BC5286 G 13360 001 0 System Specification

A company of Royal HaskoningDHV

ASHGABAT INTERNATIONAL AIRPORT

SYSTEM SPECIFICATION

Design & Build Fuel system

10 March 2014

For Comments

Document title Ashgabat International Airport System Specification

Document short title Design & Build Fuel system

Status For Comments Date 10 March 2014

Project name Ashgabat International Airport Project number BC5286

Author(s) L. Hodges Employer Naco

Reference BC5286-G-13360-001

George Hintzenweg 85

Postbus 8520 Rotterdam 3009 AM

The Netherlands

+31 10 443 36 66 Telephone Fax

[email protected] E-mail www.royalhaskoningdhv.com Internet

Amersfoort 56515154 CoC

HaskoningDHV Nederland B.V.

Industry, Energy & Mining

BC5286-G-13360-001 For Comments - 1 - 10 March 2014

CONTENTS Page

1 INTRODUCTION 7 1.1 General 7 1.2 Reading guide 7 1.3 Considerations, main parties 7 1.4 Risk management during design, construction and life time 8 1.5 Reference design and governing documents 8

2 PROJECT DEFINITION 9 2.1 Project location and security requirements 9 2.2 Breakdown Structures 9 2.3 Scope 9

2.3.1 Existing Fuel System. 10 2.3.2 Scope for New Fuel System 11 2.3.3 Excluded from scope 11 2.3.4 HOLD items 12

2.4 Scope limits and main interfaces 13 2.5 Fuel System realisation, construction steps 14 2.6 Tagging and traceability 14 2.7 Quality Assurance System 14

2.7.1 General 14 2.7.2 Verification and Validation 15 2.7.3 Verification of design development 15 2.7.4 Execution of Value Improvement Practices 15 2.7.5 Validation of execution phases. 16

2.8 Guarantees 21 2.9 Deviations, trouble shooting and repairs 21

3 APPLICABLE INPUT DOCUMENTS 22 3.1 Project documents 22 3.2 Standards and units 22

3.2.1 General codes 22 3.2.2 Civil Codes 22 3.2.3 Instrumentation codes 24 3.2.4 Piping codes and standards 25 3.2.5 Electrical Standards & Codes of Practice 25

4 ABBREVIATIONS 27

5 TOP REQUIREMENTS 28 5.1 Business case 28 5.2 Main goals 28 5.3 Budget and planning 28

6 FUEL SYSTEM 29 6.1 Products 29 6.2 Site and main interface conditions 29 6.3 General functional requirements Fuel System 29 6.4 Main design philosophy, limits and tolerances 29

6.4.1 General 29 6.4.2 TS-1 capacity 30

BC5286-G-13360-001 10 March 2014 - 2 - For Comments

6.4.3 Control & safeguarding 30 6.4.4 Capacities and velocities 30 6.4.5 Considerations for design development 30

6.5 Future reservations 31 6.6 General functional requirements civil 31

6.6.1 Fixation of plant grid and plot clearing 32 6.6.2 Excavation and backfill 33 6.6.3 (Sheet) piling 34 6.6.4 Concrete 34 6.6.5 Containments 35 6.6.6 Drainage and sewer system 35 6.6.7 Structural steel 36 6.6.8 Platforms and related access 37 6.6.9 Roads and walkways 37 6.6.10 Earth connections and lightning protection 37 6.6.11 Traffic signs and safety guards 38

6.7 General functional requirements piping & mechanical 38 6.7.1 Materials of construction. 38 6.7.2 Mechanical design general 38 6.7.3 Piping general 38 6.7.4 Prefabrication 39 6.7.5 Erection and Installation 40 6.7.6 Welding and Post Weld Heat Treatment 41 6.7.7 Special Piping Items 41 6.7.8 Pipe supports 41 6.7.9 Valves 42 6.7.10 Sample valves 42

6.8 General functional requirements instrumentation 42 6.8.1 Automation and instrumental safeguarding 42 6.8.2 Monitoring of fuel transfers 44 6.8.3 Protection against static electricity 44 6.8.4 Instruments 44 6.8.5 Analysers 48 6.8.6 Control valves 48 6.8.7 On-off valves 50 6.8.8 Pressure relief valves 50 6.8.9 Communications 51 6.8.10 Instrument cabling 51 6.8.11 Cable trays 53

6.9 General functional requirements electrical 54 6.9.1 Main power supply and distribution 54 6.9.2 LV distribution panels and VSD 56 6.9.3 UPS 58 6.9.4 Grounding, lightning- and cathodic- protection 58 6.9.5 Electrical tracing 59 6.9.6 Lighting, emergency lighting and socket outlets 59 6.9.7 Electrical cabling 60 6.9.8 Cable ladder / tray 61

6.10 RAM requirements 61 6.10.1 Reliability 61 6.10.2 Availability of main system 62 6.10.3 Availability of utilities 62 6.10.4 Maintainability 63


6.11 HSSE requirements 63 6.11.1 General 63 6.11.2 Prevent contamination 64 6.11.3 Classification of flammable liquids 64 6.11.4 Area classification 64 6.11.5 ATEX 65 6.11.6 HAZOP, SIL, PSSR 65 6.11.7 Noise reduction 65 6.11.8 Emission reductions 65 6.11.9 Waste stream management 65 6.11.10 Emergency provisions 66 6.11.11 Security 66

6.12 HSSE during construction 66 6.12.1 HSSE philosophy of Asghabat International Airport 66 6.12.2 General HSE requirements for construction 67

6.13 Operability 67 6.14 Constructability 67 6.15 General requirements during realization 67 6.16 Clear construction area, cleaning of Fuel System 67 6.17 Other general requirements 68

6.17.1 Welding 68 6.17.2 Coating 68 6.17.3 Insulation 69 6.17.4 Special tools 69

7 RAIL CAR (UN)LOADING STATION SBS 01+02 70 7.1 Scope of subsystem 70 7.2 Functional requirements 71

7.2.1 Process 71 7.2.2 Railway tracks 73 7.2.3 Access to site by road 73 7.2.4 Containment 73 7.2.5 Platforms and access ways 73 7.2.6 (Un)loading facilities and vapour return connections 74

8 TANK FARM SBS 03 75 8.1 Scope of subsystem 75 8.2 Functional requirements 76

8.2.1 Process 76 8.2.2 Buffer capacity 78 8.2.3 Containment and tank foundations 78 8.2.4 Tanks with conical roof 79 8.2.5 Tanks with dome heads and separators 81 8.2.6 Pumps 82 8.2.7 Access 83

9 FUEL DISTRIBUTION NETWORK INCL HYDRANTS SBS 04 84 9.1 Scope of subsystem 84 9.2 Functional requirements 84

9.2.1 Process 84 9.2.2 Design considerations/requirements 85 9.2.3 Piping under runway/taxiways 86 9.2.4 Water hammer 86


9.2.5 Underground obstructions 86 9.2.6 Excavation of trenches for pipe installation 86 9.2.7 Excavation for valve chambers and other structure installations 87 9.2.8 Valve Chambers 87 9.2.9 Drain and Vent Points 87 9.2.10 Hydrant Pit Assemblies 87 9.2.11 Hydrant Pipeline Installation 87 9.2.12 External coating of piping and appurtenances in valve pits 92 9.2.13 Installing and compacting pipe bedding material. 92 9.2.14 Design and install a cathodic protection system 92 9.2.15 Specific standards 93

10 GANTRY AND PETROL STATION SBS 05 + 06 94 10.1 Scope of subsystem 94 10.2 Functional requirements 94

10.2.1 Process 94

11 HANDLING AND STORAGE OF PACKAGED MATERIALS SBS 07 HOLD 96

12 UTILITY SUPPLY SBS 11 97

13 GAS AND FIRE ALARM SYSTEM SBS12 98

14 FIRE FIGHTING SBS 13 99 14.1 General Fire Protection Capabilities 99 14.2 Objectives of Fire Protection system 99 14.3 Fire Fighting philosophy Objectives 99

14.3.1 Fire Prevention Philosophy 99 14.3.2 Fire Detection Philosophy 100 14.3.3 Fire Protection and Response Philosophy 100

14.4 Firewater Supply 101 14.5 Foam supply 101 14.6 Cooling 101 14.7 General Alarms both Visual and Audible 101 14.8 Escape routes and Muster areas 102

14.8.1 Escape routes 102 14.8.2 Muster areas 102

14.9 General Electrical Considerations 102 14.9.1 Communications and Alarm 102

14.10 Emergency RESPONSE FROM landbased fire department 102 14.10.1 Firefighting equipment 103 14.10.2 Firefighting and Rescue 103 14.10.3 Command and Control 103

15 SECURITY PROVISIONS 104 15.1 Airport security 104 15.2 Tankfarm security 104

16 BUILDING FACILITIES HOLD 105 16.1 HVAC 105 16.2 Laboratory 105 16.3 Office buildings incl. technical classrooms 105 16.4 Warehouses 105


16.5 Sheds for automobiles 105 16.6 Repairing shops 105

17 DELIVERABLES 106 17.1 Document control (input and deliverables) 106 17.2 Applicable software 106 17.3 As Built documentation 106


