the
Company.
e) The Contractor shall sequence his work in such a way that there is minimum disruption to
normal activities and production and shall co-ordinate his shutdown schedule with any
maintenance outages planned by the Company, for work requiring Site shutdown.
f) Company approval for a shutdown will be contingent upon the Contractor having completed
and staged all work required to support shutdown needs.
g) Tie-ins which are required to be executed through hot tapping shall be as per
Company Standard KOC-MP-038. Hot tapping machine, labour and all consumables for
the same shall be supplied by the Contractor. Hot tapping Works shall be carried out by an
experienced Subcontractor (M/s. T.D. Willamson or equivalent). All credentials of
Subcontractor as well as procedure for hot tapping Works shall be submitted for the
Company’s review and approval.
h) At tie-in location, the existing pipelines need to be drained after shutdown and
isolation. The Contractor shall include in his submitted shutdown details, all necessary
isolation / draining detailed procedures with schedules for Company’s review and approval.
i) All spading, flushing, draining and purging activities of the existing line to facilitate hook
up job shall be in the scope of Contractor.
Page 13 of 66
j) Piping & piping spools at all the locations shall be installed, as per approved method
statement and working Drawings of the Contractor.
k) For piping to be installed on existing pipe racks and piping corridors, the modifications
required to existing structures including supply & installation of fabricated structural steel
items, brackets, U bolts, clamps, nuts & necessary drilling shall be carried out by the
Contractor.
l) Piping installed underground shall be buried such that the minimum cover is one thousand
(1,000) mm measured from the top of the pipe to the normal ground level in the area,
however the depth of burial is to be increased locally as required to eliminate minor vertical
changes in the piping route.
m) All backfilling works for buried piping shall generally be carried out in accordance with the
Company’s General Specification, Standard 381/22, and as instructed by Superintendent’s
Representative.
n) All open drains shall have sufficient slope to drain towards the drain sumps, which shall be
constructed by the Contractor.
5.1.7.6 Purging
i. For all hot work and welding on the existing pipelines, a Nitrogen blanket shall be
maintained for the full duration of the Works. Company approved gas plugs shall be
used to isolate areas of hot work and welding.
ii. The Contractor shall be deemed to have allowed in his Contract Price for providing
necessary tapping for Nitrogen purging / Nitrogen blanketing in the existing lines, as
required.
iii. The Contractor shall submit shutdown schedule and procedures for tie-in Works,
isolation, draining and purging to the Superintendent for review and approval.
iv. The Contractor shall provide for all requirements of Nitrogen gas for purging and
blanketing of lines during tie-ins and all hot work and welding on existing / new lines.
5.1.7.6 Dewatering and Drying
After the hydro-test, the line shall be dewatered, and dried prior to commissioning as
detailed below and generally in conformance with the KOC Engineering specification 015-
IH-1005. For dewatering, the Contractor shall launch an approved pig pushed by
compressed air. Pig movement shall be controlled to ensure proper draining of the line.
Pigging shall be repeated until the line is completely drained and approved by the
Superintendent’s Representative. The expelled water shall be discharged through a
suitably sized line to a safe area as approved by Company's HSE Team. The Contractor
shall be responsible to make good any damage caused by the discharge of water. After
dewatering, spades shall be removed from the line and new replacement gaskets shall be
installed at all flanges where spades have been removed.
After dewatering, the pipeline shall be air dried using batching pigs and slugs of oil free
air as specified in Company specification 015-IH-1005.
Cleaning, calliper pigging with GPS Mapping shall be in accordance with SPC-ME-04
Rotating equipment shall be isolated during hydrotesting of the connected piping.
5.1.7.7 Hot Tapping & Stoppling Works

All hot taps required for the Works shall be carried out in compliance with KOC Standard
KOC-MP-038 (KOC Recommended Practice for Hot-Tapping and Plugging) and HSEMS
Procedure KOC.SA.019 – Safety Procedure for Hot Tapping.
The hot tapping and stopple works shall be performed by a specialized Sub Contractor well
experienced in executing similar hot tapping and stopple works for pipelines. The
Contractor shall submit his procedure along with drawings for Company’s review and prior
approval.
Page 14 of 66
5.1.7.8 Coating and Painting

a. Underground pipes shall be externally coated as per KOC Standard KOC-P-004 Part 6
(three (3) layer polyethylene coating), but when Company agrees that this is impractical
due to small size then high build polyurethane or high build epoxy may be applied as
specified below for fittings and anchor flanges.
b. Underground weld joints and flanges shall be coated as per KOC Standard KOC-P-004
Part 7 (KOC Standard for coating of Field Girth welds, Fittings and Flanges).
c. Underground fittings, anchor flanges etc. that cannot be coated with three (3) layer
polyethylene shall be coated as per KOC standard KOC-P-004 Part 9 (KOC Standard for
external coating for underground piping / pipelines – High Build polyurethane Coating)
or as per KOC-P-004 Part 8 (High Build epoxy coating) at Contractor’s option.
d. All above ground pipes, equipment and structures shall be coated as per KOC-P-001.
KOC standard for painting and coating of metal surfaces – New construction.
e. All the new coating and wrapping materials shall be supplied by the Contractor and
approved by the Superintendent’s Representative prior to application. After application,
completed work shall be tested by the Contractor, using a holiday detector and standard
procedures, in the presence of and as specified by the Company’s Inspection and
Corrosion Team. Any defective coating and wrapping, thus discovered, shall be repaired
by the Contractor to the complete satisfaction of Superintendent’s Representative without
any additional cost to the Company.
f. All aboveground carbon steel piping shall be grit blasted and painted, inspected, tested
including DFT measurement, all in accordance with KOC Standard KOC-P-001, which
shall be carried out by the Contractor and witnessed by Company Inspection Team
personnel. All painting material specification shall be submitted for Superintendent’s
approval.
g. Grit blasting, coating and wrapping procedures shall be submitted for the Company’s
approval.
h. All materials for blasting, coating, wrapping and painting shall be procured from
the Company’s approved list only.
5.1.7.9 Demolition Works

a The demolishing scope of work comprises isolation, flushing, desludging, purging with
nitrogen gas to make the lines hydro carbon free and removal of existing underground gas
pipelines as given below in Table 1. The scope of work also includes excavation of a suitable
trench for cutting and removal of the pipelines and backfilling and grading after completion
of dismantling Works.
b The pipelines shall be completely purged with nitrogen gas, desludged and dismantled by
cold and removing in sections.
c Prior to commencement of dismantling of the pipelines, all its containment shall be removed
by the Contractor using vacuum tanker and shall be transferred to nearby facilities in Burgan
area as approved by the Company.
d The Contractor shall provide piping, fittings and valves required for the temporary draining
lines. The pipeline shall be completely desludged. Draining and desludging procedure shall
be submitted to the Superintendent for approval. Vacuum tanker with operator shall be
provided by the Contractor including all other required manpower, tools, etc.
e All the discarded and the redundant steel pipe materials, structural items, concrete and other
materials shall be transported and unloaded at the Company designated storage area.
f The lines to be dismantled shall be isolated as follows:
i) The lines shall be cold cut and blanked by welding / bolting a suitable steel plate /
blind flange.
Page 15 of 66
ii) At the manifolds, the connection to the manifold headers shall be removed and
provided with a blind flange.
iii) The pipelines shall be positively isolated from the existing lines by blinding all
branch connections in order to carry out the demolition Works.
iv) At Road Crossings
v) At all locations where the existing pipe lines crosses under asphalt roads, the section
of sleeve pipe shall be left in situ. A clear length of approximate 1 meter (minimum)
shall be retained on either side of the sleeve pipe section under road crossing. The
pipe shall be completely desludged, cleaned by steam injection if required and
provide with a suitable rubber end cap to seal the two ends. The type and design of
end cap shall be approved by the Company.
vi) A trench with a working clearance of 1 meter all around the pipeline shall be
excavated. After removal of the pipeline, the trench shall be backfilled and graded.
5.2 Process Engineering
5.2.1. The Process Engineering scope of work shall include carrying out the detailed process design
for the works, and issue of detailed engineering documents and drawings (to Company for
approval), incorporation of the comments and issue of final documentation and drawings.
5.2.2. The Contractor’s services and deliverables under the process engineering scope portion of
this project shall comprise, but not be limited to, the detailed engineering activities required
during the execution of engineering detailed design, procurement, construction, installation,
pre-commissioning testing, commissioning and performance testing. The scope also includes
the submission of “As-built” documentation, manufacturers’ data and operating and
maintenance manuals for the project.
5.2.3. Process Engineering Deliverables:

The following drawings and documents as a minimum shall be developed by the
Contractor based on the information provided in the Tender documents and results of
design and detailed engineering
a. Process Design Basis
b. PFD’s with Heat and Material Balance
c. Hydraulic calculation report for the new 52” LP Lean gas pipeline including the
following
 New 10” pipeline to Al-Ahlia B/L
 Downstream portion after tie-in point TP-006, consisting of portions of
existing pipelines 52” FG-073 & 52”-FG-071 up to the 52” branch-off to
new LP compressors in BS-180 (total of approx.3.7 kms). Refer P&ID SK-
P-LP-005.
 52” inlet pipeline (52”-FG-1001-C15B) for new LP gas compressors
(approx. 900 meters). Refer P&ID SK-P-LP-005.
d. Editable simulation files of pipeline simulation.
e. Line sizing calculations
f. P&IDs (with Line no’s, Instruments Tags, Valve Nos, Tie-in Nos, ICMS details,
all Missing Information, Demolition Details)
g. Depressurization calculation report for the 52” pipeline, 10” pipeline, Pig traps
and selection of MDMT of the Depressurization lines based on Depressurization
calculation.
h. Atmospheric vent dispersion calculations
Page 16 of 66
i. PSV Sizing calculation

j. ROs and PSV data sheets.
k. Line list & Equipment List
l. Operating Manuals with start-up / Shutdown Procedure
m. Training manuals for the entire facility
n. All HSE Studies & Reports for facility including vendor packages.
o. Closeout of all HSE studies recommendations.
p. Vendor print documents
q. Pressure drop calculations for metering skids
r. All other process related documents
5.3 INSTRUMENTATION
5.3.1. The Scope of Instrumentation Works shall comprise but not limited to design, detailed
engineering, procurement, inspection, supply, installation, testing, pre-commissioning
and commissioning of the complete instrumentation and control systems as defined
herein and in the attached documents and drawings.
5.3.2. WORKS TO BE EXECUTED

The works to be executed by the Contractor shall include all the works as specified in
the Contract, Technical Specifications and drawings.
5.3.3. The Contractor shall carryout the following works as a minimum:

5.3.3.1. Installation of field instruments, F&G detectors and CCTV cameras at Pig L/R-S-
1001 fenced area, near SH-01, Al-Ahlia metering skid fenced area and Pig L/R-S-
1002 fenced area.
5.3.3.2. Installation of a fiscal quality metering skid near MAA B/L (FMS-Z-001) to
measure the incoming LP lean gas flow rate. The metering skid shall have flow
computers for each run and associated instruments. Metering skid shall be provided
as per “Gas Metering Specification (SPC-I-001)”.
5.3.3.3. Installation of online Gas chromatograph at MAA B/L metering skid. Gas
Chromatograph shall be communicating with flow computers directly for metering
and gas composition and GC status shall be through RTU to CNMC/SCNMC &
GMC. Gas Chromatograph shall be provided as per “Analyser Specification (SPC-
I-002)”
5.3.3.4. Installation of a fiscal quality metering skid (FMS-Z-002) with flow computers near
Al-Ahlia tie-in point. The Gas Chromatograph located at Metering skid near MAA
B/L (FMS-Z-001) shall be utilised for the metering skid (FMS-Z-002).
5.3.3.5. RTU PLC and F&G PLC with PSU & Battery back-up shall be provided at each
locations of Pig L/R-S-1001, SH-01 branch-off to Al-Ahlia and Pig L/R-S-1002 at
M/F-F7. RTU and F&G PLC shall be provided as per “Specification for RTU (SPC-
I–006)” and “Specification for F&G (SPC–I–007)”.
5.3.3.6. Metering Supervisory system with Flow Computers, Metering PLC and Metering
Computer with HMI in Metering cabinet with PSU & Battery backup near MAA
B/L (FMS-Z-001) and near Al-Ahlia B/L (FMS-Z-002) shall be provided.
5.3.3.7. A flow meter with pressure and temperature transmitters with required upstream
and downstream lengths to be provided downstream of the Launcher/Receiver in
MF/ F-7 area.
5.3.3.8. All required data’s from Metering skid (FMS-Z-001) at Pig L/R-S-1001 and
Ultrasonic flowmeter with its Pressure & Temperature Transmitters at Pig L/R-S-
Page 17 of 66
1002 at MF/F-7 and Metering (FMS-Z-002) at Al-Ahlia shall be provided to the

existing Pipeline Leak Detection System (PLDS) at SCNMC to monitor the 52”-
PG-1003 to 52”-PG-1006 and 52”-PG-1003 to 10”-PG-1004 pipeline segments.
PLDS shall be as per “Specification for PLDS (SPC-I–003)”.
5.3.3.9. RTU PLC, F&G PLC, CCTV and Metering System shall be connected to existing
SCADA at SCNMC, CNMC and GMC through existing Fiber Optic
Communication System at nearby vicinity. Fiber Optic Comminication System
shall be as per “Specification for FOCS (SPC–I–004)”.
5.3.3.10. The Contractor shall maintain the spare capacity and system capacity in all the
existing systems as per KOC Standard and requirements.
5.3.3.11. Transfer of the control signals RTU shall be installed. Wherever existing RTUs
arEGPMe available and same shall be utilized by expanding.
5.3.3.12. All control and monitoring signals shall be connected to SCNMC SCADA system
located in Shuaiba area & CNMC in Subiya and repeated at GMC SCADA system
in Burgan.
5.3.3.13. Connection to GMIS system also shall be provided for report generation. Necessary
graphics configuration shall be done at SCNMC, CNMC and GMC.
5.3.3.14. All metering skids signals shall also be available at CNT Control rooms
CNMC/SCNMC for operating the pipelines as well as generating the fuel
consumption reports.
5.3.3.15. All valves and measuring devices shall cause extremely low pressure drop in the
process stream.
5.3.3.16. F&G alarms inside Shuaiba Industrial Area shall be repeated in the Shuaiba Public
Authority Firefighting Control room as required.
5.3.3.17. The P&IDs attached with the technical specification are indicative only and shows the
minimum requirement. The Contractor to develop the detailed P&IDs during the detail
engineering stage and supply Instruments in line with the same.
5.3.3.18. All instrument Data Sheets shall be prepared in ISA format and submitted for
Company’s review. Comments if any shall be incorporated prior to placing the order
5.3.3.19. All field Transmitters, Converters, and Positioners, shall be smart type and shall be used
in analogue mode, with HART Communication protocol. All field transmitters shall be
indicating type (even if not indicated in the P&IDs). All Instruments and related
materials shall have Company approval prior to procurement.
5.3.3.20. All wetted part material for instruments, valves and fittings shall comply with NACE
MR-01-75 requirements. The impulse tubing/ tube fittings, piping/ pipe fittings, valves,
manifolds etc. shall also meet NACE requirements for sour service.
5.3.3.21. All junction boxes and cables shall be properly identified with proper stainless steel
plates with details inscribed on it. The details shall be submitted to the company for
approval.
5.3.3.22. The Hazardous Area classification shall be specified in the drawings by the Contractor
as per KOC Standards. All instruments and devices shall be certified accordingly.
5.3.3.23. The Contractor shall survey, propose and submit for the Company approval complete
instrument cable routes related to the works specified. New instrument cable routes shall
be excavated and backfilled after laying cables for the above routes. The Instrument
cable route shall follow the Electrical cable route drawings attached.
5.3.3.24. It shall be the responsibility of the Contractor to investigate, survey and locate all
existing services crossing the area of works prior to excavating or laying any cable. Any cable
falls under the new installation, it is the responsibility of the Contractor to re-route these cable.
Contractor shall propose the re-routing layout for Company prior review.
Page 18 of 66
5.3.3.25. All instrumentation shall have necessary isolation, vent and drain valves. In case of
remotely mounted instruments, isolation valves near the instruments are required in addition to
those on the piping/ vessel.
5.3.3.26. All field instruments shall be provided with individual access and safe working platform
as needed, even when the instruments are near the vessel ladder, in order to provide safe working
environment for maintenance personnel.
5.3.3.27. The Contractor shall submit complete technical offers from the proposed vendors for
each of the instruments and the offer shall be subject to review/ approval
5.3.3.28. All field transmitters shall be electronic smart type configured in analogue mode. The
field transmitters shall be indicating type with appropriate communication protocol in line with
the existing DCS/ESD Systems at each GCs /Booster Stations
5.3.3.29. Instrumentation and controls required as a minimum shall be as per the P&IDs and
relevant documents enclosed. It is the Contractors responsibility to provide sufficient
instrumentation and controls for safe, continuous and desired operation of the new flares.
5.3.3.30. Instrument calibration, scales, readouts etc. shall be in dual system, metric and imperial.
5.3.3.31. All field Instrumentation including the Flame Front Generator Panel, Field switches,
Ultrasonic Flow Meter, Acoustic Pilot Flame Monitors, Solenoid Valves, Cable Glands,
etc. shall be weather proof to IP-65 and explosion proof (EEx ‘d’) suitable for the Area
Classification. Air purged type Flame front Generator Panel is not acceptable to the
Company.
5.3.3.32. All locally mounted instruments/ equipment shall be installed such that it is easily
accessible for maintenance to be carried out and to ensure minimum interference from
adjacent equipment.
5.3.3.33. Separate Junction Boxes shall be utilised for different levels and types of signals as per
standards.
5.3.3.34. Field instruments shall be identified by a stainless steel nameplates having the following
pertinent details: tag no., manufacturer’s name, model no. /type, serial no., electrical
classification, certification mark, range, rating, set point etc.
5.3.3.35. Calibration and testing of relief valves at Company Workshop.
5.4 Electrical Works
5.4.1. The scope of Electrical Works shall comprise but not limited to carry out site survey,
data collection, geotechnical investigations, site preparation, earth works, exploratory
slit trenching, identification, protection, re-routing / re-location of existing services and
facilities, complete design, detailed engineering, documentation, procurement, material
supply, storage, delivery to site, installation, testing and commissioning of electrical
equipment, accessories and associated power distribution network.
This part of specification for the electrical system shall be read in conjunction with
relevant Company Standards or Recommended Practices, standard drawings, data
sheets and the Project drawings referred here, its annexures and elsewhere in the
Contract documents.
Any other related electrical equipment / items / works that are not specifically
mentioned in the specification but required to complete the Project, shall be the
Contractor’s responsibility and included in the scope.
5.4.2. The scope of Electrical Works shall provide power supply to facility, equipment or
systems installed inside and outside of the Project premises including following:
Page 19 of 66
5.4.2.1. The Contractor shall design, supply & install the power distribution network and
execute all electrical related works for the following locations:
a) New 56”x52” Pig L/R Area Near KNPC Fence inside Shuaiba Industrial Area
b) New Pit Near MF-SH-01 Inside Shuiaba Industrial Area
c) Metering Skid near Ahliya Industries
d) New Pig L/R Area near MF-FM-7
e) Tie-in Area near MF-FM-7
5.4.2.2. The Scope of Work includes all locations/equipment/system as described in this
Technical Specification for works related to all the engineering disciplines.
5.4.2.3. New 56”x52” Pig L/R Area Near KNPC Fence Inside Shuaiba Industrial Area
a) Supply and install power distribution network for New 56”x52” Pig Trap (or Pig
Launcher / Receiver Area) installed near KNPC Fence inside Shuaiba Industrial
Area.
b) The Contractor shall provide power supply to all the electrically operated equipment
at this location such as MOV’s, ROV’s, CPTR unit, power outlet and instrument
loads in this location through a dedicated Compartmentalized Flameproof Power
Distribution Board and light fittings & lighting circuits through Flameproof
Lighting Distribution Board.
c) The incoming supply for flameproof Power Distribution Board shall be taken by
modifying the existing spare feeder of the existing Power Distribution Board
(supplied and installed by EF/1717 Contractor) at Metering Skid at Location-24,
refer single line diagram.
5.4.3. New Pit Near MF-SH-01 Inside Shuaiba Industrial Area
Supply and Install power distribution network for New Pit near MF-SH-01 inside Shuaiba
Industrial Area. The Contractor shall provide power supply the electrically operated
equipment such as MOV’s, ROV’s in this location from the designated spare feeders and
inclusion of outgoing feeder breaker in the existing flameproof Power Distribution Board
(supplied and installed by EF/1717 Contractor), refer single line diagram.
5.4.4. Metering Skid Near Ahliya Industries Inside Shuaiba Industrial Area
Supply and Install power distribution network for New Metering Skid near Ahliya
Industries inside Shuaiba Industrial Area. The Contractor shall provide power supply to
all the electrically operated equipment at this location such as MOV’s, ROV’s, CPTR
unit, Power outlet, Instrument loads and light fittings & lighting circuits through dedicated
Power Distribution Board. The Power Distribution Board shall take power from dedicated
Solar Power System suitably designed and rated to meet the load requirement, refer single
line diagram. The solar modules/strings shall be installed suitably over the metering skid
shed supported with design calculations. The battery set, solar control panel and DB shall
be located appropriately. The MOV actuators (if any) within the metering skid at this
location shall be 24V DC operated and to be supplied by metering skid vendor.
5.4.5. New 56”x52” Pig L/R Area Near MF-FM-7

