BC5286 G 13360 001 0 System Specification

ASHGABAT INTERNATIONAL AIRPORT
SYSTEM SPECIFICATION
Design & Build
Fuel system
10 March 2014
For Comments
A company of Royal HaskoningDHV
HaskoningDHV Nederland B.V.

Industry, Energy & Mining
George Hintzenweg 85
Postbus 8520
Rotterdam 3009 AM
The Netherlands
+31 10 443 36 66
Telephone
Fax
info@rotterdam.royalhaskoning.com
www.royalhaskoningdhv.com
Amersfoort 56515154
Document title
Ashgabat International Airport

System Specification
Document short title
Design & Build

Fuel system
Status
For Comments
Date
10 March 2014
Project name
Project number
Ashgabat International Airport

BC5286
Author(s)
L. Hodges
Employer
Naco
Reference
BC5286-G-13360-001
E-mail
Internet
CoC
CONTENTS
Page
1
INTRODUCTION
1.1
General
1.2
Reading guide
1.3
Considerations, main parties
1.4
Risk management during design, construction and life time
1.5
Reference design and governing documents
7
7
7
7
8
8
PROJECT DEFINITION
2.1
Project location and security requirements
2.2
Breakdown Structures
2.3
Scope
2.3.1
Existing Fuel System.
2.3.2
Scope for New Fuel System
2.3.3
Excluded from scope
2.3.4
HOLD items
2.4
Scope limits and main interfaces
2.5
Fuel System realisation, construction steps
2.6
Tagging and traceability
2.7
Quality Assurance System
2.7.1
General
2.7.2
Verification and Validation
2.7.3
Verification of design development
2.7.4
Execution of Value Improvement Practices
2.7.5
Validation of execution phases.
2.8
Guarantees
2.9
Deviations, trouble shooting and repairs
9
9
9
9
10
11
11
12
13
14
14
14
14
15
15
15
16
21
21
APPLICABLE INPUT DOCUMENTS

3.1
Project documents
3.2
Standards and units
3.2.1
General codes
3.2.2
Civil Codes
3.2.3
Instrumentation codes
3.2.4
Piping codes and standards
3.2.5
Electrical Standards & Codes of Practice
22
22
22
22
22
24
25
25
ABBREVIATIONS
27
TOP REQUIREMENTS
5.1
Business case
5.2
Main goals
5.3
Budget and planning
28
28
28
28
FUEL SYSTEM
6.1
Products
6.2
Site and main interface conditions
6.3
General functional requirements Fuel System
6.4
Main design philosophy, limits and tolerances
6.4.1
General
6.4.2
TS-1 capacity
29
29
29
29
29
29
30
BC5286-G-13360-001
For Comments
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10 March 2014
6.4.3
6.4.4
6.4.5
6.5
6.6
6.6.1
6.6.2
6.6.3
6.6.4
6.6.5
6.6.6
6.6.7
6.6.8
6.6.9
6.6.10
6.6.11
6.7
6.7.1
6.7.2
6.7.3
6.7.4
6.7.5
6.7.6
6.7.7
6.7.8
6.7.9
6.7.10
6.8
6.8.1
6.8.2
6.8.3
6.8.4
6.8.5
6.8.6
6.8.7
6.8.8
6.8.9
6.8.10
6.8.11
6.9
6.9.1
6.9.2
6.9.3
6.9.4
6.9.5
6.9.6
6.9.7
6.9.8
6.10
6.10.1
6.10.2
6.10.3
6.10.4
Control & safeguarding

Capacities and velocities
Considerations for design development
Future reservations
General functional requirements civil
Fixation of plant grid and plot clearing
Excavation and backfill
(Sheet) piling
Concrete
Containments
Drainage and sewer system
Structural steel
Platforms and related access
Roads and walkways
Earth connections and lightning protection
Traffic signs and safety guards
General functional requirements piping & mechanical
Materials of construction.
Mechanical design general
Piping general
Prefabrication
Erection and Installation
Welding and Post Weld Heat Treatment
Special Piping Items
Pipe supports
Valves
Sample valves
General functional requirements instrumentation
Automation and instrumental safeguarding
Monitoring of fuel transfers
Protection against static electricity
Instruments
Analysers
Control valves
On-off valves
Pressure relief valves
Communications
Instrument cabling
Cable trays
General functional requirements electrical
Main power supply and distribution
LV distribution panels and VSD
UPS
Grounding, lightning- and cathodic- protection
Electrical tracing
Lighting, emergency lighting and socket outlets
Electrical cabling
Cable ladder / tray
RAM requirements
Reliability
Availability of main system
Availability of utilities
Maintainability
30
30
30
31
31
32
33
34
34
35
35
36
37
37
37
38
38
38
38
38
39
40
41
41
41
42
42
42
42
44
44
44
48
48
50
50
51
51
53
54
54
56
58
58
59
59
60
61
61
61
62
62
63
BC5286-G-13360-001
10 March 2014
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For Comments
6.11
6.11.1
6.11.2
6.11.3
6.11.4
6.11.5
6.11.6
6.11.7
6.11.8
6.11.9
6.11.10
6.11.11
6.12
6.12.1
6.12.2
6.13
6.14
6.15
6.16
6.17
6.17.1
6.17.2
6.17.3
6.17.4
HSSE requirements
General
Prevent contamination
Classification of flammable liquids
Area classification
ATEX
HAZOP, SIL, PSSR
Noise reduction
Emission reductions
Waste stream management
Emergency provisions
Security
HSSE during construction
HSSE philosophy of Asghabat International Airport
General HSE requirements for construction
Operability
Constructability
General requirements during realization
Clear construction area, cleaning of Fuel System
Other general requirements
Welding
Coating
Insulation
Special tools
63
63
64
64
64
65
65
65
65
65
66
66
66
66
67
67
67
67
67
68
68
68
69
69
RAIL CAR (UN)LOADING STATION SBS 01+02

7.1
Scope of subsystem
7.2
Functional requirements
7.2.1
Process
7.2.2
Railway tracks
7.2.3
Access to site by road
7.2.4
Containment
7.2.5
Platforms and access ways
7.2.6
(Un)loading facilities and vapour return connections
70
70
71
71
73
73
73
73
74
TANK FARM SBS 03

8.1
Scope of subsystem
8.2
8.2.1
Process
8.2.2
Buffer capacity
8.2.3
Containment and tank foundations
8.2.4
Tanks with conical roof
8.2.5
Tanks with dome heads and separators
8.2.6
Pumps
8.2.7
Access
75
75
76
76
78
78
79
81
82
83
FUEL DISTRIBUTION NETWORK INCL HYDRANTS SBS 04

