~I J~I---", ..A.S,..:.II......

1
A 5~bskll~ ry 01 Kuwait P'1rlJ'Qle\Jm CorpOl'Bllon

STANDARDS PUBLICATION

KOCSTANDARDFOR

INTERNAL LINING OF TANKS AND

VESSELS PART 1

GUNITE LINING OF STEEL VESSELS

DOC. NO. KOC-P-002 PART 1

(Rev. 3)

STANDARDS TEAM
DOC. NO. KOC-P-002 Pt. 1 I Page 1 of 28 Rev. 3

STANDARDS PUBLICATION

KOCSTANDARDFOR
INTERNAL LINING OF TANKS AND
VESSELS PART 1:
GUNITE LINING OF STEEL VESSELS
DOC. NO. KOC-P-002 PT. 1

STANDARDS TEAM

DOC. NO. KOC-P-002 Pt. 1 I Page 2 of 28 Rev. 3

KOC STANDARD FOR

INTERNAL LINING OF TANKS AND
VESSELS PART 1:
GUNITE LINING OF STEEL VESSELS
DOC. NO. KOC-P-002 PT. 1

ISSUING AUTHORITY:

STANDARDS TEAM

3 12/03/2015
Issued as KOC
Standard
Task Force
(TF-PC/02 ) Mr. Saeid AI-Duwaisan
-
Issued as KOC
2 18/07/1999 Standard Dr. M. lIyas Dr. M. lIyas Mr. Ali H. Baba

TF-Leader Snr. Engr. Stds. Ag. Team Leader Standards

Rev. Date Description Prepared by
Tel. No. 65428 Tel. No. 61633 Tel. 61896
DOC. NO. KOC-P-002 Page 3 of 28 Rev. 3

Page No.

FOREWORD 5

1.0 SCOPE 7

2.0 APPLICATION 7

3.0 TERMINOLOGY 7
3.1 Definitions 7
3.2 Abbreviations 8

4.0 STANDARDS, CODES AND PROCEDURES 8

4.1 Conflicts 8
List of Standards, Codes and ...... rnl"cn 8

5.0 ENVIRONMENTAL CONDITIONS 10

6.0 HEALTH, SAFETY AND ENVIRONMENT 10

7.0 GUNITE LINING MATERIALS 12

7.1 and Handling

,tAr",,",,,,, 12
Material ­ and Technical Requirements 13
7.3 Approvals 13
7.4 13
7.5 Sand 14
7.6 Pozzolanic Aggregate 14
7.7 Water 14
7.8 Reinforcing Steel Wire 15
7.9 Reinforcing 15
7.10 Pitch Polyurethane :::I~TiC\rnicr,(' Joint Sealing
Compound 15

8.0 SURFACE PREPARATION 15

9.0 GUNITE LINING APPLICATION 16

9.1 General Requirements 16

9.2 Coverage 16
9.3 Proportions and Mixing Gunite Materials 16
9.4 Weather Conditions 17
9.5 Application of Gunite 17
9.6 Construction Joints 18
 DOC. NO. KOC~P-002 Pt. 1 !I Page 4 of28 Rev. 3

.
F==~=.-~~-=======.~=-=-==
~~.==~==================~======================9

9.7 Placing Steel Fabric Reinforcing Mesh 18

Shooting Strips 19

9.9 Curing 19

9.10 Sealing of Lining Joints, and Ends 19

9.11 Surface Finish 19

9.12 Gunite Lining Thickness 19

9.13 Repair of I Defects and Maintenance 20

10.0 INSPECTION AND TESTING 20

10.1 General 20

1 Materials and Equipment Inspection

10.3 Visual Inspection

10.4 Compressive Strength 23
11.0 QUALITY ASSURANCE 23

12.0 DOCUMENTATION 23

12.1 General

1 Work Proposal 24

1 Work Records I Reports

12.4 Final Report

13.0 APPENDIX 1: GUNITE LINING RECORD I DATA SHEET 25-26

ACKNOWLEDGEMENT 27-28

 DOC.NO.KOC-P-()02Pt.1 II Page 5 of 28 Rev. 3

FOREWORD I3I

This document "KOC Standard for Internal Lining of Tanks and Part 1: Gunite
Lining of Steel Vessels" (KOC-P-002, Pt. 1 Rev.3) the minimum requirements
for material selection, installation, maintenance, inspection and testing of Gunite Lining of
vessels. The earlier document (KOC-P-002, 1 Rev. 2) issued in July 1999, has
been for conformance with revisions of relevant International I National
Standards and incorporation of latest technical requirements in this field.

This Standard is part of the KOC-P-002 Series on "Internal of Tanks and Vessels".
The other parts of this series are:

Internal Lining of Above Ground Steel Tanks

Part 3: Internal Lining of Steel V~~":-'~I:-'

This KOC has approved by Standards Team in consultation with the

Standards Technical Committee (STC) for consistent use throughout the Engineering and
Operational Functions of Kuwait Oil Company (K.S.C).

