TECHNICAL SPECIFICATION

PART III- MECHANICAL AND PIPING WORKS

 Page 1 of 2

KUWAIT OIL COMPANY (K.S.C.)

(Register of Commerce No. 21835)

TECHNICAL SPECIFICATION
- for -
REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH
SMOKELESS TYPE FLARES AT NK GCs 15, 23 & 25

PART III- MECHANICAL AND PIPING WORKS

CONTENTS

1. INTRODUCTION
2. GENERAL REQUIREMENTS
3. WORKS TO BE EXECUTED
3.1 SCOPE OVERVIEW
3.2 LP FLARE STACK
3.3 HP FLARE STACK
3.4 FLARE KNOCK OUT DRUM
3.5 PIPING AND MECHANICAL WORKS
3.6 PIPE STRESS ANALYSIS STUDY, EXPANSION LOOPS, SUPPORTS AND
ANCHORAGE
3.7 SHUTDOWN
3.8 HOT TAPPING
3.9 DEMOLITION WORKS
4. WELDING AND FABRICATION
5. PAINTING AND PROTECTION
6. INSPECTION AND TESTING
7. PRECOMMISSIONING AND COMMISSIONING WORKS
8. PERFORMANCE CRITERIA
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TECHNICAL SPECIFICATION PART III - MECHANICAL AND PIPING WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE
FLARES AT NK GCs 15, 23 & 25

APPENDICES TO TECHNICAL SPECIFICATION PART III

APPENDIX 3A – Specification for Air Assisted Smokeless Flare Package

APPENDIX 3B – Flare Datasheets

APPENDIX 3C – Knock Out Drum Datasheets

APPENDIX 3D – Knock Out Drum Pump Datasheets

APPENDIX 3E – Material Selection Guide

APPENDIX 3F – Specification for Material in Sour Service 2015 - ZA-E-Z0001

APPENDIX 3G – General Welding Requirements

APPENDIX 3H - Pressure Testing of Piping Systems

APPENDIX 3I - Pipe Fabrication & Erection

APPENDIX 3J - Risk Based Inspection Requirements

APPENDIX 3K - Summary of Miscellaneous Mechanical Works for Replacement / Twinning

of PSVS

APPENDIX 3L - Criteria to KOC-MP-014 (EF2015-KOC-MP-014-CRT)

APPENDIX 3M - Criteria to KOC-MP-015 (EF2015-KOC-MP-015-CRT)

APPENDIX 3N - Criteria to KOC-MP-033 PT. 1 (EF2015-KOC-MP-033 PT 1-CRT)

APPENDIX 3O - Specification for Potable Water Services

 Page 1 of 25
KUWAIT OIL COMPANY (K.S.C.)
(Register of Commerce No. 21835)

TECHNICAL SPECIFICATION
- for -
REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH
SMOKELESS TYPE FLARES AT NK GCs 15, 23 & 25

PART III- MECHANICAL AND PIPING WORKS

1. INTRODUCTION

1.1. The Mechanical and Piping Works shall comprise of design, procurement, supply, installation,
inspection, testing, pre-commissioning, commissioning and hand-over of new Low Pressure
(LP) and High Pressure (HP) Air Assisted Smokeless flares along with all the piping, equipment
and the associated Works in accordance with the specifications and Drawings provided in this
Contract and as specified herein, as follows:

a. New Self-supported air assisted LP & HP Flares, complete with Flame Front Generator
and Air blowers as follows:

New HP New HP Blowers New LP New LP Blowers

Location
Flares (nos.) (nos.) Flares (nos.) (nos.)
GC-15 Two (2) Four (4) One (1) Two (2)
[Two for each flare]

GC-23 Two (2) Four (4) One (1) Two (2)

[Two for each flare]
GC-25 --- --- One (1) Two (2)

b. Knock Out Drum complete with 100% standby KO Drum pumps as follows:

New HP KO New HP KO Drum New LP KO New LP KO Drum

Location
Drum (nos.) pumps (nos.) Drum (nos.) pumps (nos.)
GC-15 Two (2) Two (2)@ One (1) Two (2) @,$
[One (1)+ One(1) [One (1) @+
spare] One(1) spare @]
GC-23 Two (2)# Four (4) One(1)# Two(2)*
[Two (2) for each KO [One(1)* +
Drum- One(1)* + One(1) spare*]
One(1) spare* ,
One(1)* + One(1)
spare*]
GC-25 One(1) Two (2) @ One(1) Two (2) @
 Page 2 of 25

TECHNICAL SPECIFICATION PART III- MECHANICAL AND PIPING WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE
FLARES AT NK GCs 15, 23 & 25

One(1) @ + One(1) [One (1) @+

spare@ One(1) spare @]
# Located inside concrete pit
* Vessel-mounted
@ Vertical Can pumps
$ Common for both existing and new LP K.O. drums

c. GC-15, GC-23 & GC-25: Replace existing Conventional PSVs with Balanced Bellow
type PSVs. Additionally, install new PSVs for twinning operation with existing single
PSVs along with mechanical key interlock arrangement having individual isolation
valves. PSVs shall be provided with platforms for proper access for
Maintenance/Inspection. For the list of PSVs and PSV data sheets, refer Technical
specifications Part V – Instrumentation Works.
Miscellaneous works associated with the replacement / twinning of PSVs is
summarized in Appendix 3K to Technical Specification, Part III – Mechanical and
Piping Works.
All materials and Works for the PSVs shall be as per KOC-MP-027 Part 1 & 2,
associated piping shall be as per KOC-MP-010.

d. Tank Vapour Line/ Header in GC-23

- Demolition of dual tank T-91 TV outlet line, which is at grade level.

- Reroute the dual tank T-91 TV outlet line (30”) at higher elevation and tie-in at
downstream with 42” TV header next to the wet tank TV connection.
- Replacement of 32”/36”/42” flare header after the branch connection going to the
CRU suction scrubber (573-C-205) till the flare Knock out drum.
- Water dump line (6”) from CB-CRU is connected to the TV flare header shall be
Rerouted directly to flare KOD to avoid water stagnation
- Corrosion Monitoring System (CC, CP), Fuel gas piping and other connections
shall be as per P & ID.

e. 10” underground Fire Water Line (Line Class Q35A) including Fire Water hydrants,
Post Indicator type sectioning block valves etc., from tie-in at existing Fire water
header to HP Flare Knock-out Drums in GC-23 as shown in the Piping Layout
drawing as per KOC-L-009.

f. Associated Piping and Mechanical Works for all the above.

g. Works at GC-15 Existing Auxiliary Building 24V DC Battery Charger Room.

1.2. The Contractor shall carryout site visits and surveys to study the existing facilities and prepare a
detail engineering package comprising of design calculations, datasheets, construction drawings,
method statements etc. for review and approval by the Superintendent.
 Page 3 of 25

TECHNICAL SPECIFICATION PART III- MECHANICAL AND PIPING WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE
FLARES AT NK GCs 15, 23 & 25

1.3. Existing utilities like instrument air, pilot gas, purge gas etc. shall be used in the new flare system.

1.4. All the new facilities shall be in accordance with the drawings and specifications attached with
this document. The details, the construction drawings and material procurement shall be
executed by the Contractor by updating, site survey / investigation and detailed engineering
based on the documents and project drawings provided as part of Contract documents.