9.1
Scope of subsystem
9.2
9.2.1
Process
9.2.2
Design considerations/requirements
9.2.3
Piping under runway/taxiways
9.2.4
Water hammer
84
84
84
84
85
86
86
BC5286-G-13360-001
For Comments
-3-
10 March 2014
9.2.5
9.2.6
9.2.7
9.2.8
9.2.9
9.2.10
9.2.11
9.2.12
9.2.13
9.2.14
9.2.15
Underground obstructions
Excavation of trenches for pipe installation
Excavation for valve chambers and other structure installations
Valve Chambers
Drain and Vent Points
Hydrant Pit Assemblies
Hydrant Pipeline Installation
External coating of piping and appurtenances in valve pits
Installing and compacting pipe bedding material.
Design and install a cathodic protection system
Specific standards
86
86
87
87
87
87
87
92
92
92
93
10
GANTRY AND PETROL STATION SBS 05 + 06

10.1
Scope of subsystem
10.2
10.2.1
Process
94
94
94
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

14.1
General Fire Protection Capabilities
14.2
Objectives of Fire Protection system
14.3
Fire Fighting philosophy Objectives
14.3.1
Fire Prevention Philosophy
14.3.2
Fire Detection Philosophy
14.3.3
Fire Protection and Response Philosophy
14.4
Firewater Supply
14.5
Foam supply
14.6
Cooling
14.7
General Alarms both Visual and Audible
14.8
Escape routes and Muster areas
14.8.1
Escape routes
14.8.2
Muster areas
14.9
General Electrical Considerations
14.9.1
Communications and Alarm
14.10
Emergency RESPONSE FROM landbased fire department
14.10.1 Firefighting equipment
14.10.2 Firefighting and Rescue
14.10.3 Command and Control
99
99
99
99
99
100
100
101
101
101
101
102
102
102
102
102
102
103
103
103
15
SECURITY PROVISIONS
15.1
Airport security
15.2
Tankfarm security
104
104
104
16
BUILDING FACILITIES HOLD

16.1
HVAC
16.2
Laboratory
16.3
Office buildings incl. technical classrooms
16.4
Warehouses
105
105
105
105
105
BC5286-G-13360-001
10 March 2014
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For Comments
16.5
16.6
17
Sheds for automobiles

Repairing shops
105
105
DELIVERABLES
17.1
Document control (input and deliverables)
17.2
Applicable software
17.3
As Built documentation
106
106
106
106
BC5286-G-13360-001
For Comments
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10 March 2014
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
BC5286-G-13360-001
10 March 2014
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For Comments
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 startup assistance, correction of defects and shipping conform to the requirements of the specified
codes and standards, as well as legal requirements.
BC5286-G-13360-001
For Comments
-7-
10 March 2014
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:
1.5
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.
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.
BC5286-G-13360-001
10 March 2014
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For Comments
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.
BC5286-G-13360-001
For Comments
-9-
10 March 2014
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.
BC5286-G-13360-001
10 March 2014
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For Comments
2.3.2
Scope for New Fuel System
The scope definition in the table below is based on appendix 1.

SBS
Description
00
01
02
03
04
05
06
07
Fuel System general provisions

Railway track and related foundation
Rail tank cars (un)loading station
Tankfarm; all provisions related to tanks including pumps and
containments
Fuel distr. network incl. hydrants
Gantry and petrol station near tankfarm
Gantry and petrol station near aprons
Handling and storage of packaged materials
11
12
13
14
Utility supply (incl. safety showers)

Gas and fire alarm system
Firefighting system
Security provisions for Fuel System area; partly airside security
99
Demolishing of existing tankfarm
See
paragraph
6
7
7
8
9
10
10
11
12
13
14
15
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, s c a f f o l d i n g , testing, a n d 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
00
subject
Office building, maintenance shop, lab and
guard houses
00
Service road at Airside adjacent to the new Fuel
System
01
New access road to the new Fuel System
01
Railway track and related foundation
02
Other structures/constructions at the rail car
(un)loading bays
07
Handling and storage of packaged materials
99
Demolishing of existing tankfarm
Table 2.3
design
others
construction
DBC
others
others
others
others
DBC
DBC
DBC
DBC
others
others
DBC
others
BC5286-G-13360-001
For Comments
- 11 -
10 March 2014
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.
BC5286-G-13360-001
10 March 2014
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For Comments
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
00
Subject
Automobile roads in Fuel
System area
00
WP-1B Airside systems
00
00
01
Rail connection
02
Connections to rail tank

cars
Connections to air planes
04
+
vehicles
04
WP-1A Airside Infra
11
WP-3A/4 Buildings
11
Polimeks
farm area
11
WP-3 Main power feed
11
WP-3
utilities
11
11
WP-5B Connections
utilities; instrument air
Potable water
12
Gas and fire alarm system
13
WP-4F Fire Safety
buildings
Connections
fuel
to
to
ISBL WP-3C
Access for vehicles and
operators within Fuel
System plot
Containments,
block
valves
and
process
sewer
branches,
rainwater
Rainwater
sewer
branches
Control room for controls
and safeguarding
Rail tracks for shunting
and (un)loading
Facilities to connect
OSBL
WP-2A/B Landside roads
Facilities to connect
Air plane valves
Crossing of piping with

existing and new runway
Utility connections to
buildings
Outgoing feeder modules
as part of LV distribution
panels
LV distribution panels in
MEP building 6
Runways
Outgoing feeder modules

as part of LV distribution
panels
Instrument air distribution
in Fuel System area
Distribution
in
Fuel
System area
Detectors, alarms in Fuel
System area, cabling to
local control room
Fire water ring with
hydrants, fire monitors,
cooling and foam lines to
top of tanks
Header to airfield process

sewer
Header to airfield rainwater

sewer
Cabling for alarms to Central
Control Room (CCR)
Existing single track railway
Rail tank car valves
Wall of the buildings

Electrical installations to and
inside buildings fuel farm
area
High voltage feed including
trans-former to 400 V
400V feed to plot utilities
outside tank farm
Instrument air supply

Header to battery limit
Cables to CCR + Alarm
panel in CCR
Fire water system with mains
connected to the Fuel
System fire water rings. Fire
fighting controls.
Fire fighting at aprons.
Table 2.4
BC5286-G-13360-001
For Comments
- 13 -
10 March 2014
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.
BC5286-G-13360-001
10 March 2014
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For Comments
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.
BC5286-G-13360-001
For Comments
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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).
BC5286-G-13360-001
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For Comments
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.
BC5286-G-13360-001
For Comments
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10 March 2014
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
BC5286-G-13360-001
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For Comments
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.
BC5286-G-13360-001
For Comments
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10 March 2014
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.
BC5286-G-13360-001
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For Comments
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 shortcomings. 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.
BC5286-G-13360-001
For Comments
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10 March 2014
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
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For Comments
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
Floors
Pipe support beams
Equipment support beams
Girders and joists under masonry walls
Grating
L/250
L/300
L/300, max 25 mm
L/500, max 25 mm
L/500
L/300
Where L = the span of the beam or twice the length of the cantilever.
3.2.2.2
3.2.2.3
Maximum horizontal deflections (minimum requirements)