This Standard sets out to achieve the following objectives:

a) outline general technical for material selection,

installation, maintenance and inspection I testing of gunite lining systems for
the protection of internal surfaces of subjected to aggressive
environment.

b) To provide the technical guidance for field application, surface preparation,

inspection and testing requirements in order to achieve quality, reliability and
positive Health, Safety and Environment (HSE) performance.

c) To harmonize current practices by codification, rationalisation, standardisation

internal control existing practices.

d) To set out minimum requirements and guidance for monitoring compliance of materials
testing within a Project.

e) Tool for internal communication from which future environmental and

technological changes can be measured.

Feedback as well as any comments or suggestions derived from application of this

Standard at any of construction, maintenance and field are invited and
should directed to:

Team Leader Standards

(Chairman, Standards Technical Committee)

Projects Support Services Group, K. O. c.

Box- 9758, Ahmadi-61008

State of Kuwait
~-.---~------------
DOC. NO. KOC-P-002 Pt. 1 Page 6 of 28 Rev. 3
I I

Task Force Responsible for Revision of this Standard

The revision of this Standard has been entrusted by the Standards Technical Committee
(STC) to the Task Force (TF-PC/02) comprising of the following Members:

Mr. Amer Jaragh Insp. & Corr. (N&WK) Team TF Leader Tel. No . 65428

Mr. Mohd. Emam Insp . & Corr. (S&EK) Team Member Tel. No . 65254

Mr. Hasan Sabri Insp. & Corr. (S&EK) Team Member Tel. No. 65434

Mr. Umair A. Usmani Standards Team Member Tel. No. 61869

Revision 3: Summary of Major Changes In this Revision (Rev.3}

SI. No. Clause Description of the Major Changes

Title Title Modified.

1
Foreword Revised & Updated.

2
4.2 Revised & Updated.

3
6.0 Revised & Updated.

Existing Clause 7.2 renumbered to Clause 7.3 and

modified.

4 7.2
New Clause 7.2 Added and subsequent clauses are re­
numbered. Table 1 Added.
7.3.1 Sub-Clauses are re-numbered to 7.4.1 & 7.5 (b) and
5
& 7.4 (b) modified .
Sub-Clause 7.5.2 re-numbered to 7.6.2 & modified and
7.5.2, Table 1 is referred .

6
7.6 Clause 7.6 re-numbered to 7.7 & Sub-Clause 7.7.2
& 7.9 modified.

& 7.9 Clauses re-numbered to 7.10 and modified.

Clauses 7.7 re-numbered to 7.8 and Title modified &

7 7.7 & 7.8

Clauses 7.8 re-numbered to 7.9.

Clauses 8.4 modified and

8
8.0 New Clause 8.5 added & subsequent clauses are re­
numbered .
9.3.4, 9.4.1,
9 Sub-Clauses are modified.
& 9.5.7
10 9.7 , 9.9 & 9.10 Clauses modified.

11 10.1 New-Sub Clause 10.1.4 and Table 2 Added.

Clause deleted and subsequent clauses are re­

12 10.3
-- numbered.
13 10.4.1 Clause Renumbered to Clause 10.3.1 and modified .
Clause Renumbered to Clause 10.4
14 10.5
and Sub Clause 10.4.4
-.- - -
Modified
­ .
Item C: Renumbered to Item D. Subsequent Items are re­
15 Appendix 1 numbered.

Item C: "Primary lining Details" added.

DOC. NO. Rev. 3

1.0 SCOPE

1.1 Standard specifies the minimum requirements surface preparation,

materials, application method, inspection and for Gunite Lining applied on
internal of primarily for the I processing of
fluids in the oil I gas industry or the storage of fresh I brackish / sea water.

1.2 This Standard covers both new and maintenance works of Gunite Lining of
Vessels.

2.0

1 The materials and equipment used for surface preparation, lining application

inspection & shall conform to the requirements of this Standard and

ra.n,('Qri standards I and mentioned herein,

Any exceptions or deviations from this Standard, along with their merits and
justification, shall be brought to the attention of KOC's Controlling Team, for their
review, consideration and amendment by Standards (if required).

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

3.0 TERMINOLOGY

3.1

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

3,1.1 Coat

A continuous layer of a coating material that results from a single application.

1.2 Curing

Curing is setting up of hardening of Gunite material generally to

chemical of cement and lor pozzolan with water.

3,1.3 Gunite

A term used to describe mixture of sand, cement, and water placed into
position under pneumatic pressure by means of a called "Cement Gun."

3.1.4 Lining

A cold curing, surface bonded, barrier used for corrosion internal

of corrosive fluids storage and processing equipment.
 80f28 Rev. 3

3.1 Pozzolan

A siliceous or and aluminous material, which in lJu;:);:,t;:;:,;:,\:;;:, little or

no cementitious value but will, in finely divided form and in nro,col',",O

chemically react with calcium hydroxide at ordinary

compounds possessing cementitious properties.

3.1.6 Welded Wire Fabric

A material composed of cold-drawn steel wire, galvanized fabricated into by

the process of electrical resistance welding. The finished material shaH consist
essentially of a of longitudinal and transverse arranged substantially
right angles to other, and welded together pOints of intersection.

