Professional Documents
Culture Documents
October 2008
Sultanate of Oman
Ministry of Transport and Communications
Development of Salalah International Airport
Main Contract 5
Project Specification
Civil Works - 3600 Fuel Hydrant Systems
Special Specification
October 2008
Prepared FRA/PVN
Checked JMJ
Approved STJ/NIER
Main Contract 5 -Special Specification 1
Civil Works - 3600 Fuel Hydrant Systems, Project Specification
Table of Contents
3600 Fuel hydrant systems 5
3601 General 5
3601.1 Description 5
3601.2 Functional requirements and materials 9
3601.3 Installation and execution 10
3601.4 Testing and commissioning 10
3601.5 Documentation 12
3601.6 Operation and Maintenance 12
3602 Piping items 13
3602.1 Description 13
3602.2 Functional requirements and materials 13
3602.3 Installation and execution 14
3602.4 Testing and commissioning 14
3602.5 Documentation 14
3602.6 Operation and maintenance 14
3603 Valves 14
3603.1 Description 14
3603.2 Functional requirements and materials 14
3603.3 Installation and execution 17
3603.4 Testing and commissioning 17
3603.5 Documentation 18
3603.6 Operation and maintenance 19
3604 Valve operators 19
3604.1 Description 19
3604.2 Functional requirements and materials 20
3604.3 Installation and execution 21
3604.4 Testing and commissioning 21
3604.5 Documentation 21
3604.6 Operation and maintenance 21
3610.5 Documentation 31
3610.6 Operation and maintenance 32
3611 Wall penetration seals 32
3611.1 Description 32
3611.2 Functional requirements and materials 32
3611.3 Installation and execution 32
3611.4 Testing and commissioning 32
3611.5 Documentation 32
3611.6 Operation and maintenance 33
3612 Geomembrane 33
3612.1 Description 33
3612.2 Functional requirements and materials 33
3612.3 Installation and execution 33
3612.4 Testing and commissioning 33
3612.5 Documentation 33
3612.6 Operation and maintenance 33
3613 Leak detection system 33
3613.1 Description 33
3613.2 Functional requirements and materials 35
3613.3 Installation and execution 35
3613.4 Testing and commissioning 35
3613.5 Documentation 35
3613.6 Operation and maintenance 36
3614 Cathodic protection system 36
3614.1 Description 36
3614.2 Functional requirements and materials 40
3614.3 Installation and execution 47
3614.4 Testing and commissioning 49
3614.5 Documentation 50
3614.6 Operation and maintenance 51
3615 Control and monitoring 51
3615.1 Description 51
3615.2 Functional requirements and materials 53
3615.3 Installation and execution 58
3615.4 Testing and commissioning 60
3615.5 Documentation 60
3615.6 Operation and maintenance 60
3616 Emergency shutdown system 60
3616.1 Description 60
3616.2 Functional requirements and materials 61
Revision Log 66
3601 General
3601.1 Description
Introduction
The Fuel Hydrant System (FHS) for Salalah International Airport is designed to
supply fuel to a traffic level of 2 million passengers per year (mppa),
corresponding to 6 departures in the peak hour, and simultaneously supply fuel
to 0.8 departing cargo aircrafts in the peak hour see below tabulation. The FHS
has been designed with two supply lines to form a ring connection to facilitate
fuel supply in case of repair or emergency situations.
The design assumption for fuel demand is based on the following distribution
percentages on aircraft categories and number of departures in the peak hour for
passenger and cargo aircraft respectively.
Passenger
Departures
2 mppa and C Aircraft D Aircraft E Aircraft F Aircraft
in peak
0.8 cargo percentage percentage percentage percentage
hour
departures
Passenger
aircraft 66.0 8.0 26.0 0.0 6
distribution
Cargo
aircraft 0.0 20.0 80.0 0.0 0.8
distribution
It is further estimated that each aircraft shall be refuelled to 60% of the nominal
fuel capacity of the aircraft and calculations made for dispenser capacities 45
l/s, 65 l/s and 75 l/s. Aircraft in category C and D are served by 1 dispenser
whereas aircraft in category E and F are served by 2 dispensers simultaneously.
Scope
The fuel supply system shall in the peak hour be able to deliver 940 m3/h with a
pressure drop of maximum 2.5 bar from valve chamber 01 to the outmost pit
valve and a maximum velocity of 2.5 m/s assuming a maximum start pressure
at the fuel farm of 12 bar.
The FHS comprises the supply lines from the connection to the Fuel Farm
Pump Station including the distribution system to the apron areas comprising
tees, bends, tees, block valves with actuators, manual valves, pit valves, drains,
vents, insulating flanges, spacers, cathodic protection system, control and
monitoring system, leak detection system, emergency and shutdown system and
cabling.
The Contractor shall, based upon the tender material drawings and
specifications, make the necessary shop drawings.
Interfaces
The interface to the pump station is 10 m inside the Security fence at the first
block valve chamber as shown on dwg. No SA-986-303-P-60101.
The control and monitoring system will be terminated at cabinets with terminal
blocks in the Fuel Farms control room.
Abbreviations
AC Alternating current
ACN Airport Community Network
API American Petroleum Institute
ATEX Equipment and Protective system intended for use in Potentially
Explosive Atmospheres
AWG American Wire Gauge
Class F900 Classification of gully tops according to EN 124
CP Cathodic Protection
D Diameter of a pipe
DC Direct current
DFT Dry Film thickness
DN Nominal diameter of a pipe
Materials
The fuel supply system has been designed for the transport of Jet A-1 only, and
shall comply with the requirements in API/IP Recommended Practice 1540
The design pressure rating of the system, pipes, valves, fittings, flanges and
other items shall be 19.0 barg at 50 ºC (~ASME pressure rating class 150).