Single story buildings and semi closed structures
Closed (multiple storey) buildings
o complete height (h)
o per storey (H)
Pipe racks
o complete structure
o single beams
Sensitive equipment supporting structures
h/200
h/500
H/300
h/200
6 mm
h/400
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.
BC5286-G-13360-001
For Comments
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10 March 2014
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
API STD527
API STD598
API STD607
ASME B1.20.1
ASME B16.5
ASME B40.1
ASME B40.3
ASME B46.1
ASTM A153
ASTM A182
ASTM A216
ASTM A249
ASTM A268
ASTM A269
ASTM A351
BS 2779
BS 6755
BS 6755/1-D.8
BS 6755/2
DIN 19234
DIN 43713
EIA RS485
EN 10204
EN 50170
EN 61219
FCI 70-2
IEC 60079
IEC 60079-1
IEC 60079-7
IEC 60079-11
IEC 60079-15
IEC 60079-18
Sizing, selection, and installation of pressure-relieving devices in refineries

Seat tightness of pressure relief valves
Valve inspection and testing
Fire test for soft-seated quarter-turn valves
Pipe threads. General purpose (inch)
Pipe flanges and flanged fittings. Steel, nickel alloy, and other special alloys
Gauges. Pressure indicating dial type. Elastic element
Bi-metallic thermometers
Surface texture (surface roughness, waviness, and lay)
Standard specification for zinc coating (hot dip) on iron and steel hardware
Standard specification for forged or rolled alloy-steel pipe flanges, forged
fittings, and valves and parts for high-temperature service
Standard specification for steel castings, carbon, suitable for fusion welding,
for high-temperature service
Standard specification for welded austenitic steel boiler, superheater, heat
exchanger, and condenser tubes
Standard specification for seamless and welded ferritic and martensitic
stainless steel tubing for general service
Standard specification for seamless and welded austenitic stainless steel
tubing for general service
Standard specification for castings, austenitic, austenitic-ferritic (duplex), for
pressure-containing parts
Specification for pipe threads for tubes and fittings where pressure-tight
joints are not made on the threads (metric dimensions)
Testing of valves
Part 1: Specification for production pressure -testing requirements. Section
D.8: Leakage classes of on/off valves
Part 2: Specification for fire type testing requirements
Measurement and control; electrical distance sensors; DC interface for
distance sensor and signal converter
Measurement and control; electrical temperature sensors; wires and
stranded wires for compensating and extension wires
Electrical characteristics of generators and receivers for use in balanced
digital multi-point systems
Inspection documents for the delivery of metallic products
General-purpose field communication system
Earthing
Quality control standard for control valve seat leakage
Explosive atmospheres
Part 1: Equipment protection by flame-proof enclosures d
Part 7: Equipment protection by increased safety e
Part 11: Equipment protection by intrinsic safety i
Part 15: Equipment protection by type of protection n
Part 18: Equipment protection by encapsulation m
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For Comments
IEC 60364
IEC 60529
IEC 60534
IEC 60584
IEC 60751
IEC 61000
IEC 61131-3
IEC 61508
IEC 61511
IEC 61518
IEC 61882
IEEE 802
ISA S88
ISO 724
ISO 9001
ISO 15848-1
ISO 80000
NAMUR NE43
VDI 2440
VDI/VDE 3513
VDMA 24422
3.2.4
Electrical installation of buildings

Degree of protection provided by enclosures (IP code)
Industrial-process control valves
Thermocouples
Industrial platinum resistance thermometer sensors
Electromagnetic compatibility (EMC)
Programmable controllers. Part 3: Programming languages
Functional safety of electrical / electronic / programmable electronic safetyrelated systems
Functional safety. Safety-instrumented systems for the process industry
sector
Mating dimensions between differential pressure (type) measuring
instruments and flanged-on shut-off devices up to 413 bar
Hazard and operability studies. Application guide
Information processing systems. Local area network
Batch control systems
ISO general-purpose metric screw threads. Basic dimensions
Quality management systems. Requirements
Industrial valves. Measurement, test and qualification procedures for fugitive
emissions. Part 1: Classification system and qualification procedures for type
testing of valves
Quantities and units
Standardization of the signal level for the breakdown in information of digital
transmitters
Reducing emissions for mineral oil refineries [TA Luft]
Variable area flow meters
Valves; guidelines for noise calculation; control and on/off valves
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)
BC5286-G-13360-001
For Comments
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10 March 2014
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
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For Comments
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
BC5286-G-13360-001
For Comments
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10 March 2014
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
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For Comments
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 selfsupporting. Buildings are also contributing to self-supporting facilities; however buildings are
no part of the scope.
6.4
6.4.1
Main design philosophy, limits and tolerances

