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(:J.~.~) ~~\.k.a3 a5"~ KUWAIT OIL COMPANY (K.S.C.)
~~''''''''''''''''wU"'''':' __1 A Subikllary oIlWwa1l Plllrolwm CctporetJon
STANDARDS PUBLICATION
KOCSTANDARD
FOR
WATER FOR SITE HYDROSTATIC TESTING
AND LAY-UP (Formerly 015-CG-1001)
DOC. NO. KOC-G-Oll
II DOC.NO. KOC-G-011 Page 1 of 33 J REV. 1
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STANDARDS PUBLICATION
KOC STANDARD
FOR
TEST WATER FOR
SITE HYDROSTATIC TESTING
AND LAY-UP
DOC.NO. KOC-G-011
STANDARDS TEAM
DOC.NO. KOC-G-011 II Page 2 of 33 REV. 1I
KOC STANDARD
FOR
TEST WATER FOR
SITE HYDROSTATIC TESTING
AND LAY-UP
DOC.NO. KOC-G-011
(FORMERLY 01S-CG-1 001)
ISSUING AUTHORITY:
STANDARDS TEAM
07.09. 10 Issued as Final KOC Standard
Task Force (TF-G/08)
Rev. Date Description Prepared by Tel. No. 66394
Snr. Engr. Stds. Tel. No. 61407
/T-ej~~erslandardS /,..,.../fel. ~o. 61896
III DOC.NO. KOC-G-011 I Page 3 of 33 I REV. 1
TABLE OF CONTENTS
FOREWORD
1.0 SCOPE
2.0 APPLICATION
3.0 TERMINOLOGY 3,1 Definitions 3,2 Abbreviations
4.0 REFERENCE STANDARDS, CODES AND SPECIFICATIONS 4,1 Conflicts 4,2 List of Standards, Codes and Specifications
5.0 ENVIRONMENTAL CONDITIONS
6.0 HEALTH, SAFETY AND ENVIRONMENT
7.0 GENERAL TECHNICAL REQUIREMENTS
8.0 WATER SUPPLY AND ANALYSIS 8,1 Supply 8,2 Analyses 8,3 Filtration
9.0 WATER TREATMENT FOR HYDROSTATIC TESTING 9.1 General 9.2 Water Treatment for Carbon / Low Alloy Steel
Equipment and Pipelines 9.3 Water Treatment for Stainless Steel Equipment,
Pipelines and Tanks
10.0 WATER TREATMENT FOR LAY-UP 10.1 General 10.2 Wet Lay-up 10.3 Dry Lay-up 10.4 Inert Gas Lay-up 10.5 Ambient Lay-up
11.0 DISPOSAL OF TEST WATER
12.0 QUALITY ASSURANCE
Page No.
5
6
6
7 7 8
8 8 9
10
10
11
12 12 13 13
14 14
16
18
20 20 21 22 22 23
23
25
DOC.NO. KOC-G-011 Page 4 of 33 I
13.0
14.0
DOCUMENTATION 13.1 General 13.2 Deliverables
APPENDICES
Annexure-I : Typical Brackish Water Analysis
Annexure-II : Ambient Seawater Quality Criteria
Annexure-III : Maximum Limits of Pollutants in Industrial Water Waste Permissible to be Discharged in the Sea
Annexure-IV: Treated Waste Drainage Water Discharged into Sewerage
ACKNOWLEDGMENT
REV. 1
25 25 26
28-31
28
29
30
31
32-33
DOC.NO. KOC-G-011 Page 5 of 33 REV. 1
FOREWORD
This document "KOC Standard for Test Water for Site Hydrostatic Testing and Lay-Up (KOC-G-011, Rev. 1)" is intended to provide the minimum technical requirements for test water to be used during hydrostatic testing and lay-up of eqUipment at KOC Facilities in Kuwait. It includes also guidelines to dispose the Test Water after completion of hydrotesting in order to protect the environment.
This Standard has been approved by Standards Team in consultation with Standards Technical Committee (STC) for consistent use by KOC User Teams throughout for the corporate engineering and operational functions of Kuwait Oil Company (K.S.C).
The purpose of this Standard sets out to achieve the following objectives:
a. To provide the basic requirements for test water, that has applicability in hydrostatic testing and lay-up of Facility / Plant equipment including pressure vessels, atmospheric vessels, drain sump vessels, drums, pipes, heat exchangers, pipelines and aboveground tanks at Site, and to help ensure a consistent and effective approach in its analysis , treatment and disposal in environmentally safe and acceptable way.
b. To cover the necessary aspects of supply, filtration, chemical analysis, chemical treatment and disposal of test water for hydrostatic testing at Site so as to minimize the need for technical clarifications and disputes.
c. This Standard supersedes 015-CG-1001 "KOC Engineering Group Specification for The Use of Brackish Water for Site Hydrotesting of Equipment", which is now withdrawn.
Feedback, comments or suggestions, derived from the application of this Standard at any stage of design, purchase, installation, operation and testing are encouraged, and should be directed to:
The Team Leader Standards (Chairman, Standards Technical Committee) Industrial Services Group, KOC P. O. Box 9758, Ahmadi 61008 State of Kuwait
Task Force Responsible for This Standard
The Standards Technical Committee (STC) has entrusted the preparation of this Standard to the Task Force l\lo. TF-G/08, conSisting of the following members:
Mr. Abdul R. AI-Shamari Insp. & Corr. (N&W) TF Leader Tel. 66394 Mr. Mirza Mohsin Standards Team Member Tel. 61371 Mr. Mohd . Imadi DeSign Team Member Tel. 61102 Mr. N. Ramanathan Major Projects (EFP) Member Tel. 66960 Mr. S.H. Shah Gen. Projects Team Member Tel. 61190 Mr. Saad Jaber Construction Team Member Tel. 61376 Mr. Bader AI-Qahtani OTS (SK) Team Member Tel. 22384 Dr. Waseem Siddiqi Health & Environment Member Tel. 71628
III DOC.NO. KOC-G-011 Page 6 of 33 I REV. 1
1.0 SCOPE
1.1 This Standard specifies the minimum requirements for the supply, pretreatment using filtration, chemical treatment and chemical analysis of test water for use as a Site hydrostatic testing medium at Kuwait Oil Company Facilities in the State of Kuwait in order to control internal corrosion of facilities during and after hydrostatic testing .
1.2 The Standard covers the disposal of the test water after completion of hydrostatic testing or lay-up.
1.3 This Standard covers the test water to be used in Site hydrostatic testing of the following components installed at KOC facilities within the production and export operating areas:
a. Facility / plant equipment including pressure vessels, atmospheric vessels, drain sump vessels, drums, pipes, heat exchangers and storage tanks;
b. All onshore and offshore pipelines installed outside facilities, which include but not limited to crude oil pipelines, flow lines, gas and condensate pipelines, fuel pipelines, water injection pipelines, drain sump vessels, and pig launchers / receivers .
1.4 Lube oil systems and instrument air systems are not covered within this Standard as water should not be used as a test fluid for these systems.
1.5 This Standard does not cover procedures / methods of carrying out the hydrostatic testing or the performance / results of hydrostatic testing , which shall fully comply with all relevant KOC Standards or Contractual requirements as specified in the Project Scope of Work and Technical Specification of the Contract.