However, the operating pressure shall not exceed 14 barg as stated in API/IP
1584.
1 All piping materials, pipes, valves, fittings, flanges and other items
including instrumentation shall be purchased fully marked for
identification.
After completion of construction of the fuel hydrant system the whole piping
system shall be pressure tested with water in accordance with DVGW 469 and
IP 1594.
The strength test pressure shall be 1.5 times the design pressure = 1.5 x 19 barg
= 28.5 barg and shall be held for a minimum period of 4 hours.
The Contractor shall obtain and pay for the necessary approvals by Authorities
as well as for the water for testing including disposal of water after pressure
testing.
All the low point drains shall be removed from the main line during the test to
allow for passage of spheres during water filling and subsequent drying of the
line. Hydrant pit valves shall not be installed before the line is emptied of water
and the line has been dried to the required criteria. Blind flanges with an option
to install vents shall be fixed.
The water used for the test shall be potable water quality.
In order to avoid the influence of temperature changes on the pressure test, the
line shall be temporarily covered with sand and backfilled to a depth before the
start of the test.
The criteria for the approved test procedures are according to DVGW 469
Method B2.
• Official relevant
Immediately after approval of the pressure test the water shall be emptied from
the line. Pipeline laterals are designed to be sloped back to the main line in all
cases possible.
Soft foam spheres shall be used in trains in order to remove the residual water.
The water left at low points shall be removed by demounting the blind flange
and using a suction pump.
When a foam sphere no longer absorbs water, the line is considered void of free
water.
The hydrant system shall then be dried using dry air. Installation of the pit
valves shall await the completion of the drying process.
The moisture content of the dry air shall be continuously measured in the inlet
air.
The line shall be considered dry when dew point of- 10 C atmospheric pressure
have been reached.
In case the hydrant system can not be commissioned within one month after
drying, the piping system it shall be filled with nitrogen and sealed to a pressure
of 1 barg.
After drying and before commissioning, a low-pressure test with dry, oil-free
air or nitrogen, to a pressure 0.5 barg, shall be carried out after installation of
valves and fittings, which were not included in the pressure test with water. The
duration of the test shall be a minimum of 1 hour.
Commissioning
The commissioning of the fuel hydrant system is part of the Contractors work
and shall be carried in accordance with the guidelines in API/IP 1540 Chapter
5.8 and API/IP 1585 Chapter 10.
It is assumed that the Fuel Farm and the Pump Station are fully operational
when commissioning of the fuel hydrant system shall commence.
3601.5 Documentation
General requirements for testing and documentation are described in the above
mentioned Specification SA-000-R-11130, Sections 3003.4/3003.5.
Training
The Employers maintenance personnel shall be trained with regards to function,
operation and maintenance of the fuel hydrant system.
Long radius elbows (radius = 3.0 * D) shall be used for running flexible, soft
cleaning pigs through the system. Tees shall be barred when branches are more
than 0.5 * diameter of the header pipe.
Pipes shall be delivered with a shop or mill applied external coating for
corrosion protection of polyethylene, polypropylene. For details see section
3608 Protective Coating.
Furthermore pipes shall be delivered with a shop or mill applied internal epoxy
resin lining suitable for Jet A-1 as well as water. For details see section 3608
Protective coating.
Materials
Piping materials for fuel hydrants shall be carbon steel in accordance with
ASTM 106-B Grade B or API 5L Grade B, Standard wall (STD).
Cold bends
Fabrication of cold bends is permitted assuming a suitable bending machine is
available on site and the coating of the pipes is left undamaged. Suitable and
well supporting matrices shall be used. Bending operations may only take place
when the coating over the last 12 hours has had a surface temperature not
higher than 40ºC measured on the sunlit side.
Each bending step shall have a length of 0.2 m and the maximum bending angle
per step is 0.75º. A straight length of min. 1.5 m shall be left at each end.
3602.5 Documentation
All piping materials and components shall be supplied with certificates in
accordance with BS EN 10204: 2004, clearly marked with material quality and
manufacturer's name.
3603 Valves
3603.1 Description
Valves include main block valves (full bore) with electric actuator, hand
operated valves (full bore) in the supply system, drain and vent valves in the
block valve pits, hydrant pit valves, drain and vent units.
The valves shall be of the double trunnion design and top and bottom access for
easy replacement of seals.
The valves shall be equipped with a manual body bleed valve to verify the
bubble tightness when the valve is closed. The bleed valve shall be supplied
with a "goose neck" pipe to prevent drainage of the body liquid when opened.
The valve shall also be supplied with a valve cavity check, valve to the
upstream side.
The valves shall be equipped with locking devices and with position indicators.
All block valves, used for separation of leak detection sections and indicated on
the P&I diagram, shall be supplied with electric motor actuator. The
closing/opening times for these valves shall be in the interval 35 to 40 seconds.
Other block valves shall be gear operated and suitable for future installation of
electric motor actuators.
The valves shall be supplied with a valve cavity check, valve to the upstream
side.
The valves shall be equipped with locking device and with position indicators.
The block valves shall be gear operated and suitable for future installation of
electric motor actuators.
Drain, vent and instrument valves in the block valve pits and other valves
DN100 and below
The valves shall be ball valves with flanges in accordance. with ASME/ANSI
B16.5, Class 150, raised face.
Valves shall be full bore, fire safe with body of carbon steel, stem and ball of
stainless steel.
Instrument valves
Instrument valves for pressure transmitters shall be in accordance with Drawing
No. SA-986-000-P-60528.
The under-hydrant isolating valve shall have DN150 ANSI Class 300 inlet
valves and DN100 ANSI Class 150 outlet flanges. The inlet flange is bolted to
a standard DN150 riser pipe.