18 APPENDICES 107

APPENDIX 1 - SYSTEM AND WORK BREAKDOWN STRUCTURE 108

APPENDIX 2 - FUEL FARM LAYOUT 109

APPENDIX 3 - FENCING AIR LAND SIDE 110

APPENDIX 4 - ARCHITECTURAL SYSTEMS CONFIGURATION 111

APPENDIX 5 - STANDARDS FUEL HYDRANT SYSTEM 112

APPENDIX 6 - LAYOUT FUEL HYDRANT SYSTEM 113

APPENDIX 7 - TYPICAL VALVE PITS 114

APPENDIX 8 - METHOD OF MEASUREMENT 115

APPENDIX 9 - PFD SHOWING PIPING DIAMATERS FOR BOQ 116

APPENDIX 10 - PROPOSED PIPING AND E&I ROUTES 117

APPENDIX 11 - STANDARD RAIL CAR 118

APPENDIX 12 SITE AND MAIN INTERFACE CONDITIONS 119

APPENDIX 13 DOCUMENT CONTROL LIST 120

APPENDIX 14 CONTROL & SAFEGUARDING PHILOSOPHY 121

APPENDIX 15 - BILL OF QUANTITY 122

APPENDIX 16 - EQUIPMENT LIST 123

APPENDIX 17 - HOLD LIST 124

APPENDIX 18 - HAZARDOUS AREA CLASSIFICATION (INCL. SOURCE & PRODUCT LIST) 125

APPENDIX 19 - KEY ONE LINE DIAGRAM 126

APPENDIX 20 - ELECTRICAL LOAD LIST 127

APPENDIX 21 CALCULATIONS 128

APPENDIX 22 - FUEL HYDRANT SYSTEM LINE SIZING 129

APPENDIX 23 - G124 ANNEX 8 130

APPENDIX 24 - TAGGING 131


1 INTRODUCTION

1.1 General

Arup has been engaged to undertake a review of the masterplan for the construction of a new passenger terminal and extensive development of the overall airport facility on the site of the existing Ashgabat international airport in Ashgabat, Turkmenistan. The Job is called Ashgabat International Airport, Arup Job number 21900. The Job is defined based on information provided by Polimeks. RHDHV/Naco has been engaged to develop the concept design. This enquiry concerns design and construction for the Fuel System for above mentioned Job. The government of Ashgabat is the Employer of the Airport. 1.2 Reading guide

This System Specification describes the requirements for design and construction of the Fuel System. This specification has relations with the following main contract documents:

Contract Specification (based on FIDIC yellow book) Basic Agreement (legal document)

Main outline in this System Specification:

Overall project scope is defined in chapter 2. The additional applicable documents as basis for design and construction are described in

chapter 3. Top requirements for the Fuel System are described in chapter 5, general requirements are

described in chapter 6. The requirements for the sub systems and main components are described in chapters 7

and further. The required deliverables are described in chapter 18.

1.3 Considerations, main parties

The Design and Build Contractor (DBC) is expected to design and construct the Fuel System including management of interfaces with other parties. The Principal is Ashgabat International Airport ILF. Main other parties are:

Employer of the existing Ashgabat International Airport - ILF / Polimeks / Arup Employers Consultant - Naco / RHDHV Other Design and Build Contractors

Interfaces are to be communicated with Naco / RHDHV being responsible for overall Project Management. It shall be responsibility of DBC that all aspects of engineering design, fabrication, inspection, testing, packing, operating and maintenance manuals, spare parts, commissioning and start-up assistance, correction of defects and shipping conform to the requirements of the specified codes and standards, as well as legal requirements.


DBC shall deliver all documentation about the Fuel System including documents related to the Permit request. The Interface with the Authorities will be handled by other parties. 1.4 Risk management during design, construction and life time

Risk analysis matrix shall be updated along the project. DBC shall apply risk management during all project phases and keep the riskfile up to date. The risk file shall consist of the following aspects minimum:

Risk description with cause and effect; Quantification (time, money, quality, surroundings); Control measures; Actionkeeper control measures; Status of the risk and control measure; If the risk is controlled by means of design and/or construction solutions: refer to specific

document.

1.5 Reference design and governing documents

A concept reference design is made. The functionality described in this specification is governing over the reference design. The final design shall at least fulfil the functionality described in this specification and translated in the reference design. The ranking in governing documents is:

Local standards and regulations (governing) International standards This functional specification Reference design

In case of contradiction the governing document should be followed. DBC should inform the Employer in writing about the contradictions.


2 PROJECT DEFINITION

Ashgabat International Airport in Turkmenistan has initiated a project to expand and upgrade the existing airport facilities. The total project is implemented by Architectural Project Erol Tabanca Polimeks. The consultancy and engineering services for the main part of the project is subcontracted to Naco en will be executed as project nr. 1198-102-101. Naco, as part of RHDHV, has defined work packages and spread them over various Business lines. Services for Work Package WP-1C "Fuel System" are delegated to AG Industrial Engineering Rotterdam. The services are executed as project BC5286. The expansion and upgrade should be implemented before the Asian Games in 2017. 2.1 Project location and security requirements

The project location is indicated on the overall lay-out fuel lines, drawing 123_1.19_GP_2100_HK_0001, showing the Ashgabat International Airport. Plot plan 123_1.19_GP_0802_HK_0002 shows the construction area (see appendix 2). For the fuel hydrant lines to the aprons and for the gantry near the aprons temporary construction areas are to be provided on the Airside. The orientation of the plot plan in relation to the Airport is not fixed yet. The final location may deviate 200 m as a maximum from the location shown on 123_1.19_GP_2100_HK_0001. The exact location of the fuel tank farm is to be determined by DBC. The security requirements are:

Airside; only access with specific permit from Airport Security. DBC is responsible for the security on the construction area. During and after

commissioning a specific permit is required by Airport Security. Lay down area within the construction area; no specific security requirements. Existing tank farm; only access when released for demolishing or with specific permit

from Airport Security (no part of this scope). 2.2 Breakdown Structures

The scope is defined based on a System Breakdown Structure (SBS) as indicated in appendix 1. The main system is the Fuel System SBS 00. Subsystems are numbered SBS 01 and over. General requirements for the Fuel System are described in the chapters for Top Requirements and for the Fuel System (SBS 00). Specific requirements, additional to the general requirements, are described in the chapters for the subsystems (SBS 01 and over). An additional Work Breakdown Structure (WBS) is applied for typical activities within (sub)systems. The meaning of the WBS codes is shown in the matrix of appendix 1. 2.3 Scope

The new Fuel System is a facility meant to be self-supporting, replacing the existing Fuel System described in 2.3.1. The new Fuel System is described in 2.3.2. A reference design is made. The documents of the reference design are listed in BC5286-13300-001 of appendix 13. Some activities will be executed by other parties as indicated in 2.3.3. Interfaces with the existing airport are described in paragraph 2.4.


2.3.1 Existing Fuel System.

The existing Ashgabat International Airport has already an existing Fuel System with the following facilities:

Railway tracks Loading and unloading bays for rail cars with fuel Loading and unloading bay for rail car with packaging materials Pump station for unloading of rail cars Tank farm for aviation fuels, automobile fuels and de-icing fluid Pump station for transfer of aviation fuels, automobile fuels and de-icing fluid Laboratory Warehouse Gantry (filling unit) for bowsers/refuellers Access road and roundabout for bowsers/refuellers

There are no existing fuel hydrants. The existing Fuel System at the existing Ashgabat International Airport should remain operational until the new fuel tank farm system for the new Ashgabat International Airport will be fully operational. All the main functionality of the existing Fuel System will be replaced by the new Fuel System. The construction of the new Fuel System should not be of any obstruction for the (safe) operation of the existing Fuel System.


2.3.2 Scope for New Fuel System

The scope definition in the table below is based on appendix 1. SBS Description See

paragraph 00 Fuel System general provisions 6 01 Railway track and related foundation 7 02 Rail tank cars (un)loading station 7 03 Tankfarm; all provisions related to tanks including pumps and

containments 8

04 Fuel distr. network incl. hydrants 9 05 Gantry and petrol station near tankfarm 10 06 Gantry and petrol station near aprons 10 07 Handling and storage of packaged materials 11 11 Utility supply (incl. safety showers) 12 12 Gas and fire alarm system 13 13 Firefighting system 14 14 Security provisions for Fuel System area; partly airside security 15 99 Demolishing of existing tankfarm Separate

contract The scope of the DBC shall comprise the design and procurement of materials, setting out, construction and reinstatement associated with the Work. The scope includes fixation of plant grid and plot clearing. The DBC shall provide all necessary components, accessories, materials, manpower, equipment tools, scaf fo ld ing , testing, and testing facilities & supervision, at his own expense to execute a complete and safe Fuel System. The construction scope includes receiving of materials and transportation between DBCs warehouse (for pre-fabrication), the site lay down area and the actual construction spot for the duration of the work. The documentation shall include as built. 2.3.3 Excluded from scope

The Fuel System has interfaces with other work packages as specified in 2.4. Some parts of the Fuel System will be executed by others as shown in table 2.3. SBS subject design construction 00 Office building, maintenance shop, lab and

guard houses others DBC

00 Service road at Airside adjacent to the new Fuel System

others others

01 New access road to the new Fuel System others DBC 01 Railway track and related foundation others DBC 02 Other structures/constructions at the rail car

(un)loading bays DBC DBC

07 Handling and storage of packaged materials others DBC 99 Demolishing of existing tankfarm others others Table 2.3


Items to operate the Fuel System, like rail cars, refuellers, dispensers and fork lift trucks, are excluded from the scope. 2.3.4 HOLD items

A part of the scope needs clarification and is HOLD for further specification. HOLD items are listed in appendix 17.