1.5. Unless otherwise specified hereunder and in the appendices, the Mechanical and Piping Works
shall be performed in accordance with ASME B 31.3, API STD 521, API 537, API 610, KOC-
ME-008 Part-2, ASME SEC VIII Div. 1, KOC-MV-001, KOC-ME-021 and other relevant
standards referred in this Contract.

1.6. The Works shall be executed at GC-15, GC-23 and GC-25 in North Kuwait Area.

2. GENERAL REQUIREMENTS

2.1. Site Survey and Verifications:

2.1.1. The Contractor shall acquaint himself with the site conditions, the topographical conditions/
data, location & status of the existing facilities & the utilities available at the Site.

2.1.2. The Contractor shall survey and obtain all the requisite site data as required to satisfactorily
complete his design work to meet the Project objective, under information and reference to the
Superintendent.

2.1.3. The Contractor shall survey the sites, carry out slit trenching and determine all existing
underground and aboveground services and pipelines. Contractor shall verify all dimensions,
elevations and co-ordinates wherever given in the Company supplied drawings.

2.2. Flare Gas Analysis and Verifications:

a) Typical analysis of the flare gas has been furnished in Appendix 2A to Technical
Specification Part II - Process Design Basis for the Contractor’s reference. However,
during detail engineering, selection of equipment and execution Works, it shall be solely
the Contractor’s responsibility to collect the gas samples for the new flare systems and
analyze the same for establishing the correct compositions prior to proceeding with the
design works, since the Company provided compositions are preliminary and indicative.

2.3. Utilities, Fuel Gas Analysis and Instrument Air Supply Details Verifications
 Page 4 of 25

TECHNICAL SPECIFICATION PART III- MECHANICAL AND PIPING WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE
FLARES AT NK GCs 15, 23 & 25

a) During detail engineering, selection of equipment and execution of works, it shall be sole
responsibility of the Contractor for site verification and data collection prior to proceeding
with the design and construction Works.

b) Instrument Air required for igniters, control valves and other instruments shall be taken
from the nearest existing instrument air header. The contractor shall verify the maximum
air consumption and pressure available at the Tie-in point before finalization of the
detailed design.

c) Fuel gas for ignition, pilot and purge shall be taken from the nearest existing header. The
contractor shall verify the pressure available at the Tie-in point before finalization of the
detailed design.

2.4. The Contractor shall develop and prepare detailed piping drawings with isometrics and material
list with specification. The Contractor shall use the information provided in the Company
supplied Drawings and prepare all the necessary engineering and construction drawings, data
sheets and documents as required to complete the work carried out by him. These drawings and
documents shall be submitted by the Contractor to the Company for prior approval before
execution of the works.

2.5. All the auxiliaries, accessories and related works shall meet the requirements and conform to the
specifications included in this Contract. The Contractor shall ensure the requirements of Section
15.1.6 KOC-MP-027 Part 2 –Standard for Pressure Relief devices are implemented. In
particular, this requires that the contractor shall ensure all pressure relief devices (safety valves,
pressure relief safety valves and pressure vacuum valves) are re-tested and subsequently fitted
with tags showing a unique number assigned to each device.

2.6. All such engineering Works shall be carried out by the Contractor as necessary to ensure a
complete operating facility in accordance with the Contract requirements and objectives for the
flare lines, flare stack & soak-away pit locations, piping locations, flare stack heights, other
system requirements.

2.7. The Contractor shall submit the following for Company review and approval, specifically:-

a. Design Documentation & Drawings

b. Calculations
c. Material Selection Guide
d. Overall Piping Plan Layout
e. Pipe Stress analysis
f. Draft & Final Purchase Specifications
g. Material Take–offs
h. Data sheets
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TECHNICAL SPECIFICATION PART III- MECHANICAL AND PIPING WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE
FLARES AT NK GCs 15, 23 & 25

i. Tie-in Register
j. Construction Drawings
k. Procedures
l. Vendor data , document and drawings

Notes:

a. The number of copies and any related requirements shall be as specified elsewhere in this
Contract.
b. All Vendor’s submittals shall be first reviewed, commented, and approved by the
Contractor and then submitted to the Company for review and approval. The Vendor’s
submittals shall therefore bear the stamp and mark-up of the Contractor.
c. Contractor’s detailed engineering submittals related to the flare system including knock-
out drums shall be vetted by the Flare Vendor prior to submission to Company for review.

3. WORKS TO BE EXECUTED

3.1. Scope Overview

3.1.1. The Contractor shall design, procure, supply, install, test, pre-commission and commission
vertical, self-supporting, Smokeless Air Assisted LP and HP Flare Stacks at the locations
specified in GC-15, GC-23 and GC-25, in accordance with Technical Specification Part II –
Process, Appendix 2A - Process Design Basis, Specification No. SPC-2015-ME-01
(APPENDIX 3A – SPECIFICATION FOR AIR ASSISTED SMOKELESS FLARE
PACKAGE) and Data sheets enclosed herein.

3.1.2. The Contractor’s scope shall cover the design, detailed engineering, fabrication, supply,
installation, testing and commissioning of smokeless flare including all associated accessories /
auxiliaries, Flame Front Generator, KO drum, KO drum pumps and associated piping in
accordance with Project Specifications and all relevant Standards, Data Sheets, Specifications
and drawings specified in this Contract.

3.1.3. The flare stack base shall be of circular conical design with base plate and anchor bolts for
installation on a RCC foundation, as further elaborated in Technical Specification Part VI – Civil
and Structural Works. The vessel base and RCC foundation shall be designed to take loading as
specified in Company’s Standard KOC-C-001.

3.1.4. The Contractor shall be responsible for the design and mechanical integrity of the flare stack,
KO drum and connected piping.

3.1.5. The flare stacks shall be provided with a working platform and approach ladder for inspection
and maintenance of flare tip, pilots and thermocouples. The Contractor shall design and supply
the same.
 Page 6 of 25

TECHNICAL SPECIFICATION PART III- MECHANICAL AND PIPING WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE
FLARES AT NK GCs 15, 23 & 25

3.1.6. The Flare stack shall be factory coated. The flare stack, if shipped in sections, shall be aligned
and assembled at site prior to installation on the foundation.

3.1.7. Testing and touch-up painting of the stack shall be done after installation.

3.2. LP Flare Stack

The LP flare stack shall consist of the following as a minimum. The Contractor shall note that
the listed requirements are not exhaustive and the Contractor shall ensure that the system
supplied complies with this specification, Appendix 3A to Technical Specification Part III-
Specification for Air Assisted Smokeless Flare Package, project Drawings including P&IDs,
Appendix 3B to Technical Specification Part III – Flare Datasheets and relevant standards
like API STD 537, API STD 521 and KOC-ME-021.