Hydrant pit valves shall have DN100 API standard adaptors, dust cap and with
DN100 ANSI Class150, RF base flange to fit the under-hydrant valve. The
hydrant pit valve shall be equipped with a stone guard strainer, size 10 mesh.
The hydrant pit valve shall be equipped with a dual pilot (air operated &
lanyard). The air supply shall be governed by a dead man button. The dead man
system shall also be used should an emergency occur.
Each vent and drain unit shall include two DN40 (1½") fire safe ball valves and
a DN40 stainless steel tank unit adaptor with bleed valve and dust cap.
Each unit shall be fitted with a standard DN150 ANSI Class 300, raised face
flange for installation in a standard diameter 457mm (18") hydrant pit on top of
a DN150 pipe riser, see Drawing No. SA-986-000-P-60504.
Main block valves and hand operated valves with full bore DN300 and
above
The valves installed in concrete valve chambers shall have an insulating flange
connection on the upstream side and an insulating flange connection combined
with a spacer on the downstream side, see Drawing No. SA-986-000-P-60701.
The insulating flange connection insulated the valves from the cathodic
protected piping system.
Line spacers shall be in accordance with API 590 and Drawing No. SA-986-
000-P-60525, Insulating flange joint with spacer Class 150 and Drawing No.
SA-986-000-P-60526, Spacer for ASME flanges Class 150.
Functional, pressure and leak tests shall meet the requirements of API 598 and
the fire test the requirement of API 607.
Supplemental test of double block and bleed valves: An air seat test in
accordance with test specified in API 598 shall be made at 20 bar and 3 bar
differential pressure. The test time shall be 15 minutes for each test. The
acceptance criteria are that no leakage is observed.
The leakage test shall be performed with pressure from both sides (backseat
test).
After installation of valves, the installed valve will be pigged and tested with
water up to 1.5 times the design pressure (28.5 barg). The Contractor shall
describe the necessary procedures, to be followed in connection with the
pressure test of the complete installation.
Functional, pressure and leak tests shall meet the requirements of API 598 and
the fire test the requirement of API 607.
An air seat test in accordance with the test specified in API 598 shall be made
at 20 bar and 3 bar differential pressure. The test time shall be 15 minutes for
each test. The acceptance criteria is that no leakage is observed.
The leakage test shall be performed with pressure from both sides (backseat
test).
After installation of valves, the installed valve will be pigged and tested with
water up to 1.5 times the design pressure (28.5 barg). The Contractor shall
describe the necessary procedures, if any, to be followed in connection with the
pressure test of the complete installation.
Other valves
Other valves shall be tested in accordance with API 6D and API 598.
3603.5 Documentation
All valves
All valves shall be supplied with material certificates 3.1 according to BS EN
10204 for pressure testing retaining parts.
Test certificates for the completed valve shall be 3.1 in accordance with BS EN
10204 for valves bigger than DN25 and 2.2 for valves DN25 and below.
The certificates shall be supplied as packages for each manufacture, type and
size of valves.
Valves shall be marked on their bodies with a unique serial number. The
nameplate shall additionally bear the control authority stamp. All other
markings shall be in accordance with API 6D.
A list of recommended tools, spare parts, lubricants etc. necessary for 2 years
operation shall be supplied with the valves.
For each type and size of valve DN200 and above, a start up kit and
recommended spare parts for 2 year operation shall be supplied for each 10
valves or part thereof.
For hydrant pit valves, an extended spanner shall be supplied for each 10 valves
or part thereof.
Training
The Contractor shall include a short course on bleeding the valve cavity on
valves DN250 and replacement of the valve seals in a line filled with fuel for
the double block and bleed valves.
Sizes for both hand wheel and wrench operated shall be taken into account
during installation in block valve pits and hydrant pits.
The gears shall have a position indicator showing "open - 1/2 - closed".
The gear box shall be furnished with the manufactures mark, full type no. and
number of turns from close to open.
Electric actuators
Electric actuators shall include necessary gear devices.
Outdoor located actuators shall be suitable for operation under the climatic
conditions in Oman.
For above ground valves, the enclosure protection shall be a minimum IP 65.
For valves in block valve pits, protection it shall be a minimum IP 54.
All electrical connections shall be minimum Pg 16/M20 and placed beneath the
terminal boxes.
The motors of electric actuators shall be attached to the housing of the gears
through bolting or other means enabling easy replacement of motors.
The actuators shall have a position indicator showing "open - 1/2 - closed".
The actuator shall possess a hand wheel for valve operation at upset condition.
The hand wheel shall declutch and may not rotate when under electric
operation.
The actuator shall posses a local switch for "remote-off-local" operation. In the
"local" position it shall be able to close, open and stop the valve motion by push
buttons on the actuator.
The actuator shall have "local text display", performance monitoring and data
logging including the valve torque signature.
It shall be possible to configure the actuator and transport log files with a
handheld communicator.
The actuator shall fulfil the requirements to the Ex-zone in which it is placed.
All valve chambers and pits are classified as Zone 1.
The number of turns for operating the valve from open to closed shall normally
be less than 50 (DN150) and shall never exceed 200 (DN250).
Electric actuators
The number of turns of the hand wheel required to perform an opening or
closing operation shall not exceed 200. Closing shall be with clockwise
rotation.
The actuator shall be able to be operated with an average of 1,000 times per
year over a period of at least 10 years and a minimum of 1 operation every 3
months.
The factory test shall as a minimum include a functional test, test of the
specified open-close and close-open travel time, correct open and close
position, adjustment of the torque switches.
In the field at the cold commissioning, the same test as above shall be
performed from the control centre.