2.4 Scope limits and main interfaces

The Fuel System is described as Work Package WP-3C. It has interfaces with other work packages and other components. In table 2.4 the main scope limits of the Fuel System are defined. ISBL is inside battery limit; part of scope WP-3C. OSBL is outside battery limit. SBS Subject ISBL WP-3C OSBL 00 Automobile roads in Fuel

System area Access for vehicles and operators within Fuel System plot

WP-2A/B Landside roads

00 WP-1B Airside systems Containments, block valves and process sewer branches, rainwater

Header to airfield process sewer

00 WP-1B Airside systems Rainwater sewer branches

Header to airfield rainwater sewer

00 WP-1B Airside systems Control room for controls and safeguarding

Cabling for alarms to Central Control Room (CCR)

01 Rail connection Rail tracks for shunting and (un)loading

Existing single track railway

02 Connections to rail tank cars

Facilities to connect Rail tank car valves

04 + vehicles

Connections to air planes Facilities to connect Air plane valves

04 WP-1A Airside Infra Crossing of piping with existing and new runway

Runways

11 11

WP-3A/4 Buildings Polimeks buildings fuel farm area

Utility connections to buildings Outgoing feeder modules as part of LV distribution panels

Wall of the buildings Electrical installations to and inside buildings fuel farm area

11 11

WP-3 Main power feed WP-3 Connections to utilities

LV distribution panels in MEP building 6 Outgoing feeder modules as part of LV distribution panels

High voltage feed including trans-former to 400 V 400V feed to plot utilities outside tank farm

11 WP-5B Connections to utilities; instrument air

Instrument air distribution in Fuel System area

Instrument air supply

11 Potable water Distribution in Fuel System area

Header to battery limit

12 Gas and fire alarm system Detectors, alarms in Fuel System area, cabling to local control room

Cables to CCR + Alarm panel in CCR

13 WP-4F Fire Safety Fire water ring with hydrants, fire monitors, cooling and foam lines to top of tanks

Fire water system with mains connected to the Fuel System fire water rings. Fire fighting controls. Fire fighting at aprons.

Table 2.4


2.5 Fuel System realisation, construction steps

The functionality of the existing Fuel System shall remain available during expansion to the new situation. The existing Fuel System can be taken out of use after the new Fuel System is validated to be able to perform for the required capacity. 2.6 Tagging and traceability

Each component shall be provided with an unique tag number shown on a nameplate. Tagging shall be documented in one central document in accordance with Appendix 24. The DBC shall ensure full traceability of all materials including all related certificates and other documentation based on tag numbers. 2.7 Quality Assurance System

2.7.1 General

All engineering and architectural services regarding planning, design, construction and supply are subject to an ISO Quality control / assurance management system provided and maintained by DBC, mutually agreed with the Employer and controlled by the Employer. The QM-System will include as a minimum:

QM-plan including traceability and full documentation Material Control Reports Defect Reports Testing and Commissioning Reports ITP Inspection and Test Plan NCR Non Conformity Reports CAR Corrective Action Report PAR Preventive Action Report Handling Packing and Preservation Procedures Quality Procedures Test sheets and Reports

The Quality control procedures for all materials and elements to be planned, fabricated, constructed, and installed during design stage, preparation and construction stage, as well as during the test stages before hand-over and the hand-over itself will be established by DBCS according ISO Standards. The standards and procedures will be listed by DBCs in a formal report to be issued to the Employer. Quality control of all elements in the design phase as well as in the construction phase (to be designed, to be fitted and/or installed) will be controlled before installation by DBC. It is the sole responsibility of DBC to guarantee that all specialists as engineers, manufacturers, and installer are qualified and therefore meet all requirements to support all relevant responsibilities related with the specification, planning and construction of DBCs related scope of work. All activities will be performed in accordance with the procedures, prepared in-house by DBC professionals. These procedures will be submitted to the Employer and the Employers Consultant for approval before the activity start dates. These procedures will contain information about the method, work crew, necessary tools, equipment, and machinery. The control points and check points will be clarified for the representatives of the Consultant and/or Employer to be able to control and check at every phase.


2.7.2 Verification and Validation

The results of design and construction will be verified and validated (V&V) based on the specified functionality. V&V shall prove that the Fuel System is fit for purpose at all levels. The DBC is responsible for the V&V plan, for the management related to the execution of the V&V plan and for reporting about the V&V results. The draft V&V plan for verification of the design development shall be submitted to the Employer together with the for comments engineering documents. In a next issue the pre-commissioning documentation, all inspection and test details, the processing time, the applicable approval criteria and the way of reporting shall be added to the V&V plan. This plan shall be submitted to the Employer at least 10 working days before the pre-inspection meeting. In general the design and construction will be verified and validated based on the description in this specification and the reference design. This specification is governing over the reference design. Specific additional V&V requirements including a basic timing of V&V actions shall be specified in a V&V matrix. Authority acceptance criteria and all certificates related to the Work shall be listed in the plan. Inspections and tests may be witnessed by an independent party (e.g. Notified Body as Authority representative). DBC is responsible for obtaining all approvals by the independent party. 2.7.3 Verification of design development

DBC shall prove that the design meets the requirements by means of submittal of engineering documents for verification by the Employer at a certain design development stage. Main verification steps of the design development:

Engineering documents for comments Execution of Value Improvement Practices (see next paragraph) Technical design reviews Permit request packages HAZOP documentation (input, report and close-out) Engineering documents released for construction

2.7.4 Execution of Value Improvement Practices

Setting Business Priorities is a communication process that identifies the stakeholders requirements & expectations associated with a business opportunity and ultimately translates them into measurable project objectives, ranked according to their relative importance to the business strategy. It puts the stakeholders of the business opportunity in sync with the project team who can deliver the business results. Technology Selection is a systematic search both inside and outside the company for manufacturing/processing technology that may be superior to that currently employed on projects to ensure that the technology used is the most competitive available technology aligned with the Projects Business Objectives.


Constructability Review provides a systematic method that enables a project team to optimize the use of construction knowledge and experience in planning, engineering, design, procurement, fabrication and installation to achieve overall project and safety objectives. Value Engineering is a facilitated, structured workshop to identify and achieve the needed functionality of a selected work process, facilities design, or equipment design at the lowest life cycle cost Process Simplification is a facilitated, structured workshop focused on simplifying development, facility, processing, or equipment requirements while satisfying needed functionality Waste Minimization and Management is proactively addressing environmental issues and opportunities to reduce waste as an integral part of the design process. Included is a formal stream by stream waste minimization analysis during Select to develop concepts that reduce, or better yet, eliminate each waste stream source Facility Systems Performance (FSP): provides a form of computer modeling used in forecasting performance to balance sales, operation and maintenance needs at the best cost. It provides a project team a more effective means of assessing, in advance, the cost/benefit impact of changes in design, operations, spares, training and/or maintenance of a facility. Predictive Maintenance is an approach to design for maintainability whereby all maintenance techniques (breakdown, preventative, predictive, etc.) are integrated to achieve project objectives and maximize business value. Maintenance Excellence enhances business value through increasing uptime, product quality, yield, and capital productivity. Design to Capacity ("includes Capacity Alignment") is a structured methodology to challenge design allowances against business needs and eliminate "hidden capacity." It focuses on the precise alignment of units, systems, equipment and bulk within a range of capacity performance. The outcome of the Design to Capacity Value Improving Practice will provide the base case process design for your detailed design. Energy Optimisation is an analytical study (utilizing "pinch technology") in order to focus on energy options. The intent of energy optimization is to identify the optimal energy types and energy usages within a process and/or site by considering economic trade-offs and overall operability. Codes, Standards & Specifications Review is a structured review of standards and specifications to ensure that they do not exceed the actual business requirements of a particular service. Standards and specifications that cannot be value justified are eliminated. Life Cycle Engineering Information Management is the management of engineering information (including drawings, documents and data) using computer systems so that it can be of value throughout the life cycle of the asset, including the project phases, operations and maintenance and final decommissioning and demolition. 2.7.5 Validation of execution phases.

DBC shall validate each phase of execution of the Contract by means of inspections and tests. 2.7.5.1 Main execution phases are:

Engineering resulting in documents for approval. Fabrication, resulting in deliverables subject for Factory Acceptance Tests (FAT).


Construction, resulting in deliverables subject for Inspection of Mechanical Completion.

Commissioning resulting in a commissioning report. Start-up, resulting in a Site Acceptance Test (SAT). Engineering documents as built.