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.
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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 Max capacity Parallel
m3/h
m3/h
systems
100
250
1
200
500
2
400
750
3
600
1000
4
800
1250
5
1000
1500
6
Table 6.4A velocities in parallel systems
Min velocity m/s
Max velocity m/s
1,2
1,2
1,6
1,8
1,9
2,0
2,8
2,8
2,8
2,8
2,8
2,8
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.
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For Comments
SBS
1
Recommendation
TS-1 collection header and slops collection header
under foot path between railways instead of 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.
3
Space reservation for future vapour treatment unit
3
Funnels via headers connected on slope to slops tanks
for all sample locations.
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.
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.
Table 6.4B recommendations for design development
6.5
priority
High; prevent or
minimize
piping
under containment
High; quality item
Medium
Low
Low
Medium;
consideration
cost reduction
for
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
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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,
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For Comments
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
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
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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.
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For Comments
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.
6.6.6.1
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.
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
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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
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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.
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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
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 6.17.1, coating shall be in accordance with 6.17.2.
Fabrication and Installation of Pipe-work and associated components shall follow the RFC
Isometrics. Piping spools shall be prepared strict in accordance with approved isometrics.
DBC shall indicate the number and location of the field welds or joints on the isometrics.
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DBC shall be responsible for the supply, fabrication and installation of all required standard
and non-standard pipe supports in accordance with the relevant drawings and specifications.
Standard Pipe supports are defined in specification. Installation shall include cleaning of the
painted pipe surface at the weld location and touch-up paint as required if support is site
welded to pipe saddle/shoe/pads.
DBC shall supply and install all flange bolts, washers, nuts and gaskets including greasing
bolts. DBC shall supply and install bolts with the correct bolt lengths as shown on RFC
isometrics.
DBC shall execute all Non Destructive Examination (NDE), cleaning, testing, flushing and
removing test water as indicated in specifications and or drawings.
DBC shall execute installation and adjustment of spring hangers/supports and cold supports
on instruction/approval from Employer.
A complete quality control document, also called Manufacturing Inspection Verification Report
(MIVR) shall be prepared and maintained highlighting as a minimum the following:
Material certificates (MTRs)
Welding / jointing procedures
Welders / Jointers
Weld / Joint numbers
Test report references
Construction and / or isometric drawings shall be marked up such that all material and each
joint make a reference to the quality control documents.
DBC is responsible to align pipe to equipment to meet the pipe strain/load limits as specified
by vendor or in accordance with applicable standards. The application of bellows should be
prevented by means of a configuration with sufficient expansion loops.
Long straight lines shall be provided with axial supports sized to withstand reaction forces
resulting from waterhammer.
Holds on isometrics will not be solved by RHDHV, but should be solved by DBC during
construction.
The installation of piping also includes the mounting of:
all valves
all inline & online instruments, DBC shall ask the E&I DBC for supervision during
installation.
6.7.4
Prefabrication
DBC shall remove all dirt, conservation materials, etc. from pipe materials both inside and
outside prior to fabrication and inspect again prior to installation and prevent ingress of dirt and
damage during all phases of work. DBC shall blow out all fabricated spools with air and cap,
plug off all open ends with plastic end caps before release from the shop.
DBC shall include the fabrication of cradles, reinforcing pads and trunnions and dummy
supports from same pipe class material as main pipe. Cradles shall be fabricated from suitable
plate when the pipe wall thickness is greater than ten (10) mm. In this case the plate shall also
be supplied by DBC as part of its scope and shall be fully documented.
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Pipelines, which are to be installed sloped, are shown on RFC isometrics with work point
centre elevations. Shown elevations are mandatory. The bent elbows or standard elbows and
tees in such a sloped line are consequently some times more or less than 90 degrees. The
exact angles of these bends are indicated on the isometric. DBC shall verify and instruct its
fabrication shop before pipe fabrication.
For pipe cut by DBC, DBC shall re-stamp the heat number on the cut piece of pipe before
cutting. For primer coated pipe material DBC shall indicate the location of the heat number
with marking ink. Under a valid power conferred by the NOBO, DBC can stamp themselves.
Otherwise stamping shall be authenticated by the NOBO.
DBC shall not assume automatically that the start/stop points on any isometric indicate actual
breaks or field welds in the piping. Standard field welds are not indicated on the ends of an
isometric but in normal circumstances they may be considered as such. DBC shall determine if
field welds are required, taking into account fabrication and installation tolerances of
equipment, foundations, structures, pipelines etc. and in this cases DBC shall check
connecting isometrics in order to arrive at the most economic and minimum number of field
welds.
DBC shall maximize economical and effective straight pipe utilization to obtain the least
amount of scrap pipe together with the least number of welds. For small length spool pieces,
remaining pipe cuts shall be used to the maximum extent.
The Work is inclusive of non-welding activities such as drilling, taper-boring and welds end
preparation of the ends of piping components for the matching wall thickness. The work shall
also include threading of pipe as required by pipe class.
6.7.5
Erection and Installation
DBC shall install all piping in accordance to the piping isometrics and relevant specifications.
DBC shall supply, fabricate, install and subsequently remove all temporary supports, bracing,
spacers, spool pieces and bolts, nuts, washers and gaskets required for erection.
For testing and flushing DBC shall supply, fabricate and install all temporary dummy spool
pieces for not installed valves or inline piping or-Instrument items, including subsequent
removal of these items as required upon installation of inline item. Fabrication, installation and
removal of dummy spool piece and installation of the inline item shall be included in the scope
DBC shall perform all fit-up and final alignment of piping to flanged connections.
DBC will be responsible for protecting structures, cables, grating, support beams etc., from all
weld spatter and hot material particles, including grit blasting.
Insides of pipe shall be thoroughly checked for cleanliness, and cleaned before installation to
achieve a cleanliness of pipe internals prior to connecting spools for butt welding or flanged
bolt-up, such that flushing before hydro-test shall be minimized, this includes; no temporary
storing of weld rods and tools inside the pipes. DBCs Quality Control shall document pipe
cleanliness checks.
Pockets in sloping lines are not allowed. DBC shall perform all required measurements and
make all required adjustments to guarantee a positive fall in the required direction of the whole
line. Correction of any failures will be for DBC's account.
DBC shall check all inline items for proper operation prior to turnover to Employer. Alignment
of bellows shall be in the centered position after installation. In case proper operation is not
possible DBC shall overhaul the subject item until proper operation is achieved. DBC is fully
responsible for inline items from receipt from Employer until turnover.
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For Comments
6.7.6
Welding and Post Weld Heat Treatment
See 6.17.1 for general requirements.

For welded valves pre- and/or post weld heat treatment shall be executed on one side of the
valve at the time, with the valve in open position. Under no circumstances both valve sides
shall be heat treated simultaneously. DBC shall measure the temperature at the inside middle
of the valve and will inform Employer if temperature is rising above 450 degrees Centigrade.
Any damage to the valve internals due to post weld heat treatment activities shall be for DBC's
account.
6.7.7
Special Piping Items
DBC shall install all special piping items, such as, but not limited to; special fit-up pieces,
barred-tee, safety shower and eye wash units, and Y-pieces where indicated on isometrics and
special item list.
6.7.8
Pipe supports
Standard Pipe Supports are identified by type and locations, and summarized on the standard
pipe support list. DBC shall supply, fabricate, paint/coat and install these pipe supports.
Including touch up of damages, incurred during installation. DBC shall supply and install bolts,
nuts and washers. Standard pipe supports also include supports to stops, guides, anchors,
hangers.
All galvanized lines will be supported by U-Bolts.
All steel lines will be supported with welded shoes only.
Pipelines, which are to be installed sloped, are shown on isometrics with work point centre
elevations. Shown elevations are mandatory. The exact height of the shoe-supports is not
indicated on the isometric. DBC shall verify the height of shoe and modify before installation.
Non-Standard or Modified Standard Pipe Supports (identified as SPS on Isometrics) are
defined for unique situations, and based on Standard Pipe Supports. They are designed or
modified per individual detail drawing or Isometric. DBC shall supply, fabricate, paint/coat and
install these pipe supports. Including touch up of damages, incurred during installation. DBC
shall supply and install bolts, nuts and washers.
Engineered Pipe Supports are designed for unique situations. An example of these supports
are, cold supports, spring supports, spring hangers, struts and snubbers.
DBC shall install and adjust spring supports, spring hangers, struts, and other supports. The
"Limit Stops" in spring supports/hangers shall not be removed, until instructed by Employer.
Installation shall be as per suppliers manual or Employers specification.
DBC's Work includes the supply and installation of all Standard and Non-Standard or Modified
Pipe Supports including and Engineered Pipe Supports as indicated on the applicable
isometrics.
DBC shall supply, fabricate, paint and install all gussets and bracing as indicated on the
applicable isometrics.
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For Comments
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10 March 2014
DBC shall supply and install the required anchor bolts and shims for all pipe supports. Certain
pipe supports will be attached to foundations, floor slabs and/or paving with expansion bolts
and/or drilled inserts as indicated on the support drawings. All associated drilling, supply of
expansion bolts and anchoring including the supply and installation of grout are part of DBC's
Scope of Work and included in the unit prices.
6.7.9
Valves
Fire safe isolation pipeline valves shall be applied where required to separate fuel systems,
e.g. between tanks and connected piping. Fire safe double block and bleed valves shall be
applied for the inlet and outlet lines of each TS-1 storage tank.
Check
are:
valves shall be installed on all locations where backflow might result in risks. Examples
Pump discharge
Loading connection
Utility to process connection
Valve position, open or closed, shall be easy visible.