3604.5 Documentation
A certificate for a satisfactory factory test shall be issued. The certificate shall
conform to BS EN 10204, 3.1B
A software package for analysing the data from the electrical actuators shall be
supplied.
Training
The Contractor shall include a short course on configuring of the actuator and
downloading of log files as well as analysis of the files.
Construction
Bolted or threaded joints are not permitted. The design of welds joining
coupling element and pipe pup-pieces shall permit radiographic examination of
joining welds.
The bore shall not be less 96% of abutting pipe internal diameter.
Materials
Fully killed fine grain carbon steel conforming to recognized standard.
Seal and dielectric shall be inert to and resistant for blend of organic and
inorganic corrosion inhibitors, and biocide microbiological growth inhibitors
normally added to Jet A1.
The insulating coupling supplier shall obtain from the Contractor necessary
information regarding allowable inhibitors to ensure proper selection of seal
and dielectric material.
Surface treatment
The bore of the insulation coupling assemblies shall be lined with an approved
coating to be approved by the Engineer, with minimum DFT (Dry Film
Thickness) of 300 microns. This shall exhibit electrical and abrasion resistance
properties to prevent a decrease in electrical resistance across the isolation
coupling as caused by debris bridging the isolating ring.
Marking
The approved couplings shall be marked as follows:
• Manufacturer's mark
• Contract identification number
• Allowable bending moment
• Material grade of pipe pup-pieces
• Unique coupling number
• Inspection authority mark
5 All forgings shall be magnetic particle tested over the entire surface.
Hydrostatic testing
8 Each coupling shall be hydrostatic pressure tested to 1.7 times the system
design pressure as stated in the Data Sheet.
10 The pressure test is accepted with the full test pressure applied for a
minimum of 15 minutes for DN ≤ 450 mm and no leakage is detected.
Electrical test
11 The insulation couplings shall be electrically tested in a fully dried
condition.
3605.5 Documentation
Reference is made to Special Specification SA-000-R-11130.
Bolting and gaskets - other than insulating gaskets - shall be in accordance with
the recommendations of ASME/ANSI B16.5.
All bolt ends with nuts shall be protected from destructive corrosion with
corrosion inhibitor grease and protection caps.
Material
"Inch bolts" shall be used.
14 Bolts sizes M12 or ½" or larger shall be hot dip galvanized according to
BS EN ISO 1461.
Insulating flange gaskets shall be full faced with the same internal diameter as
the pipe, an external diameter as shown on Drawing SA-986-000-P-60525.
Insulating gaskets shall not be tightened with force above that recommended of
the supplier by the gaskets.
All flange connections and other loose cable connections shall be checked for
tightness.
3606.5 Documentation
All piping materials and components shall be supplied with certificates in
accordance with BS EN 10204: 2004, clearly marked with material quality and
the manufacturer's name.
The pit boxes shall be of the environmental friendly type with positive sealing
between the inner catch chamber and the outer chamber to be cast into the pit
flagstone.
The pit box shall be supplied with a lockable cover which is secured to the pit
box.
The riser pipe shall form part of the inner chamber and shall be to DN150 API
5 L Grade B standard. weight, with DN150, Class 300, raised face, weld on
flange according to ASME/ANSI 16.5 and with stud bolts.
Functional requirements
The pit boxes shall be able to absorb both lateral and vertical movements
between the flagstone and the riser pipe.
Materials
The cover shall be made of non sparking material.
Both the inner and outer surface of the pit shall be protected with a fuel
resistant coating (epoxy)
Pit boxes shall be installed such that they project 50 mm above the general
apron. The slope away from the pit shall approximately be 4.0°.
Drain and vent units located in unpaved areas shall be installed such that they
project 60 mm above the surrounding terrain to prevent ingress of water.
The inner and outer part of the pit box shall be placed to allow a distance of 35
mm between the API connection of the pit valve and the closed cover.
The vent valve shall however be installed to allow venting of air before the test
is commenced.
After the hydraulic test, the hydrant pit valves and the drain valves shall be
installed.
After filling with fuel, all valves shall be checked for tightness and correct
function by drawing fuel from the system to a tank dispenser.
3607.5 Documentation
A certificate for compliance with API/IP recommendations shall be issued.
A general assembly drawing, and spare part list, recommended spare part list,
installation, operation and repair manual shall be supplied the Contractor.
All pit boxes shall as routine maintenance, be inspected once every month for
integrity and non reported spills.
• 3-layer polyethylene (PE) coating system for normal purpose pipes with
epoxy primer, adhesive layer and polyethylene layer
• 3-layer butyl rubber tape (polyethylene film with butyl rubber on each
side) together with primer and when necessary, butyl rubber mastic,
thickness of tape 0.75 mm
or
the temperature sensitive type that converts colour when the correct
temperature is reached.
3608.5 Documentation
All the above mentioned checks shall be documented and be a part of the final
documentation.
3609 Transmitters
3609.1 Description
The type chosen shall be of a type which has both a 4 - 20mA and a protocol
outlet, HART.
The transmitter shall fulfil the requirements for Zone 1 due to possible Jet A1
vapours in the valve chambers.
Transmitters and sensors for the measuring of fuel temperature will be placed
in a concrete underground valve chamber with a temperature range 0-50 °C.
Pressure transmitter
The type chosen shall be of a type which has both a 4 - 20mA and a protocol
outlet, HART. The transmitter shall be supplied with an instrument and block
valve and bleed valve attached direct to the instrument.
The transmitter shall fulfil the requirements for zone 1 due to possible Jet A1
vapours in the valve chambers.