Each execution phase is concluded in accordance with an Acceptance Procedure. DBC is not permitted, other than at their own risk, to proceed with the next execution phase without acceptance of the prior phase. 2.7.5.2 Inspection and Test Plan (ITP)

The DBC should recommend all inspections and tests to verify that the Works fulfill the performance requirements. It may be appropriate for DBCs Proposal to include detailed arrangements, and/or to define any instrumentation required, in addition to that included in the Plant. The Tests after Completion will be carried out by the Employer and his operating personnel, with guidance from DBCs staff. The Employer will provide consumables, personnel and power. 2.7.5.3 Inspection and testing general

DBC reports the scheduled inspections and tests at least 10 working days before execution in writing to the Employer. Basically the Employer and / or his representatives will be present during inspections and tests. The scheduled time for tests and inspections shall allow the Employer to perform hold points, witness point and they like. DBC shall make available accurate calibrated measuring equipment for inspections and tests including trained employees, if required for specific measuring equipment. Calibration of the measuring equipment should have taken places 6 months in advance of the test date as a maximum. At the request DBC shall provide the corresponding calibration certificates. A manufacturing book shall be made for each piece of equipment. In advance of each inspection or test it shall be updated to be available for the Employer or his representative. A release certificate will be issued when the manufacturing book is approved by the Employer or his representative. Results of inspections and tests are valid only after Employer Acceptance. Water for testing purposes can be provided via the existing fire water system. Starting and stopping of the fire water pump takes place in consultation with the Employer. Fuel costs for the pump will be borne by the Employer. Any addition of inhibitors is only allowed after approval of the Employer. Vacuum in equipment resulting from emptying after testing shall be limited well within the design pressure. Test water can be discharged to the existing sewer after approval of the Employer. The water quality shall be within agreed limits and the water amount shall be within the agreed maximum capacity. DBC is responsible for connecting the tank to the sewer. Drying and cleaning of tested equipment is part of the mission of DBC.


The total time between start filling and release of dry and clean equipment may not exceed 250 hours. Tanks shall be calibrated after cleaning. After calibration the tanks shall be cleaned again. All flange connections temporarily blinded for the water test shall be provided with new gaskets. 2.7.5.4 Non Destructive Examination (NDE) and Inspection

DBC shall perform all required Non-Destructive Examination (NDE) as required by relevant specifications. DBC's organization shall include at least one individual who is qualified to review and interpret radiographs. Non-Destructive Examination includes, but is not limited to, radiography, magnetic particle, and liquid dye penetrant, ultra-sonic examination and hardness tests. DBC's NDE organization and procedures shall be subject to final approval by Employer. Additional radiography and other NDE examination due to rejected welds will be for DBC's account as well as the re-welding. DBC shall provide and maintain proper and retrievable filing facilities for all required records and all radiographs. At completion of work DBC shall hand over the original and a copy of the documentation to Employer. DBC shall perform all NDE radiography activities at Worksite after normal working hours in properly barricaded / segregated areas and shall coordinate such activities with Employer 24 hours in advance and meet the required safety regulations for Gamma and X-ray. DBC shall prepare and perform Positive Material Identification (PMI) or Alloy Verification (A.V.) during and after fabrication when so indicated in the specifications. This is to verify welded materials and welding consumables. This includes weld rod and/or welding filler material. DBC is fully responsible to meet local requirements for radiation safety and handling / transportation of isotopes. 2.7.5.5 Testing, Flushing and Cleaning of Piping

DBC shall prepare and where required modify the hydrostatic test diagrams defining limits of each test and submit drawings for review to Employer. DBC shall perform hydrostatic testing when a work package is installed 100%. This is to allow efficient start of painting, tracing and insulation work. The equipment tools and all material to perform these partial tests shall be provided by DBC. DBC will remove and re-install all instruments or other parts, (check valve flappers) from the system before hydro static testing. DBC shall pressure test all installed piping systems in accordance with the Specifications

and/or Employer instructions. Pressure testing includes: Update of hydrostatic test diagrams Preparation of take-off for and supply of temporary material including Temporary

supports, test valves. Preparation for pressure testing Hydro testing Service testing


Pneumatic testing Flushing (not limited to draining) Removal of temporary test valves. Connections shall be cut-off, capped, plugged or

blanked after completion of the tests as per applicable specification. DBC shall supply, fabricate and install all temporary spool pieces, bypasses, vents, drains, valves, blind flanges, caps, test spades, test blinds, gauges, gaskets (use of non-spec gaskets for testing is not allowed), saddles, spools, restraints, long bolts for temporary spades/strainers where necessary, and all and any other item/piece of equipment required for pressure testing, including subsequent removal of these items as required by testing operations. DBC shall prepare test packages in accordance with the relevant specifications, including inspection reports signed by inspectors. DBC shall submit a sample test package for approval by Employer six (6) weeks before commencement of testing. The piping shall be emptied immediately after testing and/or flushing and DBC shall remove all residual test water to a disposal point, in accordance with Employers requirement. Use of test/flushing media other than according to Employer specification is prohibited. If a corrosion inhibitor is required to be added to test flushing water Employer will advise. Employer will deliver test/flushing media. If needed, DBC shall test through the battery / boundary limit interface to the first convenient blind. If no natural battery limit interface is present, Contactor shall propose a means of blinding off for testing pipe as per approved test package and procedures. DBC shall make use of high point vents and low point drains, as indicated on the isometric. DBC shall supply Test valves which shall be located on these branches. DBC shall use his own valves for conducting the leak testing in accordance relevant specifications. DBCs valves shall be of a pressure class sufficient to withstand the testing pressure. Additional test vent and drain branch locations, not indicated on the isometrics, needs approval by Employer before installation of branch. After leak testing has been completed by the DBC and accepted by the Employer, DBC shall remove his hydro test valve and re-instate branch built-up as per isometric. DBCs shall blind-off / reinstate the branches used for testing purposes, according isometrics and assure that reconnections are leak free. Any repairs Work shall be performed by DBC at his own cost. Blind flange is not foreseen in MTO. DBC shall supply and install temporary supports during testing. Temporary supports shall be provided to accommodate the additional weight of the test fluid. The location and provision of temporary installation supports shall be the responsibility of DBC Permanent valve vent and valve drain assemblies, built-up as per isometric, may be used by DBC for testing. Any repair Work shall be performed by DBC at its own cost. Chemical cleaning by DBC is not foreseen.


Final supporting or alternative with relation to bellows shall be installed prior to hydro testing. 2.7.5.6 Inspection and testing of underground fuel lines (SBS 04)

Inspection and testing shall be executed as described above for piping. DBC shall ensure that the new underground fuel lines will be handed over to the EMPLOYER (or Representative) in a clean and dry condition and under a nitrogen pressure of 0.5 bar. DBC shall invite EMPLOYER (or Representative) to witness the pigging and drying process. After nitrogen filling all connections to the sections including the entrances of the valve chambers shall be clearly marked with yellow signs DANGER SYSTEM UNDER NITROGEN PRESSURE and DANGER-NO ENTRY- NITROGEN ASPHYXIATION HAZARD. 2.7.5.7 Factory Acceptance Tests (FAT)

FATs shall be executed by Manufacturer at Manufacturers works. Manufacturer shall provide personnel, test facilities and test procedures. The test procedures shall include: timing of activities, Manufacturer personnel attending the FAT, their responsibilities, methods by which deficiencies are detected, recorded and corrected etc. The FATs will be witnessed by Employer or his representative. DBC/Manufacturer shall furnish Employer with one copy of the inspection and test report in which the results are accurately described. If any deficiencies are discovered, Manufacturer shall remedy them as soon as possible. All system equipment shall be inspected and tested in accordance with international inspection and test practices. The FATs shall also include checks on good workmanship with respect to assembly and installation. FAT for Distributed Control System (DCS) and Safety-Instrumented System (SIS) DBC / DCS manufacturer and DBC / SIS manufacturer shall arrange FATs for the DCS and SIS respectively. The FATs shall pay special attention to the functionalities of the DCS and SIS. All I/O shall be simulated: transmitters by potentiometers; detectors by hand switches; control valves and Variable Speed Drives (VSDs) by ammeters; and solenoid valves and relays by lamps. The following inspections and tests shall be carried out:

System start-up Graphic displays Aliveness of in- and outputs Calibration of ADCs and DACs Operator interface functions Regulatory control functions Sequential control functions Safety-instrumented functions Data acquisition functions Proper working of printers System shut-down

Site Acceptance Tests (SAT) SATs shall be executed by Manufacturer on Employers site. Manufacturer shall provide personnel independent from construction personnel, test facilities and test procedures. The test procedures shall include: timing of activities, Manufacturer personnel attending the SAT, their responsibilities, methods by which deficiencies are detected, recorded and corrected etc. The SATs will be witnessed by Employer or his representative.