2.0 APPLICATION
2.1 For the application of test water to be used in Site hydrostatic testing, refer to clauses 1.3 and 1.4 of this Standard.
2.2 The test water and its filtration , chemical analyses, chemical treatment and disposal shall conform to the requirements of this Standard and the relevant standards and codes mentioned herein.
2.3 Any exception or deviation from this Standard shall be brought to the attention of the KOC Controlling Team with merits and justifications for review & consideration and for necessary amendments by the Standards Team (if required).
2.4 Compliance with this Standard does not of itself confer immunity from legal or statutory obligations.
III DOC.NO. KOC-G-011 Page 7 of 33 REV. 1 I I
3.0 TERMINOLOGY
3.1 Definitions
For the purposes of this Standard, the following definitions shall apply:
3.1.1 Ambient Lay-Up
During ambient lay-up, the Test System is completely drained off all standing test water to remove all test water.
3.1.2 Chemical Manufacturer / Supplier
Any firm approved by KOC to manufacture / supply the chemicals required for the treatment of test water.
3.1.3 Company
Means Kuwait Oil Company (KOC).
3.1.4 Dry Lay-Up
During dry lay-up, the Test System is completely drained off all standing test water, and then dried to achieve the specified dew point before being shut-in under positive pressure during the lay-up period .
3.1.5 Equipment
Equipment refers to the pressure vessels, drums, drain sump vessels, atmospheric vessels, pig launchers / receivers and / or storage tanks subject to hydrostatic testing.
3.1.6 Inert Gas Lay-Up
During inert gas lay-up, the test water is drained and the Test System is typically charged with an inert gas to a pre-defined drying requirement and shut-in under positive pressure, until it is ready for commissioning and start-up.
3.1.7 KOC Controlling Team
Any KOC Team that is responsible for implementing and controlling the project, tasks or works as designated and authorized by KOC .
3.1 .8 Lay-Up
Lay-up is the period after successful hydrostatic testing when the test water completely drained, until the Test System is ready for commissioning and start-up.
is
3.1.9 Piping
Process or utility pipes that are installed inside the onshore / offshore facility.
III DOC.NO. KOC-G-011 Page 8 of 33 REV. 11
3.1.10 Pipelines
All onshore and offshore pipelines installed outside facilities , which include but not limited to crude oil pipelines, flow lines, gas and condensate pipelines, fuel pipelines, and water injection pipelines.
3.1.11 Site
The KOC Site at wh ich hydrostatic testing will be conducted .
3.1.12 Wet Lay-Up
During wet lay-up, the Test System is allowed to remain full of treated test water until ready for commissioning and start-up.
3.2 Abbreviations
API American Petroleum Institute CRA Corrosion Resistant Alloys EPA Environmental Public Authority, Kuwait HSE Health, Safety and Environment ICT Inspection and Corrosion Team ISO International Organization for Standardization KOC Kuwait Oil Company (K.S.C.) MSDS Material Safety Data Sheet ppm Parts Per Million ppb Parts Per Billion
4.0 REFERENCE STANDARDS, CODES AND SPECIFICATIONS
4.1 Conflicts
4.1.1 In the event of conflicts between this Standard and any other National/International standards and codes referenced herein , or other contractual or purchase requirements , the same shall be brought to the attention of KOC Controlling Team in liaison with ICT for their decision. In general, most stringent requirements shall apply with the order precedence as given in clause 4.1.3 of this Standard .
4.1.2 In case further clarifications are required , the subject shall be brought to the attention of KOC Standard Team and KOC Controlling Team .
4.1.3 Order of Precedence
In general, the following order / sequence of precedence shall apply:
a. Kuwait Government Rules and Regulations
b. KOC HSE Management System Requirements
c. This KOC Standard (KOC-G-011)
DOC.NO. KOC-G-011 Page 9 of 33 REV. 1 i I d. KOC Integrity Management Standard Requirements
e. KOC Fire & Safety Regulations
f. KOC Technical Specifications
g. Project SpeCification and Data sheets
h. International codes and standards
i. Contractor's / Manufacturer's / Supplier's standards and speCifications.
4.2 List of Standards, Codes and Specifications
The latest edition of the following standards, codes and specifications shall apply:
4.2.1 National/International Standards
API RP 45
API RP 1110
API PUBL 1157
EPA, Kuwait
Recommended Practice for Analysis of Oilfield Water
Recommended Practice for Pressure Testing of Liquid Petroleum Pipelines
Hydrostatic Test Water Treatment and Disposal Options for Liquid Pipeline Systems
Regulations implemented under Law No. 21 of 1995 as amended by Law No.16 of 1996, Oct. 2001
4.2.2 KOC Standards and Procedures
KOC-G-007 KOC Standard for Basic Design Data
KOC HSE Management System
KOC Integrity Management Standard
KOC Fire & Safety Regulations
KOC Health & Safety Guidelines
KOC.SA.010 Procedure on Protective Clothing and Equipment
4.2.3 KOC Engineering Group Specifications
015-1 H-1 004 Pipeline Pigging and Hydrostatic Test
015-IH-1005 Pipeline Dewatering , Drying and Purging
DOC.NO. KOC-G-011 II Page 10 of 33 REV. 1
5.0 ENVIRONMENTAL CONDITIONS
5.1 The environmental conditions in Kuwait are severe. Hydrostatic Testing at the Facilities, where atmosphere is generally dusty and corrosive and may contain traces of hydrogen sulphide, shall take place under high ambient temperatures and humidity. Environmental conditions observed at the time of hydrostatic testing shall be recorded and reported in the hydrostatic testing report submitted to KOC.
5.2 Refer to KOC-G-007 "KOC Standard for Basic Design Data", which provides general design information regarding the environmental , site and utility supply conditions prevailing throughout the Facilities.
6.0 HEALTH, SAFETY AND ENVIRONMENT
6.1 The Contractor shall employ necessary HSE procedures to protect personnel and the surrounding environment during all on-site field work.
6.2 All MSDS requirements for the chemicals chosen for treatment and Kuwait EPA regulations for the eco-friendly treatment and disposal shall be fully complied.
6.3 The Site shall be equipped with all required safety equipment related to the use of chemicals such as emergency shower and eye wash station.
6.4 Selection of environmental friendly water source for hydrostatic testing shall be guaranteed. Test water that could result in harming to humans must not be used for hydrostatic testing, such as water containing hydrogen sulfide and other toxic gases that can be released to the atmosphere with concentrations of 10 ppm hydrogen sulfide or greater.
6.5 The use of chemical treatment is recommended to be eliminated or minimized.
6.6 Precautions must be applied during the use of any toxic or flammable chemicals.
6.7 It is a must to ensure that explosion will not happen due to mixing chemicals or due to any other reasons such as mixing air and gas during lay-up.
6.8 All relevant safety requirements of the Manufacturer, KOC HSE Management System Procedures, KOC Integrity Management Standard, and KOC Fire & Safety Regulations shall be adhered to while performing work within KOC areas for protection of personnel, adjacent equipments, properties, and environment.
DOC.NO. KOC-G-011 I Page 11 of 33 I REV. 1
7.0 GENERAL TECHNICAL REQUIREMENTS
7.1 Hydrostatic testing should be scheduled as close to the commissioning of the Equipment and / or Pipelines in order to minimize the requirements of chemical treatment and corrosion risks .