The Contractor shall provide solar powered lighting pole to provide lighting for the
facility, refer equipment layout diagram.
Page 20 of 66
5.4.6. Tie-in Area Near MF-FM-7

The Contractor shall provide solar powered lighting pole to provide lighting for the
facility, refer equipment layout diagram.
5.4.7. Any modifications/extensions in the existing Switchboard/MCC Panel/Distribution

Board and/or related equipment/component, as required to make it suitable to meet the
Project requirement (including design, supply, installation, inspection, testing &
commissioning) shall be included in the scope of the Contract. The Original Equipment
Manufacturer (OEM) only shall carry out any modification / extension work. The
Contractor shall submit all supporting drawings and document for Company review
and approval related to all modification / extension works.
5.4.8. Electrical design, equipment and materials shall be manufactured and tested to meet
dusty and corrosive environmental conditions as specified in KOC-G-007. In
particular, it shall be noted that for the electrical design, ambient temperature limits
shall be -3°C to 50°C for all indoor and outdoor equipment. Electrical system design
shall be in line with KOC Recommended Practice for Design Basis and Selection of
Electrical Systems KOC-E-003. Electrical equipment to be located in hazardous areas
shall be certified and selected as per KOC-E-004.
5.4.9. Wind-blown sand and extremely fine dust is very difficult to exclude from enclosures
in Kuwait. As a result, outdoor control panels, junction boxes will be kept to an absolute
minimum. All the electrical equipment installed within an enclosed building suitably
constructed to prevent the entry of dust & water shall have an ingress protection of IP
42 (minimum) and outdoor type electrical equipment shall have an ingress protection
of IP 65 (minimum) in accordance with IEC 60529.
5.4.10. Safety of life and preservation of installation are the most critical factors to be
considered in the design of the electrical system. Due consideration shall be given to
ease of maintenance, and availability of replacement parts. The Electrical system shall
be designed considering a design life of 20 years.
5.4.11. Electrical System and Equipment shall be rated for :

 415V AC (±6%), 3-Phase, 4-wire, 50Hz (±2.5%)
 240V AC (±6%), 1-Phase, 50Hz (±2.5%)
 110V AC 1-Phase, 50Hz (±2.5%)
 110V DC Supply System
 24V DC Supply System
5.4.12. The Contractor shall develop load list based on engineering inputs and finalise the loads
with 25% spare margin for future requirements. The Contractor shall consider design
all the equipment considering minimum 25% spare capacity for each category of the
application/works.
5.4.13. The Contractor shall liaise with the KNPC / MEW (Ministry of Electricity & Water)
and/or Contractors of the other KOC projects, if required, to collect the relevant data
to incorporate (if any) in the project design document/drawings and co-ordinate the
work execution as required for completion of this project.
Page 21 of 66
5.4.14. The Contractor shall relocate equipment / items / services if available at site as necessary
to carry out the civil / electrical works of this project. Any new material / services required
for the identified relocating / dismantling shall be in the Contractor’s scope. The
Contractor shall identify, prepare and submit list of all the electrical equipment / materials
/ items to be relocated / dismantled including Distribution Boards, underground & above
ground Cables, Junction Boxes, and Switches/Sockets, Light Poles, Lighting fixtures etc.
All the items shall be dismantled/removed to clean the area. The Contractor shall
disconnect and dismantle the identified equipment and handover to Company Stores. The
Contractor shall identify and prepare list of all the material / items to be scrapped. The
Contractor shall remove the identified scrap material and handover to Company
scrapyard.
5.4.15. In event of any conflicting requirement in the Contract documents, the Contractor shall
notify it immediately in writing (within two weeks from the commencement of the
Works) to the Superintendent. The Superintendent shall take decision on the priority of
implementation, which shall be binding on the Contractor. In general, the most
stringent requirement at the discretion of the Company shall be applicable to the
Contract.
5.4.16. Contractor shall prepare / carry out engineering drawings, schedules, calculations,
studies, diagrams, documents and reports and submit as part of this contract but shall
not limited to following:-
 Site Survey Report
 Overall Location Layout
 Single Line Diagram
 Load List / Load Schedule
 Equipment Layout
 External Power Cable Route Layouts
 Underground / Above Ground Cable Route Layouts
 Cable Tray and Cable Support Structure Layout
 Lighting & Small Power Layout
 Earthing System Layout
 Installation Drawing
 Equipment foundation, cable trenches, duct banks, equipment shelters, manhole
etc.
 Schematic & Control Diagrams
 Interconnection Diagrams
 Equipment Data Sheets
 Cable Schedule
 Distribution Boards Schedule
 Cable Sizing Calculation
 Lighting Calculations
 Earthing System Calculations
 Solar Panel Sizing Calculations
 Battery Sizing Calculations
 Solar Panel Structure Sizing Calculaitons
 Protection Co-ordination Study (including fuse/MCB discrimination tables)
 Material Take-Off
 SAT, Commissioning & Start-up Procedures
Page 22 of 66
5.4.17. The Contractor shall submit the vendor document that includes but not limited to the
following:
 Engineering Requisition for procurement
 Vendor’s Technical Offer & Statement of Compliance
 Manufacturers’ Technical Specification and Catalogues etc.
 The Contractor’s technical evaluation
 Unpriced Purchase Orders with delivery period mentioned
 Vendor Technical Submittal (General Arrangement Drawings with
elevation/plan/side view, panel internal arrangement & gland plate view, Cross
sectional drawing, Schematics & Wiring Diagrams, Vendor Filled-up Data
Sheets, relevant calculations, Supply Record List, Catalogues etc.,)
 Inspection & Test Plan (ITP)
 FAT and SAT Procedures
 Copy of Type Test Certificates for similar equipment
 Internal Test Reports
 Painting Procedure
 Spare Parts List
 Installation, Testing, Commissioning, Operation and Maintenance Manual
 MRB index
The Contractor with necessary mark ups shall have reviewed all Vendor drawings, data
and documents prior to submit to the Company.
5.4.18. Procurement & Supply
a The Contractor shall be responsible for procurement, inspection, temporary storage,
supply and delivery at site of the Complete Electrical System including all the
electrical equipment/ items/ services required for completion of the Project based
on Material Take Off and note that no materials or services shall be provided by
the Company.
b The Contractor shall be fully responsible to ensure all actions to avoid any delays
caused by the procurement and any shortfall in the quantities of the Project
material.
c The Contractor shall submit manufacturer’s proposal for the following equipment/
items/ system and procure & supply, but not limited to:
 Flameproof Power Distribution Board
 Flameproof MOV DB
 Flameproof Lighting DB
 MOV Local Isolator
 LV Power Cables, Control Cables and Accessories
 Lighting System including flameproof lighting fixtures & Associated
Materials
 Perimeter/ Area Lighting Poles with LED Light Fixtures, Junction Boxes
and associated accessories
 Socket Outlet with plug/ Welding Receptacles/ Junction Boxes etc.
 Earthing Systems and associated material
 Equipment foundation, base frames, cable trenches, conduit systems, duct
banks, equipment shelters, manhole, solar panel structure etc.
 Cable Trays, Cable Support Structure and Accessories
 Cable Glands and Termination Accessories
 Solar Power System along with all associated component & accessories
 Solar powered lighting pole
Page 23 of 66
d The Contractor shall verify /assess the requirements based on selected vendor data
and update or amend as required prior to proceeding with purchase action.
5.4.19. Inspection & Testing

All the work and equipment shall be subject to an on-going inspection and testing both
at key stage and throughout the construction period. The Contractor shall furnish
Inspection and Test Plan (ITP) and Factory Acceptance Test (FAT) procedure & Site
Acceptance Test (SAT) procedure for all the equipment for Company approval. The
Contractor shall arrange Vendor Pre-Inspection Meeting (VPIM) and Factory
Acceptance Test (FAT) at manufacturer’s facility for the applicable equipment in line
with ITP and Project Quality Plan. Company may depute personnel to attend VPIM,
witness FAT and inspection & other testing as specified in the Contract documents. The
Contractor shall issue invitations for VPIMs and FATs to the Company to reach the
Company in not less that fourteen (14) days for all VPIMs and Witness/FATs outside
Kuwait.
5.4.20. Installation
a The Contractor shall carry out all electrical works and equipment installation in
accordance with Company standards / recommended practices / specification:
KOC-E-003 Part-1 and Part-2, 381/020, 015-PH-1901 and other applicable
standards/regulations.
b The Contractor shall be responsible for proper installation of all the electrical
equipment/ items/ services required for completion of the project.
c The Contractor shall carry out all the works, in order to make the entire electrical
system operational and functional, to the satisfaction of the Superintendent, in full
compliance with relevant KOC standards, recommended practices and codes
incorporated in the project.
5.4.21. Commissioning and Handover

The Contractor shall carry out SAT and other testing as per Contract requirement in
presence of Company personnel to proceed with necessary commissioning activities. The
Contractor shall handover all the equipment/system (fully commissioned) with As-Built
documentation to the Company as per the Project requirement.
5.4.22. Other Related Works

a Contractor shall carry out all the Civil works related to electrical equipment
installation & services, such as excavation of cable trenches, supply and installation
of manholes, hand-holes, cable protection tiles, thrust boring/asphalt
cutting/horizontal drilling, duct banks for asphalt and gatch road crossings, cable
trench backfilling, warning tapes, compaction and installation of cable route markers
for the new underground cables. All the works shall be carried out as per relevant
KOC standards. Cable tiles shall be inscribed in English and Arabic language.
b Contractor shall provide required fabricated steel or foundation for installing various
electrical equipment as per approved drawings and as per the directions of
Superintendent’s Representative. Contractor shall provide supports, stanchions,
sunshades and mounting accessories for Distribution Boards, Local Isolators, junction
boxes, lighting pole/tower and other electrical equipment to meet Kuwait climatic
condition and KOC-G-007 standard.
Page 24 of 66
c Contractor shall compact/level the surrounding area (minimum one (1) meter) of
electrical equipment viz. PDB, LDB, Socket, Isolator, etc. for safe operation of
electrical equipment with adequate clearances.
d Contractor shall submit structural calculations for poles, supports, frames, brackets,
etc. for Company review prior to ordering, to ensure adequacy of structural design.
e Galvanized cable trays, conduits, trunking etc., for supporting the cable runs shall be
provided. No cable shall be laid or run unsupported. All cables shall run either in the
trenches, trays, conduits, stub ups etc., as applicable for proper protection of cables.
f Contractor shall provide accessories like cable clamps, cleats, supporting brackets,
cable tags etc., for providing neat and clean cable runs in line with good engineering
and construction practices, KOC Standards and specifications.
g Contractor shall provide 150mm dia. (or more) PVC ducts as per KOC standard
drawing 55-7-8, at all road crossings, paved areas, building entries as per site
requirements, approved drawings and as per the directives of Superintendent’s
representative for Electrical cables, Instrument cables, Telecom cables and Fiber
Optic cables. Separate duct(s) shall be used for each cable type. Decide the number
of cables in each duct considering 60% duct area filled. Minimum 50% or 2 nos. spare
ducts (whichever is higher) shall be provided at each road crossing and building
entries for future use by the Company.
h Contractor shall provide minimum two set of tools for operation and maintenance as
applicable for the electrical equipment.
i Contractor shall survey the area for cable route, identity all underground and above
ground services at cable crossings by means of cable detectors, slit trenching, etc., and
propose exact cable route with complete details for Company’s approval. If any
services are present in the proposed cable route, the Contractor shall identify and
submit a proposal for rerouting the existing services/cables etc. for Company
approval. The underground electrical services shall be re-routed by the Contractor.
The Contractor shall reroute or provide sleeves for the services as protection after
obtaining Company’s approval. The Contractor shall identify asphalt road crossings
along the cable route during survey and provide concrete duct wherever required as
per relevant Company’s standards. After survey and slit-trenching Works, the
Contractor shall propose and submit cable route layout, following the existing route
as much as possible, for Company’s approval.
j Contractor shall supply and install the required new cables, joints & termination
accessories for re-routing the existing above-ground / under-ground cable/ electrical
services as required.
k Contractor shall provide cable lugs, cable glands, straight/right angle boots and other
accessories as required to terminate / connect LV power cables, control cables,
earthing cables and MICC cables at both ends in line with project requirements.
l All fabrication/installation materials, cable glands, adapters and other related items
shall be supplied and installed by the Contractor with KOC approval
m Isolators for all electrical equipment such as MOV, RTU, F&G panel, Cathodic
Protection TR, etc. shall be provided as per technical specification
n Contractor shall provide nameplate designations on the feeder compartments clearly
showing the feeder designation (distribution board tag no. and the location).
o Design, supply and install Fire Extinguishers in the facility and other area as per
relevant company standards and International standards. Fire Extinguishers shall
be in accordance with the requirements given in this specification.
Page 25 of 66
p The Contractor shall carry out any modifications required at upstream substation and
upstream 415V switchboard / MCC / Distribution board and related
equipment/outgoing feeder to make it compatible to supply power. All materials and
services required for above modification, cable installation & termination, testing and
commissioning, shall be in the Contractor’s scope.
5.4.23. Material Specific Requirements

a) General
i. All materials supplied by the Contractor for incorporation into the works shall
comply with the relevant specifications, data sheets, drawings and standards
as mentioned in clauses hereunder.
ii. All equipment and material shall be suitable for continuous operation and
provide satisfactory service without any damage in the worst climatic
conditions prevailing in Kuwait that are described in KOC-G-007, KOC-G-
002 and other relevant standards mentioned in this specification.
iii. All outdoor electrical equipment, which is subjected to direct sunlight/rain,
shall be provided with sun shield/canopy designed to protect from direct
sunlight and suitably protected for operation in a hostile salt-laden marine
environment.
iv. Equipment in hazardous areas shall comply with KOC standards KOC-E-004
parts 1&2, KOC-G-002, IEC-60079& BS EN 50014 to BS EN 50018,
approved drawings and to the satisfaction of Superintendent’s representative.
All equipment shall be suitable for respective area classification identified on
the Drawings and project documents.
v. Electrical equipment shall be manufactured to the approved standards and
certified by an international testing laboratory or approval authority and shall
carry the corresponding marking on the equipment.
vi. All items for use in Hazardous areas shall be certified in line with
requirements specified in clause 9.15 of Company Standard KOC-E-004 Part-
2.
vii. All equipment manufacturers shall be selected only from the Company
approved list of manufacturers included in the Contract.
viii. Supply and installation of raceways, hardwires and accessories (Cable tray,
conduit, angles, channels, cables tiles, duct banks, ferrules, cable tags, cable
ties etc.), as required, shall be the contractor’s responsibility.
ix. No deviations from specification, data sheets and drawings shall be
acceptable. Any changes, proposed with respect to Company approved
design, shall not be acceptable unless agreed in writing by Company.
x. The Technical Specifications, Datasheets, Project Drawings and Contract
dossier shall be part of the Contractor’s scope. The material requirements and
fabrication of all components shall meet or exceed the applicable sections of
the specifications that are listed in the tender documents.
b) Flameproof Distribution Board (PDB/LDB)
i. Flameproof Distribution Board shall be rated for 415V, 3-Phase, 4-Wire 50Hz
Ex’d’ IIB T3 minimum, Zone-1 and minimum degree of protection IP 65.
Page 26 of 66
ii. Flameproof Distribution Board shall be compliant with Specification of