 Smokeless TV flare stack (self-supported) with flare tip and pilot burners
 Flame retention rings
 Purge gas seals (Buoyancy seal)
 Dual element type retractable Thermocouple for flame detection (2 nos. per pilot burner)
 Windshield
 Pilot gas piping
 Pilot ignition piping
 Flame front generator complete with control panel, flow control valves, mixing chamber,
spark plug, piping, drain etc.
 Vane axial axial-flow direct driven two speed electric blowers complete with inlet filter,
trash screens, mufflers, inlet and backdraft dampers etc. Vibration monitor probes shall
be provided for the Air blowers.
 All instrumentation required for the safe and proper functioning of the flare package.
 Retractable type aircraft warning lights.
 Radiation shield for all instrumentation.
 Ladders and Platforms with handrails for access the Flare Tip.
 Lifting lugs and tailing lugs for lifting the complete unit with all equipment installed.
 Retractable davit, rope and all other necessary equipment for flare tip removal and
maintenance.
 Flare stack material shall confirm the requirements of NACE MR 0175/ISO 15156 latest
edition, for sour service.
 Page 7 of 25

TECHNICAL SPECIFICATION PART III- MECHANICAL AND PIPING WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE
FLARES AT NK GCs 15, 23 & 25

3.3. HP Flare Stack

The HP flare stack shall consist of the following as a minimum. The Contractor shall note
that the listed requirements are not exhaustive and the Contractor shall ensure that the system
supplied complies with this specification, Appendix 3A to Technical Specification Part III -
Specification for Air Assisted Smokeless Flare Package, project drawings including P&IDs,
Appendix 3B to Technical Specification Part III – Flare Datasheets and relevant standards
like API STD 537, API STD 521 and KOC-ME-021.

 Smokeless HP flare stack (self-supported) with flare tip and pilot burners
 Flame retention rings
 Purge gas seals (Buoyancy seal)
 Dual element type retractable Thermocouple for flame detection (2 nos. per pilot burner)
 Windshield
 Pilot gas piping
 Pilot ignition piping
 Flame front generator complete with control panel, flow control valves, mixing chamber,
spark plug, piping, drain etc.
 Vane axial axial-flow direct driven two speed electric blowers complete with inlet filter,
trash screens, mufflers, inlet and backdraft dampers etc. Vibration monitor probes shall
be provided for the Air blowers.
 All instrumentation required for the safe and proper functioning of the flare package.
 Retractable type aircraft warning lights.
 Radiation shield for all instrumentation.
 Ladders and Platforms with handrails to access the Flare Tip.
 Lifting lugs and tailing lugs for lifting the complete unit with all equipment installed.
 Retractable davit, rope and all other necessary equipment for flare tip removal and
maintenance.
 HP Flare stack material shall confirm the requirements of NACE MR0175/ISO 15156
latest edition, for sour service.

3.4. Flare Knock Out (KO) Drums

Design, procure, supply, install, test and commission horizontal HP and LP Knock out drums
as specified in the P&IDs and elsewhere in Technical Specifications. The KO drums shall be
installed upstream of the flare stack at the locations as indicated in the project drawings. The
location indicated in the project drawings are preliminary and shall be finalized by the
Contractor during detailed design and subject to approval by Company. KO drums shall be
sized to accommodate the maximum liquid relieved during an emergency. KO drums shall
be suitable to limit the size of liquid droplets to 300microns. KO drums shall comply with
this specification, Appendix 3C to Technical Specification Part III–KO Drum datasheets,
Company’s Standard KOC-MV-001 and relevant API/ASME standards. The KO Drums size
stated in the specification are minimum requirements.
 Page 8 of 25

TECHNICAL SPECIFICATION PART III- MECHANICAL AND PIPING WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE
FLARES AT NK GCs 15, 23 & 25

The KO drum shall include, but not limited to the following:-

 Horizontal vessel designed to ASME VIII Div 1 , KOC-MV-001 for sour service
 KO drum shall be provided normally with one (1) no. flare gas inlet and one (1) no. gas
outlet and 1no. Liquid outlet. In case of high flare gas load two symmetrical gas inlets to
the KO drum shall be considered.
 KO drum pumps (1 working + 1 standby) to transfer the liquid back to the tanks (Refer
appendix 3D - KO drum pump datasheet) shall be designed as per Company’s Standard
KOC-ME-008 Part 2 & API 610 11th Edition.
 Corrosion allowance of 3mm
 Internal High Build Epoxy coating as per KOC-P-002 Part 3
 External coating as per KOC-P-001
 Cathodic Protection for internal surfaces as per KOC-L-018 as further detailed in
Technical Specification Part IV-Electrical Works
 Saddle supports
 All required nozzles for purge gas connection, instrumentation, vent, drain, water fill and
steam out.
 All required instrumentation like pressure gauges, temperature gauges, temperature
transmitters, pump control level transmitters and level gauge transmitters etc.
 Manway for maintenance.
 KO Drum sizing shall take in to consideration to maintain a dead volume of liquid to
prevent dry running of pumps.
 KO drum pumps shall be programmed to operate simultaneously during peak loads.
 Flare KO Drum materials shall confirm the requirements of NACE MR0175/ISO 15156
latest edition, for sour service.
 Internal water / electrolyte immersed surfaces of vessels shall be provided with CP system
as per KOC-L-018. All internals and piping inside vessels shall be coated regardless of
the material specification. All contact between dissimilar metals shall be isolated with
isolation gasket / device.

3.5. Piping and Mechanical Works:

3.5.1. The Contractor shall procure, supply, install, test and commission all new equipment, piping,
valves, pipe fittings and components for the new flare stack and KO drum as per the approved
detailed engineering drawings developed in accordance with Technical Specification, datasheets
and Drawings as per this Contract .

3.5.2. The Mechanical and Piping Works shall include the following:

Tie-ins with existing flare piping and new flare piping shall be installed as shown in the
P&IDs and Piping Layout Drawings. The routing of piping, support locations, expansion
loops etc. shown in the piping Drawings are indicative and for guidance only. Expansion
loops, drains/ vents, supports and guides and the like shall be included in the new piping
system based on stress analysis of the system. Wherever, the lines indicated in the P&IDs
are not shown in the piping Drawings, the same shall be developed during detailed
engineering by the Contractor.
 Page 9 of 25

TECHNICAL SPECIFICATION PART III- MECHANICAL AND PIPING WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE
FLARES AT NK GCs 15, 23 & 25

a. Minimum Pipe wall thicknesses for the flare piping shall be as follows:
42” API 5L Gr. B, PSL2, LSAW – 12.7 mm (0.5”)
36” API 5L Gr. B, PSL2, LSAW – 12.7 mm (0.5”)
24” API 5L Gr. B, PSL2, LSAW – 9.53 mm (0.375”)
Other sizes – as per KOC-MP-010 with minimum thickness limitations as per
015-LH-1002.

b. A 2” drain line (underground) from the new flare stack to new or existing drain/
soak away pit shall be installed with Cathodic Protection as further detailed in
Technical Specification Part IV-Electrical Works.

c. The Works shall include installation of instrument air piping, ignition piping,
purge gas piping, pilot gas piping, any other piping Works and related auxiliaries
required for the safe and proper functioning of the system. The tie-ins to the
existing Instrument Air and Fuel Gas Lines shall be performed by the Contractor,
with a ball valve at each tie-in point.

d. The Contractor shall install new piping to route the liquid collected and pumped
from the flare KO drum back to the tank.

e. Fire water piping shall be provided as shown on the Drawings.

f. All necessary piping Works including tie-ins for the replacement of PSVs,
twinning of PSVs, including all necessary materials like valves, pipe, flanges, pipe
fittings, stud bolts and gaskets etc. and associated miscellaneous works as more
elaborated in Appendix 3K to Technical Specification Part III. Vents shall be
provided on both upstream and downstream of PSVs.