7.2 Test water used as test fluid shall be treated for control of corrosion and bacteria when applicable as per this Standard .
7.3 Prior to hydrostatic testing of a pipeline, all debris shall be removed from the pipeline by using brush scrapers and magnetic scrapers or application of cleaning pigging.
7.4 In the case of pipelines, the requirements of 01S-IH-100S "KOC Engineering Group Specification for Pipeline Dewatering, Drying and Purging" (or the latest KOC Standard that replaces it) shall be adopted unless otherwise agreed in writing by KOC.
7.5 Equipment(s) or pipelines constructed entirely of either non-metallic or internally lined materials do not require chemical treatment of the test water at the time of hydrostatic testing. However, the requirements for a partially either non-metallic or internally lined systems shall be the same as those for internally unlined steel equipment(s) or pipelines.
7.6 Piping systems for potable water (drinking water and raw water) shall be hydrotested, using fresh potable water without any chemical treatment.
Other utility piping systems including CRA shall be hydrotested with low chloride water without any chemical treatment except that the maximum chloride content for hydrostatic test water shall be limited to 30 mgll at the time of introducing water into the system.
7.7 Hydrostatic testing and lay-up procedures shall be compatible with the most corrosion susceptible material as well as the corrosion resistant metallic / non-metallic material in the system being tested .
7.8 The Contractor shall describe in the hydrostatic testing procedure the source and quality of test water and details of the water treatment, including types of chemicals to be used; dosing rates that are necessary to bring the water to the level of required quality and details of monitoring program and sampling frequencies.
The Contractor shall describe the possibility of generating solid waste during hydrostatic testing and shall submit the safe solid waste disposal procedure for KOC approval.
7.9 All relevant KOC HSE requirements shall be included within the hydrostatic testing procedure.
7.10 The disposal of the test water after use, including timing, rate of discharge, treatment methods, and disposal location shall also be described in detail in the hydrostatic testing procedure.
DOC.NO. KOC-G-011 II Page 12 of 33 REV. 1
7.11 Stainless Steel equipment and piping shall be tested only with water having less chloride as described in clause 9.3 of this Standard.
7.12 For equipment(s) that are fabricated and hydrotested outside the State of Kuwait, hydrostatic testing and lay-up procedures shall be submitted for approval to KOC Controlling Team. At least, one lay-up method as per clause 10.0 of this Standard shall be utilized to prevent the equipment against internal corrosion during the shipping period to the installation. Vapour phase corrosion inhibitor may be required.
7.13 When test water is removed from the Test System either at the end of the hydrostatic testing or the end of the lay-up, the Test System shall be completely dried as per 015-1 H-1 005 "KOC Engineering Group Specification for Pipeline Dewatering, Drying and Purging" (or the latest KOC Standard that replaces it). Nitrogen, sweet gas, glycol or methanol shall be used for drying if drying cannot be completed within a week. Air drying is not allowed except for small plant piping.
8.0 WATER SUPPLY AND ANALYSIS
8.1 Supply
8.1.1 The Contractor shall ensure the availability of sufficient amount of test water at Site without disruption to hydrostatic testing or any KOC operations.
8.1 .2 Test water quality of intended hydrostatic testing waters shall be determined well ahead of the actual testing date so that alternative test water sources with the required treatment may be identified if the original source water fails to meet requirements.
8.1.3 Brackish water, obtained from Abdulliyah Water Centre or from the North Kuwait Source Wells, can be used if approved by KOC Controlling Team, unless specific dispensation is given by KOC to use seawater or any other source of water.
8.1.4 Sea water may only be used with approval from KOC Controlling Team, if there is no other practical alternative.
8.1.5 Typical fluid analysis data for brackish water and seawater streams are presented respectively in Annexure-I & " of this Standard.
8.1.6 Use of fresh / potable water or low chloride water shall be restricted to the applicable conditions.
8.1.7 The Contractor shall establish the size of test piping, the availability and flow rate of test water for each equipment or pipelines to be tested.
8.1 .8 For each equipment or section of pipeline to be tested, the Contractor shall use test water from only a single source, to avoid the risk of scale and deposit formation.
8.1.9 Re-use of test water is encouraged by KOC when potable water or low chloride water is used, when logistics permits and when the quantity under consideration is large enough to achieve significant benefits by reduction in test water consumption and by reduction of environmental impact.
DOC.NO. KOC-G-011 I Page 13 of 33 REV. 1
The Contractor has to submit an effective strategy to the Controlling Team for the management of reusing the test water for review and approval. All required tests, analyses, filtration and chemical treatments shall be maintained as per the requirements of this Standard.
8.2 Analyses
8.2.1 All laboratory analyses shall be performed by a KOC approved laboratory that has been accredited and / or certified to ISO 17025. Laboratory and field analysis instrumentations shall be approved by KOC Controlling Team / ICT and calibration certificates shall be presented to KOC for acceptance. All Contractor's personnel involved in the Site analyses shall be qualified and shall be subject to KOC approval.
8.2.2 The Contractor shall perform full chemical analyses of the test water source to accurately determine all relevant parameters, including but not limited to oxygen content, pH, chloride content, total suspended solids (TSS). total dissolved solids (TDS), H2S concentrations, turbidity, appearance and measures of the microbiological populations. Requirements for such sampling and analysis and subsequent approvals of results shall be consulted' with KOC Controlling Team in liaison with I CT.
8.2.3 The Contractor shall perform tests to determine whether the test water is corrosive, biologically active for microbial growth and has scale forming tendency. Test procedures and test results shall be submitted for approval by KOC Controlling Team in liaison with ICT.
8.2.4 Detailed analytical test procedures covering all relevant parameters shall be submitted to KOC Controlling Team to liaise with ICT for review and approval prior to performing any test water analyses.
8.2.5 If reuse of test water is considered for application, analyses shall be undertaken to comply with the requirements as described in clause 8.2.2 of this Standard; and also to determine whether additional applications of corrosion and / or bacterial control are needed to maintain the required concentrations and residuals as per this Standard.
8.3 Filtration
Test water shall be filtered prior to any hydrostatic testing to ensure that there is total removal of all particles larger than 50 microns. Filters that do not allow particles above 50 microns shall be installed at the entry of the test water to the Test System.
DOC.NO. KOC-G-011 Page 14 of 33 I REV. 1III Il
9.0 WATER TREATMENT FOR HYDROSTATIC TESTING
9.1 General
9.1.1 The Contractor shall submit to KOC Controlling Team for review and approval the hydrostatic testing procedure as per clause 13.2.1of this Standard.
9.1 .2 Suitable chemical treatment shall be undertaken by the Contractor to inhibit corrosion and biological growth. Wherever possible, chemicals shall be chosen which are easily biodegradable and also not bio-accumulative so that after use they are not harmful to the environment. The chemical vendor shall provide the MSDS indicating that the chemicals are biodegradable for review and approval by KOC Controlling Team in liaison with ICT.
The Contractor shall ensure the safe storage facility for all chemicals required for hydrostatic testing as per KOC procedures. Storage facility shall be approved by KOC Controlling Team.
9.1.3 The concentration of the chemical treatment shall be verified by appropriate measurement techniques approved by KOC Inspection and Corrosion Team. The use of excessive chemicals shall be avoided . Guideline concentrations of chemicals for dosing shall be determined in accordance with the international practices and site conditions.