Flameproof Distribution Board (SPC-E-LP-001), Data Sheet for Flameproof
Distribution Board (EGPM/014-DAS-E-LP-002), Project Drawings and other
related codes/standards.
iii. Flameproof Distribution Boards (PDBs & LDBs) shall comply with relevant
KOC standards & Recommended Practice KOC-E-003 Part 1 & 2, KOC-E-
004 Parts 1 & 2, KOC-E-006, KOC-E-008, KOC-E-017, KOC-E-019, KOC-
E-024, KOC-G-004, KOC-G-007, KOC-G-009, KOC-Q-014 & KOC-P-001
and Technical Specification.
iv. Adequate space shall be provided between any terminal face and gland entry
for proper cable termination and to meet the minimum bending radius
requirement of the power cable.
v. Flameproof Power Distribution Boards shall be single front,
compartmentalized (separate enclosure section of busbar, breaker and
termination) type with canopy and Flameproof Lighting Distribution Board
may have common enclosure (for busbar, breaker and termination) & separate
enclosure for photoelectric cell.
vi. Flameproof Distribution Boards shall be installed to receive the incoming 4-
core CU/XLPE/LC/PVC/SWA/PVC cables from source and deliver power to
all the connected loads with suitable cables.
c) LV Power Cables, Earthing Cables & MICC Cables

LV Power Cables, Earthing Cables and MICC Cables shall be in accordance with
Project Data Sheet EGPM/014-DAS-E-LP-001, KOC standards KOC-E-008, KOC-
E-023 & KOC-G-007 and other relevant IEC standards
All the above ground cables viz. cable from lighting JB to the light fixtures etc. shall
be suitably sized MICC cable.
d) MOV Actuator
i. MOV Actuator shall be compliant with Project datasheets (EGPM/014-DAS-
E-LP-004) for Motor Operated Valve Actuator, which is applicable for MOV
and ROV.
ii. MOV’s design, specification, supply and installation shall be as per KOC
standard KOC-E-013, KOC-E-003 Part-1 & 2, KOC-E-004 Part-1, KOC-E-
010 & KOC-G-007 and technical specifications.
iii. MOV Actuator and Local Isolator shall be matching and compatible to perform
its functionality.
iv. MOV Actuators (if required) inside the metering skid near Ahliya industries
shall be rated for 24V DC (to be supplied by Metering Skid Vendor) and shall
be compliant with Project datasheet (EGPM/014-DAS-E-LP-005).
e) Local Isolator for MOV Actuator

i. Isolator for MOV Actuator shall be in line with project datasheet EGPM/014-
DAS-E-LP-003. The isolator shall be designed to match motor operated valve
(MOV & ROV).
Page 27 of 66
ii. The isolator shall be rated for 415V 3-Phase 4-Wire 50Hz Ex’d’ IIB T3
minimum, Zone-1 & minimum degree of protection IP 65 and shall include all
necessary fixtures and brackets for mounting as per site conditions and
requirements.
iii. Design and supply of Isolator for MOV Actuator shall be in accordance with
KOC standards KOC-E-013, KOC-E-003, KOC-E-004 Part1 & KOC-G-007,
Project Data Sheets and relevant instrumentation requirement of the Project.
f) Junction Boxes
i. Junction box shall be made from galvanized cast iron or stainless steel and rated
for 415V 3-Phase 4-Wire 50Hz Ex’d’ IIB T3 minimum, Zone-1 & minimum
degree of protection IP 65.
ii. Adequate space for wiring shall be provided between any terminal face and
gland entry. No more than one wire shall be inserted into any one terminal.
Terminal blocks shall be non-hygroscopic and terminals shall be either tinned
or silver-plated, suitably rated and sized terminals of Klippon or equivalent
shall be provided in the junction boxes.
iii. JB shall be provided with sun and rain canopy, where it is exposed to direct
sunlight. Junction Box shall be provided with internal and external earthing
studs.
iv. Design and supply of Junction Boxes shall be in accordance with KOC
standards KOC-E-003, KOC-E-004, KOC-E-017 & KOC-G-007 and relevant
standards.
g) Cable Glands
i. Cable glands shall be suitable for termination of types and sizes of cables
specified, the relevant specification shall be submitted for Company
review/approval.
ii. All cable glands shall be made of brass, double compression types E2W to BS
6121 for termination of Cu/XLPE/LC/PVC/SWA/PVC cables. All cable glands
shall be flameproof type EEx‘d’ IIB T3. However, glands for termination of
cables inside the Control Room/Electrical substation building shall be
industrial type.
iii. Cable glands for termination of MICC cables shall be hexagon type, from the
same manufacturer of MICC cables and be certified for use in the hazardous
area concerned. Suitable sleeves shall be installed at every gland after cable
termination.
iv. Design and supply of Junction Boxes shall be in accordance with KOC
standards KOC-E-003, KOC-E-004 Part1, KOC-E-008 & KOC-G-007 and
relevant standards.
h) Earthing System
i. The earth electrode set shall comprise of copper earth rod, phosphor bronze
couplers, steel driving tip, steel driving head, conductor clamp, and concrete
inspection pit. `Furse' make or similar shall be accepted.
Page 28 of 66
ii. Earth rods shall not be less than 16mm diameter extendable type, driven
directly into the ground to a minimum depth of 3.6m without excavation or
drilling.
iii. A brass clamp shall be provided for clamping the earth copper cable/tape to the
earth rod. The rod shall be driven in to the earth by means of power hammer.
The top of the earth electrode shall be housed in an appropriate brick lined pit
with a removable concrete cover for periodical testing of the electrode.
iv. Earthing cable for lighting circuit shall be multi-stranded and mechanically
protected.
v. The earthing system materials shall be design, supply and installed in line with
KOC standard KOC-E-024, KOC-E-003 and KOC-G-007 and relevant IEC
and BS standards.
i) Lighting Poles
i. 8 Meter height perimeter/area lighting tower/pole shall be provided with cage
ladder and maintenance platform, having minimum 2 nos. of high-efficiency
240V AC flameproof LED luminaires, producing minimum 25000 Lumens per
luminaire certified Zone-1 Ex-d IIB T3 ( min.), with necessary control gear,
flameproof isolator-type junction boxes and accessories.
ii. The poles shall be galvanised steel in line with ASTM and structural design
calculations, fitted with a base plate and a junction box suitable for loop-in and
loop-out cables & MCB for fixture and protective hardware. Contractor shall
submit structural design calculations.
j) Light Fittings
i. All light fixtures shall be of high quality and suitable in all respects for trouble-
free operation for the specified system voltage at the site. They shall be
complete with all internal wiring between lamp holder and termination point,
in silicon rubber or equivalent insulated flexible cables of appropriate sizes
ii. All light fittings shall be complete with all accessories and with correct wattage
lamps as approved. Superintendent’s decision shall be final in determining
equivalency of fixtures of various approved manufacturers.
iii. Light fittings shall be 25000 lumen output (±10%), high efficiency (~100
lumen/watt) 240V AC LED luminaires, certified Zone-1, Ex-d IIB T3
minimum, IP 65 suitable for ambient temperature of 50deg C, with control gear
& associated accessories as required including switched junction boxes and
cables. The quantities and wattage of lights shall be determined as per the
lighting level calculations as per Company Standard KOC-E-017.
iv. Light fittings shall be supplied with sealing frames and supporting device rods,
chains and the like as per manufacturer’s recommendations and Site
requirements.
v. The Contractor shall forward manufacturer’s confirmation of suitability of the
lighting fixtures for specified voltage, outdoor ambient temperature and Kuwait
climatic conditions.
Page 29 of 66
k) Cable Tray and Accessories

i. Cable trays (perforated or ladder type) shall be used wherever required and
shall be in line with KOC-E-008, KOC-E-017 and other relevant standards.
ii. Cable trays, ladders and all associated accessories including saddles, cleats and
bolting material shall be manufactured from good quality heavy gauge
materials, suitable for hazardous locations and corrosive atmosphere. All
standard accessories such as bends, tees, joints, couplers, etc. shall be factory-
fabricated and shall be made of the same material as cable tray (hot dip
galvanized steel).
iii. Cable trays and all associated accessories shall be manufactured from hot
dipped galvanised steel, shall be robust to support and secure the cable. Saddles
and cleats shall be of robust construction and sufficiently rigid to support and
secure the cables.
iv. The minimum coating of galvanisation shall be 610gms/m2 to BS EN ISO
1461.
v. Suitable covers shall be provided throughout the route of cable trays/ladders to
protect the cables from mechanical damage and direct sunlight.
l) Conduit and Conduit Fittings

i. All conduit and conduit fittings used for the electrical installation shall be
galvanized rigid steel type, suitable for installation at hazardous areas and
industrial type as applicable. The conduits and conduit fittings shall be in line
with KOC-E-017 standard.
ii. The steel conduit and conduit fittings shall be of the heavy gauge (Rigid) type
and shall provide adequate mechanical protection to cable contained therein.
The inside and outside surfaces of the conduit shall be smooth and free from
burrs.
iii. The interior and ends of the conduit fittings shall have no sharp edges and the
surfaces and covers over which the cables are to be drawn shall be smooth and
well rounded.
iv. All conduit fittings shall be suitably rated for installation in flameproof
atmosphere.
m) Switches
i. All lighting switches shall be rated for use on 240V AC, 50Hz. supply and shall
comply with KOC-E-017. Switches installed outdoor shall be suitable for
outdoor installation with enclosures of IP65 rating minimum. Lighting switches
in hazardous areas shall be rated for 240V AC, Ex-d, flameproof, IIB T3
minimum.
n) Power Sockets
i. Three Power sockets shall be 415V, 50Hz, 32A, 3-Phase, 5-pins 4-pole and
earth connections, switched, interlocked type, certified Zone-1 Ex-d IIB T3
minimum, flameproof type, IP 65, with matching plug of same ratings.
Page 30 of 66
ii. Single Phase Power socket shall be 240V, 50Hz, 16A, 1-Phase, 3-pins double
pole and earth connections, switched, interlocked type, certified Zone-1, Ex-d
IIB T3 minimum, flameproof type, IP 65, with matching plug of same ratings.
iii. Contractor shall design the installation drawing considering the equipment
layout and provide the required number of outlets at suitable locations as per
site conditions. Power sockets shall be in accordance with KOC-E-017,
relevant IEC and BS standards as applicable.
o) Photoelectric Cell
i. Photocell shall be in line with KOC-E-017 standard. The photocell switch for
outdoor lighting control shall be 240V AC, 50Hz minimum 10A rated and shall
be suitable for flameproof execution (flameproof DB) installed in enclosure
with glass diffuser, suitable for outdoor use, to control triple pole contactor for
external lighting distribution board.
ii. Contacts arrangement for N/O and N/C operation terminals shall be suitable for
cable up to 6 mm² complete with suitable cable glands.
5.4.24. Installation Specific Requirements

a) Wiring
i. The Contractor shall install electrical wiring in line with the KOC
Recommended Practice KOC-E-008.
ii. Minimum size of copper conductor shall be:
 2.5 mm2 for indoor lighting circuits
 4mm2 for outdoor lighting circuits
 4mm2 for power sockets
 4mm2 for motor power circuits
 2.5mm2 for motor control circuits
b) Earthing
i. The Contractor shall design the Earthing system in accordance with KOC-E-
024 standard. Earthing system shall be complete with the following as a
minimum:
 Sufficient nos. of earth electrodes shall be provided so that resistance
between any point in the equipment earth & earthing system and the
combined earth grid resistance shall not exceed the limits specified in
KOC-E-024 standard.
 Earthing calculation for step voltage, touch voltage, conductor sizing
adequacy and combined grid resistance shall be submitted.
 Earthing and bonding of all the equipment(s), current carrying
components and non-current carrying components shall be made via earth
conductor to earth bar and further earth bars shall be connected to earth
grid. Major electrical equipment shall be earthed at two location connected
to different busbars.
Page 31 of 66
 lighting and small power sub-distribution boards shall be earthed through

70mm2 earth cables 35mm2 earth cables for lighting poles 70mm2 and
35mm2 earth cables for all motors (depending on the motor size).
 All exposed metal parts, equipment/ machinery etc., fence and gate shall
be connected to earth through 35mm2 earth cable to the main earth
conductor.
 Lighting circuits shall be earthed trough 2.5mm2 earth wire
 Small power circuits shall be earthed through 4 mm2 earth wire
ii. Earthing cables and wires shall be PVC insulated green/yellow stranded copper
conductor or non-insulated tinned copper as applicable in line with KOC-E-017
and KOC-E-024 standard.
iii. Each earthing conductor for equipment shall emanate from earth bus bar and get
terminated on the equipment. Looping of earthing conductors for various
equipment is not acceptable.
iv. Earthing conductors shall be continuous lengths. If jointing becomes absolutely
necessary, they will be joined by fusion welding with the prior approval of the
Superintendent.
v. Connections between earth bars and equipment frames shall be made thru
stranded copper cables with appropriate compression lugs, bolts, nuts and lock
washers. Contact surfaces shall be thoroughly cleaned and tinned.
vi. Lugs, bolts, nuts, washers, screws, clamps, cleats and other items which come
in direct contact with copper earth bars, tapes and cables etc. shall be non-ferrous
and manufactured from brass, bronze or other suitable conducting material
which will not cause electrolytic corrosion. Connection between copper and
galvanised structures shall additionally be tinned.
vii. Earth cables shall be run in same trench as power/control cables wherever
possible. Where earth cables run separately, they shall be buried at a minimum
depth of 600mm. An approved excavation permit shall be obtained by the
Contractor and all excavations shall be carried out by hand excavation.
viii. Earth electrodes shall be driven into the ground without drilling. A concrete
inspection pit with cover shall be supplied and installed by the Contractor as per
the relevant drawing. Before driving the electrodes, the Contractor shall obtain
the excavation permit covering the full depth of rod penetration.
ix. The top of electrodes shall be protected from any damage and shall be easily
accessible being enclosed in pits with covers. The position of the electrode/pit
shall be marked in Arabic/English.
c) Cabling
c.1. Cable installation system shall be designed by the Contractor and shall be
submitted for Company’s approval. Contractor shall follow installation
requirements given in KOC standards 381/020 General Specification for
Electrical Engineering and KOC-E-008.
c.2. It is Contractor’s responsibility to estimate the cable lengths by conducting
actual site survey. Cables shall be sized to meet the load requirements within the
Page 32 of 66
limits of voltage drop specified in the Technical Specifications and KOC