PSVs shall be provided with platform for proper access for

Maintenance/Inspection.

Hot tapping shall be carried out for the tie-ins in case shutdown is not available.

For the list of PSVs, refer Technical specifications Part V-Instrumentation Works.

g. Internal Corrosion Monitoring Systems as shown in the project P&IDs and as per
the requirements of Companys’s Standard for Internal Corrosion Monitoring
Equipment for Facilities and Pipelines (KOC-MP-035 Rev 2).

- All the internal corrosion material shall be supplied from Company’s approved
vendors (VEC Category – Corrosion Monitoring Probe System). All materials
shall be subject to Company approval.
 Page 10 of 25

TECHNICAL SPECIFICATION PART III- MECHANICAL AND PIPING WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE
FLARES AT NK GCs 15, 23 & 25

- Detailed procedure for fabrication, installation and testing of corrosion monitoring

equipment shall be prepared by the Contractor and submitted for Company’s
approval.
- Permanent access platforms / pits shall be provided as per KOC-MP-035 Rev 2
clause nos. 8.1.10, 8.1.11 and 8.1.12.
- Inspection and Test Plan shall include witness / hold points for Company for
internal corrosion monitoring equipment installation activities such as material
receiving inspection, location marking, access fitting fit-up inspection, installation
of hollow / solid plug, data collection unit and inspection of monitoring pit /
platform etc.
- Data sheets for OCM points along with vendor’s General Arrangement drawing
shall be prepared by the Contractor and submitted for Company’s review and
approval.
- Distance between two OCM points shall be as a minimum clearance of 600 mm
from each other as per KOC-MP-035 Rev 2 clause not. 8.2.12.
- Quantity of OCM points shall be shall be as per latest approved P&ID’s in
compliance with KOC-MP-035 Rev 2.

h. The flares, equipment and pipe Works rendered redundant by the new facilities
shall be demolished as specified elsewhere in the Contract. The Contractor shall
submit his proposed demolition procedure along with demolition drawings for
prior approval of the Company.

i. Insulation flanges shall be provided for all dissimilar metal interface as per clause
9.8 of KOC-L-018. Insulation flanges shall be considered at aboveground /
underground interface of all metallic piping. Insulation flanges shall also be
provided on cathodically protected pipelines at existing to new pipe interface,
equipment with electrical grinding, reinforcement bars of concrete etc. Buried
underground metallic piping / pipeline shall be provided with cathodic protection
as per KOC-L-015. Internal surfaces of all storage tanks shall be provided with CP
system as per KOC-L-018.

3.5.3. All sizes shown on the Drawings are for guidance only. The Contractor shall design and review
the sizes, schedules and materials in accordance with this Contract and shall submit his sizing
calculations and selection justification for prior approval by the Company.

3.5.4. Stress analysis shall be done for all the new flare headers/lines, liquid return lines in accordance
with ASME B31.3 and design data shall be as specified in Company’s standard KOC-G-007,
Basic Design Data.

3.5.5. All the piping materials and equipment material selection shall conform to the Company’s
Standard KOC-MP-010 and Project Material Selection Guide.
 Page 11 of 25

TECHNICAL SPECIFICATION PART III- MECHANICAL AND PIPING WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE
FLARES AT NK GCs 15, 23 & 25

3.5.6. All the piping materials, valves and equipment shall conform to NACE-MR-0175/ISO 15156
for sour service.

3.5.7. The piping works shall be executed in accordance with the ASME B31.3, following Project
Specifications and other relevant International Standards stated in this Contract:

2015-ZA-E-Z0001 - Specification for Materials in Sour Service

SPC-2015-WH-01 - General Welding Requirements
SPC-2015-PM-01 - Pressure Testing of Piping Systems
SPC-2015-PM-02 - Piping Fabrication and Erection
SPC-2015-DA-01 - Risk Based Inspection Requirements

3.5.8. All piping materials including fittings, flanges, valves and other items shall be shop tested by the
manufacturer/s as per the applicable codes. Heat marks/numbers shall be provided on all the
pipes, fittings etc.

3.5.9. The test and materials' certificates along with the Contractor's/ Vendor’s Inspections & Test
Reports shall be provided for all the items, for Company's verification and acceptance before
installation.

3.5.10. The pipes, valves and accessories material shall conform to the following Company’s standards:

KOC Material Specification Line Pipe for Sour Service : KOC-MS-001 Part 1
KOC Standard for Piping Material Classes : KOC-MP-010
KOC Standard for Stainless Steel Pipe : KOC-MP-020
KOC Standard for Seamless Pipe to API 5L : KOC-MP-018
KOC Standard for Submerged-Arc Welded (SAW) Pipe to API 5L: KOC-MP-019
KOC Standard for Electric Welded Pipes : KOC-MP-017
KOC Standard for Valves: Part 1-Ball Valves : KOC-MP-033 Part 1
KOC Standard for Globe Valves : KOC-MP-014
KOC Standard for Gate Valves : KOC-MP-013
KOC Standard for Check Valves : KOC-MP-015
KOC Recommended Practice for Hot-Tapping and Plugging : KOC-MP-038
Criteria to KOC-MP-014 (EF2015-KOC-MP-014-CRT)
Criteria to KOC-MP-015 (EF2015-KOC-MP-015-CRT)
Criteria to KOC-MP-033 Pt. 1 (EF2015-KOC-MP-033 Pt 1-CRT)

3.5.11. Carbon steel piping shall be API 5L Gr. B, PSL2 with other details as specified in KOC-MP-
010 for the applicable Line class. Line pipes shall be LSAW (single longitudinal weld seam) or
seamless pipes (in double random length), as specified in KOC-MP-010, depending on pipe
sizes. Pipes shall be suitable for “sour hydrocarbon service” and shall comply with KOC-MS-
001 Rev.2, NACE MR-0175 / ISO 15156 requirements and pipes shall be HIC tested as per
NACE TM 0284 and all other testing shall be carried out as per relevant codes and standards.
Acceptance criteria shall be as specified in KOC-MS-001 Rev.2.
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FLARES AT NK GCs 15, 23 & 25

3.5.12. Procure, supply and install valves as specified in the technical specifications, P&IDs and piping
layout drawings. All valves shall be suitable for “sour hydrocarbon service” and shall comply
with NACE MR-0175 / ISO 15156 requirements.

3.5.13. The Contractor shall submit datasheets duly filled for each size / type of pipe and valve, for
Company review prior to placement of Purchase Order.

3.5.14. Pipe fittings such as elbows, flanges, tees etc. shall be procured and supplied as per project
specification KOC-MP-010.

3.5.15. The Contractor shall appoint its third party inspection agency, approved by the Company, who
shall witness / review all tests and documents as per the approved Inspection & Test Plan. All
material inspection reports shall be submitted to the Company for approval prior to shipment
from manufacturer’s workshop. The certificates shall be in original or copies signed by the
Contractor’s Third party Inspection agency. The Company reserves its right to send a third party
inspection agency to witness stage wise and final inspection of the material.