CRA Corrosion Alloy

KOC Kuwait Oil Company (K.S.C)

MC Moisture Content

MSDSI Material Safety Data Sheet I Safety Data Sheet

Health, Safety and Environment

4.0

4.1

In the event of conflict between this Standard and the standards !

herein, or other contractual requirements, the most stringent
requirement shall apply.

4.2 131

latest edition of the following Standards, and Specifications shall apply:

1 International! National Standards and Codes

ASTM A615! 5M Standard Specification for Deformed and Plain Carbon

Steel for Reinforcement

ASTM A641! A641M Standard Specification for Zinc-Coated (Galvanized)

Carbon Steel Wire
II IDOC;. N10. ~COC-P-002 1 3

ASTM A 1064 1 A 1064M Standard for Carbon-Steel Wire and

Welded Wire Reinforcement, Plain and Deformed, for
Concrete

ASTM C33 1 C33M Standard Specification for Concrete Aggregates

ASTM C391 C39M Standard Test Methods for Compressive

Strength of Cylindrical Concrete Specimens

ASTM C150 1 C150M Standard Specification for Portland cement

ASTM C618 for Coal Fly Ash and Raw

or for Use in

ASTM C920 Standard Specification for Elastomeric Joint

Sealants

ASTM C1260 Standard Method for Potential Alkali Reactivity of

Aggregates (Mortar-Bar Method)

ASTM 04940 Standard Method for Conductimetric Analysis of

Water Soluble Ionic Contamination
Abrasives

ASTM E11 Standard Specification for Woven Wire Sieve

Cloth and Sieves

ISO 8501-(1 & 3) Visual Assessment of Surface Cleanliness

Part (1 & 3)

ISO 8502-(3,4,6 & 9} for the of Surface Cleanliness

(3,4,6 & 9)

NACE 21 SSPC o Joint Preparation Standard Near-White Metal

Blast Cleaning

NACE RP 0287 of Profile of Abrasive

Steel Surfaces Using a Replica Tape

NACE 0178 Fabrication, and Finish Practices for

Tanks and Vessels to Be Lined for Immersion Service

SP1 Solvent Cleaning

KOC Standards

KOC-G-002 KOC Standard for Hazardous Area Classification

KOC Standard for Basic Design Data

DOC. NO. KOC-P...o02 1 Page 10 of 28

KOC-L-010 1 KOC Standard for Personal Protective

KOC-P-001 KOC Standard for Painting Coating of

Metal Surfaces

4.2.3 KOC Health, Safety & Environment Management System (HSEMS)

KOC.EV.008 Waste Management Procedure

Training, Awareness and

Learning Process

KOC.PS.001
Safety Management Manual

KOC.SA004 Permit to Work Procedure

KOC.SAOO? Entry Into Confined Spaces

KOC.SA010 Procedure for Personal Protective Equipment

KOC.SA011 High Pressure Water Jetting, Abrasive Blast

and Steam Cleaning

KOC.SA013 Mobile Equipment Procedure

KOC.SA024 Job Safety Analysis (JSA) Procedure

KOC Policy & KOC HSEMS Guide

Any other KOC HSEMS . . . ,", ....." as applicable

5.0 ENVIRONMENTAL CONDITIONS

5.1 The environment of Kuwait is severe and must be considered

selection and before procurement of lining materials.

environmental conditions in Kuwait, refer to KOC-G-OO? "KOC

Basic Design Data", which provides the detailed deSign information
site conditions, utility supply conditions and units of measurements
prevailing throughout KOC Facilities.

6.0 131

6.1 The Contractor shall assure compliance of necessary

a view to minimise consequences and impacts of hazards on the
environment and adjoining facilities, as well as the occupational
safety of working personnel.
II [)OC. NCI, KC)C-F>-OO:Z Pt, 1 Page 11 of 28 Rev. 3

6.2 All relevant recommendations of the coating Manufacturer(s) and the

application equipment Manufacturer(s) shall be followed.

6.3 Appropriate Permit to Work (PTW) with applicable Job Safety Analysis (JSA)
document for the work to be carried out and shall prepared in accordance to
KOC.SA004 "Permit to Work prior to commencement of work. The
PTW and JSA documents shall address all relevant HSE requirements specified
by the Coating Manufacturer and applicable KOC HSEMS Procedures. KOC
Policy and all applicable KOC HSEMS procedures shall be adhered to
within KOC areas at all times.

JSA of the work including confined entry shall be in accordance with with
KOC.SA007 into Confined and control measures mentioned in
the JSA documents shall implemented at work site and the pertinent hazards
identified in shall be communicated to all workers before commencing the
work.

6.4 KOC Health, Safety and Environment (HSE) policy, relevant HSE Management
System procedures and other contract HSE requirements, as applicable, shall be
adhered to while carrying out KOC works.

All Contractor / Applicator personnel shall have successfully undergone applicable

training and I or awareness course(s) as identified in "Matrix of Identified
categories of personnel 'HSE Training, and Awareness' for Contractor's
Employee" HSEMS procedure KOC.GE.028 and personnel shall
able produce valid documentary evidences at the time of evaluation.