Standards.
c.3. The incoming cables and feeder cables shall be sized for the current rating of
the circuit breakers as a minimum. Cables shall be de-rated for the ambient
conditions in accordance with KOC Standards. The Contractor shall submit all
calculations, cable layouts and sections, clearly showing the number of cables,
separation etc. to the Company for approval.
c.4. All cables outside the building shall be directly buried underground. Cables
inside the building shall be laid on heavy duty galvanised metallic trays. All
wires for small power sockets and lighting inside the building shall be installed
in conduits with not more than one circuit in a given conduit.
c.5. The width and depth of laying for the cables shall be in line with KOC standards.
The cable trenches are to be cut square at the bottom and levelled to full depth
prior to cable pulling. Excavations shall be inspected and approved by the
Superintendent’s Representative before cables are pulled in.
c.6. Before back filling the trench, the cable installation shall be tested by the
Contractor and approved by the Superintendent’s Representative.
c.7. Cables shall be bedded in clean sand (sifted sand) with 75mm minimum layer
below the cables and 100mm layer above the cables, between cables and cable
tiles.
c.8. Direct buried cables shall be protected by purpose made concrete tiles, which
shall be installed 100mm above the cable. Cable tiles shall be manufactured
using sulphate resistant cement and KOC Class 4 mix concrete. The size of each
tile shall be 270 x 240 x 65 mm. Engraved in English and Arabic.
c.9. Back fill may be rough soil but not rubble or large stones. Back fill shall be
soundly compacted in layers.
c.10. Each cable shall be provided with an identity tag made of lead, with cable
numbers, source, and destination (from-to) and the relevant approved drawing
no. punched, securely fastened at every 30 metres of its run, at every bend, at
each end before the cable enters or leaves the ground, at each termination point,
and at both sides of every cable joint.
c.11. All electrical works and cable installation shall be carried out by the contractor
in accordance with company standards 381/020, COP-E-002, KOC-E-003,
KOC-E-006, KOC-E-008, KOC-E-017, KOC-E-024, KOC-L-002, KOC
standard drawings 55-07-8, 55-07-7, 55-07-17, 55-07-18 and other applicable
standards.
c.12. Where the new cable installation crosses the existing cable routes or pipelines,
they shall run 300mm below the existing services and shall be laid in ducts.
Where the depth of existing services is substantial, new cable route can run
above in ducts.
c.13. Contractor shall provide 600/1000V grade power cable from upstream source
feeder to the distribution board/equipment at the new facility (pig trap /tie-in)
including all associated materials and accessories (route markers, civil works,
etc.) as required in line with applicable standards.
Page 33 of 66
c.14. Contractor shall develop and submit detailed cable layout & cable trench layout
drawings with cross sectional details for each typical section/area for company
approval.
c.15. The location of all the equipment/electrical items (DB, cables, isolator, sockets,
earthing, light poles, etc.) shown in the drawings are tentative. However, final
location and cable routing shall be based on site conditions and detailed
engineering requirements.
c.16. Cable laying and clearances between underground services shall be in
accordance with KOC standards 381/20, KOC-L-002, KOC-L -028 and KOC-
E-008 standards.
c.17. Where buried cables are to be routed under walkways / roads, they shall be
installed in ducts encased in concrete, with ducts extending 500mm beyond the
edges. Ducts shall be sealed with a suitable oil-resistant filler after cable
installation. No. of ducts shall be such that 40% of duct area is filled. Minimum
25% spare ducts shall be provided for future use.
c.18. Wherever walkways are to be cut for cable laying, the same shall be restored
after completion of cable installation.
c.19. Cables must be kept clear of all process and services pipes by a minimum
horizontal distance of 400mm.
c.20. Cable routes and lengths shown are approximate, tentative and for general
guidance only. Exact cable routing and length shall be verified during detail
engineering by the contractor and made optimum to suit as per site conditions
with the approval of superintendent's representative.
c.21. Route length given is from edge of the substation (utility) building to edge of
new pig trap / tie-in area. Contractor shall survey the cable route and check the
cable lengths at site prior to procurement and cutting the cables. All cables shall
be procured and laid in single lengths only. Provision of joints on the cables is
not acceptable, except for exothermic welding points on earth cables.
c.22. Contractor shall ensure that adequate cable length and suitable terminal sizes are
provided at both ends of cable termination.
c.23. Cable route markers of approved type shall be supplied and installed by the
Contractor. The markers are to be positioned at every 30 metres on straight runs,
cable crossings, and at points where the route changes direction.
c.24. The cable route markers shall be co-ordinated and placed directly above the
underground cable identification tags. Markers shall be suitably inscribed in
Arabic and English to indicate the position of the underground cable and joints.
c.25. All cable routes shall be carefully measured and cables cut to required lengths,
leaving sufficient length for termination. Cable Joints except for the main
incomer cables are not allowed. At each termination location a loop of minimum
one (1) meter shall be provided at a convenient location. Where the cable is to
be terminated to a Switchboard, sufficient loop length shall be provided external
to the building to allow for cutting and re-termination of cable.
c.26. Cut ends of XLPE cables shall be capped immediately unless termination is
carried out same day. Cut ends of PVC insulated cables shall be protected by
polythene covers until termination is carried out.
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c.27. All cores shall be properly identified and cables tested to the satisfaction of
Superintendent’s Representative before jointing is carried out. Adequate
precautions shall be taken during jointing and necessary covers shall be used to
ensure that weather conditions do not affect the joints during the jointing and/or
curing period.
c.28. Cables rising from ground at equipment locations shall be protected by
galvanised pipe sleeves or UPVC sleeves up to 150mm above grade level. No
cables shall be run above ground unsupported.
c.29. Cables crossing the road or pavement areas shall be laid within UPVC ducts.
The ducts at road crossings shall be encased in concrete. Cables entering the
concrete lined trench from buried trench shall be provided with ducts at the entry
point. All ducts shall be sized considering 40% pipe area filled.
c.30. Cable glands shall be compression type suitable for the type of cable specified.
PVC shrouds and earth tags shall be fitted for all cable glands.
c.31. All cable entry ducts and pipes shall be sealed after installation of the cables
using non-flammable non-setting compound.
c.32. Where earth cables are laid along with power cables they can be laid at the same
depth of the power cable. Where earthing conductors are running separately,
they shall be laid at a depth of 600mm.
c.33. The Contractor shall ensure that his safety requirement and protection
arrangement regarding the road crossing shall meet the requirement of
Company’s fire and HSE regulations. The Contractor shall satisfy fully all his
requirement for smooth operation of the works.
c.34. The Superintendent’s Representative shall be informed in writing two (2) weeks
in advance of cutting any road and the Contractor shall obtain permission from
the appropriate authorities if required.
c.35. The temporary diversion road shall consist of one carriageway of suitable width
for smooth flow of traffic divided by barrels. The temporary diversion shall be
consolidated to the Superintendent’s Representative satisfaction. The
Contractor shall submit for Company’s approval the sketch for the diversion
road showing all the necessary precautions to complete the work. The
Contractor shall keep the diversion road well maintained during the period of
the road cutting, and remove and clean all disturbed work after completion of
the work at the road crossing.
c.36. The installed UPVC ducts shall be extended minimum 2m on both sides of the
road edges.
c.37. The asphalt road way shall be excavated and after installing the cable ducts,
backfilled, compacted in 150mm layers to proctor 95% dry density, up to the
required level of the compacted surface.
5.4.25. Testing & Commissioning – General Requirements

5.4.25.1. Contractor shall submit “Inspection & Test Plan (ITP)” for all equipment related to
electrical Works for Company review. The ITP shall include all the systematic
chronological activities along with responsibilities of undertaking, reference
controlling document / procedure / standard, the acceptance criteria, the role of each
Page 35 of 66
involved party (Vendor, AI, Contractor, and KOC) as per Appendix-K of KOC-Q-
014 (typical ITP format). It shall be duly filled-in by the Vendor with all the
necessary tests, criteria, parameters, values, references and test involvement viz.
“Information (I)”, “Review (R)”, “Witness (W)”, “Hold (H)”.
5.4.25.2. VPIM and FAT shall be conducted at manufacturer’s facility for all major electrical
equipment viz. Flameproof Distribution Boards (PDBs & LDBs), power cables,
flameproof junction boxes, flameproof light fixtures, flameproof MOV isolators and
MOV actuator in line with KOC-Q-014. The inspection level of this system is Level
2 as per KOC-Q-014 .
5.4.25.3. Contractor shall be responsible to conduct FAT as per approved ITP regardless of
witness by Company representatives.
5.4.25.4. Detailed SAT procedure and SAT schedule for all the electrical equipment shall be
submitted for Company review.
5.4.25.5. Inspection and Testing of the electrical installations (SAT) shall be carried out in
accordance with relevant KOC Standards and approved ITP.
5.4.25.6. The Contractor shall submit all necessary applications and other details to Company
sufficiently in advance prior to testing all installations. Prior to notifying the
Company, the Contractor shall perform initial checks and tests and take corrective
measures to ensure that all Works are satisfactorily completed.
5.4.25.7. Contractor shall be responsible for providing temporary power supply such as
portable generator for testing of installed cables and electrical equipment prior to
energization for KOC power source.
5.4.25.8. The Contractor shall inform Superintendent's Representative at least one week
before the date of conducting the actual tests at Site. Prior to carrying out testing and
commissioning activities contractor shall forward testing and commissioning
procedures for Company’s review and approval.
5.4.25.9. All installations after completion and prior to energizing, shall be inspected, tested,
and approved by the Company representatives.
5.4.25.10. The complete works shall be subject to inspection and test for compliance with
requirements given in relevant KOC standards. Final testing and commissioning
shall be executed by the contractor, for the approval of the superintendent’s
representative. The testing and commissioning shall in general be in accordance
with the requirements of "commissioning instruction manuals" of the manufacturers
and the company's "General Spec. For Electrical Eng." Standard No. 381/020 and
the following requirements.
5.4.25.11. CHECKS APPLICABLE TO ALL EQUIPMENT
a) Verify that all approved Vendor drawings are available at site.
b) Check equipment nameplates and labels against drawings and specifications.
c) Check the equipment against latest issue of drawings. Any deviations detected
shall be recorded for incorporation in the as-built drawings.
d) Check the suitability of all equipment and materials against area classification
e) All fuses and breakers shall be checked to ensure that voltage and current ratings
are in accordance with the latest approved drawings and that no damage has
been incurred during shipment
f) All wiring identification tags shall be checked to ensure that they are properly
installed, legible and correct.
Page 36 of 66
g) The equipment shall be visually inspected for damage and cleanliness.

h) The alignment of all equipment shall be checked in accordance with
manufacturer’s instructions.
i) Check the tightness of all bolted connections
j) Check all wiring for continuity
k) Proper functioning of all draw-out mechanism, mechanical and electrical
interlocking devices shall be checked.
l) Correct functioning of all internal space heaters shall be checked
m) Correct functioning of all indicating lamps shall be checked
n) All protective device settings shall be checked
o) Proper phasing of all connections and phase rotations of all rotating machines
shall be checked.
5.4.25.12. The Contractor shall carry out the following testing and commissioning activities in
addition to manufacturer recommended test and commission activities on 415V
Distribution boards:
 Inspect for damage and missing parts.
 Inspect for loose bolts and nuts.
 Inspect insulators,
 Inspect bus bars, bus joints & bolted connections.
 Check torque on bus bolts.
 Check ground connection.
 Check insertion & withdrawal of circuit breakers.
 Check current transformer ratios.
 Check CT & PT polarities.
 Check test, operate breaker as per instructions.
 Test protective relays on minimum, maximum & recommended setting & set
the relays.
 Check magnetic trip circuit breaker settings if provided.
 Check cubicle doors & interlocks.
 Test insulation resistance of power circuits phase to phase & phase to ground.
 Test space heaters & thermostat.
 Test insulation resistance of internal wiring.
 Test breaker / MCCB operation open, close & trip devices.
 Test all meters and relays by secondary injection.
 Test changeover scheme and associated interlocks.
 Check IP protection.
 Test H. V. withstand.
 Energize the switchboard.
5.4.25.13. The Contractor shall carry out the following testing and commissioning activities in
addition to manufacturer recommended tests and commissioning activities on Sub
Distribution Boards.
 Measure the insulation resistance of each bus from phase to phase and phase to
earth with Main incoming circuit breaker open and all out going feeders open.
 Check mechanical operation of incoming and all outgoing feeder MCB’s for
proper operation and mechanical indication.
 Check internal wiring of the incoming feeder and outgoing feeders for their
correctness.
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 Energize the Distribution board

 Check the labels of individual circuits for their correctness
5.4.25.14. The Contractor shall provide all necessary assistance to the Company inspector for
carrying out all such tests.
5.4.25.15. The Contractor shall record the results of all such tests in forms produced by the
Contractor to a format agreeable to the Superintendent’s Representative.
5.4.25.16. The Contractor shall provide all labour, required materials and instruments, tools,
consumables and necessary testing equipment for the full and proper testing and
commissioning of the installations.
5.4.25.17. For all cables insulation resistance values from phase to earth and phase to phase
shall be measured before termination. Cable continuity shall be checked for all
cables.
5.4.25.18. The Contractor shall provide all necessary testing equipment for the full and proper
commissioning tests of the installations including the H.V.D.C. test equipment,
primary injection test equipment, secondary injection test kit for relays and the like.
5.4.25.19. Check that the battery chargers are charging the battery banks correctly and make
all necessary adjustments required. Energize the chargers temporarily from
Contractor’s own power supply arrangement to ensure that the batteries are kept
charged.
5.4.25.20. Before energizing the new equipment, the tests listed hereunder but not necessarily
limited to these shall be conducted. If the Superintendent’s Representative decides
that certain modifications are required to the control circuits and wiring to make the
scheme function properly or to make the indications, annunciation and the like
function correctly, the same shall be carried out by the Contractor.
a) Measure the insulation resistance of each bus from Phase to Phase and Phase to
Earth with all circuit breakers in service position, but with circuit breakers open.
b) Draw out each circuit breaker out of the panel and push it back to ensure that
the operation is smooth.
c) Draw out each circuit breaker to the isolated position, close them manually and
measure the insulation resistance from phase to phase and phase to earth.
d) Draw out each potential transformer to the isolated position and measure the
insulation resistance from phase to earth.
e) Check all current transformers by primary injection testing.
f) Close and open each circuit breaker in test position electrically using the control
switch/push buttons at the H.V. switchboard. Check tripping of the circuit
breaker with its emergency mechanical trip device at the H.V. switchboard.
g) Check all interlocking between earthing switches and circuit breakers. Close
and open the earthing switches and check for correct operation.
h) Check the control circuit of each circuit breaker with all interlocks and checks
for correct operation. The feeders shall be checked for proper functioning of
process interlocks / remote annunciation.
i) Check the phase sequence.
j) Check the characteristics and operation of each relay by secondary injection
testing.
k) Simulate the operation of each of the protective relays, trip receives and
auxiliary relays and ensures energizing of the lock out relays and tripping of the
respective circuit breakers.
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l) Set all protective relays to their correct setting.