3.5.16. All Ball valves shall be side entry type and bolted construction and shall be full bore as per API
6D. All Ball Valves with double block and bleed arrangement shall be provided with a valved
tapping at the bleed point and a valved body vent tapping and these valves shall be plugged. Ball
valves with soft seats and socket ends shall be provided with pipe nipples of minimum 100 mm
length on both ends to avoid damage to seat during field welding.

3.5.17. The main flare line MOV’s shall be tight Shut-off butterfly valves as per API 6D, fire safe, and
shall be in accordance with the Contract documents.

3.5.18. Location / type of supports shown on the project drawings are preliminary and indicative only.
Supports for all aboveground piping and the equipment shall be provided based on pipe stress
analysis by the Contractor. Wear plates shall be provided for all above ground piping at support
locations. The thickness of wear plate shall not be less than the wall thickness of the pipe.

3.5.19. Tie- in Works:

a. The Contractor shall prepare a Tie-in register and schedule for carrying out works
indicating separately the shutdown Works in the restricted areas, i.e. Gathering
Centers etc. specifying the duration of works required at each location. This schedule
shall show the period of shutdown required. Such shutdown work should be based on
24-hour basis in order to minimize the facilities shutdown period.

b. The tie-ins to be performed by the Contractor shall be as mentioned in this document

and shown on the Drawings. All new flare line tie-ins to the existing flare header shall
be carried out by cold cutting and providing a flanged joint as shown in the piping
layout drawings. All tie-in execution related documents & drawings like spading list,
procedures for Isolation, Spading / De-Spading, Flushing and Nitrogen Purging shall
be submitted to the Superintendent for approval. The procedures for the nitrogen
purging of systems before hot work and prior to the introduction of hydrocarbons /
commissioning shall include the proposed method of purging to be used, the duration
of the purge, the purge medium and the acceptance criteria used to determine a
successful purge.
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FLARES AT NK GCs 15, 23 & 25

c. The Contractor shall Site survey, Tag the tie-ins at locations, identify valves on
existing piping & equipment for isolating the System, fabricate spades of required
size/rating, positively isolate the system as per the spading list, supply the required
quantity of inert gas (nitrogen), flush and purge with inert gas till the specified LEL
is attained, cold cut, use gas plugs, vent gases thru hoses to water barrels, continuously
monitor gas readings, use Site Supplied Air Respirator/SCBA whenever breaking
containment while performing cutting, welding and grinding for tie-in joints, perform
NDT, de-spade and make ready for start-up in accordance with approved procedures.
The Contractor shall carry out risk assessment as per HSEMS guidelines and
procedures including the control measures for unexpected H2S/Toxic gas release at
tie-in location and hazardous residual stagnant /contaminated materials from the
existing piping and equipment.

3.5.20. The new flare lines shall be installed on supports and the lines shall be sloped to avoid stagnant
of condensate liquid. Slope shall be monitored during installation of pipe system to ensure the
slope maintained as per process requirement. Contractor shall ensure that the flare line shall have
no pockets. The supports shown in the project Drawings are indicative only. The Contractor
shall design the complete supporting system for the piping based on stress analysis, site survey,
slit trenching etc. and obtain Company’s approval on the same.

3.5.21. All cold cutting shall be with mechanical cutters and the Contractor shall provide bonding cables
across the line of cut to reduce possibility of incendiary spark and ensure line is checked by
Superintendent’s representative for presence of any combustible gas/ liquid. The Flare Line’s
spading shall be as approved by the Superintendent.

3.5.22. The Contractor shall provide nitrogen support/ injection at the time of cold cutting and welding,
as required. Necessary tapping for nitrogen shall be provided by the Contractor.

3.5.23. After cold cutting, the open ends of the main lines shall be cleaned for a minimum length of one
(1) meter and gas plugs installed. Prior to welding flanges on the main line, edge preparation of
the pipe shall be done.

3.5.24. The Contractor shall design the Fuel Gas and Air Piping System to meet the entire requirement
of his installed flare system.

3.5.25. The Contractor shall perform tie-in works and extend the existing and install the new lines to
and from the Flame Front Generator (FFG) panel and Flare Stacks.

3.5.26. The supporting and placement of these lines shall be as per the approved detailed engineering
drawings.
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FLARES AT NK GCs 15, 23 & 25

3.5.27. Any redundant connection points on the existing LP and HP flare lines, Fuel Gas Lines or
Instrument Air Lines shall be blinded or/and Capped & Welded as per the instruction of the
Superintendent.

3.5.28. The Contractor shall modify/ extend the existing Fuel Gas Lines and Instrument Air lines as per
the approved drawings, to facilitate installation of the tie-ins and new lines.

3.5.29. During installation Works, the existing flare lines and fuel gas line shall be isolated by spading
as per the Contractor's recommendations and as instructed by the Superintendent’s
Representative.

3.5.30. The Contractor shall take all precautions against damage to the existing services during
construction operations and shall repair any damage so incurred by the action of his labor/ his
activities at his own cost and as directed by the Superintendent.

3.5.31. Permanent blinds, spectacle blinds, ring spacers and spades shall be installed as required by the
Project and the same shall be as per the relevant API and/or MSS standards. For Blinds and
Spades, the Contractor shall refer to Company’s Standard Drawing No. 55-4-69 and API STD
590.

3.5.32. Where two different wall thicknesses of pipe or pipe fittings are required to be welded, the
welding shall be carried out in accordance with ASME B31.3, with Company approved
procedure.

3.6. Pipe Stress Analysis Study, Expansion Loops, Supports and Anchorage:

The Contractor shall carry out detailed pipe stress analysis & support adequacy study as per
ASME B31.3 and supply & install his designed expansion loops, supports, anchors and
guides with prior approval of the Company.

3.7. Shutdown

The Contractor shall ensure that all the necessary preparatory Works are completed before
taking shutdown of the line. It is essential that any shutdown must be minimized to the
shortest possible period. Hence, to ensure the same, some of such preparatory Works have
been identified and stated hereunder.

The Contractor shall submit detailed procedures with schedules for all the shutdown Works
to the Superintendent’s Representative for review and approval.
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FLARES AT NK GCs 15, 23 & 25

3.8. Hot Tapping

3.8.1. The Contractor shall carry out hot tapping, wherever shutdowns are not available. However,
subject to availability of shutdown, the Contractor shall be prepared to carry out the tappings /
tie-ins during shutdown, if available.

3.8.2. All hot taps required shall be carried out by the Contractor. All manpower, services and
equipment shall be provided by the Contractor. The hot tapping Works shall be carried out under
the supervision of the Company. The fittings / weldolets, nipolets and fillet weld on the existing
pipes shall be hydro tested prior to hot tapping operation.

3.8.3. The Contractor shall furnish his proposed hot tapping procedure for the Superintendent’s prior
approval.

3.8.4. Before carrying out any hot tap operation, Ultrasonic examination for wall thickness and
lamination check of the existing line shall be carried out by the Contractor and will be witnessed
by the Company. Hot tapping shall then be carried out as specified above subject to approval
from the Superintendent.