Pressure Transmitters
The minimum requirements to transmitters are:
• Accuracy:± 0.04 % of full scale or better
• Repeatability:± 0.04 % of full span or better
• Long term stability ± 0.05 % of full scale or better for 10 years
Pressure transmitter
Installation, fuel: Each section shall have a pressure measurement. The
pressure transmitter shall be installed at an angle of 45°
from the top of the pipe with the possibility of venting
of air.
When the pressure tapping is connected to cathodically
protected piping, the transmitter must be electrically
isolated from the tapping.
3609.5 Documentation
The calibration shall be documented with a certificate confirming to BS EN
10204 3.1.
The detector does not require to have display at the sensor but shall have a
plug-in connection for a handheld terminal and display unit to be used during
maintenance checks.
+
Measuring error shall be within − 5%.
3610.5 Documentation
The sensors shall be supplied with a factory calibration certificate for Jet A1.
Training
The Contractor shall include a short course on calibration and testing of the
sensors.
The seal design shall permit axial pipe movement due to thermal expansion or
contraction.
3611.5 Documentation
After installation, the seals shall be visually inspected by the Engineer.
3612 Geomembrane
3612.1 Description
A geomembrane shall be installed below the fuel lines as it appears from
drawing SA-986-000-P-60506 in order to protect the environment from
contamination in case of a leakage in the pipeline. .
The membrane shall at low points be drained to a concrete drainwell with F900
cover, diameter 600 mm. The drainwell shall be equipped with a level alarm.
3612.5 Documentation
The results of the inspections shall be gathered in a numbered file with clear
reference from the drawings to the documentation.
Scope of work
The LDS shall in this stage cover a total length of lines of pipes approx. 4,200
m corresponding to a total volume of approx. 185 m3.
The Contractor shall himself verify the exact length and volume from the
Drawings.
The LDS system shall be easy expandable to cover a total length of 6,000 m in
later stage.
For first stage the total FHS has tentatively been divided into 4 discrete sections
on the basis of Double Block and Bleed valves and temperature and a pressure
transmitter on the downstream side of the valves see P&ID Drawing number
SA-986-000-P-60701.
The supply shall also include equipment, necessary software and hardware
including computer, screens and printers.
Design
The LDS system shall be chosen among the systems in API Publication 4716,
Buried Pressurized Piping Systems Leak Detection Guide" preferably among
the systems based upon:
• Pressure decay - dual pressure
• Volumetric - dual pressure
• Pressure decay with temperature compensation.
Interfaces
The LDS must be capable of interfacing with the Main Contract MC-6
regarding control and monitoring, which shall be accomplished through the
SCADA system described in Sub-section 3615, Control and monitoring
General Requirements
• The offered LDS shall be able to detect a leakage of min. 0.04 l/m3 within
1 hour.
• A trained operator shall be able to operate the system having attended the
Contractor's training course
• The LDS can be hosted in the SCADA server. Alternatively the Contractor
can choose to host the LDS in a separate computer with a network
connection to the SCADA server.
3613.5 Documentation
The Contractor shall forward an example from a similar installation covering
the documentation supplied as:
• System Manual for the LDS
• Operators Manual
• Other relevant documentation
Scope of work
The cathodic protection (CP) system shall inhibit corrosion of the underground
steel components, primarily coated pipes, of the fuel hydrant system.
The CP system shall cover the fuel hydrant system installations for stage 1,
expandable to provide sufficient protection for the future extensions of the fuel
hydrant system, Stage 2.
For information only, the amount of coated steel pipe surface to be protected is
approximately:
• Stage 1: 3,500 m2
• Stage 2: 1,500 m2
The Contractor shall himself calculate the area and determine the coating
breakdown factor for Stage 1 based on the amount, type and size of pipe work
and coating actually to be installed by him.
The system shall provide cathodic corrosion protection of the entire fuel
hydrant system described in the sub-sections above. The CP-system shall be
designed for extension in parallel with the extension of the fuel hydrant system.
• Test systems
The cathodic protection system shall also include cables, connectors, splices,
corrosion protection test stations, LV power supply cabling, and any other
components, apparatus or plant and all work required for a complete operating
system to provide the specified protection.
Design basis
The cathodic protection system shall be of the impressed current type,
providing sufficient current to the pipes and structures to be protected with the
current sufficiently distributed, so that the selected criteria for CP system
operation are effectively achieved.
The installation shall meet the specified protection criteria for 25 year's service
life.
General information about the existing soil conditions in and around Salalah
International Airport is given in the report: "Geothecnical and Geological
Interpretative Report - August 2008", Document No. SA-000-G-10001.
The latest revision of the referred codes and standards published at the time of
Tender shall be used wherever applicable. In case of conflict, the Contractor
shall propose plant conforming to one group of codes and standards always
maintaining this Special Specification as the prevailing document.
Cathode: The negative electrode of the cathodic protection system, which is the
structure to be protected.
Service life: The time until safety, serviceability and acceptable appearance of
the structure or its main components falls below a defined minimum level or
requires unduly high costs for maintenance and repair.
Test station: Installation that provides measuring and test facilities for the
buried structure. Such installations will include cabling and structure
connections.
Interfaces
The CP Works have indirect interfaces with Main Contract MC 6 regarding
remote control and monitoring, which shall be accomplished through the
SCADA system described in Sub-section 3615.
General
The cathodic protection system shall be based on the impressed current
principle.
The CP system shall be centrally monitored through the fuel hydrant system
control- and monitoring system (FHSCMS) and associated SCADA system.
Remote measuring and data acquisition shall be possible through the same
system.
Protection requirements
The system shall achieve a minimum pipe-to-soil instant off potential of minus
850 mV with reference to a saturated copper-copper sulphate reference cell
above the underground metallic components of the piping.
This potential shall be obtained over 95 percent of the metallic area without the
instant off potential exceeding minus 1200 mV.