5.4.25.21. After completion of all terminations, the entire cable run shall be subjected to high
voltage DC test followed by insulation resistance check.
5.4.25.22. Phase sequence and matching checks shall be conducted in the presence of
Superintendent’s Representative before connection of each and every high voltage
cable.
5.4.25.23. Contractor shall test and commission Lighting system and power system to the
satisfaction of Superintendent’s Representative.
5.4.25.24. Earth resistance value of each electrode shall be measured and recorded.
5.4.25.25. The continuity of the earthing system shall be measured. Earth resistance value of
the complete earthing system shall not exceed 4 ohms.
5.4.25.26. Prior to energizing equipment, the contractor shall ensure that all warning and other
labels on equipment are permanently fixed in position.
5.4.25.27. All test measurements shall conform to the minimum acceptable values as per
standards unless otherwise specified.
5.4.25.28. The Contractor shall submit two sets of test results to the Company upon successful
testing at each Site. The test results shall be checked and countersigned by the
Superintendent’s Representative before acceptance.
5.4.25.29. Contractor shall provide samples of various materials such as cables, glands, lugs,
cable trays, conduits, nameplates, etc. to be installed for the project.
5.4.25.30. FIELD ELECTRICAL TESTING
a) Test Procedure
Details of Inspection & Tests are given in the Company Standard COP-E-002.
The list is not exhaustive and is meant only for guidance. Contractor shall
prepare detailed inspection & test plans with due consideration to
manufacturers’ manuals and submit for Company’s approval.
b) Testing Instruments
In addition to normal testing instruments like ammeter, voltmeter etc., the
following instruments shall also be used as required.
 Insulation resistance measurements shall be made with hand cranked or a
battery operated type 100 megaohm megger rated at 500 volt DC for low
voltage circuits, and 1kV megger for 3.3kV circuits. In general, insulation
resistance shall be measured one (1) minute after applying the voltage. If
insulation value does not stabilise within 1 minute, measurement shall be
postponed until it has stabilised, preferably during dry temperature weather.
 Power frequency High Voltage Test Set for 3.3kV Panels and High Voltage
DC test set for Testing of cables
 Grounding resistance shall be measured with a portable hand cranked
ground testing instrument or a direct reading grounding resistance testing
instrument, using two reference electrodes (Fall of Potential or 3 terminal
earth resistance test).
 Primary and secondary injection test set up for testing protection relays.
 All thermal overload relays shall be calibrated for proper operation.
Page 39 of 66
 All other equipment and test instruments required for testing and
commissioning.
c) Cables
Insulation resistance between phases and phase to earth together with continuity
tests shall be carried out on all cables.
d) Insulation resistance tests
i) Insulation resistance tests shall be conducted prior to energising the
equipment.
ii) A 500 Volt megger shall be utilised for low voltage equipment (600 Volts
and below)
iii) The following resistance values shall be recorded:
 Phase-to-phase
 Each phase to neutral
 Each phase to earth
 Each phase to equipment frame
 Each equipment frame to ground
iv) The contractor shall reinstall any connections removed to perform the above
tests, e.g. neutral connections.
v) Minimum resistance values shall be minimum 5 mega Ohm.
vi) Any solid-state devices, meters and any other equipment that could be
damaged by the resistance tests, shall be disconnected and reconnected after
the tests are completed.
e) Earthing Test
i) Test the earthing installations to the satisfaction of Superintendent's
representative. The test shall comprise but not limited to the following:
 Earth Resistance test.
 Effectiveness of earthing.
ii) The continuity of earthing shall be checked. Earth resistance value shall
not exceed 4 ohms.
iii) Prior to energising equipment, the contractor shall ensure that all warning
and other labels on equipment are permanently fixed in position.
iv) The Superintendent’s representative shall be given 7 calendar days’ notice
of when all tests are due to be conducted. Whether or not the
Superintendent’s representative intends to witness such Tests or not, the
Contractor shall report the results of the Tests to the Superintendent’s
Representative immediately after the Test completion.
v) The Test results shall be recorded in standard forms produced by the
Contractor to a format agreeable to the Superintendent’s representative
and submitted to Company.
vi) All test measurements shall conform to the minimum acceptable values as
per standard unless otherwise specified.
vii) Superintendent's Representative reserves the right to approve the test
results before energising.
viii) The contractor shall submit two sets of test results to the Company upon
successful testing at the site. The test results shall be checked and
countersigned by the Superintendent's representative before acceptance
Page 40 of 66
5.5 Civil and Structural Works
This Technical Specification describes in general terms the scope of civil and structural works
and shall be applicable in conjunction with all other parts of the Technical Specification
included in the Contract.
Further to the General Conditions of Contract, the Contractor shall carryout the Works as
specified in this Part of the Technical Specification and elsewhere in the Contract. The scope
is given not by way of limitation but in amplification of the details shown on the drawings in
accordance with Technical Specifications, International codes and Company Standards &
Recommended Practices.
5.5.1. Works to be executed
5.5.1.1 The scope shall include Design, Supply, Installation, Construction, Inspection and
Testing of all Civil and Structural Works including topographical survey, slit
trenching, Site preparations, identification, protection, re-routing / re-location of
existing services / facilities, earth works such as cutting, filling, grading, excavation
in all types of soils, backfilling, leveling, compaction, hauling, disposal etc., complete
drainage works, access road works, concrete works, structural steel works including
painting, galvanizing and fire proofing, removal, treatment and disposal of
contaminated soil, modification & installation of fencing, protection of pipes at road
crossings, protection of cables at road crossing (Duct bank), provision of pipeline
markers, swamp weights and all other works and activities of whatsoever nature
required for execution of the Contract to the complete satisfaction of the
Superintendent.
5.5.1.2 The Contractor’s scope of work shall also include supply of materials, manpower,
labor, tools & equipment and temporary facilities to the complete satisfaction of the
Superintendent.
5.5.1.3 The Scope of Civil and Structural Works to be executed by the Contractor shall consist
of, but not be limited, to the following:
a Construction of fenced enclosure with interlock tile for new pig launcher / receiver
stations at two different location. (New 56”x52” PIG L/R Area near MF-FM-7 (S-
1002) & New 56”x52” Pig L/R Area(S-1001) near MAA Battery limit .
b Design & Construction of PIG L/R foundation, JIB crane foundations, Concrete pad
with sump in front of PIG trap, wind stock foundation and anchor blocks at 56”x52”
PIG L/R Area near MF-FM-7 (S-1002) & 56”x52” Pig L/R Area near MAA Battery
limit (S-1001)
c Design & Construction of corrosion monitoring station pits in line with KOC Standard
KOC-MP-035 with fence enclosure for new pipelines as shown in relevant project
drawings. Location of corrosion monitoring stations shall be as per approved piping
drawings.
d Design & Construction of Tie-in pit at existing 42” pipeline (FG 068) near MAA
battery limit/near new PIG L/R 56”x52”station & at existing 52” pipeline near MF-F7
as shown in the relevant project drawing.
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e Design & Construction of drain pit with vacuum tanker connection shall be provided
at New 56”x52” Pig L/R Area station (S-1001) and near metering skid (FMS-Z-002)
at Al-Ahlia Battery limit.
f Design & Construction of new reinforced concrete valve, drain, Tie-in / access pit and
modification/extension of existing of reinforced concrete pit.
g Construct the fence enclosure with interlock tile for the metering skid inside Shuaiba
Industrial Area near MAA battery limit (FMS-Z-001) & near Al-Ahlia tie-in point
(FMS-Z-002).
h Design Construction of new reinforced concrete support for metering skid & Gas
Chromatograph (FMS-Z-001 & FMS-Z-002) and provide the required access
platform.
i Design, fabrication & Construction of steel shelter and associated civil works for
metering skid including gas Chromatograph.
j Construction of fence enclosure with interlock tile for the future connection tie-in near
SH-01 and install the associated civil pipe supports and foundation.
k Design, supply, fabrication and installation of elevated steel frame structure including
its foundations, pedestals, base plate, anchor bolts etc., for pipe / valve supports. And
also design and construction of reinforced concrete sleepers as required for pipe / valve
supports. Layout of piping, type, spacing and height of pipe supports shall be as per
approved piping layout drawings.
l Supply, fabrication and installation of platforms, crossovers, ladders, stairs and their
foundation for inspection, operation, service and maintenance requirements for piping,
valves, controls, equipment’s, instrument panels, gauges, their appurtenances etc .
m Installation of pipe sleeves at all road crossings by thrust boring / open cutting method
as directed by Superintendent Representative. Installation of pre-cast concrete slab
panels for protection of pipes at all gatch/track crossings.
n Design & Construction of foundations and enclosures for cathodic protection

rectifiers.
o Design & Construction of foundations, support structures, sun-shade canopies for all
electrical and instrumentation equipment and panels, fire extinguishers covered under
this contract.
p Design, fabrication & Construction of shelter and associated civil works for RTU
panels and Construct the fence enclosure with interlock tile for the RTU shelter.
Location of RTU shelter shall be as per approved instrument equipment layout
drawing.
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q Design & Construction of foundation support for CCTV camera at PIG L/R station –
S-1001, PIG L/R Station – S-1002, metering skid (FMS-Z-002) fence area near Al-
Ahlia tie-in point and future connection fence area near SH-01
r Design & Construction of foundation support for solar powered lighting pole.
Location of solar powered light pole shall be as per approved electrical equipment
layout drawing.
s Construction of concrete duct-banks crossing the existing roads as per Electrical /

Instrumentation discipline requirements (55-07-08)
t Contractor shall carryout all necessary modification works as required for connection
of drain pipe to the existing burn pit.
u Construction of gatch road approximately 500 meter length from existing road to new
pig launcher / receiver station (S-1001)
v Construction of right of ways for all new pipe lines.
w Removal, transportation and treatment/disposal of contaminated and hazardous soil at

the Solid Waste Treatment Plant in Shuaiba industrial area.
x Demolition and repair works of any associated to civil/structural items required for
the Works.
y All Civil and Structural Works related to new pipelines / piping’s pertaining to the
project Scope of work.
5.5.2. Design and Drawings
a. The Contractor shall perform detailed engineering design for all civil and structural
works, prepare & submit working drawings and design calculations for the Company’s
approval prior to execution of any part of the work. Drawings provided by the
Company are for guidance only and are the minimum requirements for the project.
Final design of all items related to the civil and structural Works shall be in accordance
with the project scope, applicable specifications, codes, standards, approved process,
mechanical, piping, electrical, instrumentation layouts, Drawings, documents, details,
Vendor information and to the complete satisfaction of Company Superintendent.
b. All design works shall be in compliance with KOC-C-001 (KOC Standard for Basic
Civil Engineering Design Data), KOC-C-002 (KOC Recommended Practice for
Engineering Design Basis of Civil and Structural Works) and other applicable codes,
standards and specifications listed in Part I General of the Technical Specifications.
c. Design of reinforced concrete structures shall be in compliance with ACI 318M (latest
edition) and the design of steel structures shall be in compliance with AISC 325 Steel
Construction Manual – WSD (latest edition).
Page 43 of 66
d. Wind load shall be calculated using the recommendations of ASCE 7 for basic wind
speed of 45m/sec (162km/hour), as specified in KOC-C-001 (KOC Standard for Basic
Civil Engineering Design Data) and exposure type “C”.
e. Lateral earth loads shall be calculated on the basis of recommendations of final geo-
technical investigation report to be prepared by the Contractor. Soil bearing capacity
shall also be on the basis of the same report.
f. Minimum design surcharge load for calculation of lateral earth load on concrete pit
walls shall be 10 KN/m2.
g. All other loads shall be as specified in KOC-C-001 (KOC Standard for Basic Civil
Engineering Design Data).
h. Structural design shall be made on the basis of load combination(s) that yields the
worst result.
i. All design calculations shall be in SI units. All standards, codes and specifications
shall conform in design and construction with the current issues and amendments
prevailing on the effective date of the Contract. Where conflict exists between
different standards, codes, specifications, drawings or other contractual requirements,
the most stringent requirement shall apply.
j. Compliance with specifications, codes and standards shall not relieve the Contractor
of its responsibility to design and produce the required work suited to meet the
specified service conditions and applicable regulations
k. All correspondences, instructions, drawings, data sheets, design calculations or any

other information shall be in English language.
l. All documents (calculations, texts, specifications, data sheets, methods, drawings etc)
shall be provided with electronic files in approved software (MS Word, Excel, Auto
CAD etc.). Structural Analysis and design shall be in compliance with ACI
318M/318RM (latest edition) and the design of steel structures shall be in compliance
with AISC Manual of Steel Construction – WSD (latest edition). All design
calculations shall be in SI units. STAAD-Pro (latest Version) software shall be used
for analysis and design. Spread sheets, verified with hand calculation based on
ACI318M (latest version) can also be used for design.
m. The Contractor shall prepare the drawings exclusively on the UNI formats (A1/A0)
unless agreed otherwise by Company.
n. The Contractor shall not commence work until approval has been provided by
Company in writing. However, approval shall not relieve the Contractor of his
responsibility for accuracy and sufficiency of works.
o. The Contractor shall prepare and submit As-Built drawings incorporating all field
changes, Company comments, directives and instructions reflecting the final approved
position of works in terms of locations, details, notes, dimensions, levels etc.
complete, upon completion of the works and obtain Company approval.
Page 44 of 66
p. The Contractor shall be solely responsible for the accuracy and details of the works to
be performed, including where incorrect or inconsistent or omission of any
information has appeared in the drawings and documents supplied by Company.
5.5.3. Survey and Investigations
a. The Contractor shall carry out a Site survey prior to construction on Site; prepare and
submit the actual route of the new pipelines in the Contract scope, along with the
proposed locations of pig launchers/receivers anchor blocks, R.C. Pits for corrosion
monitoring stations, valve pits in addition to the proposed location of the ROW (right
of way) etc. The Contractor in his survey shall confirm the levels and measurements
shown on the relevant Drawings. The survey shall cover all the existing services and
facilities in the vicinity of the new pipelines including those services and facilities
which need to be rerouted, protected and/or sleeved and also taking note of oil lake
(dry or wet) and high ground water table (marshy) areas in the vicinity of the new
pipelines route. The Contractor’s survey shall also cover all the existing asphalted
roads, gatch tracks and gatch rig roads. The Contractor’s survey shall confirm the
existence of any underground services. The Contractor’s submitted survey and
proposed locations shall be subject to the review and approval of the Superintendent’s
Representative. The survey details shown on the Contract Drawings are provided by
the Company for Contractor guidance purpose only.
b. Topographical survey shall be carried out in compliance with KOC-C-004 “KOC

Recommended practice for Topographical Survey”. All levels shall be in metres and
shall be with respect to “Mina Ahmadi Construction Datum (MACD)”. All
coordinates shall be in metres and shall be referenced to UTM WGS-84 Zone 38N.
The Contractor’s submitted survey and proposed locations shall be subject to the
Superintendent’s review and approval.
c. The Contractor shall establish horizontal and vertical control for new construction
monuments to be utilized for the layout of work and shall protect all existing
monuments, and replace any monument destroyed or disturbed during construction.
All pertinent levels, lines and locations must be checked and verified by the Contractor
before commencing the construction works.
5.5.4. Slit Trench:
The Contractor shall manually excavate exploratory slit trenches prior to

commencement of any construction works at locations of new Pig launcher / receiver
stations, anchor blocks, corrosion monitoring pits, valve pits, new foundations and at
intermediate locations across the new pipeline routes wherever deemed necessary to
determine presence of underground services running parallel to or crossing the
pipeline route. Clearance between new pipeline and existing aboveground and
underground services shall be in accordance with the relevant KOC Standards and
Specifications. Slit trenches shall be minimum 1.0 meter wide and 1.5 meters deep. In
some locations the Contractor may have to excavate deeper in order to locate the
existing services. After excavating the slit trench, the Contractor shall detect the
presence of deeper existing underground services at the bottom of excavation by using
pipe locators or other manner.
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The Contractor shall be responsible to protect, sleeve and/or re-route the underground
services as necessary to hand over the work in operable manner. All the protection
and/or re-routing Works shall be to the satisfaction of the Superintendent’s
Representative.
5.5.5. Geo-Technical Investigations:
a. The Contractor shall carry out his own geo-technical investigations to ascertain the
properties of existing soil and determine the existence of ground water table at
locations of new Pig launcher / receiver stations, anchor blocks, corrosion monitoring
pits, valve pits, new foundations and at all other required locations as deemed
necessary based on guidelines provided in the Company Standard KOC-C-003, by
sinking bore holes of minimum 10.0 metres depth. The Contractor shall submit his
geo-technical investigation report for the Company’s review and approval. The
Contractor’s design shall be based on his approved geo-technical investigation report.
The Company has carried out Geotechnical Investigation at MF-7 location nearby
proposed pig launcher / receiver station and the same report is attached as an Appendix
to this Specification for Contractor guidance purpose only.
b. Geo-technical investigation works shall be carried out in accordance with the

recommendations of KOC Standard for Geo-Technical Investigation (Onshore)
(KOC-C-003).
5.5.6. Relocation and/or Protection of Existing Pipes and Cables:
The Contractor shall relocate/reroute/and/or protect all existing aboveground and

underground utilities/services, and structures that are in conflict with the proposed
work which may be discovered during surveying and slit trenching and/or during the
progress of the Works. The Company will review and approve the proposed
relocation/rerouting and/or protection of the existing utilities and structures to be
undertaken by the Contractor prior to relocation/rerouting and/or protection of any
existing utilities/services and structures.
5.5.7. Coordination with Existing Facilities:
The Works shall be coordinated with the existing facilities. The required field
adjustments shall be made to elevations and grades as necessary. These adjustments shall
be submitted to the Company by the Contractor for review and approval prior to the
commencement of the Work.
5.5.8. Site Preparation and Earthworks
a. All site preparation and earthworks including testing of earthworks shall be in

accordance with Company Standard (KOC-C-005).
b. The Contractor shall perform all site preparation and earthworks including but not
limited to excavation, grading, hauling, backfilling and compaction to the required
grades and levels. Before starting any construction activity at any location, clear the
area of Works by removing vegetation and rubbish and stripping (approximately 300
mm thick layer) top loose soil / sand from locations of new construction and cart away
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debris to approved location. This shall include removal of all abandoned structures or
debris from the Site. Backfill with approved gatch in layers upto finished ground level
after construction of the foundations and concrete necks at prescribed levels. Each
layer of gatch shall be uniformly spread and compacted and shall not be more than
150mm thick. Selection of gatch, its compaction and tests shall be in accordance with
KOC Standard KOC-C-005.
c. Gatch or other filling materials shall not be provided by the Company. Suitable imported
materials shall be procured by the Contractor and hauled to sites from borrow pits located
outside the Company areas. The Contractor shall bear all costs pertaining to testing,
procurement and transportation of the gatch. The Contractor shall submit test certificates
of the gatch material of his proposed borrow pit for the Company’s approval before
commencing procurement of gatch. The Contractor shall also be responsible for
obtaining all necessary permits and license from relevant authorities. All excess
materials shall be removed and hauled to the approved locations.
d. The Contractor shall be responsible for removal, transportation and