3.8.5. During hot tap Works the Contractor shall provide water tanker with pumps at the Site. All the
necessary protection according to Company’s HSEMS Procedures shall be provided by the
Contractor.

3.8.6. Hot tapping shall be carried out in compliance with API RP 2201, KOC-MP-038 and
KOC.SA.019 Safety Procedure for Hot Tapping.

3.9. Demolition Works:

3.9.1. At least two (2) Months prior to starting dismantling and demolition activities, the Contractor
shall submit a detailed Demolition Schedule and Demolition Procedure for Company for
approval.

3.9.2. The Contractor shall not undertake any demolition Works unless and until specifically permitted
by the Superintendent in writing.

3.9.3. The demolition Works shall be allowed only after successful commissioning of the new
facilities.

3.9.4. The dismantling and demolition shall be executed for the items made redundant by the new
Works as shown on the Drawings.
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FLARES AT NK GCs 15, 23 & 25

3.10. Works at GC-15 Existing Auxiliary Building 24V DC Battery Charger Room:

3.10.1. Supply and install one (1) number 1000 US Gallon capacity GRP Potable Water Storage Tank
on the roof of the existing Auxiliary Building along with tanker filling line with an isolation
valve and quick fix coupling located outside the Auxiliary Building for flexible hose
connection. Potable Water Storage Tank shall be filled with water received through Tankers.

The tank shall be GRP panel water storage tank and shall comply with Company’s standard 015-
DH-1004. The tanks shall be installed on suitable steel supports with ladder and platform for
maintenance access to the tank. Relevant certifications from MOE/MEW, MOH, MPW and/ or
other relevant authorities indicating the suitability of GRP Tanks for potable water services shall
be provided.

3.10.2. Supply and install one (1) number Self-contained (wall mounted / self-standing) emergency
eye wash as per Company’s standard KOC-L-009 with integrated indoor water tank and
necessary arrangements. The eyewash station shall be designed to deliver fluid to both eyes
simultaneously.

3.10.3. Supply and install one number stainless steel sink with drainer, water supply mixer valve and
drainage system including drain pipes, neutralization pit etc.

3.10.4. Supply and installation of all associated piping and plumbing Works including, but not
limited to all piping, valves, supports, plumbing fixtures, all other necessary accessories,
testing and sterilization. Fresh water piping shall conform to project specification SPC-PW-
001 and standards/ specifications referenced therein.

Water supply system to be designed in accordance with the requirements of the Uniform
Plumbing Code (UPC), British standard code (BS), American Society for testing and materials
(ASTM), American Society Plumbing Engineer (ASPE), MEW Guidelines, and Company’s
standards with adaptation to suit the local conditions.

3.10.5. Supply and installation of two (2) nos. 5 kg Fire Extinguishers in the existing Auxiliary Building.
Fire Extinguishers shall comply with the requirements of Company’s Standard KOC-L-009. Fire
extinguisher location and spacing requirement shall be in accordance to KOC-L-009, NFPA 10
and codes/ standards referenced therein and shall be as per Company’s approval.

3.10.6. The pipe sizes and equipment capacity given in the drawing and this specification are minimum
requirements and the Contractor shall do its hydraulic study and check / verify adequacy of
piping to meet the flow and pressure requirements at consumption points. This hydraulic
calculation shall be submitted for Company’s review.

3.10.7. The installation shall also be in conformity with the Bye-laws and requirements of the local
authority in so far as these become applicable to the installation. Wherever this specification
calls for a higher standard of materials and/or workmanship than those required by any of the
above regulations and standards, then this specification shall take precedence over the said
regulations and standards wherever drawings and specifications require something which will
violate the regulations, the regulations shall govern.
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FLARES AT NK GCs 15, 23 & 25

3.10.8. EQUIPMENT/MATERIALS

3.10.8.1. Fresh Water Piping

Fresh water piping shall be installed for all services as per Specification SPC-PW-001,
Appendix-3O to Technical Specification Part III - Potable Water Services and the standards/
specifications referenced therein. As a minimum, the Contractor shall provide
polypropylene piping system. All piping materials shall be approved by the Superintendent
and the Contractor shall provide documentary proof of successful installation in similar
projects.
3.10.8.2. Fresh Water Tanks

a) The above ground, FRP (GRP) storage tanks for fresh water tanks shall be supplied and
installed as described hereunder and further in Specification SPC-PW-001.

b) The sealing material shall be special rubber sealant of 3mm. thickness suitable to
withstand the water quality and extreme weather conditions. The width of the sealant
should not be less than 7cm. to cover the full flange area to avoid crevices.

c) Bolts, nuts and washers used for assembling the panels and which come in contact with
the water, including the internal roof shall be of SS 316. However, all external bolts,
nuts and washers which do not come in contact with the water can be hot dipped
galvanized conforming to BSI BS EN ISO 1461 or equivalent.

d) The tanks shall be braced with rigid external galvanized steel corsetry support.

e) The tanks shall be provided with one double hinged heavy duty or bolted insect proof
access hole with cover.

f) All accessories shall be made from GRP panels.

g) The roof cover shall be heavy duty GRP panels constructed, bolted and seated as the
tanks are built and supported from the base of the tanks with ABS/ GRP/ SS 316 struts.

h) The tanks shall be provided with flanged openings for inlet, outlet, drainage; magnetic
level gauge with Transmitter. The panels around these openings shall be extra
reinforced.

i) The Contractor shall design, supply and install the external base support, submit design
calculations and detailed drawings for the Company's approval. The external support
frames, bracings, plates, angles etc., shall be rolled steel sections.

j) A floating valve chamber with hinged/ bolted access panel for inspection shall be
constructed from standard GRP panels.

k) The tanks shall have following accessories:

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 Internal ladder, GRP

 External ladder, galvanised steel with safety hoops
 Vents, GRP, screened
 Magnetic level gauge with transmitter.
 Overflow with insect screen

l) The capacities of the tanks shall be as indicated on the project drawings and the colour
shall be grey.

m) The GRP panels and other components in contact with the potable water shall not
constitute any toxic hazard. They shall not support any microbial growth and shall not
give rise to unpleasant taste or odour, cloudiness or dis-colorization of the water.
Concentration of substances, chemicals and biological agents leached from GRP in
contact with potable water and measurements of organoleptic/ physical parameters shall
not exceed the maximum values permitted by the World Health Organization. A
certificate to this effect shall be produced by the Contractor.

3.10.8.3. Sterilization of Potable Water System

Potable water shall be sterilized in accordance with BSI BS 8558. The Contractor shall
supply all necessary fittings to enable the chlorination to be carried out.
Sterilization water shall be disposed of in compliance with the requirements of the
Company’s HSE team. On conclusion of the process, samples will be taken from each
system for bacteriological analysis. A Sterilization certificate shall be submitted for all parts
of the system.

4. WELDING AND FABRICATION:

4.1. All fabrication and welding Works, procedures and weld tests shall be carried out in accordance
with ASME B31.3 and ASME Sec. IX and as per the following specifications:
a) SPC-2015–WH–01 General Welding Requirements
b) SPC-2015–PM–02 Piping Fabrication and Erection
a) 015-WH-1001
b) 015-WH-1002

4.2. The Contractor shall submit the proposed fabrication procedure with all details, welding
procedures and PQR’s for approval of the Superintendent.