Anode system
The anode system shall consist of the anodes (impressed current type), anode
ground bed, associated power distribution cables and all hardware for
placement of the anodes. The anode system may consist of different anode
types specific for the particular structure being protected or the specific
application.
The resistance between the anode cable and the anode shall be less than
0.005 ohm.
Cathode system
The cathode system shall consist of the negative cabling from the rectifier to
the buried metal structures (fuel pipes, etc.) to be protected as well as structure
continuities.
The design of the impressed current anode system shall contain sufficient
redundancy, such that no anode is made inoperative during one random break
in the power feed. The anode assembly and its attachment shall be designed to
have a high resistance to mechanical damage.
• Road crossings.
If, in the Contractor's opinion, his range of Cu/CuSO4 reference electrodes are
not suitable for the chemical environment of the soil, Ag/AgCl or packaged
zinc type electrodes may be proposed for the Engineer's approval.
Each reference electrode shall be accompanied by its own discrete test link
connection to the metallic structure being monitored, positioned adjacent to the
reference electrode. The test stations shall be permanently wired to the
transformer-rectifiers for remote measuring and data acquisition. For long
distances between the test station and the T/R, 4-20 mA transmitters should be
used for the transmission of the potential measuring signals.
Transformer-rectifiers (T/R)
The specifications for switchboards as given in Section 4000: Electrical
installations, shall apply where relevant.
General
The transformer-rectifiers shall provide fully controllable DC output to the
anodes.
• Integrated cyclic timer for interruption for "on/off" testing. The timer shall
include a synchronization system which will enable synchronized instant
off within each section of the fuel hydrant system being protected. The
interruption facility shall be rated to safety switch 200 A DC.
Current measurement shall be by voltage drop across a 0.01 ohm shunt resistor
(0.5%). Voltage measurement shall be by precision resistor (0.5%) fitted in a
voltage divider configuration to attenuate voltages of 50 to 2 V. The
multiplying factor and attenuation factor shall be clearly marked in each case.
DC positive output to the anodes shall be taken from a common output, via a
suitably rated copper bus bar or similar, to the anode cables.
Electronic components
To protect against atmospheric corrosion, all electronic component assemblies
shall be encapsulated in epoxy resin or varnishes as recommended by the
component manufacturer and shall be approved by the Engineer.
The rectifiers shall be silicon type with suitable AC surge protection. Semi-
conductor fuses shall be used to protect the rectifiers on the AC side and metal
oxide varistors on the DC side. Rectifiers shall be rated for continuous
operation at the maximum design outputs with a peak inverse voltage of at least
800 V. Varistors shall be compatible with the rectifier peak inverse voltage
levels.
The factory-mounted anode cables shall be min. 10 mm2 stranded copper cable
insulated to minimum 600 V. The inner insulation of anode head- or deep well
anode cables shall be chlorine- and hydrogen resistant, such as Halar or
fluorocopolymer.
Cables for connecting the anodes / anode beds with the transformer-rectifier
shall be minimum 25 mm2 stranded copper wire with 600 V heavy-duty
insulation.
All anode cables shall have an outer jacket of high molecular weight
polyethylene; min. thickness 1.6 mm. PVC insulation or PVC- jackets shall not
be used.
Test wires shall be minimum 2.5 mm2 insulated stranded and screened copper
cables. Test cables longer than 100 m, notably cables from test stations to
Test stations
Test stations for insulation level measurement shall be provided for each buried
insulated joint of the pipeline system. Such test stations may be used also for
testing the pipe-to-soil potential, otherwise separate test stations for such
measurements shall be provided for each individual isolated section of the
pipeline system, or per maximum 500 m whichever is the smallest distance, and
where indicated on the Drawings.
General
T/R units, cables and monitoring and control systems shall be installed in
accordance with the requirements given for electrical installations in Special
Specification 4000.
The T/R units and cables shall be installed as indicated on the Drawings.
Anode systems
The anode systems shall be installed in accordance with the Contractor’s
method statement for installation, as shown on the Contractor's shop drawings
and as described in this Specification. The Employer's design is based on
vertical tubular type anodes with the anodes located minimum 8 m below
ground surface level.
If the Contractor's design requires more than one anode in the positions
indicated on the Drawings, or in other positions selected by the Contractor, the
distance between adjacent anodes shall be greater than 10 m.
Lead wires shall be securely connected to the anodes, preferably at the centre,
and inspected for damage. Care shall be taken to avoid all cable damage during
installation.
Multi-anode beds shall not be placed under paved areas. Single anodes or well-
mounted anodes shall, where placed under paved areas, provide future access
that will not require subsequent repair of the pavement. For example by
removable cast iron covers Class F900 or equal.
Underground anode cables shall not be directly buried, but shall run in buried
high density polyethylene (HDPE) ducts.
Cathode systems
System negative connections shall be made in accordance with the Contractor’s
method statement, as shown on the Shop Drawings and as described in this
Specification.
Each reference electrode point shall be mounted in a shallow pit with a cover,
placed vertically above the buried pipe.
For insulating joint testing one test lead from each side of the joint shall be
brought to the test station.
For potential testing, one test lead shall be brought from the pipe and one test
lead shall be brought from a reference electrode point to the test station.
Each test station and sensing electrode shall be connected to the pertinent
transformer/rectifier for automatic potential control and for conveying the
measurements to the central control and monitoring system.
General
Testing and commissioning shall be performed in a systematic manner,
comprising the relevant of the procedures described in Special Specification
3000: Electrical and Mechanical Works - General requirements.
Inspection, verification and testing shall as a minimum comprise the items and
methods specified in the relevant standards, ISO 15589-1, API 1632 or BS EN
12954.