treatment/disposal of hazardous wastes including contaminated soil (defined as soil
having hydrocarbon content greater than 1% by weight) encountered during the course
of Works, at the solid waste treatment plant in Shuaiba Industrial Area in accordance
with KOC HSE and HSEMS procedures and the applicable statutory guidelines of
Kuwait Public Authority of Industry and Kuwait Environmental Public Authority
(KEPA), through KEPA approved Subcontractor like NCC or similar.
e. The Contractor shall include in its bid price an estimated quantity of 50 cubic meter
of contaminated and hazardous soil for removal, transportation and treatment/disposal
at the Solid Waste Treatment Plant in Shuaiba industrial area. However, the Contractor
shall be paid based on the actual quantity of soil removed and disposed against
submission of authorized vouchers/challans.
5.5.9. Shoring, Dewatering and Disposal of Oil Spills:
a. The Contractor shall consider in the scope of work the necessary due allowance for
shoring the sides of the excavation and dewatering the accumulated water “whether
because of rain water or the underground water table” that may occur during the course
of work. The shoring and dewatering shall include but not be limited to excavation of;
trenches, RC pits, foundations and anchor blocks etc. The work also includes disposal
of oil spills from the excavation when it happens so as to carry out the work in an
appropriate and acceptable manner. Any hazardous waste including contaminated soil
shall be transported to a designated location in Shuaiba Industrial area and dispose
after necessary treatment. Removal, transportation, treatment and disposal of the
contaminated soil shall be strictly in compliance with KOC HSEMS Procedures,
Kuwait EPA regulations and any other applicable State’s regulations.
b. The Contractor shall install and operate dewatering system for laying pipelines and
construction of foundations, anchor blocks, RC pits and etc., in all areas of high water
table. Dewatering system shall be operated continuously during construction in these
areas.
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c. The Contractor shall design and install adequate anchorage system (swamp weight or
others) to prevent pipes and other structures from uplift in the high water table area.
The Contractors shall prepare details and obtain the Company’s approval prior to start
work at site.
5.5.10. Pig Launcher/Receiver Stations:
a. The Contractor shall construct fenced pig launcher/receiver stations for the new 52”
pipeline as described in Technical Specification Mechanical and Piping Works.
Layout drawings for these have been provided for guidance. The Contractor shall
prepare detailed drawings on the basis of these drawings to suite his detailed piping
design. Exact location of the pig launcher / receiver stations shall be as per approved
piping design. The pig launcher / receiver station facilities shall be complete with
foundations two (2) Nos. for each pig launcher / receiver, metering skid foundation &
shelter , valve supports, pipe sleepers / supports, reinforced concrete drain pits with
cover, anchor blocks, jib cranes, reinforced concrete pad in front of pig trap for pig
launching, wind stock foundation, cross-overs, platforms, ladders, fence enclosure for
pig launcher / receiver station, signboards etc.
b. Area clearance, grading and preparation of ground
Before starting any construction activity at any location, clear the area of Works by
removing vegetation and rubbish and stripping (approximately 300 mm thick layer)
top loose soil / sand from locations of new construction and cart away debris to
approved location. This shall include removal of all abandoned structures or debris
from the Site. Backfill with approved gatch in layers upto finished ground level after
construction of the foundations and concrete necks at prescribed levels. Each layer of
gatch shall be uniformly spread and compacted and shall not be more than 150 mm
thick. Selection of gatch, its compaction and tests shall be in accordance with KOC
Standard KOC-C-005.
5.5.11. Pig Launcher/Receiver Foundations:
a. The Contractor shall design and construct two (2) numbers reinforced concrete
pedestals and footings for each pig launcher / receiver. Design of these pedestals and
footings shall be based on actual forces obtained from pipe stress analysis, prevailing
soil conditions at the locations and the Manufacturer’s recommendations. Locations
of these pedestals and footings shall be in accordance with detailed Mechanical /
Piping drawings.
5.5.12. Jib Crane:
a. Design, supply, fabricate and install one number Jib Crane for each new pig
launcher/receiver near the pig trap gate. This includes design and construction of
reinforced concrete foundation and anchor bolts also. The Contractor shall develop the
construction drawings for the reinforced concrete foundations along with base plates and
anchor bolts design details based on the Technical Specification Mechanical Works of
the Contract and in accordance with the Manufacturer’s recommendations.
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b. The crane capacity, its boom height and outreach etc. shall be in accordance with the
requirement of mechanical and piping Works. The Company standard drawing for jib
crane (Dwg. No. 55-04-73) and for jib crane foundation (Dwg. No. 55-02-48) are
included in the Contract for guidance of the Contractor only.
5.5.13. Metering Skid Foundation & Shelter
a. Design, supply, fabricate and install metering skid foundation at different location as per
mechanical/piping drawing. Design of foundation shall be based on actual forces
obtained from Manufacturer drawing, prevailing soil conditions at the locations and
the Manufacturer’s recommendations. Locations of footings shall be in accordance
with detailed Mechanical / Piping drawings.
b. The Contractor shall design, supply, fabricate and install a pre-fabricated steel shed
covering for the metering skid. Reference Drawings provided for guidance only. Final
size and detail of steel shed shall be in accordance with the Contractor’s detailed
design.
c. Roof shall have 22 gauge thick white colour roof sheet on the top, 100mm thick vinyl
faced fiberglass insulation (density – 12kg.m3), purlins and 22 gauge thick white
colour rib roof liner fixed to the bottom of purlins by self-tapping screws.
d. Wall shall have 22 gauge thick white colour wall sheeting on the outer side, 100mm
thick vinyl faced fiberglass insulation (density -12kg/m3), wall girts and 22 gauge
thick white colour liner fixed to the inner side of wall grits.
e. Later bracing shall be as per the detailed design.
f. All Primary load carrying structural steel members including main frames, base plates,
anchor blot top and nuts shall be provided with passive fire protection by covering
them by minimum 40mm thick layer of proprietary light weight concrete “Fendolite
MII “ or approved equivalent to provide fire resistance of minimum 2 Hours.
g. All Secondary structural steel members shall be painted in accordance with KOC
Standard for Painting and Coating of Metal Surfaces (KOC-P-001)
h. Provide Ridge Ventilator and removable panel on the top of roof.
i. Provide access platform on roof top accordingly arrange the stair and ladder.
j. The Contractor shall provide the downspout to collect the rainwater from the roof.
k. Construct Concrete trenches with heavy duty grating for electrical and piping and
provide all necessary civil works.
l. Design and construct foundation and pedestal for the steel structures.
m. Inside the shelter, Construct reinforced concrete floor slab of 200mm thickness with
top and bottom layers of reinforcement dia. 10 @ 200 E/W. Slab shall be cast on top
of a layer of polyethylene sheet (1000 gauge thickness) laid over well compacted
ground.
n. Construct reinforced concrete ramp and 2m walkway around the shed. Reinforced
Concrete Ramp shall be cast on top of a layer of polyethylene sheet (1000 gauge
thickness) laid over well compacted ground and walkway shall be Interlock type
bricks. Interlock type bricks shall be heavy duty “UNI” Type-made by NIC or other
approved equal, having minimum thickness of 80mm, and comply with the requirements
of BS6717 (Part-1) or ASTM C-1272 and have compressive strength not less than 40
N/mm2. Brick installed over cables shall have a different colour to surrounding brick and
all the brick shall be anti-slip and antistatic type.
o. Concrete kerb wall shall be provided around the periphery of the walkway/Fence.
p. Fence enclosure shall be as per clause 5.5.17
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5.5.14. Valve and Pipe Supports
a. Design, supply, fabricate and install valve and pipe supports including reinforced
concrete foundations at different locations as per mechanical/piping design. All valves
shall be supplied with supporting legs to carry the valve support load. Pipe support types
and locations shall be in accordance with detailed piping design.
b. Design and fabrication of steel structure for supports shall be in accordance with AISC
Manual of Steel Construction – ASD (latest edition) for worst load combination.
c. All structural pipe/valve supports shall be fire proofed for minimum 2 hour fire rating
with Fendolite M-II or approved equivalent system in accordance with KOC Standard
KOC-C-027.
d. Design the foundations to carry the loads of the approved valve / pipe from approved
piping stress report.
e. The Contractor shall ensure checks for Cathodic Protect on supports / instruments
connected to the buried pipelines.
5.5.15. Platforms and Cross-overs
a. Design, supply, fabricate and install platforms and cross-overs with handrails and stairs
/ ladders including their foundations at locations in accordance with final
mechanical/piping design and drawings for new pig launcher / receiver stations and as
required for inspection, operation, service and maintenance requirement.
b. Platforms, ladders, crossovers and other miscellaneous steel structures shall be hot dip
galvanized and painted (if needed for colour coding) in accordance with KOC Standard
KOC-P-001.
c. Holes and edges of open grid floor panels shall be banded and welded properly. The
Contractor shall submit the design calculation sheets, and the fabrication drawings for
the Company’s approval before installation.
5.5.16. Reinforced Concrete Hard standing:
a. Construct one (1) no. reinforced concrete hard standing (slab on grade) of size 9000 mm
x 4000 mm x 300mm in front of each pig trap. The hard standing shall be provided with
an adequately sized reinforced concrete sump with grating cover and hard standing slab
shall be sloped to the sump to collect and removal of sludge & wastes. Sump shall be
rough broom finished. Minimum 150mm thick & 200mm high reinforced concrete curb
wall shall be provided on periphery of the hard standing.
5.5.17. Fence Enclosure:
a. Supply, fabricate and install new security chain link fence including vehicle and
personnel entry gates enclosures to enclose the pig launcher/receiver, RTU Shelter,
Metering Skid, Corrosion Monitoring Station, future connection, Valve pit and
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associated equipment and facilities. Tentative size and locations of fence enclosures shall
be shown in relevant piping Drawings for Contractor guidance purpose.
b. Security fence and gates shall be as per Standard Drawings Nos. 55-02-17 and 55-02-20.
Fence foundation shall be reinforced concrete type as per Company standard KOC-C-
006.
c. All steel posts, chain line fabric, concertina, extension arms, barbed wires, horizontal
arms and all other miscellaneous supports structures and fixtures shall be hot dip
galvanized in accordance with ASTM A153.
d. Fence enclosure shall have one (1) No. vehicle access double leaf gate of 7 m width and
two (2) Nos. single leaf 1 m wide personnel access gate (one (1) each on opposite sides).
All gates shall be provided with suitable locking facilities.
e. Vehicle access way inside fence enclosure and ramp shall be paved with reinforced
concrete slab of minimum 200mm thickness
f. Interlock type bricks shall cover the area inside the fence enclosure and 2 meter outside
the fence on all sides. Interlock type bricks shall be heavy duty “UNI” Type-made by
NIC or other approved equal, having minimum thickness of 80mm, and comply with the
requirements of BS6717 (Part-1) or ASTM C-1272 and have compressive strength not
less than 40 N/mm2. Brick installed over cables shall have a different colour to
surrounding brick and all the brick shall be anti-slip and antistatic type.
g. Kerb wall shall be provided at the periphery of the Fence enclosure and walkway.
h. Proper grading Slope shall be prepared inside Fence enclosure to drain out the rain water
to adjacent ground.
i. Fence enclosure (outside) shall be graded to slope away from the fence. This may require
filling in certain locations which will be deemed included in the Contractor’s scope of
work. Finished Grade level shall be 300mm elevated from the Natural ground level to
avoid the surface water flow from surrounding area.
j. Install one (1) number signboard of size approximately 800mm (high) X 1200mm (wide)
on the gate of fence. In addition to the Company’s name and logo and the manifold name
and number the following information shall be written on these signboards: “IN CASE
OF GAS LEAK OR EMERGENCY CALL KOC TEL. 23986373”. All writings shall
be both in English and Arabic languages. The Contractor shall submit drawing of
signboard for the Company’s approval prior to its fabrication.
5.5.18. Anchor Blocks
a. Design and construct reinforced concrete anchor blocks near pig launcher/receiver
stations for new 52” pipeline. Anchor blocks shall be located in accordance with final
mechanical/piping design and drawings. The Contractor shall design the anchor blocks
for final anchor forces and prevailing soil conditions at site location. The Company
standard drawing for anchor block (Dwg. No. 55-02-45) is included in the Contract for
Page 51 of 66
guidance of the Contractor only and it provides the minimum requirement of the
Company.
b. In confined areas use completely saturated sand (Gatch is not permitted) to backfill
around the anchor blocks. Material shall be desert windblown sand or building sand free
from injurious stones, lump and gypsum in layers 300 mm thick, up to the uppermost
one metres of the anchor block.
c. Apply MC-70 spray at top of back-fill above anchor block.
d. Fabricate and install pipe crash barriers in accordance with drawing No. 55-02-40 at
ground level around the anchor blocks. The crash barriers shall be blasted and coated
with black and yellow stripes of reflective paints.
5.5.19. Corrosion Monitoring Station Pits:
a. The Contractor shall design and construct reinforced concrete pits for corrosion
monitoring stations with chain link fence enclosures including gates in accordance
with the relevant Contract Drawings. The Corrosion Monitoring Stations shall be
located in line with KOC Standard KOC-MP-035. However for sand ingress areas
corrugated type of fence shall be preferred with prior approval of the Company.
b. Construct the corrosion monitoring station pits in accordance with the applicable details
given on Drawing No. 55-02-39 except as noted herein. Fencing shall be constructed in
accordance with Company Standard Drawings 55-02-17 and 55-02-20. The minimum
clearance between the fencing and the outer wall of the pit shall be 4 m all around. The
fencing shall be provided with one (1) No. vehicle access double leaf gate of 4m width
and one (1) No. single leaf 1 m wide personnel access gate. All gates shall be provided
with suitable locking facilities.
c. Depth of pits shall be as per the actual invert levels of new pipe lines with adequate
minimum clearances for accessing sampling point underneath the pipe while standing in
the pit. Minimum clearances on the sides of the pipes shall be in accordance with KOC
Standard drawing No. 55-02-39. Tentative corrosion monitoring station pit layout details
are shown in relevant drawings for Contractor guidance purpose only.
d. The pit shall be provided with an adequately sized reinforced concrete drainage sump
with galvanized grating cover and pit base slab shall be sloped to the drain sump for
collecting sludge or wastes.
e. Additionally, the Contractor shall also design, supply, fabricate, erect/construct the
following items pertaining to the pits:
i) Access caged ladders,
ii) Pipe cross-overs and access platforms with handrails
iii) Chequred plate cover for the pit as per 55-02-39.
f. Walls of the pit shall be designed for active soil pressure, surcharge and ground water
pressure (if present). Base of the pit shall be designed for moments from walls,
equipment load and uplift pressure if ground water is present. Construction of
corrosion monitoring pits shall be as per the following minimum requirements:
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g. Where pipes penetrate walls of pits below the highest expected water table, the pipe
should be fitted with puddle flanges located in the centre of the wall and the wall near
to the pipe shall be at least 250mm thick.
h. Provide and fix proper steel sleeve (s) where pipe crossing through pit walls. Fill and
seal gap between pipeline and sleeve using approved mastic or similar approved joint
filler and sealant
i. The pits shall be made of water tight construction to prevent any ingress of ground water
or rainwater through the side walls and bottom slabs. In-case the water table is less than
5 m from the natural ground level the Contractor shall install a layer of 4 mm thick
elastomeric water proofing membrane to the outer sides of pit walls. After installation of
water proofing membrane, the Contractor shall construct 100 mm thick protection wall
of cement sand blocks all around and shall paint the exposed face of this block wall with
bituminous paint in accordance with KOC Standard KOC-C-006 before commencing to
back-fill.
j. Fence enclosure shall be as per above relevant clause.
k. Construct minimum 7 m wide gatch access roads for access to the fenced enclosures of
the pits connecting to the nearest existing asphalted/gatch roads in the vicinity. The gatch
road shall comprise of minimum 150 mm thick gatch layer of minimum properties as per
Table III, clause 8.4.2 of Company Standard KOC-C-024 Part-1, laid over a well
compacted subgrade and compacted to ninety five percent (95%) of maximum dry
density at optimum moisture content. Where the soil at the specified sub-grade level is
unsuitable, excavation shall continue until a suitable foundation is encountered The
surface of acceptable ground shall be scarified for a depth of 200 mm and shall be leveled
with approved batch of fill materials in layers not exceeding 150 mm and compacted to
ninety five percent (95%) of maximum dry density at optimum moisture content. The
Contractor shall submit complete details of the gatch road prior to commencement of
construction Works.
l. The Contractor shall submit detailed construction drawings of corrosion monitoring

pit for Company’s approval before construction of the same.
5.5.20. Reinforced Concrete Pits (Access pit for Hot Tap/ Stoppling or Tie-in/Drain pit/
Valve)
a. Design and construct reinforced concrete pits with cover for valve / tie-in / drain pit
as required by process / mechanical design. Reinforced concrete pits shall be in
accordance with the details provided in KOC Standard Drawing No. 55-02-39.
Location, numbers and size of RC pits shall be in accordance with mechanical/piping
design and Drawings.
b. Walls of the pit shall be designed for active soil pressure, surcharge and ground water
pressure (if present). Base of the pit shall be designed for moments from walls,
equipment load and uplift pressure if ground water is present. Construction of RC pits
shall be as per as described in this technical specification.
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c. Fabricate and install crash barrier all around the pits as per KOC standard drawing 55-
02-040, if these pits are located inside the plant or fence enclosure of pig L/R station. If
pits are located outside the plant and pig L/R stations, the Contractor shall supply,
fabricate and install security fence enclosure with gates as per KOC standard drawings
55-02-17 and 55-02-20.
5.5.21. Construction Right-of-Way:
a. The Contractor shall construct Right-of-Way, hereinafter (ROW) in accordance with