In general, dOSing rates shall follow chemicals suppliers' recommendations as required to prevent against corrosion . The Contractor may be requested by KOC to arrange with approved independent laboratory for any testing requirement, put forward by the KOC I&C Team to establish such dosing rates values.
9.1.4 The proposed chemical treatment including specific chemical formulations used as individual component or combination of corrosion inhibitor, biocide and oxygen scavenger, concentration of those chemicals and MSDS shall be submitted to KOC ICT as part of the procedure for approval.
9.1.5 Treatment chemicals shall be injected continuously, in such a manner that their concentration in test water is homogenous, in accordance with this Standard, while the equipment/pipeline is being filled to ensure the proper application of treatment.
9.1.6 Where multiple treating chemicals are required , compatibility of chemicals shall be ensured.
9.1 .7 Proper chemical injection methods shall be identified on the basis of chemicals selected for application. Separate proportioning pumps, having an accuracy of not less than 5% or more than 7% of KOC approved dosage rate, shall be used for each chemical to avoid adverse reactions between the chemicals if multiple chemicals are considered for treatment. Chemicals shall not be mixed prior to injection. Chemical injection rates shall be verified by displacement gauges.
DOC.NO. KOC-G-011 Page 15 of 33 I REV. 1
9.1.8 Injection points of different chemicals shall be positioned at least 2.0 m apart. Concentrated chemicals shall not be mixed. The injection points shall be upstream of the filling pumps to allow thorough mixing before entry into the test system.
9.1.9 The pH of the test water shall be in the range 6.0 to 10.5 at the time of injection into the equipment / pipeline. Sodium carbonate (soda ash) or sodium hydroxide (caustic) may be added , as necessary, to satiSfy this requirement.
9.1 .10 Oxygen scavenger treatment shall be applied to the test water to prevent corrosion occurring due to the presence of dissolved oxygen. Organically catalysed ammonium or sodium bisulphite in liquid form are the examples for typical oxygen scavenger. The dissolved oxygen in test water shall be accurately measured, such that the appropriate dosage of Oxygen scavenger can be applied. Oxygen must not be permitted to enter the Oxygen Scavenger holding tank. Nitrogen blanketing may be required for ternporary storage of Oxygen Scavenger.
9.1.11 Biocide treatment shall be applied to the test water to prevent biomass solids buildup and bio-corrosion occurring . Selection of environmental friendly biocides shall be warranted where discharge to environmentally sensitive locations is considered.
Tetrahydroxymethyl Phosphonium Sulphate (THPS) and polymeric biguanide based products are examples for such biocides. Under any circumstance, biocide containing formaldehyde shall not be used. The dosage rate would typically be expected in the range 200 - 500 ppm (active ingredient) .
9.1.12 Corrosion inhibitor treatment shall be applied to the test water to prevent corrosion occurring due to the presence of corrosive species other than dissolved oxygen.
9.1.13 During the chemical treatment of test water, Oxygen scavenger shall be added first, and all Oxygen shall be scavenged, before any biocide is added, to prevent adverse interaction between the Oxygen scavenger and the biocide. The Contractor's procedure shall clearly demonstrate compliance to this requirement.
9.1 .14 Chemical testing procedures shall be submitted to KOC Controlling Team for review and approval.
9.1.15 Chemical content and activity shall be spot verified using the analysis type and test methods complying with the requirements specified in clause 8.2 of this Standard at a frequency approved by KOC Controlling Team in liaison with ICT or at least at the beginning and end of short-duration hydrostatic testing .
9.1.16 If test water is transferred from one test section to another, the quality of water shall be checked for compliance with the requirements specified in clause 8.2 .5 of this Standard.
The Contractor shall submit to KOC Controlling Team for approval , a procedure to achieve the speCified test water treatment and quality. No debris shall be permitted to be transferred from one section to another.
III DOC.NO. KOC-G-011 Page 16 of 33 REV. 1 II t
9.2 Water Treatment for Carbon I Low Alloy Steel Equipment and Pipelines
9.2.1 General
a. In order to avoid excessive chemical usage, the Contractor should complete the hydrostatic testing in a minimum period of time.
b. The Contractor shall submit to KOC Controlling Team for review and approval all the necessary documents including the estimated duration of the hydrostatic testing as per clause 13.2.1 of this Standard.
The Contactor shall ensure that the test water contact time will not exceed the durations indicated in the subsequent clauses (c), (d), and (e) below for any reasons including operational reasons. If there is any doubts to drain the water within the specified period, chemicals shall be added regardless of the contact time.
c. Control of corrosion caused by Oxygen is required, where total test water contact time will exceed 14 days, and shall be achieved by the addition of an Oxygen scavenger to the test water. Dosage shall be sufficient to maintain a residual sulphite content of 20 mg/I and Oxygen concentration of less than 10 ppb.
d. Control of corrosion caused by bacterial action is required where total contact time with brackish water will exceed 28 days, and this shall be achieved by the addition of a biocide to the test water.
If seawater is used as the test medium, biocide shall be added irrespective of the contact time.
e. Control of other forms of corrosion is required where total contact time with test water will exceed 28 days, and this shall be achieved by the addition of a corrosion inhibitor to the test water.
f. The pH of the test water shall be verified at the Site before the test water is introduced into the test system.
g. It is strictly prohibited to exceed the periods indicated in paragraphs c, d, and e above for the requirements of the chemical treatments to be injected in the Test System; or otherwise the test water shall be drained completely and the hydrostatic testing exercise shall be repeated fulfilling all requirements of the new duration.
h. It is strictly prohibited to allow the test water to remain in the equipment and / or pipeline for a period more that 60 days from the date of starting the test water filling, otherwise lay-up shall be implemented as per clause 10.0 of this Standard.
Sea water is not allowed to be used as a test fluid, if the tested system is intended for lay-up as per clause 10.1.3 of this Standard.
i. In case of Heat Exchangers, test water shall not remain more than 14 days after completion of the hydrostatic testing . Lay-up shall be implemented as per clause 10.0 of this Standard.
DOC.NO. KOC-G-011 Page 17 of 33 I REV. 1
"j. In case of Storage Tanks, test water shall be fully drained after completion of the hydrostatic testing.
k. The treatment of test water used for Storage Tanks shall be as indicated in clause 9.2 .2 of this Standard.
I. Test water filtration shall comply with the requirements of clause 8.3 of this Standard .
m. The required chemical treatments and corrosion management parameters for carbon and low alloy steels are indicated below in Table 1 of this Standard .
Table 1: Chemical Treatment and Corrosion Management Parameters for Carbon and Low Alloy Steels
Parameters Dissolved Oxygen
Bacteria-SRBPlanktonic
Total bacteriaPlanktonic
Test Water Contact Duration
days (D) , pH Modifier
Oxygen Scavenger
Biocide
Corrosion Inhibitor
Unit ppb
Countlml
CounUml
Chemical Treatment Brackish Water
0-14 14<D<28 > 28
Required if pH is outside 6.0t010.5
None" Required Required
None Required
None Required
Target Value < 20 <10
< 100
Sea Water 0-14 14<D<28 28<D<60
Required if pH is outside 6.0 to 10.5
None Required Required
Required Required Required
None None Required
* Oxygen Scavenger shall be added to the test water of dry gas piping/pipe line system even when the contact time is less than 14 days.