The Contractor I Applicator personnel. involved in supervisory, inspection I

testing, handling, surface preparation and lining application processes, shall use
appropriate Equipment during the pertinent
application(s)

6.7 Contractor I Applicator personnel, shall take necessary approvals from the
relevant safety authority of KOC, where is a risk of flammable atmosphere
being present in a particular work prior to performing preparation
Flame heating equipment shall not used in hazardous areas. Refer to KOC­
G-002 "KOC Standard for Hazardous Area Classification", which describes the
area classification for various Facilities. A prior approval from KOC shall
obtained before the use of any flame heating equipment at the job site.

Adequate lighting shall provided using KOC approved high flood lights
or spot lights of voltage to provide good visibility during surface
preparation, lining application, and inspection I testing. The temporary power
supply circuit shall have earth leakage circuit Temporary lighting shall
comply with the requirement specified in KOC.SA007 "Entry into Confined
KOC-P-002 Pt. 1 Page 12 Rev. 3

All chemicals being for surface preparation & lining applications shall have
a Material Safety Data (MSDS) I Safety Data (SDS) in
workplace and and the Contractor or Applicator shall aware of the
MSDSI

All equipment and utilized for coating application processes,

including pipe handling and cleaning processes, shall be certified to be in
condition. Contractor's mobile plant I equipment entering Gathering Centers I
Booster Stations must be Service" by Third Party Inspector and
shall obtain Clearance Certificate as KOC.SA.013 "Mobile Equipment
Procedure". Periodical inspection records of all equipment and accessories shall
be made available on demand.

All waste (Hazardous I non-hazardous) generated from the subject activities shall
be managed as KOC HSEMS procedure KOC. "Waste Management

The precautions required regarding entry to confined spaces shall in

accordance to the requirement specified in KOC.SA.OO? "Entry into Confined
principal precautions shall include but not limited to following:

The Vessel shall be positively isolated before commencement of any work.

Product and vapor shall drained off and purged.

b) All electrical switches supplying current to pumps and other equipment

connected to shall be "locked out". Cathodic protection system
and all tubular housing and conduits connected to the if any, for
gauging or other instrumentation purpose shall disconnected.

c) Continuous ventilation shall be provided during the entire lining process to

maintain safe working environment. rate of airflow to purge and
ventilate shall determined by the of vessel, with a minimum of
two air per hour. During the entire purging for
flammable I toxic vapor concentrations and Oxygen percentage shall
conducted.

lining materials (cement, pozzolan) shall be

from any contaminants or foreign material including
They shall be stored in separate bins or closed containers.

All Gunite materials shall be handled in a manner all matter is

excluded.
DOC. NO. 13 of 28 Rev. 3

13 I

Properties

Clause 7.5.1

Each Batch 7.6

Reinforcing Batch Clause

Clause 7.9

,-"<AU"",,, 7.10.
sealant

7.3 131

1 The Contractor's submittal for Gunite lining materials, sand pozzolan

shall include details on Manufacturer I brand, composition and technical
specifications materials to be used, for KOC's review and approval.

7.3.2 Manufacturer's certificate along with third party laboratory test reports shall be
furnished covering all materials (cement, sand, pozzolan) and shall confirm
that the comply with requirements of Table 1 of this Standard.

selected Gunite lining materials shall also comply with following or

as mentioned in relevant technical I data

7.4

7.4.1 shall be Ordinary Portland meeting the requirements

/ 50M V. of any other types of cement complying to
50 I C150M Type V be to KOC's approval. 131

7.4.2 A single brand of cement shall be used throughout any particular work.
Change of brand shall be to KOC's approval.

7.4.3 Hardened, partially hardened and contaminated cement shall rejected.

DOC. NO. KOC-P-002 1 14 of 28 Rev. 3

7.5 Sand

7.5.1 sand shall as per ASTM I C33M and meet the following requirements:

a) It shall be (free from contaminants), hard, durable

particles well from coarse to fine.

b) All particles shall a size (9.5mm). The modulus shall

not 2.30 and not more than I3I

c) The coarser grading may for thick layers or rough finishes,

the grading shall be used thin layers or smoother

d} Sand a large proportion of elongated I flat particles shall not be

e) sand shall free from injurious amounts of organic I inorganic

impurities. The sand shall not contain other deleterious in
excess 5% by weight

f) The moisture content (MC) of the sand be between 3% and

with MC > 5% shall down to limit. Any without
moisture be dampened before being placed in mix.

7.6

1 A aggregate shall be replace an equal weight of cement in the

Gunite mixture to an not than 25% weight of cement,
where applicable with prior approval of

7.6.2 pozzolanic aggregate used in Gunite work shall conform the

1 of this KOC standard. I3I

Water

7.7.1 water for hydrating the mixture at nozzle shall clean,

injurious amounts of oil, alkali, salt, organic material and any
that setting qualities of cement or
strength of the Gunite.