The inspections and tests of the SATs shall be more or less the same as those of the FATs but now on Employers site. Punch list Inspection of DBC/Manufacturers work by Employer may still reveal mistakes or short-comings. Employer will summarise these items in a punch list. DBC/Manufacturer shall do his utmost to correct or complete his work without delay in order to clear all items on this punch list. Acceptance Acceptance may be refused if the Employer or his representative decides that the works in question are not ready, not complete, not the location or not in accordance with the requirements of the Agreement. DBC shall immediately present an appropriate plan to the Employer, with the necessary improvements or renovations of to make subject work suitable for re-inspection or re-testing. If after a new inspection or test it appears that the works, or any part thereof, are not improved sufficient to meet the requirements, the Employer will require DBC to immediately replace the relevant work or part. Subject parts will be used by the Employer until their replacement, without any remuneration being paid to DBC. Replaced parts shall be validated according the same requirements as applicable for the original parts. DBC will indemnify in respect of all costs related to re-inspection, re-testing and replaced parts. 2.8 Guarantees

Performance guarantee shall be given by DBC for the capacities of the Fuel System. Mechanical guarantee shall be provided by DBC for a period of at least ten years after start-up. 2.9 Deviations, trouble shooting and repairs

Any deviation from the specified requirements shall be stated in a list for remaining points. The remaining points shall be executed in sequence of urgency within the period agreed for each point. All points shall be executed within a month after start-up, unless agreed otherwise. The scope deviation report minimally consists of:

Object or entity where the deviation is based upon; Deviations refers to the demand the deviation refers to; Cause of deviation; Proposed measures for correction including work instructions; If the deviation is permanent, a conclusion shall be written which proves that recovery

of the deviation is not possible. Date of realisation of the improvement measure provided by the signature of DBC.


3 APPLICABLE INPUT DOCUMENTS

3.1 Project documents

The applicable project related input documents and drawings are listed in Appendix 13 - Document Control List. 3.2 Standards and units

The Ashgabat authorities have indicated that the required safety distances and the required firefighting system should be based on International Codes instead of Russian SNIP Codes or Turkmenistan SNT Codes. The international recognized IP Codes (Institute of Petroleum) will be used. Metrical units shall be used. 3.2.1 General codes

The design shall be in accordance with the following general codes as if they were literally incorporated into the Agreement.

IP model code of safe practice part 2 Design, construction and operation of petroleum distribution installations

IP model code of safe practice part 19 Fire precautions at bulk storage installations IATAs Guidance Material for Aviation Turbine Fuels Specifications, 5th Edition, Part III

Cleanliness and Handling NFPA (National Fire Protection Association) 94/9/EC ATEX product directive 99/92/EC ATEX installation directive 97/23/EC Pressure equipment directive (PED)

3.2.2 Civil Codes

For codes and standards the latest published version shall apply. All civil works shall be designed in accordance with the codes and standards listed below. All structures shall be designed for a design working life of 50 years and shall be classified as design working life category 4 in accordance with EN 1990.

BS 4 Structural steel sections BS EN 124 Gully and manhole tops for vehicular and pedestrian areas. BS EN 197-1 Cement BS EN 295-1 Vitrified Clay Pipes and Fittings BS EN 752 Drain and sewer systems outside buildings BS 812 Testing aggregates BS 882 Specification for aggregates from natural sources for concrete BS EN 934 Concrete Admixtures BS 1200 Building sands from natural sources BS 1377 Methods of test for soils for civil engineering purposes BS EN ISO 1461 Hot dip galvanized coatings on fabricated iron and steel articles BS 1881 Testing Concrete BS 2499 Hot-applied joint sealant systems for concrete Pavements BS 3506 Specification for unplasticized PVC pipe for industrial uses BS 4027 Specification for sulfate-resisting Portland cement BS 4211 Specification for ladders for permanent access BS 4254 Specification for two-part polysulphide based sealants


BS 4449 Specification for carbon steel bars for the reinforcement of concrete BS 4479 Design of articles to be coated BS 4483 Steel Fabric for the Reinforcement of Concrete BS 5212 Cold applied joint sealant systems for concrete pavements BS 5328 Method of specifying concrete, including ready mixed BS 5395 Stairs, ladders and walkways BS 5950 Structural use of steelwork in building BS 6031 Code of practice for earthworks BS 6180 Barriers in and about buildings BS 8004 Code of Practice for Foundations BS 8110 Structural use of concrete BS 8666 Specification for scheduling, dimensioning, bending and cutting of steel

reinforcement for concrete BS EN ISO 9000 Series Quality management and quality assurance standards BS ISO 10931 Plastic piping systems for industrial applications BS EN 22063 Metallic and other inorganic coatings Thermal spraying - Zinc, aluminum

and their alloys The additional demands below are minimum requirements which should be used in compliance with the codes, where the stricter demands shall be applied. Concrete plinth elevations for structural elements and pipe supports shall be based on a BOB (bottom of base plate) of 200mm above high point paving (HPP). 3.2.2.1 Maximum vertical deflections (minimum requirements)

Roofs L/250 Floors L/300 Pipe support beams L/300, max 25 mm Equipment support beams L/500, max 25 mm Girders and joists under masonry walls L/500 Grating L/300

Where L = the span of the beam or twice the length of the cantilever. 3.2.2.2 Maximum horizontal deflections (minimum requirements)

Single story buildings and semi closed structures h/200 Closed (multiple storey) buildings

o complete height (h) h/500 o per storey (H) H/300

Pipe racks o complete structure h/200 o single beams 6 mm

Sensitive equipment supporting structures h/400 3.2.2.3 Environmental data

The environmental data specified in Site Data of appendix 12 shall be used as basis for the design. At the start of the Basic Design the Rainfall, Wind and Temperature maximum, minimum, variations and short bursts shall be derived from Turkmenistan national meteorological data and taken into account from 10 year records. Rainfall should be considered in such a way that roofs of buildings are calculated on water accumulation due to blockage of drain pipes.


Earthquake intensities and frequencies to be considered as per SNT standards. 3.2.3 Instrumentation codes

For instrumentation specific references are made to codes or standards. In that case the code or standard referred-to shall be considered to be an integral part of this document, but only to the extent specified. API STD520 Sizing, selection, and installation of pressure-relieving devices in refineries API STD527 Seat tightness of pressure relief valves API STD598 Valve inspection and testing API STD607 Fire test for soft-seated quarter-turn valves ASME B1.20.1 Pipe threads. General purpose (inch) ASME B16.5 Pipe flanges and flanged fittings. Steel, nickel alloy, and other special alloys ASME B40.1 Gauges. Pressure indicating dial type. Elastic element ASME B40.3 Bi-metallic thermometers ASME B46.1 Surface texture (surface roughness, waviness, and lay) ASTM A153 Standard specification for zinc coating (hot dip) on iron and steel hardware ASTM A182 Standard specification for forged or rolled alloy-steel pipe flanges, forged

fittings, and valves and parts for high-temperature service ASTM A216 Standard specification for steel castings, carbon, suitable for fusion welding,

for high-temperature service ASTM A249 Standard specification for welded austenitic steel boiler, superheater, heat

exchanger, and condenser tubes ASTM A268 Standard specification for seamless and welded ferritic and martensitic

stainless steel tubing for general service ASTM A269 Standard specification for seamless and welded austenitic stainless steel

tubing for general service ASTM A351 Standard specification for castings, austenitic, austenitic-ferritic (duplex), for

pressure-containing parts BS 2779 Specification for pipe threads for tubes and fittings where pressure-tight

joints are not made on the threads (metric dimensions) BS 6755 Testing of valves BS 6755/1-D.8 Part 1: Specification for production pressure -testing requirements. Section

D.8: Leakage classes of on/off valves BS 6755/2 Part 2: Specification for fire type testing requirements DIN 19234 Measurement and control; electrical distance sensors; DC interface for

distance sensor and signal converter DIN 43713 Measurement and control; electrical temperature sensors; wires and

stranded wires for compensating and extension wires EIA RS485 Electrical characteristics of generators and receivers for use in balanced

digital multi-point systems EN 10204 Inspection documents for the delivery of metallic products EN 50170 General-purpose field communication system EN 61219 Earthing FCI 70-2 Quality control standard for control valve seat leakage IEC 60079 Explosive atmospheres IEC 60079-1 Part 1: Equipment protection by flame-proof enclosures d IEC 60079-7 Part 7: Equipment protection by increased safety e IEC 60079-11 Part 11: Equipment protection by intrinsic safety i IEC 60079-15 Part 15: Equipment protection by type of protection n IEC 60079-18 Part 18: Equipment protection by encapsulation m


IEC 60364 Electrical installation of buildings IEC 60529 Degree of protection provided by enclosures (IP code) IEC 60534 Industrial-process control valves IEC 60584 Thermocouples IEC 60751 Industrial platinum resistance thermometer sensors IEC 61000 Electromagnetic compatibility (EMC) IEC 61131-3 Programmable controllers. Part 3: Programming languages IEC 61508 Functional safety of electrical / electronic / programmable electronic safety-

related systems IEC 61511 Functional safety. Safety-instrumented systems for the process industry

sector IEC 61518 Mating dimensions between differential pressure (type) measuring

instruments and flanged-on shut-off devices up to 413 bar IEC 61882 Hazard and operability studies. Application guide IEEE 802 Information processing systems. Local area network ISA S88 Batch control systems ISO 724 ISO general-purpose metric screw threads. Basic dimensions ISO 9001 Quality management systems. Requirements ISO 15848-1 Industrial valves. Measurement, test and qualification procedures for fugitive

emissions. Part 1: Classification system and qualification procedures for type testing of valves

ISO 80000 Quantities and units NAMUR NE43 Standardization of the signal level for the breakdown in information of digital

transmitters VDI 2440 Reducing emissions for mineral oil refineries [TA Luft] VDI/VDE 3513 Variable area flow meters VDMA 24422 Valves; guidelines for noise calculation; control and on/off valves 3.2.4 Piping codes and standards

The system shall comply with following codes, standards and guidelines: Local laws, regulations and permits IATA (International Air Transport Association) JIG (Joint Inspection Group) IP (Institute of Petroleum) API 1540 (American Petroleum Institute) and others ANSI (minimum rating 150 psi) ASTM Good Engineering Standards and Practices are to be applied. Only proven equipment and materials shall be used.