9.2.2 Water Treatment for Carbon & Low Alloy Steel Storage and Atmospheric Tanks shall comply with the following :
a. Completely internally lined storage tanks at the time of the hydrostatic testing do not require chemical treatment. However, it is mandatory to remove the test water from the tank immediately after completion of the hydrostatic test.
b. Tanks that are not internally lined at the time of hydrostatic testing and will be internally lined after the hydrostatic testing do not require chemical treatment. However, it is mandatory to remove the test water from the tank immediately after completion of the hydrostatic testing.
c. Tanks that are not internally lined at the time of hydrostatic testing and will not be internally lined after the hydrostatic testing, do not require chemical treatment. However, it is mandatory to remove the test water from the tank immediately after completion of the hydrostatic testing . Sea water is not allowed as test fluid.
DOC.NO. KOC-G-011 Page 18 of 33 REV. 1 il
The test water shall not be kept in the tank for a period more than 60 calendar days including the filling time, or otherwise the test water shall be drained completely regardless of completing the hydrostatic testing. No deviation is allowed.
d. If seawater is allowed by the Controlling Team in liaison with ICT to be used as the test medium, biocide shall be added, no matter how long the contact time will be.
For completely internally lined storage tanks, seawater cannot be used as test medium unless the lining system is suitable for sea water service. Biocide treatment is not required.
For tanks that are not internally lined at the time of hydrostatic testing and will not be internally lined after the hydrostatic testing, Sea water is not allowed as test fluid.
e. The test water quality shall be analyzed and evaluated by the Contractor and shall be submitted to KOC Controlling Team for review and acceptance.
9.3 Water Treatment for Stainless Steel Equipment, Pipelines and Tanks
9.3.1 General
a. Only low chloride water shall be used as test water in contact with all types of stainless steel or those which are lined with stainless steel.
b. The maximum chloride content for test water shall be limited to 30 mgll at the time of introducing the test water into the system.
c. The chloride content and pH of the test water shall be verified at the Site before the test water is introduced into the test system.
d. Corrosion Inhibitors need not be added for hydrotesting of process eqUipment fabricated entirely from stainless steels.
e. Test water filtration shall comply with the requirements of clause 8.3 of this Standard.
f. If the tested system is made of carbon and / or low alloy steel along with stainless steels, the system shall be treated as per the requirement of clause 9.2 of this Standard for carbon: or shall be maintained with the above reqUirements of clause 9.3.1 of this standard for low alloy steel .
g. It is strictly prohibited to allow the test water to remain in the equipment / pipeline for a period more than 60 days from the date of starting the test water filling.
h. Lay-up shall be implemented as per clause 10.0 of this Standard.
DOC.NO. KOC-G-011 Page 19 of 33 REV. 1!I
9.3.2 Water Treatment for Stainless Steel Equipment & Pipelines
a. If contact time of the test water is less than four (4) days, chemical treatment is not required.
b. Where contact time of total test water will exceed four (4) days, Oxygen scavenger shall be added to the test water, such that a residual sulphite content of 20 mgll is maintained during the whole period.
Samples of the test water shall be analyzed by the Contactor on weekly basis to maintain the test water specifications. Failure to maintain the test water specifications will subject test water for rejection; and complete drainage and then refilling.
c. Biocide shall be added to the test water where total contact time of test water will exceed 14 days.
d. Storage tanks that are not designed to take positive pressure (such as open-roof tanks, floating-roof tanks or API atmospheric cone roof tanks) cannot be sealed off from air. Chemical treatment is impractical and therefore not required.
It is mandatory to remove the test fluid from the systems as completely as possible immediately after completion of the hydrostatic test.
e. It is strictly prohibited to exceed the periods indicated in clauses (b) and (c) above for the requirements of the chemical treatments to be injected in the Test System; or otherwise the test water shall be drained completely and the hydrostatic testing process shall be repeated .
f. Samples shall be taken from each chemical tank at the end of the filling in order to ensure that no contamination has taken place.
g. The required chemical treatments for all types of stainless steels are indicated in Table 2 of this Standard below.
Table No.2: Chemical Treatment Required for Stainless Steels
Parameters Unit Target Value Dissolved Oxygen ppb < 10
Bacteria-SRB- Count / ml <10 Planktonic
Total Bacteria Count / ml < 100 Planktonic
Chemical Treatment Test Water Contact 4<0<14 14<0<60 Duration, days (D)
Oxygen Scavenger Required Required Biocide None Required
DOC.NO. KOC-G-011 Page 20 of 33 REV. 1 ~ I I 10.0 WATER TREATMENT FOR LAY-UP
10.1 General
10.1 .1 Lay-up shall not be implemented unless a written approval is obtained from KOC Controlling Team. Lay-up shall be implemented, unless the start-up date is within 60 days from introduction of the test water.
10.1.2 If the tested system is planned for lay-up, sea water is not allowed to be used as a test fluid.
10.1 .3 Lay-up procedure including lay-up method shall be submitted to KOC Controlling Team for review and approval.
10.1.4 In the case of Transit, Transfer and Gas Pipelines, the requirements given in 01S-IH-100S "KOC Engineering Group Specification for Pipeline Dewatering, Drying and Purging" (or the latest KOC Standard that replaces it) shall be adopted unless otherwise specified by KOC.
10.1.5 In case of completely internally lined or entirely fabricated with non-metallic material systems, no lay-up procedure is required.
10.1.6 In the case of heat exchangers, lay-up shall commence within 14 days of introduction of the test water. The test system shall be completely dried as per clause 7.13 of this Standard prior to start up of the lay-up
10.1 .7 In the case of stainless steel equipment, lay-up shall commence within 60 days of introduction of the test water. The test system shall be completely dried as per clause 7.13 of this Standard prior to stat up the of the lay-up,
10.1.8 In the case of storage tanks, the test water shall be removed from the system at the end of the hydrostatic testing and the system shall be completely dried as per clause 7.13 of this Standard. No lay-up is required.
10.1 .9 In case of potable water systems, the lay-up requirements shall comply with the relevant clauses of this Standard as below:
a. Clause 10.3 for dry lay-up;
b. Clause 10.4 for inert gas lay-up using nitrogen and
c. Clause 10.5 for ambient lay-up
10.1 .10 In the case of dry gas piping / pipeline system, wet lay-up or dry lay-up shall be the preferable methods. The system shall be pressurized with dry nitrogen .
10.1.11 When required, one of the lay-up methods as described in clauses 10.2 to 10.4 of this Standard shall be followed as a component of the hydrostatic testing . The preferred methods are wet and dry lay-ups.
DOC.NO. KOC-G-011 Page 21 of 33 REV. 1 I l 10.1.12 Use of ambient or inert gas lay-up for equipment and tanks will only be considered in
extraordinary cases, if both of the wet or dry lay-up methods cannot be implemented , as justified by the Contractor to KOC satisfaction.
10.1.13 The time duration between termination of lay-up and start-up of the test system shall be less than 60 days, except for clause 10.1.14 below. Upon termination of the lay-up, the test system shall be completely dried as per clause 7.13 of this Standard.
10.1.14 In the case of heat exchangers and stainless steel equipment, the time duration between termination of lay-up and start-up of the test system shall be less than 14 days. Upon termination of the lay-up, the test system shall be completely dried as per clause 7.13 of this Standard.