• All power circuits and apparatus shall withstand a power frequency voltage
test at 2000 V for 1 minute between AC and earth.
• primary to secondary
• primary to earth
• DC positive to earth
• DC negative to earth
• DC output load checking on site as per the designed voltage and current
requirements; the transformer rectifiers shall perform satisfactorily at the
ranges of voltage and current up to the maximum designed values.
• Functional tests of the communication with the fuel hydrant system control
and monitoring system (FHSCMS).
Any other tests to prove compliance with the Specification, as specified in other
relevant standards and approved by the Engineer.
3614.5 Documentation
General
The Contractor shall provide documentation in accordance with the general
requirements for documentation as described in Section 3000: Electrical and
Mechanical Works - General requirements.
• Cathodic protection design with "as built" installation drawings and all
details pertaining to the cathodic protection of the structure
The Contractor may choose to host the Leak Detection System, LDS, in a
separate computer or integrate it in the SCADA system as shown on the
Drawing.
PLC system
The PLC system shall comprise the following parts:
• A PLC central unit which carries out automatic control and monitoring
functions, including valve switching in connection with leak detection.
The Process LAN shall be a VLAN within the framework of the Airport
Community Network, ACN. An RJ45 outlet for connection to the ACN will be
provided in each room where FHSCMS equipment shall be placed.
Profibus DP shall be used for control and monitoring of valve actuators. The
signal interface to other equipment shall be parallel input/output signals.
Abbreviation Description
The specific signals are listed in the signal schedule, Drawing No. SA-986-000-
P-60533.
SCADA system
The SCADA system comprises the following parts:
• A SCADA server which communicates with the PLC system. The SCADA
shall be installed in Data Centre 1.
• A Leak Detection System (LDS), an OPC server and a web server. The
Contractor may choose whether these sub-systems shall be hosted in the
SCADA server or whether they shall be hosted in separate computers
which shall be installed in Data Centre 1.
• A laser type colour printer, format A3/A4, for hard copy of reports, curves
and screen copies. The printer shall also be able to function as black/white
and colour photocopier and scanner.
The PLC system shall carry out automatic control and monitoring functions.
The SCADA system shall acquire and record operational data in an SQL
compliant historical data base, and it shall be provided with facilities for
presenting the acquired data in lists and reports for documentation of the
operation of the FHS, including Cathodic Protection and Leak Detection. The
data to be recorded include but are not limited to:
The HMI shall also monitor the state of the Emergency Shutdown System,
FHSESD, as specified in Section 3616.2.
Report generator
The SCADA system shall be provided with a report generator as described in
Document No. SA-000-O-11143.
The scope of supply shall include at least 5 (five) preconfigured reports. The
requirements to these reports will be defined by the Employer during
implementation.
Operator Panel
The Operator Panel shall be able to function as an emergency operator station if
the SCADA system should fail. It shall enable user-friendly visualisation,
monitoring and control of all the equipment connected to the PLC, including
display and monitoring of the FHSESD. It shall not function as HMI for the
LDS, but it shall display all the pressure and temperature measurements used
by the LDS.
The Operator Panel shall provide the same colour graphic interface as the
SCADA operator station for display and issuing of operator commands, with
the modifications required by the use of a touch screen instead of a mouse.
The FHSCMS shall monitor by means of "Valve open" and "Valve closed"
feedback signals that each "Open" or "Close" command is executed within a
predefined maximum time corresponding to the travel time of the valve
actuator.
Leak detection
Leak detection, as described in Section 3613, shall be performed by the Leak
Detection System (LDS). If the Contractor chooses to host the LDS in a
separate computer there shall be a network connection between the LDS
computer and the SCADA server.
The SCADA system shall issue a low priority alarm if the signal exceeds a
specified warning level and a higher priority alarm if the signal exceeds a
specified alarm level. It shall be possible for an authorised operator to change
the two alarm levels.
Note A T/R unit can be equipped with 1, 2 or 3 current outputs with a current
measurement for each output. Tentative values of the specific numbers of
current outputs for the individual T/R units are specified in the signal schedule,
Drawing No. SA-986-000-P-60533. The contractor shall verify these tentative
values and correct them as required.
The T/R unit shall be switched off and on by operator commands at the
FHSCMS SCADA system. The signal interface for this shall be as follows for
each T/R unit:
Note: Pulse length shall be defined in accordance with the requirements of the T/R
unit, 1 s is assumed as a starting point.
The FHSCMS shall record the potentials for all test stations as time series and
store the values as time series in the historical data base. The sampling interval
and the number of measurements to be stored shall be defined by the Contractor
in accordance with the requirements for the test and to the satisfaction of the
Engineer. It shall be possible to display the stored potential values as curves as
functions of time with free selection of the time interval to be displayed.
The Contractor shall establish a shielded multicore signal cable from the I/O
subsystem to a terminal block in a junction box established by the contractor
responsible for the Fuel Pumping Station. The junction box shall be placed in
the equipment room where the FHSCMS is placed.
Interface to FHSESD
Refer to the Section "Monitoring of ESD system" above.
Central equipment
The FHSCMS central equipment shall be placed in rooms which are provided
by the contractor which implements the Fuel Farm and the pumping station.
The rooms will be provided ready for use with all building installations,
including air conditioning.
In general the electrical installations shall comply with the requirements stated
in Section 4000, Electrical Installations.
The panel shall, in all other ways, comply with the requirements stated in
Section 4000, Electrical Installations.
The Contractor shall provide furniture for the HMI equipment. The furniture
shall be of good quality office standard subject to the acceptance of the
Engineer. The following furniture items shall be included:
• One (1) terminal table for the operator station. Width * Depth = ca. 1.8m *
0.9m, height adjustable.