4.3. Weld Preparation: Weld preparation shall confirm to ASME B 31.3 requirements.
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4.4. Welding Electrodes: Welding electrodes shall generally conform to the clause 6 of specification
No.015-WH-1001. The Contractor shall use only Low Hydrogen type electrodes at the following
locations:

- All Tie-in and Hot tap locations

- Welding on existing pipes
- Weld repair locations

Welding Electrodes size of 2.4 mm shall be used for welding of root pass of SMAW process

4.5. Earthing of Welding Jobs:

Earthing arrangements to be applied to any particular welding job shall need to be reviewed and
approved by the Company’s Inspection Engineer.

4.6. Clamping method shall be used, as direct fusing of the earth lead to the pipe is forbidden.
Wherever clamping is not practical, the means of earthing shall be subject to prior written
approval of the Superintendent’s Representative.

4.7. Welder’s Certification:

The Contractor shall ensure that each welder shall identify positively his welds. All welders shall
be certified and tested by the Company prior to commencement of the welding Works in
accordance with 015-WH-1002 and its addendum.

4.8. Special Notes: The Contractor shall ensure the following for his welding works:

a) Cold cutting of galvanized and stainless pipe shall be done by using sawing or
abrasive disc.
b) Socket welds shall be made with at least two passes.
c) Butt welds in NPS 1 ½” and smaller pipes shall use GTAW process.
d) An inert gas back purge is mandatory during welding stainless steel pipes by GTAW
process.
e) Welding of galvanized pipes is not permitted.
f) Proximity of welds shall be as per Clause 4.16 of SPC-2015-PM-02 – Piping
Fabrication and Erection.
g) Temporary welds shall be minimized during fabrication and subsequently ground
flush with pipe with the pipe contour, then inspected by MPI/DP Checks.

5. PAINTING AND PROTECTION

5.1. All above ground carbon steel piping and equipment shall be externally coated as per Company’s
Standard KOC-P-001 Rev 3. Selection of coating system shall be as per maximum operating
temperature. Platforms, ladders, handrails, stair treads, open grid flooring, steel grating shall be
hot dip galvanized as per KOC-P-001 Rev 3.

5.2. All underground buried piping within the facility shall be externally coated with either High
Build Epoxy (HBE) as per KOC-P-004 Part 8 or with High Build Polyurethane (HBP) as per
KOC-P-004 Part 9. All underground buried pipeline outside the facility shall be externally coated
with 3 layer Polyethylene (3LPE) as per KOC-P-004, Part 6. All underground buried flanges
shall be externally wrapped as per KOC-P-004 Part 7.
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FLARES AT NK GCs 15, 23 & 25

5.3. The color coding of above ground piping and works shall be as per Company’s Standard KOC-
P-017: KOC Standard for Color Coding of Pipework for Identification of Fluids & Services.

5.4. Prior to coating, all surfaces shall be thoroughly cleaned using grit blasting to produce a very
clean surface corresponding to Swedish Standard SA 2½ grade, free of loose particles, grease
and other foreign matter. Metal burrs and projections or sharp points shall be filled smooth.

5.5. All abrasive materials shall be selected from Company approved list of short listed
manufacturers. All paint materials shall be selected from Company approved Vendor list. Each
batch of paint and abrasive materials shall be offered for Company inspection prior to its use.

5.6. All the required coating and wrapping materials shall be supplied by the Contractor and
approved by the Superintendent’s Representative prior to application.

5.7. A detailed painting procedure and its respective Inspection and Test Plan (ITP) shall be
submitted for Company’s review and approval prior to commencement of works.

5.8. All personnel (blaster, applicators, foreman, supervisor and inspector) involved in the coating
works shall be qualified as per KOC-P-006.

5.9. After application, completed Works shall be tested by the Contractor using a holiday detector
and standard procedures under Company’s Inspection’s supervision. 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.

5.10. Where grit blasting is not feasible, the Contractor shall use power-driven wire brushes to prepare
metal surfaces prior to the application of coating and wrapping. Contractor shall obtain
Company’s approval for the same.

5.11. All the structural steels and metal profiles used for the supports and platforms shall be well
protected and shall be hot dipped galvanized.

5.12. Selection and application of internal coating of piping shall be based on the piping class as
specified in KOC-MP-010 and KOC-P-005 Rev 2.

5.13. Vessel internal including all internals shall be coated as per KOC-P-002 Part 3, Rev 1.

5.14. If any existing piping / pipeline coating is damaged during the course of excavation, erection,
surface preparation, application etc. it is Contractor’s responsibility to inform Company
immediately and restore the damages as per respective Company standards, at Contractor’s cost.
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FLARES AT NK GCs 15, 23 & 25

6. INSPECTION AND TESTING

6.1. The Contractor shall adhere to Company’s standard KOC-Q-014 for all the Works quality
requirements.

6.2. All Inspection and Testing shall meet the requirements specified in the data sheets and the
Technical Specifications for all materials and equipment supplied by him.

6.3. The Contractor shall submit the Inspection & Test Plans and Inspection & Test Procedures for
prior approval of the Company. The procedures shall include all the Quality Control activities
including visual & dimensional checks, NDE procedures, welding and fabrication Inspection
procedures and plans, hydro test, pneumatic test and other functional and performance test
procedures.

6.4. The Inspection and testing shall include:

 Workmanship Inspection, Dimensional Checks and verification for general adherence
to the drawings and specifications
 NDE including : DP Inspection & Radiography
 Hydrostatic Pressure testing for pipework & Tie in connection, refer Para 6.6
hereunder.
 Shop and Site Inspections of all Vendor supplied items , such as:
- LP & HP Flare Stacks,
- LP & HP Flare components
- KO Drum
- KO drum pump
- Instrumentation & Electrical Items
- Valves
- Pipes
- Pipe Fittings
- And all as per Contractor prepared Material Take Off.
 Welding and Painting Inspection & Test
 Pre-commissioning and Start-up Tests

6.5. Radiographic Inspection of Welds:

6.5.1. All Inspection, material, equipment and personnel for the Radiography shall be the Contractor’s
responsibility. The responsibility of interpretation of all the radiographs shall be carried out by
the Contractor subject to acceptance by the Company.

6.5.2. The Company shall become owner of the exposed radiographic films on the job. The Contractor
shall bear the cost of all the additional radiographs which in the opinion of the Company establish
without doubt the integrity of the radiographs / welds that necessitated them.
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FLARES AT NK GCs 15, 23 & 25

6.5.3. Minimum requirements for the radiography if piping shall be as per KOC-MP-010. The
radiography shall meet ASME B31.3 requirement, in all aspects.

6.5.4. All the tie-in joints shall be 100 % radiographed. If hydrotest is impracticable for any piping
weld joint, with Company’s prior approval, such joints shall be 100 % radiographed. These joints
shall be subjected to in-process inspection as per ASME B31.3 clause 344.7.