10.2 Wet Lay-Up
10.2.1 Wet lay-up shall be only utilized if total drainage can not be verified by visual inspection or other reliable means, as justified by the Contractor to KOC satisfaction.
10.2.2 Upon verification of the proper residual sulphite level as per clause 10.2.3 below and completion of successful hydrostatic testing, the test system shall remain full of the treated test water under positive pressure, until the test system is ready for commissioning and start-up.
10.2.3 Oxygen scavenger shall be added to the test water at the starting of the hydrostatic testing. A minimum residual sulphite level of 20 ppm and Oxygen concentration of less than 10 ppb shall be established throughout the test system, including dead legs. Test water sample(s) shall be analyzed at the pertinent location(s) and test results documented in the hydrostatic testing report. Once compliance is established, the test system shall remain closed . Further testing is required at intervals of 90 days.
A new wet lay-up shall be initiated in the event of any leaks or loss of positive pressure leading to Oxygen ingress or if the Oxygen concentration exceeds 10 ppb or the minimum sulphite level is being compromised.
10.2.4 An approved biocide shall be added to the test water at the starting of hydrotesting at the dosage rate specified in clause 9.1.10 of this Standard.
10.2.5 An approved corrosion inhibitor shall be added to the test water at the starting of hydrotesting at a dosage rate typically in the range of 500 - 1000 ppm.
The actual dosage rate to be applied shall be proposed by the Contractor for KOC Controlling Team approval, based on technically justified advice from the Chemical Manufacturer / Supplier.
10.2.6 Positive pressure shall be maintained during the wet lay-up, to prevent Oxygen ingress, within the range 2-10% of maximum allowable operating pressure, but need not exceed 350 kPa (50 psig). The positive pressure shall be maintained by use of nitrogen, sweet hydrocarbon gas or hydrostatic pressure.
DOC.NO. KOC-G-011 Page 22 of 33 I REV. 1III
10.2.7 The positive pressure shall be monitored with a standard pressure gauge calibrated as per KOC standard procedure that can withstand the equipment/pipelines maximum allowable operating pressure .
10.2.8 Pressure relief devices shall be provided in each test system , when necessary, during the lay-up period and prior to the start of operations when hydrostatic pressure is used to maintain positive pressure.
10.3 Dry Lay-Up
10.3.1 The system shall be completely drained and free from all standing test water. Total drainage is an essential step in achieving dry lay-up. If total drainage cannot be verified by visual inspection or other reliable means (e .g. utilizing drains at all low points), dry lay-up shall not be considered .
10.3.2 The test system shall be dried to a dew point of -1°C (30°F) or less at all exit points by the most convenient method (e.g . methanol swab, blowing heated dry air or nitrogen through the test system or use of a vacuum) . The test system shall then be shut in for a period of not less than 12 hours to allow any remaining moisture to come to equilibrium with the dry air. Exit dew points shall then be measured again , and, if fou nd to be above _1°C, the drying procedure shall be repeated.
10.3.3 If dry air is used to achieve the specified dew point, it shall be replaced with either nitrogen or sweet hydrocarbon gas as a final step before shut-in.
10.3.4 When the required dew point is reached, the test system shall be shut-in and a positive pressure shall be maintained as per clauses 10.2.6 and 10.2.7 of this Standard during the lay-up period.
10.3.5 The dew point shall be measured after one week of shuting-in the test system. If the dew point is found to be more than _1°C (30°F) at the lay-up pressure, the system shall be dried again , and then a new wet lay-up shall be initiated.
10.4 Inert Gas Lay-Up
10.4.1 Upon completion of a successful final hydrostatic testing, the test water shall be displaced with an inert gas (nitrogen is preferred), until no test water drains out of the system. If total drainage cannot be verified by visual inspection or other reliable means (e.g., utilizing drains at all low points), inert gas lay-up shall not be considered .
Note that draining the bulk of test water out of the test system and attempting to replace the volume with an inert gas by either repeated repressurizing or sweeping shall not be considered as inert gas lay-up.
However, in the case of pipelines, sweeping with inert gas driven scraper pigs is considered acceptable , subject to compliance with KOC Engineering Specification 015-IH-1005.
DOC.NO. KOC-G-011 Page 23 of 33 REV. 1 l
10.4.2 When complete test water displacement by inert gas has been achieved , the test system shall be shut-in under positive pressure as per clauses 10.2.6 & 10.2.7 of this Standard, until the test system is ready for commissioning and start-up.
10.5 Ambient Lay-Up
10.5.1 Ambient lay-up shall not be permitted under the following circumstances:
a.
b. c. d.
Where any component of the test system has been fabricated steel materials . Where no corrosion allowance has been provided. Where the antiCipated pitting corrosion cannot be tolerated. Where rust particulates cannot be tolerated for any reason .
in stainless
10.5.2 The test system shall be closed after ensuring total drainage of test water. Any standing test water shall be swept out. Where total drainage cannot be verified by visual inspection or other reliable means (e.g. utilizing drains at all low points), ambient lay-up shall not be considered .
10.5.3 A vacuum breaker and pressure relief vent shall be installed and shall be made functional during the lay-up period unless it is demonstrated that the system will not collapse under vacuum. Setting up the vacuum breaker shall be part of the hydrostatic testing procedure and shall depend on the system design pressure.
11.0 DISPOSAL OF TEST WATER
11.1 On completion of the hydrostatic testing, the test water shall be safely disposed off to a KOC approved location in a manner not harmful to the environment. The procedures to be adopted shall be in compliance with the applicable KOC environmental guidelines and Kuwait EPA regulations .
11 .2 The test water must not be disposed off in a manner which leads to flooding the area / facility / enclosure .
11 .3 Disposal plan for the test water shall be submitted to KOC Controlling Team for review and approval. The procedure shall show the types of chemicals to be injected into the test water along with their impacts to the environment.
11.4 The test water shall be treated in such a manner that no harmful residues are allowed to soak into the surrounding environment and the underground aquifers.
If the test system contains harmful residues such as oil or iron residue as a result of hydrostatic testing of a system that has been in operation, the test water shall be treated in a manner that will render it not harmful to the environment.
11 .5 The disposed test water quality shall comply with the State of Kuwait EPA restrictions for the maximum concentration of salts and other contaminants permitted in waste water.
III DOC.NO. KOC-G-011 Page 24 of 33 REV. 1I To dispose the test water into the sea, it should be treated to the standard specified in Annexure III of this Standard.
To dispose the test water into the sewage (KOC/Municipality) system, it should be treated to the standard specified in Annexure IV of this Standard .
11.6 If KOC Controlling Team allows the disposal of test water into disposal evaporating pit(s), temporary security fencing shall be provided by the Contractor around the disposal pits.
Whenever chemicals have been injected to the test water, waterproof lining, approved by State of Kuwait EPA, shall be installed at the bottom and sides of the pit to prevent water seepage to the surrounding. Upon completion of evaporation, the disposal pit linings shall be disposed off at previously approved location I hazardous waste treatment facility at Shuaiba, after obtaining prior approval of the testing procedure. Fencing around the disposal pit(s) shall be removed, and the Site shall be reinstated to its original state.
The Contractor's hydrostatic testing procedure shall include the design and procedure for the construction of such disposal pit(s) and shall be submitted to KOC Controlling Team for review and approval.