3.2.5 Electrical Standards & Codes of Practice

The design of electrical systems and related components shall fully comply with the current editions of the following standards, as a minimum. Local of national codes shall be followed if they are more stringent than those listed below.

IEC 60364: Electrical installation of buildings IEC 60269: Low voltage fuses IEC 60050: International electro technical vocabulary IEC 60255: Relays IEC 60947: Low voltage switchgear and control IEC 60185: Current transformer IEC 60529: Degrees of protection provide by enclosures (IP code)


IEC 60934: Circuit breaker for equipment IEC 60050(441): Switchgear control gear and fuses IEC 60092-353: Single and multi-core cables with exuded solid insulation for rated

voltages 0.6/1kV IEC 60288: Conductors of insulated cables IEC 60278: Calculation of the continuous current rating of cables IEC 60540: Test methods for insulation and sheaths of electric cables and cords IEC 60811: Common test method for insulating and sheathing materials of electric

cable IEC 60079: Electrical apparatus for explosive gas atmospheres IEC 60598: Lightning protection EN 12464-1 & -2: Lighting of work places EN 1838: Lighting applications Emergency lighting BS 5489: Code of Practice for Street Lighting


4 ABBREVIATIONS

Abbreviations used in this specification are explained in the table below. Abbr Meaning BOQ Bill of quantity DB Design Basis ADC Analog-digital converter AOC Airport Operations Centre CCR Central Control Room (at airside) DAC Digital-analog converter DCS Distributed Control System DBC Design and Build DBC FAT Factory Acceptance Test HSSE Health Safety Security and Environment MCC Motor Control Center MEP Main Electrical Power MIVR Manufacturing Inspection Verification Report MOM Method of measurement POL Petroleum, oil, lubricants RAM Reliability, availability, maintainability VSC Variable speed control DCS Distributed control system ESD Emergency shut-down F&G Fire and gas I/O Input(s)/output(s) IR Infra-red IS Intrinsically safe ITP Inspection and Test Plan LED Light-emitting diode LP Local panel OS Operator station PD Positive displacement SAT Site Acceptance Test SBS System Breakdown System SIF Safety-instrumented function SIS Safety-instrumented system SOE Sequence-of-event SPS Standard Pipe Supports UPS Uninterruptible power supply UV Ultra-violet V&V Verification and Validation (review of design, inspection and testing) VSD Variable speed drive WBS Work Breakdown System Table 4.1


5 TOP REQUIREMENTS

5.1 Business case

The new Fuel System shall expand the fuelling capacity to the capacities specified in par 4.5.10 of G124 Annex 8 OS Ashgabat rev 15, see appendix 23. 5.2 Main goals

The top requirements for the Fuel System are: Top 1) Reliable and safe supply of fuel to the airplanes Top 2) Expand the fuelling capacity Top 3) Minimal refuelling time for airplanes Top 4) Flow and storage monitoring including verification monitoring Top 5) Maximal automation Top 6) Provisions to make the Fuel System self-supporting (lab analysis, storage of

packaged POL, filling station, parking and repair provisions for automobiles, offices including training rooms)

Top 7) Tailored security provisions 5.3 Budget and planning

The budget of the execution of this Work Package Fuel System is controlled by RHDHV/Naco being a part of the budget for the total scope for the upgrade of the Ashgabat International Airport. The planning is HOLD based on the following main milestones:

Design Construction of runway crossing Construction fuel (un)loading, storage and distribution Construction of all other subsystems


6 FUEL SYSTEM

6.1 Products

The products are listed in document 123_1.19_GE_LST_002 see appendix 18. 6.2 Site and main interface conditions

The design shall be tuned to the site and main interface conditions specified in appendix 12. 6.3 General functional requirements Fuel System

The Fuel System shall be designed to provide facilities to receive, buffer and distribute Fuel products. Additional facilities like vehicle filling stations shall be provided to become self-supporting. Buildings are also contributing to self-supporting facilities; however buildings are no part of the scope. 6.4 Main design philosophy, limits and tolerances

6.4.1 General

Development of the design shall be in line with this specification, the reference design documents listed in document control list appendix 13 and the standards listed in 3.2. Special attention is required for the general codes of 3.2.1. Site conditions are specified in appendix 12. All components shall be designed for seismic loads. The Fuel System shall be designed to for extreme temperature changes and sand storms. Sufficient covers against sand ingress and provisions for easy removal of sand shall be incorporated in the design. The installation must comply with all requirements of this Specification and all requirements related with good craftsmanship. DBC is responsible for a good working system within the framework of the Work. The DBC shall check and verify the dimensions shown in the project drawings and the quantities of materials listed on the Bill of Quantities (largely information only) and shall be responsible for supply all materials including allowances and contingency for the complete and safe execution of the works. DBC shall provide detailed shop drawings and design calculations. Shop drawings shall fully coordinated with other disciplines drawings, showing all dimensions, reinforcement, openings included sizes, section, wherever they are required, fabrication & erection detail of all types of structural steel & concrete element, wherever applicable, etc. The drawings shall be submitted to EMPLOYER for approval prior to commencement of construction. The constructions and the materials, even if they are not specified in more detail, must be consistent with all common operating conditions. They must be resistant to the product and environmental conditions with which these materials can come in touch. DBC is mandatory to be aware of these circumstances and conditions and to implement the consequences in the design. Special attention is required for the RAM and HSSE requirements described in 6.10 and 6.11.


6.4.2 TS-1 capacity

The TS-1 capacity to hydrants is defined in par 4.5.10 of G124 Annex 8 OS Ashgabat rev 15, see appendix 23. Based on this information a capacity calculation is made as described in par 6.4.4. 6.4.3 Control & safeguarding

Design conditions shall be safeguarded. Main layers of protection are defined in the Control & Safeguarding philosophy Appendix 14. The Fuel System shall be suitably designed and provided with necessary instrumentation for rapid starting and finishing of fuel transfers without causing undue vibration, distortion or producing excessive thermal stresses. The design of the control system and relevant equipment shall adhere to the fail safe operation at all system conditions. The fail safe operation signifies that loss of signal/air/power supply or failure of any component should not cause hazardous conditions. Occurrence of false trips should be prevented. 6.4.4 Capacities and velocities

The minimal required capacities of equipment are specified in the equipment list of appendix 16. Vessel capacities shall be met at 95% filling volume. Velocities shall be kept between acceptable limits.

The velocity of fuel flows shall be limited to 1 m/s during transfer start until the inlet of the receiving tank or vessel is covered with liquid.

During normal operations the velocity should be at least 0,9 m/s to limit sedimentation. In order to limit pressure drop the velocity should be limited to about 3 m/s. Fuel velocities shall not exceed 7 m/s at any point to limit static charging of the liquid.

Velocities can be kept within acceptable limits for a great variation of total flow by applying parallel systems. An example is given in table 6.4A. Min capacity m3/h

Max capacity m3/h

Parallel systems

Min velocity m/s Max velocity m/s

100 250 1 1,2 2,8 200 500 2 1,2 2,8 400 750 3 1,6 2,8 600 1000 4 1,8 2,8 800 1250 5 1,9 2,8 1000 1500 6 2,0 2,8 Table 6.4A velocities in parallel systems The above is applicable for the lines from TS-1 storage to hydrant system headers. Parts being applied at low velocities shall be designed for periodical flushing by circulating around with sufficient velocity. 6.4.5 Considerations for design development

Considerations for design development are to be tuned between DBC and Principal. Recommendations are listed in table 6.4B.


SBS Recommendation priority 1 TS-1 collection header and slops collection header

under foot path between railways instead of under containment

High; prevent or minimize piping under containment

3 Separate manifold for recirculation flow over the TS-1 storage tanks to keep the recirculation flow of approved TS-1 quality separated from the TS-1 received from the rail cars.

High; quality item

3 Space reservation for future vapour treatment unit Medium 3 Funnels via headers connected on slope to slops tanks

for all sample locations. Low

3 The optional connections for anti-static additives shown on PFD 123_1.19_TX_0801_HK_003 are for future provisions. TS-1 will be supplied including anti-static additives.

Low

11 Consider instrument air generation + network. That allows the application of Air Operated Valves (spring close) instead of Motor Operated Valves with UPS for closing in case of power failure. In addition the pumps for the API separators can be executed as cheap air driven pumps.