Unless otherwise authorised in writing by KOC, only water from potable

system Kuwait shall used and be in accordance with
1008 or ASTM C941 C94M. 131
II ....,.... ..,. NO. KOC-P-OO.... • ~.. II Page 15 28 Rev. 3

7.8 131

All reinforcing steel wire or mesh be in accordance with ASTM A 1064 I

A1064M. wire shall be hot dip galvanised in with
A641 I A641M.

7.9 Reinforcing Steel

All reinforcing used in Gunite work shall comply with ASTM A615 I A615M.

7.10 Pitch Polyurethane Elastomeric Joint Sealing Compound 13 I

Joint Compound shall be on polyurethane or similar

formulation blend with high grade pitch which cures to form elastomeric. highly
resilient seals with excellent recovery properties, & chemical resistance
wet operating temperature resistance as applicable to the use of
altemative sealing compound be subjected to KOC approval.

8.0 SURFACE PREPARATION 131

8.1 fabrication and surface finish requirements for internal lining work shall
NACE RP 0178.

8.2 Surface like weld spatter, and porosity shall be removed

completely (made flush or smooth). Any other observed in welds
material shall be referred KOC for disposition.

oil, dirt, temporary protective and chalk shall removed from the
to be . Degreasing shall be out using vapour
equipment or as recommended in SSPC-SP1.

8.4 Mill scale, paint and rust shall be removed by abrasive cleaning in
accordance with NACE 2 I 0 I ISO 8501-1 Sa Abrasive
cleaning follow requirements of KOC-P-001. The profile
shall be between to 1 microns when as per RP 0287.

8.5 The abrasive blast surface with a thin film lining I

coating (preferably phenolic epoxy thickness range of
1 microns. shall have excellent alkali
compatible with subsequent Gunite application. coating application
shall commenced within (4) of preparation or prior
to deterioration, whichever is earlier.

8.6 cleaning combined with vacuum collection the nozzle can be used to
atmospheric contamination within vessel.
IILJ..... C. NO. KOC-P-002 Pt. Page 16 28 Rev. 3

8.7 All surfaces be lined with Gunite shall cleaned to remove any dust, dirt
residues and debris etc. by using industrial vacuum cleaner prior to Gunite
application.

Adequate lighting of approved type used to good visibility during

surface preparation works,

9.0

9.1

11 The selection of Gunite lining material and

comply with requirements in

9.1.2 Gunite lining shall follow the shown on the drawings submitted by the
contractor and approved by KOC and shall fulfil all requirements of this
Standard.

9.1.3 Contractor shall provide all materials, scaffolding, lighting equipment

experienced manpower for carrying out the work.

9.2

9.2.1 Gunite lining shall over the total internal surface,

by the technical drawings, including the bore and over the faces of all
flanges unless later are weld overlaid with a Corrosion Resistant Alloy (CRA) in
which case the lining shall terminate on the CRA.

Where cathodic protection anodes are care shall taken to minimise

damage to the lining at the attachment points and to ensure that the
surfaces of the are not

9.3

1 The composition of Gunite shall be as follows:

a) Portland - 25% and -75%,

b) Portland 35%, pozzolan 5% and sand -

The mixture specified in above proportions shall be prior to

placed into cement gun. Any other composition for preparation of Gunite mix
shall be agreed upon by KOC.

All materials used in mixture shall be measured by volume with allowance

made for the bulking of

9.3,3 mixes be made and for strength finalising

proportion of sand cement.
II DOIC. NO. KOC-P-002 Pt. 1 Rev. 3

9.3.4 The materials be well by mechanical mixers or by manual mixing and

particles over mm shall be removed by screening being in the
131

9.4 Weather Conditions

9.4.1 shall not surface, nor during freezing weather unless it

is protected by 131

Any Gunite applied in dry surroundings be kept continuously wet from

time the surface starts drying until the curing is started to the loss of
hydrating by evaporation.

9.4.3 lining must temporarily sus,oerla if:

a) High winds occur which separate the r<.>.rn£;1,'1T from the at the

b) Temperature approaches have made for

heating

c) other than a light sprinkle, out the cement from the newly
placed Gunite. In the event of rain, the newly Gunite shall
properly covered until the has hard.

9.5 Application of Gunite

1 Gunite shall be applied on cleaned only. No Gunite shall be applied a

surface on which there is running or free water.

9.5.2 Gunite lining be applied in a uniform manner and the specified thickness
as Clause 9.12, without any sags or any other defects.

The air flowing into the gun shall maintained at

which is adequate to carry dry mixture through the hose at such a
velocity that the mixture is from the in a forceful etr.::.",rn

9.5.4 into the mixture the nozzle at

nozzle. The operator
into the mix by the valve at the nozzle body and
maintain as low water-cement ratio as is with the of the work
and the results that are wanted (adequate bonding to the surface).