• One (1) table or cabinet for support of the printer/copier (only if necessary
for elevation of printer/copier to normal working height for a standing
person). Dimensions to be agreed with the Engineer.
The details about the furniture shall be agreed with the Engineer.
The contractor which implements the Fuel Farm and the pumping station shall
provide the following:
• UPS power for the FHSCMS equipment in the equipment room and the
control room.
• Cable paths for the FHSCMS inside the Fuel Farm and the pumping
station. This includes cable paths for all types of cables, including power
supply cables, signal cables and data cables.
• RJ45 outlets in the equipment room and the control room, and the
associated data cabling. The VLAN connections through the ACN will be
established by Main Contract 6.
The Contractor shall liaise with the contractor which implements the Fuel Farm
and the pumping station, and with Main Contract 6, for the clarification of the
details of the above-mentioned interface. The Engineer shall supervise this
process and receive copies of all documentation.
The wiring between the I/O subsystems and the valve chambers shall be based
on the types of signal cable mentioned below.
The contractor which implements the equipment rooms will provide UPS
power for the FHSCMS equipment. However, the Contractor in charge of the
FHSCMS shall establish the wiring between the power supply points and the
FHSCMS equipment.
The contractor which implements the equipment rooms will also provide the
RJ45 outlets and the associated cabling for the Process LAN. The VLAN
connectivity through the ACN will be established by Main Contract 6.
3615.5 Documentation
Refer to the Document No. SA-000-O-11143, 4300 Control and monitoring
systems.
The FHSESD system shall comprise ESBs at the aircraft stands, a number of
geographically distributed input/output units, a central unit and a high integrity
communication network, the ESD LAN, which transmits the signals from the
ESBs to the central unit.
The ESD system receives 0 - 24 V DC signals from the ESBs. The signals from
the ESB are connected to input/output units situated in equipment rooms at
suitable locations within the Airport area. They shall be transmitted over the
ESD LAN to the central unit which issues the shutdown control signal to the
ESD of the Fuel Pumping Station.
The I/O signals of the FHSESD are listed in the signal schedule, Drawing No.
SA-986-000-P-60535.
The transmission of a shutdown signal from the ESB to the ESD of the Fuel
Pumping Station shall be executed with a certified integrity corresponding to
SIL2 according to BS EN 61508.
The shutdown signal from the FHSESD central unit to the ESD of the Fuel
Pumping Station shall be duplicated for maximum reliability. It shall comprise
two signals which are transferred in parallel:
1 One NO contact (open when power is off) which shall be opened for
activation of shutdown.
2 One NC contact (closed when power is off) which shall be closed for
activation of shutdown.
The time elapsed between the activation of an ESB and the activation of the
shutdown signal to the ESD system of the Fuel Pumping Station shall not
exceed 4 seconds.
The FHSESD shall be fail safe so that any internal fault which threatens the
integrity of the ESD function will result in the activation of a shutdown signal
to the ESD of the Fuel Pumping Station.
but do not compromise its general function shall not activate an ESD, but they
shall be communicated to the FHSCMS as described below.
Link to FHSCMS
The FHSCMS shall receive information on the state of the FHSESB through a
serial communication link. The Contractor can choose either a Modbus or a
Profibus connection for this purpose. The following information shall be
transmitted to the FHSCMS:
• Information about which ESBs have been activated (one bit per ESB). This
information shall be used for indication and for possible supplementing
automatic control actions.
• If both contacts of an ESB are open or closed, then the FHSESD shall
transmit an error bit for this ESB to the FHSCMS for diagnostic purpose.
When the suppression switch has been activated, the state of the shutdown
signals (both the NO and the NC signal) shall be communicated to the
FHSCMS.
• An ESB at a ramp tower shall be mounted on the wall of the ramp tower.
The ESB shall be mounted in positions between 1.0 m and 1.5 m above the
standing surface in front of the ESB. The location shall be selected to prevent
accidental activation. If this is unfeasible or incompatible with the requirement
of visual exposure, the pushbutton shall be shrouded.
2 Be equipped with one normally open and one normally closed contact with
positive action. At least one of the contacts shall change status on
activation of the pushbutton, even in case of contact welding.
be 4 core, min. 2.5 mm2 copper conductor, steel wire armoured cables with
heavy duty XLPE jacket.
All cables shall be installed underground, drawn into ducts under paved areas
and mechanically protected by concrete tiles or equal where directly buried.
All cables installed above ground shall run in heavy duty conduits of
galvanised or stainless steel for mechanical protection.
Availability of FHSESD
The FHSESD shall be available 99.5 % of the time on a yearly basis,
corresponding to maximum 44 hours of unavailability per year due to
maintenance, failure and repair.
The ESB system shall be considered to be available if all its parts - including
the ESBs, the input/output units, the ESD LAN and the central unit - function
correctly. Otherwise it shall considered to be unavailable.
Unavailability shall be calculated from the time when the service organisation
in charge of the FHSESD, is informed of the unavailability to the time when the
FHSESB is declared available again.
Reserve capacity
Each input/output unit shall be configured with hard- and software providing a
reserve capacity for connection of extra ESBs, either 20 % of the foreseen
number of ESBs according to Drawing No. SA-986-000-P-60535 or two ESBs,
whichever number is greater.
The enclosures for the FHSESD equipment shall be separate from the
enclosures for the FHSCMS equipment.
Testing and commissioning of the FHSESD shall comply with the requirements
in EN BS 61508, SIL2.
3616.5 Documentation
Refer to the Document No. SA-000-O-11143, 4300 Control and monitoring
systems.
Operation and maintenance of the FHSESD shall comply with the requirements
in EN BS 61508, SIL2.
Revision Log
Date Issue Description