Medium; consideration for cost reduction

Table 6.4B recommendations for design development 6.5 Future reservations

Space reservations for future tanks and large vessels are no part of the scope. Space reservations and future connections for additional pumps shall be provided. Space reservations shall be made for future vapour return systems for TS-1 and aviation petrol. 6.6 General functional requirements civil

Carry out all site preparation and temporary fencing and provide all temporary site facilities. Construct 2 Nos. 18 hydrant headers from Fuel tank farm to main valve chamber pit.

Construction shall include excavation of trenches to specified depth, laying fuel pipes, sand cushioning, line protection as specified in the appropriate standards, backfilling and compacting to final levels.

Construct 5 valve chamber pits at locations specified in the drawings in Appendix 6 - Layout Fuel hydrant system. Valve Chamber Pits shall include cover slab, pipe supports, ladder access, access platforms, sump and pit covers etc.

Construct fuel lines between valve chambers to all lines and levels as per drawings. Construction shall include excavating all trenches, installing bed, surround and protection and backfill after installation of all hydrant piping.

Install all Hydrant Pits in accordance with the manufacturers instructions and the project documents and drawings. Construction shall include excavation, concreting and backfilling with approved earth/gravel to all specified lines and levels.

Construct reinforced and mass concrete pipe supports as required. Construct Cable Draw Pits including supply and installation of pit covers as shown on

the drawings. Supply and installation of concrete encased duct banks for all road crossings. Excavate trenches for, install bed, surround and protection and backfill after installation

of electrical/instrument cable ducting. Should any underground services be encountered during excavation then DBC shall liaise with the Employer in order to


determine whether they are to be diverted, or agree how they are to be crossed. Any rerouting and/or protection of existing facility is deemed to be covered in DBCs scope.

Construct Cathodic Protection Test Stations and Test Points as shown on the drawings.

Elevation and details stated in specifications, drawings etc are indicative. DBC shall redesign the civil details including the covers, support beams, suitable for the heavy load and accordingly proceed with the construction after the approval of Employer. Bar bending schedule is indicative and shall be redeveloped by DBC as per the design details. All the access manhole covers for ladders and vent/drain covers shall be suitable for heavy vehicular traffic and shall be to be removed by manual means without any assistance of lifting equipment/machine. Proper tools shall be provided for same.

Inside Tank farm: Construct 2 Nos. above ground storage tank-pits including, excavation & backfilling,

membranes, construction of tank foundations and pump foundations, concreting of raft slabs, construction of precast or cast-in-situ reinforced concrete bundwalls, earthing provisions and drainage as per drawings.

Construct 1 No. underground tank pit including, excavation & backfilling, membranes, construction of tank foundations and pump foundations, provision of concreting of raft slab, construction of cast-in-situ reinforced concrete walls, floors, covers and doors, earthing provisions and drainage as per drawings.

Construction of reinforced concrete containment facility for rail car unloading and loading as per drawings and loading unloading gantries thereupon.

Construction of 2 Nos gantry and 1 No. test rig as per drawings Construction of a petrol pump with facility for two filling stations Construction of 1 No. firefighting facility Construction of parking lots for refuellers and vehicles. Security Fencing, guardhouse and gates

All items mentioned in scope of civil work should be executed to the general functional specifications mentioned below, and specific functional specifications mentioned under each sub system. 6.6.1 Fixation of plant grid and plot clearing

The DBC shall fix the plant coordinates by means of a clear physical plant grid reference point in the field. All existing structures on the plot where the new Fuel System is projected shall be removed including subsequent removal of all materials and debris from the site to a location where it is allowed to dump the materials. A soil survey shall be executed in advance if the soil may be contaminated. The DBC shall obtain a written approval for dumping of materials in advance. The demolition of any building, memorial or other structure shall not proceed until a demolition permit has been issued by the local authorities. The demolition of the designated buildings and/or other structures and the removal of all material and debris shall be executed in a workmanlike manner. In case any portion of a place of religious significance is to be demolished, the work shall be accomplished only in the presence and as per the guidance of local authorities. Prior to the commencement of operations, DBC shall make all necessary arrangements with the proper authorities for the turning off and the disconnection of all utilities such as electricity,


gas, telephone, sewer, water, and other facilities encountered, unless directed specifically to retain them, in which case DBC will make every effort to preserve and protect them from harm during the demolition operations. Under no circumstances shall any structure be set afire. Burning of debris or other matter shall not be permitted. Masonry walls shall be demolished in small sections. Structural steel, cast iron and heavy timber framing members shall be removed individually and carefully lowered. Cellars and all other subsurface spaces shall be carefully backfilled and leveled to the adjacent ground elevation, or as may be directed. After demolition, all areas within the demolition project area disturbed by the demolition work shall be graded to eliminate any low areas, which could obstruct other DBCs or where water could accumulate, and to provide for proper drainage of the area. 6.6.2 Excavation and backfill

The work covered by this section shall consist of furnishing all materials, equipment and labor for the excavating, trenching, backfilling, boring (if needed), including the shoring of open cut walls. Unless otherwise specified, all excavation in this item is intended to mean open-cut excavation. Excavation should include clearing the site of the proposed work and removal of all materials to a depth which is sufficient to permit the construction of the structure, cable or pipe in accordance with the plans. Excavated materials may be temporarily stored along the trench in a manner that will not cause damage to other properties and will not endanger the walls of the trench due to overloading. Too deep excavation is to be avoided. If it occurs, it should be recovered to the correct height with blinding concrete of specified grade. The width of the trench shall be ample to permit the item (foundation, wall, pipes or cables) to be laid, joined properly and the backfill to be placed and compacted as specified. In order to limit excessive loads on the pipe, the maximum width of trench shall not be more than 1.2 m greater than the nominal outside diameter of the pipe. If trenches of extra width or depth greater than 1.8 m are required, the width of the trench shall be such as to permit the safe placing of timber supports, sheeting, shoring and bracing of the earth. An approved pipe laying trench box may be used in lieu of sheeting where safety of the workmen and/or protection of the work is the sole consideration. DBC shall provide and maintain adequate pumping and draining facilities for removal and disposal of water from trenches or other excavations, at no extra cost. The drainage system must be maintained until the pipe has been covered with sufficient backfill material to prevent floating of the installed pipe sections. Where ground water is encountered, the water table shall be lowered so that all necessary work may be carried on in the dry. The water shall be kept down until the unit or section under construction is completed. No water shall be allowed to flow through or over unset concrete or through the completed line. At the expense of DBC, all existing structures, improvements and utilities shall be adequately protected from damage that may occur due to construction operations. Where construction comes in close proximity to existing structures or utilities, or if it becomes necessary to move services, poles, guy wires, pipelines or other obstructions, DBC shall notify and cooperate with the utility or structure Employer. After testing of the pipe or cable laid in the trench, select backfill shall be placed and compacted around the pipes or cables to a depth of 150 mm above top of the pipe. Select


backfill shall be of granular material such as sand or sandy gravel, and shall have a Plasticity index of not more than ten. Select backfill shall contain no rock larger than 5 cm in its greatest dimension. Not more than 50% of the material shall be rock. Not more than 25% shall be clay or clay lumps. Select backfill shall be compacted to not less than 95% of Modified Proctor Density in layers of not over 10cm in thickness each. A layer of well baked bricks confirming to specifications shall be laid as a warning layer, and thereafter 150 mm of the original soil shall be backfilled. For the purpose of early warning and identification of buried pipes outside of building walls during future trenching or other excavation, continuous identification tapes shall be placed along the full length of the section and the remaining soil backfilled into the trench in compacted layers of 300mm each. 6.6.3 (Sheet) piling

Steel Sheet Piling shall be domestic steel or equivalent, conforming to the requirements of ASTM A-328 or approved equal. Before installation, the sheet piles shall be dry grit-blasted and given a protective coating of 1 coat of primer and 1 coat of coal tar epoxy. Currently, there are no sheet piles foreseen. Before driving the piles, DBC shall ascertain the location of any utilities or drain lines that pass through the area in which the sheet piling is to be driven, and shall protect same during installation of sheet piling. Piles for foundation support shall be carefully located in accordance with approved Shop Drawings and driven in a plumb position, each pile interlocked with adjoining piles for its entire length. Piles shall be driven by approved methods in such a manner as not to subject the piles to serious injury and to insure proper interlocking throughout the length of the piles. Pile hammers shall be of approved sizes and types and shall be maintained in proper alignment during driving operations by use of suitable leads or by guides attached to the hammer. A protecting cap of approved design shall be employed in driving, when required, to prevent damage to the tops of piles. Vibratory drivers/Extractors are also acceptable. All piles shall be driven without the aid of a water jet, unless otherwise authorized. Piles driven out of interlock with adjacent piles or otherwise injured shall be removed and replaced by new piles at DBC's expense. DBC shall trim the tops of piles exclusively battered during driving, when directed to do so, at no extra cost. Cut-offs shall become the property of DBC and shall be removed from the site. DBC shall cut holes in the piles for bolts, rods, drains, or utilities at locations and of sizes as directed. 6.6.4 Concrete

Based on the drawings DBC shall design complete concrete structures for the buildings from the scope with, but not limited to, reinforcement, earthing provisions, cast in anchors and items. Design requirements

The concrete quality shall be according to the minimum requirements in EN 206-1. The concrete quality shall be submitted to the Employer for approval.