9.5.5 application, operator shall avoid the inclusion of any foreign or

Olel~es of hardened rorYlOlnt

shall be taken by the Contractor to prevent any damage to the

I piping and fittings during application.
DOC. NO. KOC-P-002 Pi. 1 Page 18 of 28 Rev. 3

9.5.7 Except where cramped working or local conditions interfere, the

be held between 600 mm and 1500 mm from to be coated
a position that flow of material will it as near to a right
131

When shooting around reinforcing rods or anchor bolts, nozzle shall be moved
to side of the rod and angled to apply Gunite to the back of the rod

9.5.9 While on vertical or be applied in

of such thickness that the not cause it to sag.

9.5.10 On vertical or overhead particular care shall taken to keep

mix dry enough to avoid slumping or falling without excessive rebound.

9.6

joints in shall be off to a thin edge.

shooting adjacent the sloped portion thoroughly cleaned and
WP.IIP.O with a compressed water blast. No joints shall be allowed.

9.7 131

Fabric Reinforcing Mesh shall be provided as the below details:

9.7.1 Steel Fabric Reinforcing Mesh shall to a template to conform as

as practicable to outlines of the internal diameter of the

9.7.2 fabric shall be of reinforcing steel wire fabric

gage 2 ways) or size 37 mm x mm
and wire size gage 0 (both ways). reinforcing steel wire fabric materials,
Clause 7.8 this Standard.

9.7.3 steel fabric reinforcing mesh shall be

reinforcing steel which in turn are held to
welded or otherwise securely fastened to the surface. An
holding the mesh is by fastening it to low continuous bar chairs wel,aea
Proper shall to avoid sagging of fabric
reinforcing mesh. refer Clause of this KOC
Standard.

9.7.4 steel fabric reinforcing mesh shall be about 19 mm away

surface. The fabric used in Gunite placed so that
of the mesh is not than 13 mm to the being Gunited
is at least 19 mm cover of Gunite over layer of mesh.
DOC. NO. KOC-P-002 Pt. 1 II 19 of 28 Rev. 3

9.8

In order to ensure true lines and required thickness, shooting or other

gauging devices shall used at all of structural members.

Curing 131

9.9.1 soon as dry patches begin to appear on newly Gunite, it

crOI'Orl with of water. Gunite shall cured by any of the following
methods:

a) kept damp by a water spray a period of four days after placing

with wet burlap or fabric for a period of four days

c) sprayed with water and immediately with a water

paper, all seams being to prevent circulation of air and kept
thus covered for a period of four days.

If four days period is not enough to complete curing, due to

conditions, curing shall continue for an adequate as approved by KOC.

9.10 131

A two-pack polyurethane elastomeric joint sealing compound or equivalent,

complying with requirement Clause 7.10 this KOC Standard, shall
au,ulI<::;U on all joints, lining ends (between lining), nozzle
ends nozzles that project inside vessel. Mixing and application of the
sealing compound shall in accordance with the Manufacturer's technical data
sheet.

9.11

9.11.1 The Gunite shall be on to a line near the final which all high
spots shall removed by a sharp-edged screeding device.

9.11.2 A finishing or coat shall smooth

finish. The final shall be

9.12

The of the application shall be 40 mm with tolerance limits of

0% and uniformity of texture and waviness shall be maintained
produce smooth surface finish.
DOC. NO. KOC-P-002 Pt. 1 Page 20 of 28 Rev. 3

9.13

9.13.1 Subject to KOC's approval, new Gunited surfaces having / shall

be repaired to satisfy the requirement Standard. It is mandatory that all
defective work shall corrected to satisfaction of The following describe
procedure for I defects

a) A steel been by spalling or cracking Gunite

lining shall be from any dust, dirt, sand & cement and moistened
with clean water.

Immediately after moistening, the freshly mixed shall applied by

shooting on the defective areas. A trowel or stiff brush shall
used small area application.

Where Gunite lining repair is done, the adjacent lining shall overlap
to cover any cracks and shall maintained in a moist conditions for
four using burlap or fabric pads or similar means.

9.1 lining maintenance shall, as general rule, be based on complete

removal of old lining system, surface preparation and re-guniting in accordance
with this Standard.

10.0

10.1 General

10.1.1 Inspection and testing all of preparation and lining application

be conducted by the contractor. Contractor shall perform
inspections as are to assure that the Gunite lining complies with the
requirements this

10.1.2 Surface preparation and lining application shall be subjected to inspection I testing
any by to ensure the compliance with Clauses 8.0 and 9.0 this
Standard.