6.7.10
Sample valves
The types of sample valves
6.8
General functional requirements instrumentation
Reference is made to documents Appendix 14 - Control & Safeguarding Philosophy and

Appendix 4 - Architectural systems configuration.
6.8.1
6.8.1.1
Automation and instrumental safeguarding

Process control
The Fuel System shall be provided with a DCS for process control. Process control shall
include:
Inventory management (tank gauging, stock in warehouse)
Transfer management (loading/unloading, hydrant system, flow metering)
Alarm management (ESD alarms, trip alarms, level alarms, pump alarms, system
alarms)
Data acquisition (real-time trending, historic trending, sequence-of-event (SOE))
The DCS shall meet the following minimum requirements:
Designed for industrial use
Sample time: 300 msec maximum
Scalable: the number of input/output (I/O) cards can (to a certain extent) be increased
without affecting the overall system architecture
Open architecture: the DCS is able to communicate with other systems
Communication with junction boxes, local panels (LPs) and MCC based on hard-wired
connections
Communication with the DCS operator stations (OSs) based on Ethernet and EIA
RS485.
Communication with monitoring station in the Airport Operations Centre (AOC) based
on a redundant fibre optic Ethernet network
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For Comments
In case of sequential control: provided with a batch control program as per ISA S88
Self-checking and able to produce system alarms
Power supply 230 V, single-phase, 50 Hz uninterruptible
The DCS cabinets shall be accommodated in the cabinet room, which is part of MEP building
6. The operator stations and printers will be installed in the field control room, which is one of
the offices.
All field instruments (transmitters and field switches) and final elements (control valves and
on/off valves) required for process control shall be hard-wired to junction boxes and LPs.
6.8.1.2
Functional safety
The Fuel System shall be provided with a SIS for functional safety and emergency shut-down
(ESD). Most safety-instrumented functions (SIFs) shall be intended for overfill protection of rail
tank cars, storage tanks and bowsers. Also SIFs may be considered for low flow protection of
pumps. The ESD system shall be incorporated in the SIS. On strategic locations such as the
rail tank car (un)loading platform, the pump station, the four corners of the TS-1 aviation fuel
tank pit, the road along the smaller tanks and the bowser gantry ESD push buttons shall be
installed. Also ones in the field control room and the main guard house.
The SIS can either be a section of the DCS in safe execution or a stand-alone system.
The SIS shall meet the following minimum requirements:
Sample time: 50 msec maximum
Scalable: the number of I/O cards can (to a certain extent) be increased without
affecting the overall system architecture
Semi-open architecture: reading the SIS is possible, but writing in the SIS is protected
Communication with junction boxes and LPs based on hard-wired connections
Communication with the DCS based on dual redundant Modbus and EIA RS485
Communication with the SOE printer via the DCS
Communication with the AOCs monitoring station via the DCS
Provided with a logic progam as per IEC 61131-3
Approved by TV for use in SIL 1, SIL 2 and SIL 3 safety-instrumented functions
(SIFs)
Power supply: 230 V, single-phase, 50 Hz uninterruptible
The SIS cabinets shall be accommodated in the cabinet room, which is part of MEP building 6.
The SOE printer shall be installed in the field control room, which is one of the offices.
All sensors (transmitters and ESD push buttons) and final elements (on/off valves) required for
functional safety and ESD shall be hard-wired to the junction boxes and LPs. Trip relays,
however, shall be installed in the SIS marshalling cabinets and connected to the motor starter
units in the MCC room. Trip commands to and from up-stream and down-stream systems shall
also be transmitted through hard-wired connections.
The OSs of the DCS shall meet the following minimum requirements:
Suitable for table-top installation
Amount of I/O to display: compatible with the DCS and the SIS
Sample time: compatible with the DCS and the SIS
Displays (overview, graphics, details, trends, alarm list) user-oriented
BC5286-G-13360-001
For Comments
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10 March 2014
Resolution for display variables 1:1000 or better

Communication with the DCS based on Ethernet and EIA RS485
Visualization system based on well-known real-time operating system
Power supply: 230 V, single-phase, 50 Hz uninterruptible
6.8.2
Monitoring of fuel transfers
For this subject, refer to document BC5286-G-13312-001 Control and safeguarding

philosophy, paragraph 3.10 (appendix 14).
6.8.3
Protection against static electricity
Because mineral oils such as kerosene, gasoline and gasoil are non-conducting liquids, they
build up static electricity on tank and pipeline walls, if flowing. To get rid of this static electricity,
tanks, pipelines and associated connections must all be grounded.
There will be procedures to:
Ground a rail tank car before any connection to an (un)loading hose is made
Ground a bowser before any connection to an (un)loading hose is made
For this purpose, object earthing systems shall be provided at the bays for rail tank cars and
bowsers. These object earthing systems consist of an earthed box with a grounding cable
terminated by a clamp. This clamp should be connected to the object to be
discharged/grounded. The earthed box has two lights:
A red one indicating that the rail tank car / bowser has not been discharged and
grounded yet and that no hose connection can be made.
A green one indicating that the rail tank car / bowser has been discharged and
grounded and that a hose connection can be made.
The object earthing system shall inhibit starting of the (un)loading pump, if the red light is still
on, to prevent the flow of non-conducting liquid.
All storage tanks shall be properly earthed. All piping systems including valves and fittings
shall be equipotential-bonded with braided cables and properly earthed.
6.8.4
Instruments
Generally, field instruments shall be electronic and meet the following requirements:
Accuracy for transmitters: 1% of reading or better; accuracy for gauges: 1% of full
scale or better. Drift low enough to limit re-calibration to once per 4 years. Exceptions
are mentioned in the following paragraphs.
Suitable for the physical and the chemical properties of the process fluid
Suitable for the design pressure and design temperature as per equipment
specification or pipe class
If located in a classified area, use Ex d (zones 1 and 2), Ex n (zone 2 only) or Ex i
(zones 1 and 2) instruments
For ingress protection for dust and water, use IP65 instruments
If part of a SIF, instruments shall meet the SIL requirements as per IEC 61508 / IEC
61511
Number of different makes and models as limited as possible
Provided with integral indicator to allow local read-out
The use of detectors shall be avoided as much as possible; transmitters are preferred.
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For Comments
Tuning forks for level detection, however, can be used, unless these are unsuitable for
the service.
Signals associated with field instruments shall be 4-20 mA HART @ 24 VDC nominal,
loop-powered; dry contact SPDT rated 2 A minimum; 2-wire NAMUR transistor; and 24
VDC coil tension, unless specified otherwise.
Field instruments shall be provided with a corrosion-resistant identification plate permanently
attached to the item by manufacturers standard method. The following information shall be
provided as a minimum:
Tag number
Manufacturers name or trade mark
Manufacturers model number
Manufacturers serial number
Body material
Body rating
Flange size
Flange rating
Range including unit of measure
Output signal(s)
Power supply
For vortex flow transmitters and ultrasonic flow transmitters, DBC shall take the minimum
straight lengths up-stream and down-stream of the transmitter given by Manufacturer into
account.
The arrangement of field instrumentation used for functional safety shall allow in-situ periodic
proof-testing.
Field instruments shall be mounted in such a way that their connections and adjustments are
easily accessible. Gauges and transmitters with integral indicators shall be oriented to face the
access side.
6.8.4.1
Flow
The following instruments shall be used to measure flow:

Vortex flow transmitters can be applied in almost all turbulent liquid, gas and steam services.
Turn-down ratio shall be 10:1 minimum.
Electromagnetic flow transmitters shall be applied in watery services with a conductivity of 20
S/cm minimum. Turn-down ratio shall be 10:1 minimum.
Coriolis mass flow transmitters shall be applied for accountancy measurements, for instance
for received and delivered fuel. They can also be applied for liquid flows with a low Reynolds
number. Turn-down ratio shall be 50:1 minimum.
Positive displacement (PD) flow gauges shall be applied for jet fuels if a high
accuracy (custody transfers) is required. Particular oval gear type PD flow gauges are very
suitable. It is possible to provide the flow gauge with a pick-up probe that generates a pulse for
every revolution of the gears.
BC5286-G-13360-001
For Comments
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10 March 2014
Variable area flow gauges (with transmitter) shall only be applied for clean fluids and line sizes
up to 2. They shall be metal tube type. However, for water, nitrogen gas or instrument air at
operating pressures up to 3.5 barg, glass tube type can be used. Accuracy for gauges shall be
2.5% of full scale or better; accuracy for transmitters is (necessarily) the same. For purge
meters 10% of full scale is acceptable. Turn-down ratio shall be 10:1 minimum.
Ultrasonic flow transmitters can be applied for difficult services that dont allow any obstruction
in the fluid stream. They can also be used in larger line sizes; then multi-beam types are
recommended. Turn-down ratio shall be 10:1 minimum and for larger line sizes (line size >
10) 50:1 minimum.
Flow instruments shall be provided with flanged connections. Variable area flow gauges (with
transmitter) for line sizes up to can be provided with NPTf screw connections. Body
material shall be equal to or better than what is specified for piping components.
6.8.4.2
Level
The following instruments shall be used to measure level:

(Differential) pressure type level transmitters can be applied on vessels, but also on storage
tanks. For vessels and tanks that are not atmospheric, dry leg or wet leg compensation shall
be used.
For fouled, toxic or corrosive liquids, (differential) pressure transmitters with integral or remote
diaphragm seals shall be used. Process connection shall be 3 150# RF (or, if required, a
higher flange rating).
(Guided) radar type level transmitters can be applied on storage tanks and, if mounted on a
standpipe, also on vessels. Process connection shall be 4 150# RF (or, if required, a higher
flange rating).
In tank gauging systems, the level reading shall be combined with a temperature reading, and
with strapping and density tables, to give the tank contents in kg.
Magnetic level gauges (with transmitter) can be applied on vessels for every range up to 2000
mm. Top and bottom connections shall be 2 300# RF minimum (or, if required, a higher flange
rating).
Tuning forks shall be used to detect high or low levels. Process connection shall be 1 150#
RF (or, if required, a higher flange rating).
Weigh systems for scales or weigh bridges shall consist of load cells, a special signal junction
box and a weigh computer.
6.8.4.3
Pressure
The following instruments shall be used to measure pressure:

Pressure gauges
Industrial design, dial type
Bourdon tube as per ASME B40.1
Accuracy class 1.0 (= 1% of full scale)
Able to withstand 30% over-pressure without loss of calibration
Able to withstand 400% over-pressure without tube burst
Process connection NPTm -threaded with wrench flats
Fitted with special 2-way pressure gauge valve block
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For Comments
Process-wetted parts hardened AISI Type 316 stainless steel

Moving parts stainless steel
Weather-proof stainless steel casing, diameter 100 mm
Safety glass and blow-out disc
(Differential) pressure transmitters

Gauge, absolute or differential pressure type
Accuracy 0.15% of reading or better with less than 0.25% drift in 4 years
Able to withstand 100 barg without loss of containment
Process connection(s) NPTf -threaded
Gauge and absolute type fitted with 2-way valve block
Differential type fitted with 3-way or 5-way valve block
Pressure switches
Only for gauge pressure
Snap-acting type
Adjustable over full range with accuracy 1% of full scale
Dry contact SPDT rated 2 A
Process connection NPTf -threaded
Fitted with 2-way valve block
Pressure gauges for steam or hot condensing vapours (above 65 C) shall be fitted with a pig
tail.
Pressure gauges that can be exposed to more than 30% over-pressure and that are not
provided with a diaphragm seal, shall be protected by a gauge saver.
Pressure gauges that are subject to vibrations, shall be glycerine-filled.
Pressure gauges, pressure transmitters and pressure switches for fouled, toxic or corrosive
liquids shall be provided with integral or remote diaphragm seal(s). Process connection for
pressure gauges shall be 2 150# RF (or, if required, a higher flange rating). Process
connection(s) for pressure transmitters and pressure switches shall be 3 150# RF (or, if
required, a higher flange rating).
(Differential) pressure transmitters for fluids that can plug impulse tubing, shall be purged with
nitrogen gas.
Pressure switches shall only be used for utilities such as water, nitrogen gas and
instrument air. Else pressure transmitters shall be used.
6.8.4.4
Temperature
The following instruments shall be used to measure temperature:

Thermowells
Made of drilled barstock AISI Type 316L stainless steel unless the service requires
another material
Process connection 1 150# RF (or, if required, a higher flange rating)
Insertion length as to place the tip in the heart of the pipe or vessel with a maximum of
425 mm
Internal bore shall be 6.6 mm, tip thickness 5 mm
Element connection shall be NPTf-threaded
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For Comments
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Temperature gauges
Industrial design, dial type
Bi-metallic type as per ASME B40.3
Accuracy class 1.0 (= 1% of full scale)
Flexible-angle head
Weather-proof stainless steel casing, diameter 160 mm
Including NPTm-threaded lock nut to fix temperature gauge into thermowell
Thermowell inserts
For ranges between -200 C and +550 C, 3-wire Pt100 RTDs
For higher ranges up to +1090 C, type K (chromel-alumel) thermocouples
Pt100 RTD characteristics shall be as per IEC 60751
Thermocouple characteristics shall be as per IEC 60584
Element shall be insulated at the tip (not earthed)
Insert connection in thermowell shall be NPTm-threaded
Insert diameter shall be 6 mm
Insert length shall match the thermowell
Insert sheath shall be AISI Type 316 stainless steel
Temperature transmitter
Accuracy 0.5 C
Transmitter shall be head-mounted transmitter (hockey puck)
A complete temperature transmitter assembly consists of a thermowell, a thermowell insert, a
nipple-union-nipple, a connection head and a head-mounted transmitter. The transmitter shall
be protected against heat radiation from the vessel or the pipeline by using long nipple(s). The
temperature allowed at the head shall be 50 C maximum.
Exception to this rule are temperature transmitters for measuring skin temperatures. In that
case the RTD or thermocouple element is not protected by a thermowell. Skin RTD and
thermocouple elements shall be provided with a mineral-insulated sheath. Sheath shall be 13
mm OD with a wall thickness of 3.4 mm shaped to match the contour of the vessel or the
pipeline. Sheath material shall be as follows:
Pipe material
Austenitic and high nickel alloy
Ferritic
Sheath material
ASTM A249 TP309
ASTM A268 TP446
A strap of the same material as the sheath shall be provided to maintain contact with the
vessel or the pipeline.
6.8.5
Analysers
There are no automatic process analyzers foreseen. If the fuel quality has to be measured or
checked, a sample will be taken, brought to the laboratory and analyzed there following the
JIG standard. The laboratory for analyses shall correspond to the requirements of the
international standards and provide analyses according to TDS (GOST) and ASTM.
6.8.6
Control valves
There are two types of control valve: control valves driven by an external controller; and control
valve driven by its own control mechanism: pressure regulators.
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For Comments
Control valves
In general, globe valves or V-ball valves shall be used. For the larger diameters (line size > 6)
butterfly valves can be used.
Pressure regulators
Pressure regulators are always globe valves. If the springs are relatively heavy, then the
pressure regulator design is upside-down.
6.8.6.1
Installation
Control valves shall be provided with flange connections. For the larger diameters (line size >
6) wafer type butterfly valves can be used. By-pass valves for control valves shall be globe
type. For the larger diameters (line size > 6) butterfly valves can be used.
6.8.6.2
Sizing
The cv-value of control valves and pressure regulators shall be calculated using the formulas
for compressible fluids (gas) and incompressible fluids (liquid) as per IEC 60534. The
calculation procedure shall be as follows:
Step 1: Calculate the valve-cv for normal flow conditions. The result is called cv-normal.
Step 2: Divide cv-normal by 0.7. The result is called cv-aimed for.
Step 3: Calculate the valve-cv for maximum flow conditions. The result is called cv-max.
Step 4: If cv-aimed for is greater than cv-max, continue with the former; else with the latter.
Step 5: Then, to be on the safe side, add 10%.
Step 6: Pick the nearest cv-value on the higher side in manufacturers catalogue. This is called
cv-installed.
Step 7: Select the smallest associated body size.
As a rule, single-seat control valves shall be used. The internal design of the control valve shall
guarantee that the noise level does not exceed 80 dB(A) as per VDMA 24422.
6.8.6.3
Leakage tightness
The leakage tightness of valves shall satisfy the service. For control valves and pressure
regulators Class IV as per FCI 70-2 is usually sufficient. Hydrostatic testing for control valves
and pressure regulators shall be performed as per API STD598.
6.8.6.4
Fugitive emission
Control valve are often used in gas or volatile liquid service. In that case, leakage to the
environment can be an issue. Control valve design shall be as per VDI 2440 (TA Luft) and ISO
15848-1. Sometimes a bellow must be installed on stem and valve bonnet to prevent leakage
along the stem.
6.8.6.5
Material
Body material shall be equal to or better than that specified for piping components. Trim
material shall be hardened AISI Type 316 stainless steel or better.
6.8.6.6
Actuator types
Actuators for control valves shall be electric type controlled by electronic positioners. Actuators
for pressure regulators shall be spring-opposed diaphragm type, the diaphragm is loaded by
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For Comments
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the process fluid. This is either the down-stream process fluid (for pressure reducers) or the
up-stream process fluid (for back-pressure regulators). If the process fluid cannot deliver
enough force, then a pilot is used. In that case the modulating operation of the pressure
regulator is often replaced by on/off operation. Control valves shall be either failure-close or
failure-open with respect tosignal failures. This shall be determined by a safety study.
6.8.7
6.8.7.1
On-off valves
Selection
In general, ball valves shall be used. For the larger diameters (line size
valves can be used.
6.8.7.2
>
6)
butterfly
Sizing
On/off valves shall be full line size, full bore and short-pattern.
6.8.7.3
Leakage tightness
For on/off valves often tight shut-off is required, for instance Class A as per BS 6755/1-D.8.
Hydrostatic testing for on/off valves shall also be performed as per BS 6755/1-D.8.
6.8.7.4
Fire-safe
On/off valves in fuel lines shall be fire-safe as per BS 6755/2.

6.8.7.5
Material
Body material shall be equal to or better than that specified for piping components. Trim
material shall be hardened AISI Type 316 stainless steel or better.
6.8.7.6
Electric actuators
Actuators for on/off valves shall be electrical type. On/off valves shall be either failure-close or
failure-open with respect to signal failures. This shall be determined by a safety study.
6.8.7.7
Position switches
On/off valves shall be provided with position switches to signal the open and closed valve
positions. Position switches shall be mechanical or proximity probe type.
6.8.7.8
Final element
On/off valves that are part of a SIF shall meet SIL requirements as per IEC 61508 / IEC 61511
6.8.8
The last line of defense for safety to prevent process hazards such as loss of containment
are completely mechanical safety devices such as:
Thermal relief valves
Pressure/vacuum relief valves
Breather valves
Rupture discs
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For Comments

6.8.8.1
Check valves
Selection
Safety relief valve sizes shall be calculated as per API STD520. Safety relief valve construction
shall be designed as per API STD527.
6.8.8.2
Material
Material shall be equal to or better than that specified for piping components.
6.8.8.3
Electronic features
Rupture discs shall be provided with an electronic burst detection device.

6.8.9
Communications
The communication between the cabinet room in MEP building 6 and the AOC shall be by a
redundant fibre optic network. There are two of these connections foreseen:
1.
Ethernet for monitoring the DCS and SIS signals in the AOC
2.
Proprietary for monitoring the F&G detection alarms in the AOC
Closed Circuit Television
For the supervision of operations and security reasons, it is necessary to have eye vision on
the gates, the rail tank car (un)loading platform and the bowser gantry. Therefore, a closedcircuit television (CCTV) system shall be installed.
The CCTV system shall be a completely stand-alone system with cameras, camera control
consoles, CCTV displays and a control cabinet. The cameras shall be located primarily at the
gates, the rail tank car (un)loading platform and the bowser gantry. For choosing appropriate
locations, use document: 123_1.19_GP_0802_HK_0002 Proposed plot plan fuel system
Ashgabat Airport. Some cameras will be movable, others fixed. The movable ones shall be
pan-tilt-zoom type controlled from a camera control console either in the field control room or in
the main guard house. The number of cameras shall be sufficient enough that an operator will
fill approximately 1/20 of the screen on at least one display, and his face approximately 1/200.
The CCTV displays shall be hung in the field control room and the guard houses. The control
cabinet shall be located in the cabinet room of MEP building 6. Signal connections between
the cameras, the camera control consoles, the CCTV displays and the CCTV control cabinet
shall be by a proprietary fibre optic network.
6.8.10
Instrument cabling
Signal cables from field instruments, control valves, on/off valves, sensors and final elements
shall be connected to junction boxes or LPs. The junction boxes and LPs shall be installed on
accessible locations near a concentration of instrumentation. From there, multi-pair and multicore signal cables shall be run to the marshalling cabinets of the DCS and the SIS in the
cabinet room of MEP building 6.
Construction of junction boxes and LPs shall meet environmental conditions with respect to
area classification, dust and water. In general, junction boxes and LPs shall contain 20%
spare terminals.
To discriminate signal levels the following color-coding shall be used:
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Analog (non-IS)
Analog (IS)
Digital (non-IS)
Digital (IS)
Multi-pair/multi-core (non-IS)
Multi-pair/multi-core (IS)
Power
Ethernet
Fibre optic
Fire-fighting
Grey cable
Blue cable
Grey cable
Blue cable
Grey cable
Blue cable
Grey cable
Black cable
Yellow cable
Red cable
In classified areas, cable connections shall be made to the right junction boxes and LPs. This
means non-IS signals to Ex e junction boxes and Ex e LPs; IS signals to Ex i junction boxes
and Ex i LPs. Also correct cable glands shall be used. To Ex e junction boxes and Ex e LPs:
Ex e cable glands; to Ex i junction boxes and Ex i LPs: Ex i cable glands; to Ex d instruments:
Ex d cable glands; to Ex n and Ex m instruments: Ex e cable glands; and to Ex i instruments:
Ex i cable glands.
All cables and wires shall be tagged on both ends. Cable tags shall refer to the equipment on
the other end of the cable starting from the feeding side. Cables to the field instruments,
control valves, on/off valves, sensors and final elements shall be identified by the tag numbers
of these items. Wire numbers shall refer to the terminals to which they are connected. Wires
shall not be marked with sleeves but plastic ferrules.
Clearance between cables and hot surfaces shall be 300 mm as a minimum. Clearance
between cables and the thermal insulation of hot surfaces shall not be less than 50 mm.
Power supply cables shall be rated per load requirement; minimum size of cores shall be 2.5
mm2.
6.8.10.1 Materials
The following cable materials shall be used:
1.
(4-20 mA / HART) and digital signal cable