Company specification No. 015-IH-1001.
b. The ROW shall be cleared and graded by the Contractor prior to starting the works at
the locations.
c. Clearing and grading of the ROW shall be performed as follows:
i) Irregularities in the ROW shall be cleared, graded levelled and properly compacted
to allow passage of loaded trucks and construction equipment to the satisfaction
of the Superintendent’s Representative.
ii) Services crossing the ROW shall be properly protected by the Contractor. The
Contractor shall make the necessary arrangements to preserve the continuous use
of all such services during the construction.
iii) The ROW shall be maintained during construction to the satisfaction of the
Superintendent’s Representative and upon completion of the works; the ROW
shall be graded, cleaned from drift sand and compacted where necessary and left
in a good condition.
5.5.22. Road Crossings:
The Contractor shall carry out road crossing Works at all locations where the new
pipeline crosses under any road. Road Closure / Road cutting for any new pipeline
road crossing shall comply with the requirements specified in KOC-S-001 Rev-3
“Standard Guideline for Safe Roads, Road Closure and Installation of Display Boards
/ Signs”. Road crossing Works shall be carried out in following manner:-
i) By thrust boring across main asphalt roads and installing pipe sleeve as per
Standard Drawing No. 55-04-77A without any road cutting and disruption to
traffic.
ii) By cutting secondary asphalt roads and installing pipe sleeves as per Standard
Drawing No. 55-04-77A. Adequate traffic diversion shall be constructed by the
Contractor to ensure uninterrupted traffic flow.
5.5.23. Road Crossing of main asphalt roads and highways by thrust boring:
a. The Contractor shall carry out thrust boring for installing the new pipelines, with
casing and vent arrangement, crossing under main asphalt road and as directed by
Superintendent Representative. Tentative locations are shown in relevant layout
drawings for Contractor guidance purpose only.
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b. The sleeve pipes shall have adequate vent arrangements in accordance with Company
standard drawing No. 55-04-77A. Minimum sizes and details of sleeve pipes shall be
in accordance with the Company standard drawing No. 55-04-77A. However, the
Contractor shall provide the sleeve pipes in accordance with his detail design of the
casing pipe size and wall thickness to suite the traffic load. Thrust boring work shall
be carried out by a subcontractor who has experience in performing such work and
shall be subject to the approval by the Company. If the Contractor himself is
experienced and capable of performing thrust boring and produces evidence of his
capability, the Company may approve him to carry out this work.
c. The Contractor shall obtain all permits as required for complete installation.
d. The Contractor shall submit method statements, design calculations, detailed

working Drawings and all relevant technical details and information for the
Superintendent’s approval prior to starting the work.
e. The Contractor shall carry out all Works related to pipe crossing in accordance with
the recommendations API RP 1102 and Appendix-1 to this Technical Specification
entitled “Specification for Pipeline Crossings for Roads and Highways”.
5.5.24. Road Crossing of secondary asphalt roads by cutting existing roads:
a. Cut existing asphalt roads wherever the new pipelines are crossing secondary asphalt
roads, excavate to the required level, provide pipe sleeve with vent pipes in
accordance with company standard drawing No. 55-04-07. Tentative locations are
shown in relevant layout drawings for Contractor guidance purpose only.
b. Prior to pipe sleeve installation, the Contractor shall provide the temporary diversion
roads as per the approved drawings. Minimum requirements of the construction of
diversion road as follows:
i) The diversion road shall have 2 lanes, each lane being 3.5 meters wide. The
diversion roads shall have two 150mm thick layer of compacted gatch. The
finished level of diversion roads shall not be less than 1.2 meters above the crown
level of any existing above or below ground service. If a minimum cover of 1.2
meters is not available, then mechanical protection shall be provided for the
existing service.
ii) The length of the diversion roads must allow for smooth traffic flow in the area of
construction and shall be provided with barriers, flashers and traffic signals in
accordance with the Fire and Safety Regulations and as directed by the
iii) The Contractor shall be responsible for keeping the diversion roads well
maintained during the period of the works and shall remove the diversion roads
and dispose all the remains of it to a dump area approved by the State Authorities
upon completion of the works.
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c. Upon completion of pipe sleeve installation, the Contractor shall repair the road in
following manner so that surface of repaired road is at the same level as existing
road:-
i) Backfill the trench by gatch and compact in layers not exceeding 150mm
thickness up to the bottom of asphalt base course. Compaction shall be minimum
95% of the modified Proctor value.
ii) Apply prime coat over compacted gatch surface with MC-70 bituminous
emulsion at the rate of 0.75 to 1.5 kg/sq.m.
iii) Lay Base course of asphalt concrete mix type II, and compact. Compacted
thickness of base course shall be 100mm or similar to existing.
iv) Apply tack coat over base course with SS-1h or CSS-1h at a rate of 0.25 to 0.75
kg/sq.m.
v) Lay wearing course of asphalt concrete mix type III and compact. Compacted
thickness of wearing course shall be 40mm or similar to existing.
d. Construction of asphalt pavement, including materials, machinery, equipment,

workmanship, tests and tolerances, shall be strictly in accordance with the
recommendations of Company standard for “Materials and Workmanship –
Roadways, Paving and Hard Standing : Part 1 : Flexible Pavement” (KOC-C-024
Part-1).
5.5.25. Road Crossing of gatch tracks by cutting existing roads:
Install pre-cast reinforced concrete panels above new pipelines in such a way that the
bottom of panel is minimum 350mm above the crown of pipe and minimum tentative
details of the reinforced concrete panel is shown in KOC standard drawing 55-02-36
(Sheet 03 of 03 ). Length of these panels shall be equal to diameter of the pipe plus one
(01) metre (500mm on each side). Precast panel shall be installed across the full width
of the gatch track. Actual quantity shall be in accordance with the Contractor’s detail
piping design. The cutting Service roads (Track and Gatch roads) shall be reconstructed
to match existing layers. In general (as minimum) sub-base and gatch material compact
to 95% of the modified proctor value as per specification.
5.5.26. Pipeline Markers
a. Fabricate and install pipeline markers at a spacing of 100 m along the route of the
pipeline and at additionally at each bend, valve pits, corrosion monitoring station pits,
manifold locations and two (2) at each road crossings (one on each side).
b. Pipeline marker details shall be as per Company standard drawing 55-04-67. In

general KOC Standard KOC-G-012 “KOC standard for plant equipment
identification, nameplate and pipeline marker” shall be followed. In case of conflicts
with this specification, requirements more stringent shall apply.
Page 56 of 66
5.5.27. Miscellaneous Works:

a. Relocate, remove or modify any obstacles blocking the work.
b. Design, supply, fabrication and installation of elevated steel frame structure including
its foundations, pedestals, base plate, anchor bolts etc., for pipe / valve supports at
different locations as per mechanical/piping design. And also design and construction
of reinforced concrete sleepers as required for pipe / valve supports. Layout of piping,
type, spacing and height of pipe supports shall be as per approved piping layout
drawings.
c. Platforms, stairways, crossovers, ladders with reinforced concrete foundations for

inspection, operation, service and maintenance for mechanical, electrical,
instrumentation and corrosion protection Works such as piping, valves, equipment,
panels, gauges, corrosion monitoring coupons and probes etc. complete.
d. Design and construct the reinforced concrete foundation and necessary supports for
ESDV air vessel tank and other equipment’s pertaining to this contract.
e. Supply, fabricate and install pipe crash barriers at location shown on relevant
drawings and also install pipe crash barriers for the new installations which are to be
protected against vehicle / tankers. Pipe crash barrier details shall be as per company
standard drawing No. 55-02-40.
f. Reinforced concrete foundations for light poles in accordance with the requirements
of the Electrical Scope of the Contract. Design, supply and install permanent cage
ladders for light pole for maintenance purposes, comprising of fixed access platform
with safety belts/hooks. This shall be designed to withstand wind pressure as per the
design requirements.
g. Design and construct cathodic protection rectifier foundations and enclosures.

Numbers, locations and types shall be in accordance with Technical Specification
Cathodic Protection Works. Dimensions and construction details shall be in
accordance with standard drawing No. 55-02-49.
h. Pre-engineered steel sun-shades and support structures with reinforced concrete

foundations for all electrical and instrument equipment, panels, gauges, distribution
boards, cable racks/ trays, fire extinguishers, etc. complete in accordance with the
requirements of the electrical and instrumentation scope of the Contract.
i. Design, supply and install minimum one number of wind sock at each pig launcher /
receiver station with required foundations, steel structure/pipes and fixtures. It shall
be installed at high level by considering the site condition / without obstructing the
wind direction with required epoxy painted structural steel supports / pipes.
Contractor shall submit the same for Company’s review and approval.
j. The new pipelines may pass through dry oil lake areas or the areas having
contaminated soil. The Contractor should get himself fully acquainted to the nature
of the site during the site visit and make the necessary provision for the earth work
required for backfilling and construction of right of way wherever the pipelines may
pass through such areas. Only clean earth material shall be allowed to be used for
backfilling.
Page 57 of 66
k. Temporary disposal pits to draining out the hydro-test water in accordance with
Company Standard drawing 55-02-41 and location shall be decided by the Contractor
during detail design as directive from Superintendent Representative. Provide chain
link fence enclosure around the disposal water pit at a distance of 3meters from the
edge of bund walls of the pit. Chain link fence shall have one number 7.0 meters wide
double leaf gate and one number 1.0 meter wide personnel entry gate. Fence and
gates shall be in accordance with KOC Standard drawing No. 55-02-17 & 55-02-20.
l. Demolish and remove the constructed temporary disposal pit, fence and the gates
after complete evaporation of water. The pit should be cleaned up from all visible
contamination, the sludge deposited in the pit shall be removed and transported to
Shuaiba Industrial Area and backfilled with clean soil and levelled. Any hazardous
waste including contaminated soil shall be transported to a designated location in
Shuaiba Industrial area and dispose after necessary treatment. Removal,
transportation, treatment and disposal of the contaminated soil shall be strictly in
compliance with KOC HSEMS Procedures, Kuwait EPA regulations and any other
applicable State’s regulations. Compaction and countering shall be done for the area
to match with surrounding grade level. All the above work shall be as per
Superintendent’s approval.
m. Comprehensive drainage system encompassing the complete Contract Scope along

the pipeline route, at the pig launcher/ receiver locations, at corrosion monitoring
station pits, future connection tie-in, at roads and all other areas relevant to the
contract including modification of existing drainage network, if required and
provision of tie-ins. Drainage system shall cater for storm water, fire water,
contaminated water and all other types of wastes generated. Design and construction
of drainage system shall be in accordance with KOC Standard KOC-C-025.
n. Necessary modifications of the fencing Works, structural steel Works and the
concrete Works related to the existing facilities, required for the completion of the
Contract.
o. The Contractor shall carry out all necessary civil and structural Works related to
excavation, removal, dismantling, hauling, transportation, backfilling etc. complete
pertaining to the removal of the existing pipelines in scope and its associated
facilities. All Works shall be carried out in accordance with the Contract scope and
the applicable procedures and guidelines.
p. All civil and structural works not mentioned above but required for the proper
completion of the contract to the complete satisfaction of Company Superintendent.
5.6 Cathodic Protection Works
5.6.1 The Works shall include design and detailed engineering (inclusive of surveys,
verifications, calculations, detailed Drawings, etc.), procurement and supply (material
and services), installation, testing and commissioning of all equipment and materials for
the cathodic protection (CP) of external surfaces of buried metallic sections of
pipeline/Pipework.
Page 58 of 66
5.6.2 The Contractor shall carry out a site survey to verify the scope of work given in this
Technical specification, drawings, schedules and data sheets, identify missing items if
any, and update the information as applicable and submit for Company review/approval.
The CP Contractor shall carry out a detailed Site survey together with the Company’s
representative for the CP facilities and propose his recommended CP system for the
project, along with a report on findings for Company’s approval.
5.6.3 The Contractor shall be responsible for providing the data sheets, filling in of all the data in
the Data sheets as per vendor input, coordinating Company comments & for timely
transmission of all vendor data & Drawings to / from the Company. The Contractor shall
obtain prior approval of the documents and drawings entirely at his responsibility.
5.6.4 The Contractor shall be responsible for engineering, procurement, supply, storage, delivery
at site, installation, testing, commissioning & inspection of all items and equipment,
required for the Works, based on its own Material Take Off. The Contractor shall be
fully responsible to ensure all actions to avoid any delays caused by the procurement
and any shortfall in the quantities of project materials.
5.6.5 All materials and services, required for completing the project, shall be in Contractor’s scope.
No materials or services shall be provided by the Company.
5.6.6 All equipment, items, components cables etc., shall be new and shall comply with latest
Company Standards and specifications.
5.6.7 The material specifications and drawings shall be reviewed and approved by Company
prior to commencement of works.
5.6.8 The contractor shall ensure required protection is achieved at all points along the full
length of the pipeline despite the current consumed by other bonded pipe lines crossing
or running parallel, other buried structures, earthing systems, etc.
5.6.9 All the CP works shall be witnessed by the Company representatives.
5.6.10 Contractor shall ensure that all asset owners are present and all essential check-ups have
been conducted before energizing the system.
During commissioning, potential survey shall be conducted by the Contactor in the

presence of Company representative. As a minimum this will include natural, on and off
potentials of the pipeline along the route.5.6.1.11 Drawings containing the coordinate
locations of the cables, test posts, and bonding stations shall be submitted to Company
for approvals.5.6.1.12 Equipment & Materials:
a) All equipment and material used for this purpose shall comply with the relevant latest
edition of international codes and standards.
b) All equipment and material used shall be new, of highest quality, selected and applied
in accordance with good engineering, design and construction practices.
c) Material and equipment details and samples shall be submitted for I&C Team approval
before any final purchase is made. I&C Team reserve the right to reject or accept.
d) Junction boxes, Bond boxes, Test boxes, and their Posts
Junction boxes, Bond boxes, Test boxes & Marker posts shall be as per KOC Standards
and relevant Specifications provided in this Contract.
e) Circuits
 Proper circuits shall be provided for parallel bonding. For cross bonding station, the no.
of circuits shall be according to the number of pipe shall be bonded. In addition to this,
two extra circuits shall be provided in every box for spare purposes.
 All internal components shall be mounted on an insulating panel made of a suitable
phenolic resin, as per NEMA grade C, minimum thickness 8 mm and shall be weather
resistant. Connector hardware shall be made of suitable quality material, made of
stainless steel, copper, tinned copper, brass and/or phosphor bronze.
Page 59 of 66
 The bus bar connector shall be installed at the top of the box and connected to every
shunt. Each of the shunt shall be connected to a variable resistor. The connection
terminals shall be suitable for connection of 25mm2 cables and shall be supplied with
required lugs.
5.6.7 General Technical Requirements:
a) This specification shall be read in conjunction with relevant standards, standard drawings,
data sheets, project drawings and reference drawings referred in Technical Specification,
its exhibits and elsewhere in the tender package.
b) The information given on the drawings is indicative and for describing the overall scope
of work. It shall be contractor’s responsibility to survey, verify and check at site before
proceeding with the implementation of works.
c) Unless otherwise specified hereunder, the cathodic protection Works shall be performed in
accordance with KOC Standard KOC-L-015 “KOC Recommended Practice for External
Cathodic Protection of Underground Steel Pipelines & Piping Networks”.
d) Cathodic protection materials, including transformer rectifier unit shall be in accordance
with KOC Standard KOC-L-012 “KOC standard for Cathodic Protection Material
Specification” and KOC specification number 015-PH-1910.
e) The Contractor shall be responsible for engineering, procurement, supply, storage, delivery
at site, installation, testing, commissioning & inspection of all items and equipment,
required for the Works, based on its own Material Take Off. The Contractor shall be fully
responsible to ensure all actions to avoid any delays caused by the procurement and any
shortfall in the quantities of project materials.
f) All materials and services, required for completing the project, shall be in Contractor’s
scope. No materials or services shall be provided by the Company.
g) All equipment, items, components cables etc., shall be new and shall comply with latest
Company Standards and specifications.
h) The material specifications and drawings shall be reviewed and approved by Company
prior to commencement of works.
i) The contractor shall ensure required protection is achieved at all points along the full length
of the pipeline despite the current consumed by other bonded pipe lines crossing or running
parallel, other buried structures, earthing systems, etc.
j) All the CP works shall be witnessed by the Company representatives.
k) Drawings containing the coordinate locations of the cables, test posts, and bonding stations
shall be submitted to Company for approvals.
l) Additional interference and potential tests shall be carried out on new pipeline where
existing anode ground beds are located close to the new pipeline ROW and remedial
measures shall be carried out, as required. Where found necessary from test results,
contractor shall relocate the existing anode ground beds.
m) In addition, any existing anode ground bed located within 50 m of pipeline route shall be
relocated.
n) The Contractor shall include in his scope of work, the design, supply, installation,
associated cable laying, testing and commissioning of minimum 7 Nos. new deep anode
ground beds rated 50 A each, as part of relocation of existing deep anode ground beds in
the project corridor.
o) Resistors shall be continuous variation for each circuit, 100 W, 1 Ω and10 Amps.
p) Nameplate
The Bonding station shall be provided with a nameplate, written in English, black letter on
a white background. The nameplate shall be fixed with non-corrodible screws or rivets.
The nameplate shall indicate the following
 KOC-I&CT
Page 60 of 66
 Bonding Station No. XX

 Lines bonded, diameter and service, KM: XX (Location in reference to subject line.
q) Junction Boxes shall be provided with a nameplate, written in English, black letter on a
white background. The nameplate shall be fixed with non-corrodible screws or rivets.
r) Detailed drawings showing terminal, markings, tagging and heat dissipation calculations
will be submitted.
s) The door shall be hinged type and with a suitable locking device e.g. a lock opened with a
triangle socket wrench. A terminal board with at least 10 Nos. terminals shall be fitted in
each test post by means of screws for connection of test leads.
t) Each terminal board shall be made of polycarbonate resin or a phenolic resin insulating
material, minimum thickness 8mm and shall be designed in accordance with the
requirement.
u) The dimensions of each terminal board shall be 120x60x8mm. The terminals incorporated
in the terminal board shall be colour-coded test-socket with a diameter of 4 mm.
v) The terminal colour coding and position on the board shall be shown on the drawings.
w) The terminal number shall be clearly numbered and labelled. The nameplate shall indicate
the following
 KOC-I&CT Cathodic Protection
 Pipeline name:
 Service:
 From---- to ---------
 Test Post No.
6.0 STANDARDS, CODES AND SPECIFICATIONS
All equipment and systems shall be as per prevailing Company Standards or Recommended
Practices and/or International codes and standards. Relevant Company Standard and
international standard is listed in Exhibit - II to this Technical Specification for reference.
The latest edition of codes mentioned at the Date of Contract shall be applicable unless
agreed or mentioned otherwise.
7.0 DRAWINGS
7.1. Contractor shall develop all the drawings for the entire works of the project. All the
drawings shall need review and approval of the Company, prior to execution of the said
work.
7.2. The drawings/ sketches provided in this document are ‘basic’ and indicative of the works
to be executed. The Contractor review and update all the drawings and documents to
incorporate his engineering input, HAZOP and system verification recommendations, ‘as
built’ status.
7.3. Prior to the commencement of works, the contractor shall carryout detailed site checks,
verifications and surveys to base his detailed design on specific site conditions, ground
levels, piping & equipment elevations, existing lines & services, and update the project
drawings and develop the construction and detail engineering drawings accordingly. The
contractor shall therefore consider the same and shall carryout the works with the same
understanding within the contract obligation and at no extra cost and time.
7.4. The Company supplied drawings in accordance with which the Contractor shall execute
the Works are listed at Exhibit - I attached hereto.
Page 61 of 66
7.5. Other drawings pertaining to the existing plant for reference:

All the relevant available reference drawings (subject to availability) for plant will be
given to the successful Contractor, on his specific request, only after signing the Contract.
8.0 AMBIENT CONDITIONS:
8.1. The ambient conditions are as specified in KOC Standard No. KOC-G-007 and the Process
Design Basis.
8.2. Design and Service Conditions:
The equipment and facilities installed under this project shall be, in general, suitable for
extreme climatic conditions, with high ambient temperatures and humidity. The site is
generally in desert terrain and the atmosphere is highly dusty and corrosive (with H2S traces).
9.0 SIGNBOARD
9.1 Pursuant to sub- clause 24.7 of the General Conditions of Contract, the Contractor shall
provide and erect a temporary signboard at each site. The signboard shall be lettered in both
the Arabic and English languages and shall provide as a minimum, the following
information:
- The Company’s Name and Logo
- Project Title of the Works and Contract Number
- Contractor’s Name and Telephone Number
- Commencement Date
- Completion Date
- Name and telephone Number of the Superintendent of the Contract.
-
9.2 Approval of the Signboard
a) Prior to provision and erection of the signboards, the Contractor shall submit for the
approval of the Superintendent, his proposed detailed design therefore, including layout,
colours, size, foundation and support details, materials shall be used in the manufacture
of the signboard and the proposed location of the signboard on the site.
b) The Contractor shall not erect the signboards without the prior written approval of the
Superintendent.
c) Maintenance and Removal of the Signboard:
The Contractor shall maintain the signboards in good condition during the execution and
completion of the Works. Upon the issue of the Certificate of the Completion for the
Works, the Contractor shall dismantle and remove the signboard from the site and shall
reinstate the area and leave it in a clean and tidy condition.
10.0 INSPECTION & TESTING & QUALITY ASSURANCE REQUIREMENTS
10.1 The Contractor shall implement a quality assurance program that meets the requirements
of the quality standard ISO-9000. This programme shall need prior approval of the
Company.
Page 62 of 66
10.2 Inspection and testing shall include NDE, such as Visual Inspection, DP, Material
verification, ultrasonic testing, and radiography, hydro-testing of pipe work.
instrumentation items and all the relevant inspection and test requirements in the
applicable codes, standards and the specifications as per the Contract.
10.3 The Contractor shall carryout all the Quality Assurance and Quality Control works in
accordance with the KOC Standard KOC-Q-014. The Contractor shall have an
established set up for Inspection & Tests exclusively for this Project, who shall perform
the inspection, testing and pre-commissioning activities and liaise with KOC Inspection
& Corrosion Team and the related KOC personnel as per advice of the Superintendent,
all through the Project
10.4 The Contractor shall submit, within (30) thirty calendar days of the Contract signing, its
work specific quality plan for Company approval and all procedures required to
implement and administer the quality assurance effort for the Works. This will include
all special process such as welding and non-destructive examination. A listing of the
documentation to be submitted by the Contractor and his Sub-contractors shall also be
furnished.
10.5 All inspection and testing shall meet the requirements specified in the Technical
Specifications and referenced codes, Company standards, project specifications, for all
materials and equipment supplied by the Contractor.
10.6 All the work and equipment shall be subject to an on-going inspection and testing both at
key stage and throughout the construction period. The Contractor shall furnish Inspection
and Test Plan (ITP) and Factory Acceptance Test (FAT) procedure for all the equipment
for Company approval. The Contractor shall arrange Vendor Pre-Inspection Meeting
(VPIM) and Factory Acceptance Test (FAT) at manufacturer’s facility for the applicable
equipment in line with ITP and Project Quality Plan. Company may depute personnel to
attend VPIM, witness FAT and inspection & other testing as specified in the Contract
documents. The Contractor shall issue invitations for VPIMs and FATs to the Company
to reach the Company in not less that fourteen (14) days for all VPIMs and Witness/FATs
outside Kuwait.
10.7 The Contractor shall submit progress report of all the tests performed at Vendors’
premises highlighting planned versus actual status.
11.0 PRE-COMMISSIONING, COMMISSIONING & HANDOVER
11.1 The Contractor shall carryout pre-commissioning, operational and functional testing and
commissioning of the complete new facilities. For the same he shall submit his procedure
and program well in advance to obtain prior approval of the Superintendent.
11.2 After completing all work and final checks made, the Contractor shall notify the
Company in advance of the time and date for commissioning the new pipeline.
11.3 The Contractor shall submit a detailed procedure for cleaning, purging and commissioning
the pipeline to the Superintendent’s Representative for approval prior to commencement
of commissioning activities.
11.4 Pipeline Works
a. The Contractor shall check all the pipe work and piping systems to ensure isolation and
removal of hindrances for trouble free back flow with prior approval from the
Page 63 of 66
b. Remove all pipe work isolating spades, ensuring that adjacent valves are maintained in
the closed position for pipeline cleaning and purging.
c. Prior to the commissioning of the pipeline, it is to be cleaned and purged in
accordance with the following steps:
i. Launch a batching pig, followed by a slug of Nitrogen of minimum 250 meters
length.
ii. The new pipeline/s shall be filled with Nitrogen gas at a pressure of 25 psig.
iii. Pressure gauges shall be provided at the two ends of the line to monitor the Nitrogen
gas pressure. Contractor shall also retain Nitrogen gas injection and vent piping for
future use by the Company.
d. The Contractor shall submit a detailed procedure for purging and Nitrogen filling the line
to the Superintendent’s Representative for approval.
e. The commissioned pipeline shall then be checked for any leaks before being handed over
to the Company for operation and the Contractor is to provide all necessary assistance to
meet this hand over operation requirement.
f. All the redundant pipe work, valves and fittings shall be demolished and transported to
Company assigned destination e.g. stores or pipe yard, as per Superintendent’s
Representative instructions.
g. On completion of all work, the Site is to be left clean and tidy.
11.5 Plant & Systems:
a) The Contractor shall carryout pre-commissioning, operational and functional testing

and commissioning of the complete new facilities. For the same he shall submit his
procedure and program well in advance to obtain prior approval of the Superintendent.
The key requirements for the same shall be as follows:
b) Pre-commissioning and Commissioning of the installations shall be carried out by the

Contractor.
c) This Work shall include the operation of systems, adjustment of variables and overall
performance of facilities installed by the Contractor to meet the specified requirements
to protect the plant from unsafe operation and to achieve the guaranteed operations.
12.0 UNITS AND DIMENSIONS:
12.1 Regardless of the units used by the Company in stating the requirements or providing
information, the contractor shall present all calculations, documents and drawings in
accordance with the following table for the entire Project:
Discipline Calculations, Documents Specifications/ Data Drawings

and Correspondence Sheets
Process Metric with final result also Metric with imperial Metric with imperial
shown in imperial in units shown in units shown in bracket
bracket bracket
Mechanical -do- Metric Metric

Page 64 of 66
Instruments Imperial with final result Imperial with metric Metric

also shown in metric in units shown in
bracket brackets
Civil/ Structural Metric Metric Metric
Electrical Metric Metric Metric
12.2 The units shall be used shall be as follows:

Metric Imperial
3
Capacity m BBLS (US)
Liquid Flow (Vol. basis) m3 /hr or lit / hr USGPM
Gas Flow (Vol. basis) Nm3 / hr MMSCFD
Liquid/Gas Flow (Wt. basis) kg/ hr lb / hr
Length mm ft or in
Surface Area m2 ft2
Pressure Bar psi or inch WG
[Kg / cm2 or mmWG]
0 0
Temperature C F
Power KW HP
Heat Duty MMKCal / hr MMBTU / hr
13.0 MISCELLANEOUS REQUIREMENTS:
13.1. The Contractor shall not open or disconnect or cut any valve or line by unbolting or
unscrewing or cutting piping components until the Superintendent’s Representative
has identified it as available and has advised on the depressurising and draining
procedure.
13.2. The Contractor shall restore all existing facilities back to their original condition upon
completion of the Works executed by him under approval and advice of the
13.3. All redundant materials shall be transported and transferred to a location identified
by the Superintendent’s Representative.
13.4. On completion of all work, the Site is to be left clean and tidy.
13.5. Wastes: Produced during construction, pre-commissioning, commissioning and
operation of the project should be disposed outside the KOC area either at Shuaiba
Wastes Facilities or Municipality dumping area.
14.0 DOCUMENTATION AND SUBMITTALS

The documents and submittals shall be submitted by the Contractor in accordance with the
Contract Specification.
14.1. Technical Documents:
14.1.1 Three (3) Prints along with the offer

a) Dimensional outline drawing, Weights and Base Plate dimensions, Anchor Bolt
locations & recommended concrete foundation drawing.
b) Completed Data Sheets.
c) Vendor product Catalogues & Technical Leaflets
d) Instrumentation Data Sheets/ Details
Page 65 of 66
e) Pig Traps, Valve Stations and connection/tie-ins sizes and details

14.1.2 Six (6) Prints within 30 days from the date of signing the Contract for Company’s
Review and Approval
a) P&ID
b) Table of piping, instruments, and utilities' connections at the end of skid
c) Instruments data sheets/full technical information/ Specifications
d) Dimensional layout drawings & details for the complete pipelines system
e) List of all system components and accessories with manufacturer’s names,
catalogues.
f) QA/QC Manual and Inspection & Test plan
14.1.3 Two (2) Prints within 60 days from the date of signing the Contract for
Company’s Review and Approval
a. Instruments Schedule
b. Purchase Requisitions & Material
c. Vendor offers, data sheets and details duly reviewed and attested by the
Contractor
d. Contractor’s drawings , data sheets and procedures
e. Testing and Commissioning Procedures
14.1.4 Along with the supply, six (6) prints of

a) As Built Drawings and Documents
b) Inspection & Test Certificates,
c) The final approved ‘as built’ drawings / documents (along with one electronic
copy: the drawings shall be in AutoCad.)
d) The Installation, Operating & Maintenance Manual
14.2. Deliverables:
14.2.1. The Contractor shall submit a detailed list of deliverable (along with specified
document Nos. / Drg. Nos. and the like) with in fifteen (15) days of commencement
of works. All the documents and drawings shall be submitted for the Company for
review and approval
14.2.2. The numbers of documents shall be submitted shall be in general as per the Contract
Specification and as jointly agreed with the Superintendent.
14.2.3. All deliverables and submittals as specified in the Contract shall be in sequential
and organized manner so as to facilitate and to expedite review and approvals.
14.2.4. Contractor must review Vendor Documents/Drawings before submittal to the
Company for review and approval. The evidence of his review shall be indicated on
the submitted document / drawing.
14.2.5. The Contractor’s deliverables, for review and approval by Company, shall include,
but not limited to, the following:
a Survey Reports and Site investigation information
b Studies and Reports
c Engineering documents such as stated above
d Procedures as follows:
i. Contract Execution Procedure,
ii. Project Admn. & Co-ordination Procedure,
iii. HSE related Procedures inclusive of HAZOP/EIA/QRA,
iv. Design Methodology & Procedure,
v. Procurement Methodology & Procedure,
Page 66 of 66
vi. Construction & Installations related Procedures,

vii. Inspection , Testing, Pre-commissioning and commissioning
Procedures,
- And the like as specified elsewhere in this Contract.
e Drawings, Specifications, Calculations, Data sheets, P&IDs, Drawings, Layout
Plans and the like, pertaining to engineering and construction stage.
f Calliper Pigging Reports and base line data collection records
g Thickness Survey records
h Calibration records for relief valves.
i Procurement related documents such as:
i. Purchase Specifications
ii. Purchase Requisitions & Draft Purchase Orders
iii. Inspection & Test Plan
iv. Shop Inspection & Test Reports, Witness Test Reports & certificates,
v. Mill Test Certificates for all the Materials
vi. Final Vendor Document
j As-Built Drawings, Project Record Book & Operating & Maintenance Manuals
15.0 TRAINING OF THE COMPANY PERSONNEL:
15.1 The Contractor shall in conjunction with its subcontractors and approved manufacturers and
Vendors as may be appropriate, prepare, develop and carry out a training programme to impart
all necessary skills and knowledge to Eight of the Company's engineers/Supervisors / operations
and maintenance personnel.
15.2 The objective of the training programme is to ensure that the required number of Company
engineers, operations and maintenance personnel have the necessary skills and knowledge to
operate and maintain the Facilities in a competent and safe manner.
15.3 The Contractor shall submit the training programme to the Company for approval prior to
commencing training.
15.4 The Contractor shall submit its proposed and detailed Training Programme for Company
approval at least sixty (60) days prior to the anticipated date of the commencement of the pre-
commissioning
15.5 All training under the training programme shall be carried out in Kuwait and shall be completed
prior to the issue, by the Company, of the Completion Certificate.
15.6 Theoretical classroom training for operations personnel shall be done in several lectures &
programmes. The Training Period shall be a minimum of ten (10) working days duration and
shall include a general introduction to the process and progress onto the detailed operation of
the individual units of the Facilities. Each course shall include Site visit(s) as deemed necessary.
15.7 On-the-job training for operations personnel shall be included in the Training Programme.
17.8 For the training course, the Contractor shall submit to KOC all the training materials
[documents] in both hard and electronic copies for each participant, as a minimum. The
Contractor shall provide the following as a minimum to each participant in the training courses.
- Approved Training Manual in the English Language
- One set of Instruction Notes in the English Language
- One set of reduced drawings (as deemed necessary)
- Hand-outs
----

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TECHNICAL SPECIFICATION

KUWAIT OIL COMPANY (K.S.C)

2.0 CONTRACTOR’S DESIGN AND ENGINEERING

2.4. Review of Drawings & Documents

2.5. Site Surveys, Re-Routing and Update of Data and Drawings

2.6. Piping Stress Analysis

2.7. Gas Analysis and Process Simulation:

4.0 HSE STUDIES:

4.4. HAZOP study:

4.5.Environmental and Social Impact Assessment (ESIA)

recommended measures to be taken to minimize them. It shall demonstrate that all

i) A register of significant environmental sensitivities.

iv) An assessment of any significant environmental impacts, which may be caused to

v) Recommendations regarding the manner how the facilities shall be constructed

e) Based on the ESIA Procedure, project’s HSE Coordinator (Assigned by the

Public Authority on project-specific issues, including submission and approval of

5.0 WORKS TO BE EXECUTED

5.1 General & Mechanical

5.1.3. Scope of pipeline work are summarized hereunder at Table-1:

h For all piggable pipelines caliper pigging shall be performed.

j Installation of a 1.3 km (approx.) depressurization line, originating from downstream of

5.1.5. Demolition Works

5.1.5.2. The demolition works shall include :

b. Demolition of existing pipeline, equipment and installed items/services being

5.1.6. Firefighting System

5.1.7 General Technical Requirements

5.1.7.1 Procurement and Materials

5.1.7.2 Fabrication and Welding

5.1.7.7 Hot Tapping & Stoppling Works

5.1.7.8 Coating and Painting

5.1.7.9 Demolition Works

5.2 Process Engineering

5.2.3. Process Engineering Deliverables:

i. PSV Sizing calculation

5.3.2. WORKS TO BE EXECUTED

5.3.3. The Contractor shall carryout the following works as a minimum:

1002 at MF/F-7 and Metering (FMS-Z-002) at Al-Ahlia shall be provided to the

5.4 Electrical Works

5.4.3. New Pit Near MF-SH-01 Inside Shuaiba Industrial Area

5.4.5. New 56”x52” Pig L/R Area Near MF-FM-7

5.4.6. Tie-in Area Near MF-FM-7

5.4.7. Any modifications/extensions in the existing Switchboard/MCC Panel/Distribution

5.4.11. Electrical System and Equipment shall be rated for :

5.4.19. Inspection & Testing

5.4.21. Commissioning and Handover

5.4.22. Other Related Works

5.4.23. Material Specific Requirements

ii. Flameproof Distribution Board shall be compliant with Specification of

c) LV Power Cables, Earthing Cables & MICC Cables

e) Local Isolator for MOV Actuator

k) Cable Tray and Accessories

l) Conduit and Conduit Fittings

5.4.24. Installation Specific Requirements

 lighting and small power sub-distribution boards shall be earthed through

limits of voltage drop specified in the Technical Specifications and KOC

5.4.25. Testing & Commissioning – General Requirements

g) The equipment shall be visually inspected for damage and cleanliness.

 Energize the Distribution board

l) Set all protective relays to their correct setting.

5.5 Civil and Structural Works

5.5.1. Works to be executed

n Design & Construction of foundations and enclosures for cathodic protection