10.1.3 KOC inspector have right inspect all times any tools, materials or
equipment used in the performance of surface preparation and Gunite application
to ensure the compliance with the requirements of Standard.
DOC. NO. KOC-P-002 Pt. 1

10.1 Inspection & Testing for Application shall as per Table 2

given below: I3I

TABLE 2

Test Method I
51. No. Description Frequency
Standard

1
Material Table 1 Batch to Table 1
Certificate

of area Comply to

100% of lining area Comply to Standard

5 ISO 8502-4
Conditions

Surface
ISO 8501-1 100% of lining area Sa2.5

Start of shift &

Profile NACE RP 0287 75 to 125 1.1
2 Hrs

Prior to coating / as
8 Dust Level 8502-3 < 2
requested by KOC

Surface Chloride ISO 8502- 6 &

< 5 IJg I
Level ISO 8502-9

Level 75 to 125

Lining ­ KOC
11 1 Lining
Visual Inspection Part 1

Gunite Lining ­
12 40 ±4 mm

> 20.69 N/mm2

Mix
(3000 psi)

> 27.59 N/mm2

 DOC. NO. KOC-P-002 Pt.1 Page 22 of 28 3
~===========d6==========~===.~- .- - . - ­

10.2 Materials and Equipment Inspection

1 1 Gunite lining (cement, sand, etc.) shall be inspected to ensure the

compliance with requirements of 7.0 of this KOC shall have the
right to call for test on each type of Gunite materials, if necessary, to confirm that
the materials meet the requirements specified in Clause 7.0 of this KOC Standard.

1 application equipment shall to ensure compliance with this

KOC Standard and applicable KOC HSEMS procedures.

10.3 Visual Inspection

10.3.1 Cleaned Surface 131

surface preparation, a visual inspection shall be by the contractor to

ensure no rust, sand or foreign material is left and surface can
properly Gunited. The preparation and condition of the surface shall be
inspected and cleared a KOC inspector prior to the start of Gunite application.

1 Lined

a) Gunite lined shall be inspected, before and curing,

proper application in with this Standard. shall
checked for conformance with 9.9.

b) Following the full cure hardening, the shall

inspected to ensure that the lining requirements for sealing,
surface finish and thickness (Refer Clauses 9.10, 9.11 and 9.1 Lining
shall free from the following:

i. areas, honeycombing or open lining, cracks, sags, water

cutting, holes etc. and any projections arising from
application.

ii. Spalied or areas lining.

iii. Variable composition lining.

iv. laminations.

v. Variation in lining thickness (thick and thin areas).

c) Any other surface defects such as hairline cracks, undulation etc. if

detected it shall be brought to the notice of KOC, prior same being
 Page 23 of 28 Rev. 3

10.4

10.4.1 the compressive strength of the applied Gunite, three (3) test cylinders
shall be made during the course of the shooting so that representative of
Gunite are obtained.

10.4.2 The cylinders shall be made by shooting the Gunite into a mould of hardware cloth
(W' metal mesh) to make cylinders 150 mm in and 300 mm long.
excess material outside the mould is trimmed off with a sharp edged trowel. The
open mesh mould is to permit the escape of air and rebound sand during
placing and to provide a cylindrical for trimming.

10.4.3 After hours of making the cylinders, hardware cloth shall removed and
cylinders stored under moist curing conditions at about 21°C (70°F) until
testing.

10.4.4 Gunite Mix ratio analysis: When requested by KOC, Contractor shall carry out
the quality control to determine the cement, sand and pozzolan ratios in the
Gunite as instructed by the KOC. I3I

11.0

11.1 Manufacturer(s) I Contractor(s) shall operate a quality system to ensure that

requirements of this Standard are achieved. quality system preferably be
based on the ISO 9000 of Standards and the Manufacturer(s) I
Contractor(s) shall demonstrate compliance by providing a copy of accredited
or the Manufacturer's quality manual.

11.2 Verification of the Manufacture(s) I Contractor(s) quality system is normally part of

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

12.0

12.1 General

12.1.1 All correspondence, instructions, drawings, data sheets, design calculations or any
other written information shall be in the English language. In the case of dual
languages, one language shall be English.

12.1.2 All dimensions, units of measurement, physical constants, shall in SI units,

unless otherwise specified.

1 1.3 All documents (texts, specifications, data calculations, drawings etc.) shall
be provided in Hard Copies with its electronic in the approved software
(MS Word, Auto Cad All calculations shall be submitted in
approved and widely used software duly approved by KOC.
 Page Rev. 3

1 Work Proposal

12.2.1 The Contractor shall submit his proposal for all of work, for the
KOC prior to commencement, which shall include, but limited to the following:

Information on work location, materials, and equipment

used, items on surface areas to be lined, surface preparation,
application procedure(s) etc.

b} Technical drawings of equipment to lined showing the Gunite

details of internal surfaces.

c) Manufacturer's data material performance certificates

test approvals shall provided for ail lining "''''Tan

d} Evaluation of all and provision for mitigation I control of HSE

shall be in line with applicable KOC HSEMS procedures.

Inspection I testing plans, nrf\,('orl and equipment.

f) Specific repair proposal satisfy requirements of 9.13 for

pinholes and other defects repair.

12.3

The Contractor shall a comprehensive recording and reporting

all aspects of the lining work including inspection I testing. The data shall
out on a lining work and inspection I testing record within 24 hours carrying
specific work. Samples of the data record are shown in Appendix 1.

12.4

A report shall be submitted upon completion of the lining works. final

shall include a summary on all covered, preparation,
application procedure and inspection and testing records performed. All the
shall duly signed by the Inspection & Corrosion personal.
F===============~=-==--=-==~=-==========~=======~F=======================9

DOC. NO. KOC-P-002 Page 25 of 28 Rev. 3

13.0 APPENDIX 1 I3I

Contractor's Name no . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KOC Controlling Team .................................... .