The pit deSign shall ensure that no water is able to seep into the underlying soil strata and also overflow during the period of usage.
11 .7 KOC may allow the Contractor from case-to-case to dispose the untreated test water with chemicals or fresh I low chloride test water into the desert or into the unlined disposal evaporating pit(s) .
11 .8 Only if it is specified in the Contract, KOC Controlling Team may allow the Contractor to dispose the test water into any operating facility I water disposal plant. The Contractor shall ensure that Oxygen content will be less than 20 ppb at the time of injection, unless specified otherwise.
Retreatment with Oxygen scavenger shall be carried out as necessary to achieve the specified Oxygen content. Also, the Contractor shall ensure that the total suspended solids (TOS) will be less than 20 ppm at the time of disposal, unless specified otherwise. Re-treatment with filtration shall be carried out as necessary to achieve the specified total suspended solids.
11.9 Where the test water will be disposed off to a location other than an operating facility, it shall be noted that compressed air may be bubbled through test water treated with Oxygen scavenger alone to consume the residual sulphite and thereby avoid creation of any disposal problem.
Biocides and corrosion inhibitors used in test water are toxic materials and pH modifiers may also be toxic. Use of these chemical additives will require a disposal procedure to be developed for KOC Controlling Team approval. The procedure should comply with the local environmental regulations enforced by the State of Kuwait EPA.
III DOC.NO. KOC-G-011 J Page 25 of 33 I REV. 1
11.10 Volumes of the test water to be disposed to close piping network shall be considered in order to avoid flooding or operating upsets.
11.11 The disposal of any solid waste shall comply with the State of Kuwait EPA restrictions and the disposal of solid waste procedure as well as the disposal location shall be submitted to KOC Controlling Team for approval.
11 .12 If the hydrotest water is potable and without any chemical addition, it should be reutilized in next hydrotest. This may require temporary storage. Attempt should be made to utilize the water for gardening purposes in co-ordination with KOC Ahmadi Team .
11.13 Water should not be discharged to sea as per KEPA Appendix 12 Criteria.
12.0 QUALITY ASSURANCE
12.1 The Contractor shall operate a quality system, preferably based on ISO 9000 series of standards, to support achievement of the requirements of this Standard. The Contractor shall demonstrate compliance by providing a copy of accredited certificate and a copy of their quality manual.
12.2 Verification of the Contractor's quality system is normally part of the pre-qualification procedure and is, therefore, not detailed in the core text of this Standard.
12.3 All personnel involved in the test water treatment for hydrostatic testing shall be qualified to carry out such activities. CV's shall be submitted for KOC Controlling Team for approval.
12.4 All test water quality laboratory and field testing procedures including the types of testing methods and equipments shall be submitted to KOC Controlling Team for review and approval .
12.5 Calibration certificates of all testing eqUipment shall be submitted to KOC Controlling Team Representatives.
13.0 DOCUMENTATION
13.1 General
13.1.1 All correspondence, instructions, data sheets, drawings, calculations or any other written information shall be in the English language. In case of dual languages, one language shall be English.
13.1.2 All dimensions, units of measurement, and physical constants shall be in accordance with KOC Standard KOC-G-007, unless otherwise specified in the project speCifications.
13.1.3 In addition to hard copies, all documents (text, specifications, data sheets, and drawings) shall be provided in the form of electronic files in the approved software formats (latest version of Microsoft Word, Excel, AutoCAD and PDF-Acrobat) .
il DOC.NO. KOC-G-011 i Page 26 of 33 I REV. 1
13.2 Deliverables
13.2.1 Prior to carrying out any the hydrostatic testing, the Contractor shall submit to KOC Controlling Team for review and approval all the necessary documents including the hydrostatic testing procedure, which shall include but not limited to the following:
a. Hydrostatic Testing Procedure; b. Hydrostatic Testing Water Treatment & Disposal Procedure; c. Reference standards, codes and specifications; d. System to be tested including material of construction and lining
specifications (if applicable); e. Hydrostatic testing media; f. Estimated duration of the hydrostatiC testing; g. Type of required chemical treatment; h. Chemical manufacturer data sheet; i. Chemical MSDS; j. The Laboratory responsible for chemical analyses; k. Test water chemical analysis including test type and methods; I. Chemical testing procedure; m. Test water analysis procedure; n. Test water analysis devices/equipment; o. Chemical injection dosages calculation; p. Test water monitoring and sampling frequencies ; q. Evidence of chemicals' compatibility; r. Location of injection points; s. Sampling locations/identifications; t. Lay-up method; u. Disposal procedure; and design of disposal pit, if applicable; v. Pipeline dewatering, drying and purging procedure; w. HSE procedure including chemical handling, hazard and risk
assessment, risk management, environment impact assessment and its managements, and operational control activities including and not limited to mechanical handling, safety handling, personnel protective equipments and emergency procedures ..
13.2.2 In addition, all required project documents as per the Contract specifications shall be submitted to KOC Controlling Team for review and approval.
13.2.3 All deviations and non-conformances with this Standard shall be brought to the KOC Controll ing Team(s) for review and approval.
13.2.4 The Contractor shall submit to KOC Controlling Team post completion of hydrostatic testing documents including and not limited to the following:
a. Quantity of test water used; b. Total consumption of injected chemicals for treatment; c. Test water chemical analysis conducted prior to introducing the test water and
during the hydrostatic testing period; d. Hydrostatic testing pressure and contact time ; e. Lay-up results ;
II IDOC.NO. KOC-G-011 Page 27 of 33 REV. 1
f. Disposal location; g. Any deviations / non-conformances; h. Analysis Reports:
Report shall include but not be limited to the following: i) Name of test equipment; ii) Types of injected chemicals; iii) Source of test water and its previous use, if any; iv) Sample point identification ; v) Who collected the sample; vi) When the sample was collected; vii) When the sample was analyzed; viii) Test method or standard and device; ix) Results; x) Credentials of responsible personnel.