6.5.5. Non-destructive Examination and Hardness survey requirements shall be as per KOC-MP-010.

6.6. For the Flare Stacks, the Contractor shall be responsible for the timely submission of a detailed
performance test procedure, which should include details of tests necessary to demonstrate the
compliance of the equipment to Technical Specification together with proposed log sheets to
record all significant parameters. All the shop tests including the witness tests shall be clearly
identified and documented.

6.7. Field testing shall comply with performance characteristics set forth in the equipment data sheets
and Technical Specifications of the Contract.

6.8. Pressure Testing of Pipework and Tie-In Connections;

6.8.1. Hydro-testing, flushing and drying all new pipework executed by the Contractor shall be carried
out by the Contractor. The hydrotesting shall meet the requirements of the Specification No.
SPC-2015–PM–01 - Pressure Testing of Piping Systems.

6.8.2. Hydrostatic test pressures shall be 1.5 times the design pressure of the system and shall not
exceed a hoop stress equivalent to 90% of the Specified Minimum Yield Strength (SMYS), but
not less than the minimum test pressure as per ASME B31.3, except as specified otherwise.

6.8.3. HYDROSTATIC TEST PACKAGES: Hydrostatic Test Packages shall be prepared containing
the piping Isometric drawings prepared by the Contractor with test limits clearly marked up. The
test package shall also include: (a) Visual Inspection Reports, (b) NDE Clearance Reports for
Radiography & DP Tests etc., (c) Copies of Mill Certificates, (d) Material Inspection Reports
and (e) marked up P&IDs

6.8.4. The contractor shall make arrangements for hydro testing of all the new piping works. Water for
hydro testing shall be provided by the Contractor.

6.8.5. If brackish water is used for hydro testing of pipework it shall be dosed with an approved
corrosion inhibitor/ oxygen scavenger / biocide mixture so that the water filling the line shall
uniformly contain the chemical manufacturers recommended concentrations during hydro
testing. Hydrotest water and its treatment shall be in accordance with KOC-G-011, KOC
Standard for Test Water for Site hydrotesting and Lay-up.

6.8.6. The Contractor shall supply temporary tanks, piping, all labor, materials, pumps of sufficient
pressure and capacity, valves, fittings and all other tools and equipment necessary for the
hydrostatic testing.
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6.8.7. The Contractor shall also make necessary arrangements for the safe disposal of the water after
hydro testing. The test water shall be drained and disposed in a location approved by the local
authorities.

6.8.8. The Contractor’s procedure shall include but not limited to the following:-

 Complete description of the proposed equipment, instruments and set-up

arrangement.
 Description of the sequence of all operations.
 Schedule of testing.
 Details of chemical inhibitor.
 Test and Calibration Certificates for the test pressure gauges
 Documentation and final certificates.

6.8.9. The following Company requirements shall be strictly adhered to by the Contractor in order to
successfully complete the hydrostatic testing operations and thus ensuring the integrity of the
piping system:

 The pressure testing shall not be made when water temperature is less than 10 deg C.
 The test pressure shall not produce an internal hoop stress in excess of 90% of the
pipe material SMYS at the lowest point in the line/section.
 During the test, the line shall be observed by the Contractor and the Company
inspector at least two times during the test period.
 If any leak is detected the Contractor shall rectify the leak as per his approved repair
procedure to the satisfaction of the Superintendent’s representative. The test shall be
repeated again after the repair of all leaks. At the end of the test all related records
shall be submitted to the Superintendent’s representative.
 Upon acceptance of the test by the Company, the Contractor shall depressurize the
pipe work.
 The Contractor shall be directly responsible to make good any damage caused by the
discharge of water.
 The Company’s representative shall date and sign the test certificate to confirm the
acceptance of the test.

7. PRE-COMMISSIONING AND COMMISSIONING WORKS

7.1. The Contractor shall submit a “Pre-commissioning and Commissioning Procedure" for
Company’s review and approval
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REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE
FLARES AT NK GCs 15, 23 & 25

7.2. The Contractor shall ensure that the Flare manufacturer’s representative is present to assist
during pre-commissioning and Commissioning who shall be available until the final/ successful
Commissioning and performance test of the respective new Flares.

7.3. Contractor shall invite Company for a system walkthrough and the generated punch-list shall be
closed to the satisfaction of the Company, prior to Construction Completion and
Commissioning.

7.4. Pre-Commissioning

7.4.1. To enable any portion of the Works to be placed in operation at the earliest practicable date, the
Contractor shall commence the pre-commissioning of the items required for the safe
commissioning and operation of that portion of Works prior to the mechanical completion of the
whole works thereof. Contractor shall prepare and submit for Superintendent’s approval, pre-
commissioning procedures showing those activities which the Contractor deems necessary to
enable the various portions of works to be placed in operation. These procedures shall
incorporate all applicable codes and standards.

7.4.2. All parts of the new facilities including the new KO Drums, Flare Stack and parts of the existing
facilities affected by the Works which transport or contain hydrocarbons shall be purged with
nitrogen gas. The Contractor shall provide the nitrogen gas and all arrangements for such purging
shall be detailed, provided for and carried out by the Contractor. All purging procedures shall be
submitted for the Superintendent’s approval.

7.5. Commissioning

7.5.1. Following the satisfactory completion of the Contractor’s pre-commissioning activities for the
Works the Contractor shall notify the Company that the Works are ready for commencement of
commissioning activities.

7.5.2. The Contractor shall be responsible for the commissioning of the entire new systems and shall
provide specialists, including but not limited to a commissioning engineer, one (1) electrical
engineer, one (1) instrument engineer, one (1) mechanical engineer and Vendor’s representatives
of specialized equipment such as Flare System and Pumps, all to be available from the
commencement of commissioning activities until such time as stable and satisfactory operation
of the Works at all the locations has been achieved.

7.5.3. The period for stable and satisfactory operation shall be a minimum of fifteen (15) Days from
the commencement date of commissioning activities or as mutually agreed upon by the
Contractor and the Superintendent and recorded in writing.
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TECHNICAL SPECIFICATION PART III- MECHANICAL AND PIPING WORKS

REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARES WITH SMOKELESS TYPE
FLARES AT NK GCs 15, 23 & 25

Completion of stable operation period shall be through the issue of a notice to the Contractor
by the Company confirming the date on which stable and satisfactory operation has been
achieved.

7.5.4. The new air-assisted smokeless flare and connected piping, inclusive of all equipment, FFG and
instrumentation & controls shall be in stable operation for a minimum period of fifteen (15) Days
prior to demolition of the existing flare stacks. The Contractor shall make all necessary provision
in the flare piping to put back the redundant flare stack in operation in the event of operational
problems with the new Smokeless Air Assisted flare.

8. PERFORMANCE CRITERIA

The Flare Stacks shall be designed to operate within the process and performance ratings as
per Appendix 2A to Technical Specification Part II - Process Design Basis And the
Contractor shall guarantee the performance as listed in clause 5 of Appendix 2A to Technical
Specification Part II - Process.

8.1. The Contractor shall submit 60 Days prior to commissioning his procedure for performance
criteria measurements. The Contractor shall provide all necessary equipment to measure/ record
all the data for performance testing. The Contractor shall ensure that the flare manufacturer
representative shall be present during the performance tests.

8.2. The Contractor shall guarantee the performance of the new smokeless flare systems in
accordance with the performance and process criteria specified above.