Proposed by..................................... Checked Date: ........... ..

Item being lined................................ Surface Area ...................... Time: ............ .

Location..................................... ..... New I Maintenance Work.....................

Drawing No..................................... .

Ir-------~-·~----------~ - -..- - - - . - . - - - ­

A. Surface Preparation

Surface Cleanliness............................................... Cleaning Method(s)

(Visual Standard)

Surface Conditions:

1.

2.

3.

B. Weather Conditions

Ambient Temperature °c ............................

Relative Humidity

Surface Temperature °c .............................

Wet/Dry/Hot Surroundings ....................... .

Other Weather Conditions .......................... ..

(Rain, Wind, etc ..)

C. Primary Lining Details:

Manufacturer: ....................................... Product: ............................

Batch No: .......................................

Dry Film Thickness: .......................................

Ii
DOC. NO. KOC-P-002 Rev. 3

Gunite lining Record I Data Contd.l-.....

rr========================~=-~=-==-=~ .= ==. =====--==~==============,

D. Lining Materials

Manufacturer I Brand ................... .

Manufacturer I Source ....................

Grading I

Product I Batch No ...................... .

Sieve Size ................................. ..

Packing ................................... .
Fineness modulus........................ .

Moisture ContenL ..................... .

H!ldrating Water

Manufacturer I Source .................. .

ASTM-Type .............................. .
Source ................................

Reinforcing Fabric I Mesh

Sealing compound

Size ................................... .

Application

Gunite Mix. Proportions:

Cement ............. '%

Pozzolan ........... %

Sand ................ %

Mixing Method .................. .

Areas to be Sealed ...................... .

Inspection / Testing

Prepared Surface ............................... ..

Test Cylinder:

Size (length I

Lined Surface .....................................

Compressive Strength:

At age of 7

At age of 28 days ..................... N/mm2.

DOC. NO. KOC-P-002 Pt. 1 I Page 27 of 28 Rev. 3

ACKNOWLEDGEMENT

This KOC Standard (Rev. 3) has been approved by the Standards Technical Committee
(STC) consisting of the following Members:

Mr. Saeid AI-Duwaisan Standards Team Ag. Chairman

Mr. Mohd. Emam Insp. & Corr. (S&EK) Team Deputy Chairman
Mr. A. Unnikrishnan Standards Team Secretary / Member
Mr. Mohd. Aslam Imadi Tech. Exp. Team Member
Mr. G. Unnikrishnan Tech. Exp. Team Member
Mr. Amer Jaragh Insp. & Corr. (N&WK) Team Member
Mr. Nandkumar Aravind HSE Systems Team Member
Mr. Mohammad AI-Ajmi Tech. Systems Team Member
Mr. Haitam Aboughaith Gen . Projects Team Member
Mr. Abdulla AI-Yousef Project Mgmt. (NK) Team Member

The Draft of this Standard (Rev. 3) had been circulated to the KOC User Teams for review
and responses were received from the following Teams:

INDUSTRIAL SERVICES GROUP CORPORATE INFO. TECH. GROUP

Team Leader Insp. & Corr. (S&EK) Team Leader Tech . Systems
Team Leader Insp. & Corr. (N&WK) Team Leader Info . Tech . Services

SUPPORT SERVICES GROUP (WK) OPERATIONS SUPPORT (GAS) GROUP

Team Leader HSE (WK) Team Leader HSE-Gas

SUPPORT SERVICES GROUP (NK) EXPORT OPERATIONS GROUP

Team Leader HSE (NK) Team Leader HSE (Exp . Opns. & Mar. Opns .)

AHMADI SERVICES GROUP OPERATIONS GROUP (EK)

Team Leader Corporate Proj. I Team Leader Maintenance (EK-II)

FIRE GROUP OPERATIONS SUPPORT GROUP (S & EK)

Team Leader Fire-Support Services Team Leader HSE (S&EK)

HEALTH, SAFETY & ENV. GROUP TECHNICAL SUPPORT GROUP

Team Leader Health & Environment Team Leader Drlg . & W/Over Tech .Svcs.-11
Team Leader Safety
F=====~================~====================Y==.~... ==~~~===-== . . ..
~=-=
-=~==~

Page 28 of 28 Rev. 3
..
~========~==========~=-=~=-=====-=-===-==c====~====================~

Team Leader Tech ....."''''.".....

Team PMC Mgmt.(AMEC. FLUOR, WPK, Technip)

The revision of this Standard (Rev. 3) been entrusted by the Standards Technical
Committee to the Task Force No. (TF-CP/02) comprising of the following Members:

Mr. Amer Jaragh Insp. & Corr. (N&WK) Team TF Tel. No. 65428
Mr. Mohd. Emam Insp. & Corr. (S&EK) Team Member Tel. No.
Mr. Hasan Sabri Insp. & Corr. (S&EK) Member No. 65434
Mr. Umair A Usmani Standards Team Member Tel. No. 61869