DOC.NO. KOC-G-011 Page 28 of 33 REV. 1 1 14.0 APPENDICES
ANNEXURE-I (Informative)
~-----------------------------------------------------,
ITypical Brackish Water Analysis
Analysis
Sodium Na
Calcium as Ca
Magnesium as Mg
Total Iron as Fe
Potassium as K
Barium as Ba
Strontium as Sr
Phophorus as P
Chloride CI
Carbonate as C03
Bicarbonate as HC03
Sulphate as S04
Fluoride as F
Silica as Si02
Nitrate as N03
Nitrite as N02
Sulphide as S
Phosphate as P04
Total Chlorine as CI2
Sodium Chloride as NaCI
Caustic Alkalinity as CaC03
Total Alkalinity as CaC03
Oxygen Content
Oil in Water Content
Dissolved H2 S
Dissolved CO2
pH at 25°C
TSS
TDS
Electrical Conductivity
Specific Gravity at 60 OF
Unit
PPM
PPM
PPM
PPM
PPM
PPM
PPM
PPM
PPM
PPM
PPM
PPM
PPM
PPM
PPM
PPM
PPM
PPM
PPM
PPM
PPM
PPM
PPM
PPM
PPM
PPM
PPM
PPM
Mmhos/CM
Test Results
3349
4160
923.4
0.66
24
<1.0
24
0.35
3950
NIL
183
1200
12.4
19.4
0.6
0.004
1.07
0.01
6517
NIL
150
8
NIL
NIL
35
6.4
NIL
6300
9000
1.002
DOC.NO. KOC-G-011 Page 29 of 33 REV. 1 I
ANNEXURE· II
(Informative)
--.--.. ... -- ---. Ambient Seawater Quality Criteria
I Chemical Symbol UnitPollutants Maximum Limit
6.5-8.5
Salinity
pH
33-42
Dissolved Oxygen
%
mg/L >4
Total Suspended Solids mg/L 32.8
jJg/L 33.7Phosphate P04
Ammonia jJg/L 60
Hydrocarbons
NH3
ppm 5
Cadmium Cd j.Jg/L 0.7
Nickel Ni j.Jg/L 20.0
Nitrate jJg/L 94.7
Mercury
N03
Hg j.Jg/L 0.37
Iron jJg/LFe 91.3
Copper jJg/LCu 15.5
Lead Pb jJg/L 12.0
Vanadium V jJg/L 9.4
Silicate Si03 j.Jg/L 893.2
Nitrate jJg/L 33.7N0 2
III DOC.NO. KOC-G-011 II
Page 30 of 33 REV. 1
ANNEXURE-III
(Normative)
Maximum Limits of Polutants in Industrial Water Waste Permissible to be Discharged into the Sea_____--1
I I ' Pollutants Chemical Symbol Unit Maximum Limit
Color clear pH pH 6-8 Temperature DC *10 Bilogical Oxygen Demand BOD (5 days 20°C) mg/L 30 Chemical Oxygen Demand COD mg/L 200 Oil/grease mg/L 10 Total Suspended Solids TSS mg/L 10
Total Soluble Soilds mg/L 1500 Phosphate PO mg/L 2 Ammonia NH3-N mg/L 3.0 Nitrate N03 mg/L 30 Total Kaldal Nitrogen mg/L 5 Total Nitrogen mg/L 30 Total Recoverable Phenol mg/L 1.0 Fluorides F mg/L 25 Sulfides S mg/L 0.5 Chlorine CI2 mg/L 0.5 Dissolved Oxygen DO mg/L >2 Turbidity NTU 50 Floatables mg/L Nil Aluminium AI mg/L 5 Arsenic As mg/L 0.1 Barium Ba mg/L 2 Boron B mg/L 0 .75 Berylium Br mg/L 0.1 Cadmium Cd mg/L 0.01 Cyanides Cn mg/L 0.1 Chromium Cr mg/L 0.2 Nickel Ni mg/L 0.2 Mercury Hg mg/L 0 .001 Cobalt Co mg/L 0.2 Iron Fe mg/L 5 Antimony Sb mg/L
Copper Cu mg/L 0.2 Manganese Mn mg/L 0.2 Zinc Zn mg/L 2 Lead Pb mg/L 0.2 Lithium Li mg/L 2.5 Molybdenum Mo mg/L 0 .01 Vanadium V mg/L 0.1 Silver Ag mg/L 0.1 All herbicides mg/L 0.2 Most probable number of total Coliform MP/N/100 ml 1000
* The subtraction of the external and internal water temperature entry and exit point.
DOC.NO. KOC-G-011 Page 31 of 33 REV. 1
ANNEXURE-IV
(Normative)
Treated Waste Drainage Water Discharged into Sewerage
~---------- ----
Pollutants Chemical Symbol Unit Maximum Limit
Biological Oxygen Demand BOD5 (5 day, 20° C) mg/L 400
Chemical Oxygen Demand COD mg/L 750
Total Suspended Solids TSS mg/L 300
Phenol Total Recoverable Phenol mg/L 1
Fluorides F mg/L 1000
Sulfides S mg/L 10
Arsenic As mg/L 0.1
Cadmium Cd mg/L 0.1
Cyanides Cn mg/L 0.1
Chromium Cr mg/L 1.0
Nickel Ni mg/L 0.2
Mercury Hg mg/L 0.002
Copper Cu mg/L 0.5
Zinc Zn mg/L 2.0
Lead Pb mg/L 0.5
Silver Ag mg/L 4.0
Tar& Tar Oil mg/L Nil
Floating Oil & Grease mg/L 5
Emulsified Oil & Grease mg/L 5
Most probable number of total coliform MPNI 100 ml 1000
Most probable number of faecal coliform MPN /100 ml 100
Egg parasites Nil
Worm parasites Nil
DOC.NO. KOC-G-011 II Page 32 of 33 REV. 1
ACKNOWLEDGEMENT
This Standard has been approved by the Standards Technical Committee (STC) consisting of the following:
Mr. Hamzah Ahmad Standards Team Chairman Mr. Mohd. Emam Insp. & Corr. Team (S&E) Deputy Chairman Mr. S. Kumar Standards Team Secretary/Mem ber Mr. A. Unnikrishnan Standards Team Member Mr. N. Ramanathan Major Projects IV Team Member Mr. Daniel Pino Utilities Team Member Mr. Abdul R. AI-Shamari Insp. & Carr. Team (N&WK) Member Mr. Haithem Aboughaith Gen. Projects Team Member Mr. Gopal Murti Opns. Tech. Svcs. (WK) Team Member Mr. Mohd . Aslam Imadi Design Team Member Mr. G. Unnikrishnan Design Team Member Mr. Fahad AI-Qattan HSE System Team Member Mr. Abdulla AI-Yousef Project Mgmt. Team (NK) Member Mr. Richard Arthur Info. System Planning Team Member
The draft of this Standard had been circulated to the KOC User Teams for review and the responses were received from the following:
ENGINEERING GROUP GAS MGMT. GROUP
Team Leader Design Team Leader Gas Opns. (S&EK)
AHMADI SERVICES GROUP EXPORT & MARINE OPNS. GROUP
Team Leader Project Design Team Leader Export Tech. Svcs
Team Leader Utilities Team Leader HSE (E&MO)
NDUSTRIAL SVCS. GROUP OPERATIONS GROUP (WK)
Team Leader Insp. & Corr. (S&EK) Team Leader Opns. Tech . Svcs. (WK)
Team Leader Insp. & Corr. (N&WK) Team Leader Maintenance (WK)
OPERATIONS GROUP (NK) SECURITY & FIRE GROUP
Team Leader MSR (NK) Team Leader Fire
HSE GROUP OPNS. SUPPORT GROUP (S&EK)
Team Leader HSE Systems Team Leader OTS (S&EK)
Team Leader H&E Team Leader HSE (S&EK)
Team Leader Safety
DOC.NO. KOC-G-011 Page 33 of 33 REV. 1
Task Force Responsible for This Standard
The Standards Technical Committee (STC) has entrusted the preparation of Standard to the Task Force No. TF-GI08, consisting of the following members:
Mr. Abdul R. AI-Shamari Insp. & Corr. (N&W) TF Leader Tel. No. 66394 Mr. Mirza Mohsin Standards Team Member Tel. No. 61371 Mr. Mohd . Imadi Design Team Member Tel. No. 61102 Mr. N. Ramanathan Major Projects IV Member Tel. No. 66960 Mr. S.H. Shah Gen. Projects Team Member Tel. No. 61190 Mr. Saad Jaber Construction Team Member Tel. No. 61376 Mr. Bader AI-Qahtani OTS (SK) Team Member Tel. No. 22384 Dr. Waseem Siddiqi Health & Environment Member Tel. No. 71628
this