The exposure class shall be according to the minimum requirements in EN 206-1. The exposure shall be submitted to the Employer for approval.

The reinforcement quality shall be B500B. All anchors shall be grade 4.6, 8.8 or 10.9. The quality of carbon steel cast in items such as plates, curb angels, strips shall be

according to EN 10025 hot rolled products of structural steels.


The concrete cover shall be 50 mm. Blinding layers shall be unreinforced constructions. A blinding layer shall be of such

quality that it is capable of bearing the loads from reinforcement, anchors, construction and formwork. The minimum thickness of blinding layers is 50 mm

The concrete should be designed for seismic loads. All visible concrete edge shall be chamfered 25 x 25 mm.

6.6.5 Containments

Containments shall be on slope to a pit. Each containment shall drain via a valve to an API sewer as indicated in the Process Flow Diagrams (see document list of appendix 13) to prevent product spills to enter the storm sewer. 6.6.6 Drainage and sewer system

Surface drainage includes all surface water discharge from clean plant areas attributable to rainwater, firewater (except from bunds) and overflow water from water tank to drain via open surface water drains, trenches and natural water courses to ultimate discharge point avoiding accidental oily contaminated water system. Drain section shall be rectangular type Material of construction shall be brick drains with 20thk. Cement mortar plaster (1:4) and neat cement punning shall be provided. Hot dipped Galvanised electro forged steel grating covers, or pre-cast RCC (M20) covers of designed thickness, hand railing, chain link fencing wherever necessary shall be provided to minimise the risk of falls by personnel. Oil water separator shall be provided with trenches, sumps, valves and pipes including connecting to nearest OWS network for disposing the collected oil to OWS. The separated oil to be transferred to the slop tank and the remaining water to the nearest storm water drain outlet. Design rainfall specified in Site Data (appendix 12) shall be considered for design of storm water drainage system. Generally, the slope of the paving shall be 1:100 but the maximum drop in paving shall be limited to 150 mm. Two way slopes in paving shall be avoided as far as possible.

Slope of main drain along shall be 1:1000. Slope of secondary drain shall be 1:750. Slope of tertiary drains along north-south shall be 1:500.

6.6.6.1 Storm Water Drainage

Storm water drains shall be sized for the higher discharge arising out of either rain water or firefighting water and shall be connected to existing drain of adequate capacity. Rain water run-off shall be computed by the formula:- Q= (KIA)/360 where, K= Surface run off coefficient A= Catchments Area in hectares contributing towards the drain I= Design Rainfall intensity in mm per hour Q= Discharge Runoff Coefficient shall be considered as follows;

Concrete Paved area = 1.0 Bituminous Paved area = 0.9 Compacted but Unpaved areas = 0.7 Unusable/Green Belt area = 0.4


Design of drains shall be based on Mannings formula. Roughness Coefficient shall be considered as follows;

Plastered surfaces = 0.013 Cast in situ concrete = 0.015 Concrete/Brick Lining = 0.017

The following points are to be followed while sizing the storm water drains

Minimum velocity in drains = 0.6 m/s Maximum (Scouring) velocity in drains = 2.4 m/s Preferred (Self cleansing) velocity in drains = 1.0 m/s Minimum depth of drains = 300 mm Minimum width of rectangular drains = 300 mm (for depths 500 mm) Minimum width of rectangular drains = 500 mm (for depths 500 mm)

Contaminated rain water/Oily water drainage is routed underground to OWS tanks as appropriate. Sewage to be passed to septic tank and then routed through soak pit & sewage treatment plant. Concrete pavement run-off surfaces shall slope at 1:100 to perimeter channels. Systems shall be sized to cope with worst of storm water run-off or fire water run-off. 6.6.6.2 Oily Water Sump system (OWS):

Oily water sewers carry water contaminated with oil, e.g. from tank dykes, pump, floor and paving drains in oily areas etc. These are conveyed to oil separators by means of pipes through trenches/pipes. RCC oily water sumps shall be provided as per requirement. All of these shall be connected through pipes to convey the contaminated water to OWS. 6.6.7 Structural steel

The DBC shall design complete steel structures including main pipe supports and lifting beams where required. DBC shall design and provide steel structure for supporting the piping at road crossings. The loads of the future pipes and pipe-racks shall be taken into account. The steel columns of the road crossing shall be protected against vehicular impact by means of safety barriers. The structural steel should be designed for seismic loads. DBC shall execute the following deliverables/activities, but not limited by:

strength and stability calculations general arrangement drawings work shop drawings design and calculation of connections

Design requirements

European structural profiles HE, IPE, UNP and angles (or equivalent) are applicable. All steel structure members not in direct contact with soil and/or groundwater will be

designed for a corrosion loss of 1mm over the 50 years design life. Steel quality S235 JR


All bolts and other fasteners should be grade 8.8 with rolled thread, nuts shall be grade 8.

Connections

Moment connections shall be designed as "stiff" connections. All strength welds shall be continuous fillet welds. For fillet welds, the minimum weld

size "a" shall be 6 mm, or thickness of material when less than 6 mm, where "a" is the dimension of the throat.

Field welding shall be kept to the utmost minimum and shall be subject to Employers approval.

Bolted connection shall have a minimum of two bolts M16-8.8. DBC shall design, supply and construct earthing bosses on the steel structures when

applicable. All holes in grating and sides of floors shall be foreseen with a kicker-plate 130 x 6 mm.

6.6.8 Platforms and related access

Bund crossings, pipe trace crossings, platforms, stairs, walkways shall at least conform to the following demands:

The width of platforms, stairs and walkways shall be 800 mm as a minimum. All platforms and stairs shall be provided with anti-slip grating and railings. Hand railing, ladders and cage ladders shall be as per national standards Grid type floor grating shall be used and shall be in accordance with the standards.

The grating shall be pressure welded and hot dip galvanized. Stair treads and fasteners shall be hot-dip galvanized.

Each grating panel shall be fixed with a minimum of 4 clamps (hot dip galvanized). All stair treads shall be of open-grating type. Top exits of cage ladders shall be provided with a safety bar which closes due to

gravity. The other requirements are identical to 6.6.7. 6.6.9 Roads and walkways

Adjacent to the new main railway track will be a new access road to the new fuel tank farm system of the new Ashgabat International Airport. The new access road should be suitable for automobiles, tankers and trucks and should be suitable for both driving directions. Entrance/exit gates will be required for the new main railway track and for the new access road. Gates are described in chapter 15. A parking lot/turning area for unauthorized automobiles and trucks will be required east from the gates at the public area. Plant roads are indicated in 123_1.19_GP_0802_HK_0002 proposed plot plan. 6.6.10 Earth connections and lightning protection

DBC shall provide a completely embedded earthing system for the concrete foundations. A mild steel earthing net (FeB 220, 16 mm) shall be provided in concrete foundation.

This earthing mesh shall be welded at cross points to the reinforcement. The earthing net shall also be welded to the two earthing bars of the foundation piles. Two mild earthing bars (FeB 220, 16 mm) shall be applied over the full length of the piles.


The earthing net shall be a closed circuit with lengths as large as possible. The layout of the earthing net shall be in such a way that there is enough redundancy. Redundancy means for example that earth plates shall be connected to two earthing piles.

Connections of earthing bars shall be welded over a minimum length of 100 mm over the full height of the bars.

Earth-plates brand "Cadweld B-164-12-K" or equal shall be installed and welded to the earth grid.

Before pouring of the concrete a resistance test shall be performed on the earthing system. The maximum resistance may not be larger than 0,1 ohm. The test results shall be register in a report and submitted to the Employer. The resistance test and making of the report are part of the scope of DBC.

The earthing system shall be designed with enough earthing piles with a minimum of two piles.

6.6.11 Traffic signs and safety guards

The rail road crossings within the Fuel System area need to be provided with signs without alarm. Safety guards shall protect steel structures, piping and other vulnerable components. 6.7 General functional requirements piping & mechanical

6.7.1 Materials of construction.

The application of materials shall be in accordance with the equipment list and the Bill Of Materials. The allowable materials shall prevent product contamination. Flange insulation sets shall be applied to prevent galvanic contact between different materials. For details see appendix 5 cathodic protection par. 2.6. The DBC is responsible for the final material selection and the specification of incompatible materials. These are to be defined in the detail engineering phase and shall be subject for approval by the Employer. 6.7.2 Mechanical design general

Specific requirements about mechanical components, like tanks and pumps, are described in the chapters of the sub-systems. 6.7.3 Piping general

Pipe specifications are added as appendix 5. More pipe specifications are expected to be provided by the Employer. DBC shall note that within the pipe class specifications references can be made to other related specifications. These related specifications are also part of this contract. Welding shall be in accordance with 6.17.

BC5286 G 13360 001 0 System Specification

Documents

general codes

piping general

mechanical design general

fuel system realisation

existing fuel system

new fuel system

sewer system

reference design