Shielded and twisted pair
Conductors 1.3 mm2 stranded copper
Wire and sheath insulation: PVC, rating 600 V
Pair shields: tin foil
Overall screen (sometimes combined with armour)
Overall braided armour
Thermocouple lead (compensation lead)

As per DIN 43713
Solenoid signal cable

Parallel-core
Conductors 1.3 mm2 solid copper
Wire and sheath insulation: PVC, rating 600 V
Overall screen (sometimes combined with armour)
Overall braided armour
2.
3.
4.
Ethernet cable
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For Comments
Category 5E UTP
All internal wiring in the marshalling cabinets of the DCS and the SIS shall be of PVC-insulated
copper wire with an adequate cross section, 1.0 mm2 minimum. Wire ends at electronic
components and terminals shall be provided with suitable compression type wire pins. If
electronic components are provided with screw-type connection terminals, the wire ends shall
be provided with spade lugs. Each wire shall be identified using plastic sleeve ferrules with
terminal numbers at all terminal points.
All wiring including wires from incoming cables shall be laid in PVC wire ducts with cover lids.
Ducts shall be sized for 20% spare. Wire bundles running from electronic boxes, instrument
frames etc. to wire ducts shall be run in PVC flexible conduits. Wiring carrying signals
susceptible to electromagnetic interference shall be adequately screened off.
IS wiring/cabling shall be segregated from non-IS wiring/cabling.
Colour code for wiring/ducts
Colour code for wiring shall be DBC/Manufacturers standard, approved by Employer. Wiring
and ducts for IS circuits shall be blue.
6.8.10.2 Terminals
For incoming and outgoing signal cables, knife terminals shall be used. Terminal rows shall
contain 20% spare.
For non-IS signal cables grey terminals shall be used; for IS signal cables blue ones.
Removable cover plates shall be provided over all terminals with voltages above 50 V marked:
"DANGER".
All terminals rows shall be suitably marked according to the appropriate drawings and provided
with partition plates, where necessary.
6.8.10.3 Earthing
The marshalling cabinets of the DCS and the SIS shall be provided with two copper earth rails,
one for cable screens (protective earth) and one for pair shields of the signal cables (insulated
from steel structure), both with sufficient screws, for incoming and outgoing cables.
Apart from these rails the marshalling cabinet shall be provided with one external protective
earth M8 bolt, not to be mounted in the sidewalls.
All hinged parts (doors, sheeting etc.) shall be grounded to the steel structure with flexible
earth braids (litze). All electrical devices shall be installed in such a way that positive earthing
is assured by metal contact with the construction of the cabinet.
6.8.11
Cable trays
Overhead signal cables shall be laid in cable trays. The supports for cable trays shall be
attached to structural elements of the tank pit or gantry, not to the piping. Cables trays shall be
sized with 20% spare capacity.
For cable support between field instrumentation and junction boxes or LPs, small cable
trays or conduit pipe shall be used. For cable support between junction boxes or LPs
BC5286-G-13360-001
For Comments
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10 March 2014
and main cable trays, small cable trays shall be used.

Cable routes shall be protected against electrostatic and electromagnetic interference as
per IEC 61000.
To minimize interference between different types of cables the following segregation
shall be made:
Power cables ( 50 V) and signal cables (< 50 V): different cable trays
Non-IS signals and IS signal cables: same cable tray but on the left-hand side and
right-hand side of this tray respectively (or vice-versa)
The following material shall be used:
1.
Cable tray
Stainless steel type
Conduit pipe
Galvanized carbon steel as per ASTM A153 with rubber end grommets.
2.
Communication cables such as Ethernet cables shall be mechanically protected, for instance
by running them through a dedicated cable tray with cover lid or a conduit pipe with open ends.
6.9
General functional requirements electrical
DBC shall design, supply, install, inspect, test and pre-commission the following electrical
facilities and systems for the fuel system:
Low Voltage electrical power distribution installation (MCC, VSD & UPS)
Grounding, lightning- and cathodic- protection installation
Electrical tracing
Electrical cabling
Cable trays
6.9.1
Main power supply and distribution
The following preliminary documents are produced in relation to the electrical installation of the
fuel system:
123_1.19_EC_0300_HK-0001 Electrical key one line diagram
123_1.19_EL_LST_001
Electrical loadlist
The electrical consumers of the new fuel farm area will be fed from LV distribution panels
locate in LV room of MEP Building 6, also VSD and UPS shall locate in this LV room.
MEP Building 6 will be situated in a non-hazardous area at the north side of fuel farm area.
MEP building 6 consists of 35kV switchgear, emergency power generators, power
transformers 35kV/400V, LV distribution panels (MCCs), VSD, UPS, etc.
The secondary connections of power transformers forms the scope split between work
package fuel system (WP3C) with MEP building 6 (WP3).
WP3C includes LV connections at transformers to LV installation of fuel system.
WP3C LV distribution panels shall be equipped with outgoing feeder modules for MEP building
DBC (WP3) and Polimeks fuel tankfarm buildings.
Parts of scope WP3 MEP building 6 includes but is not limited to:
MEP building 6 incl. HVAC;
35kV cabling;
BC5286-G-13360-001
10 March 2014
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For Comments
6.9.1.1
35kV switchgear;
Emergency generators;
Power transformer(s);
LV distribution panels (not related to fuel system);
LV cabling / trays (not related to fuel system);
Grounding and lightning protection installation MEP building 6;
Lighting / emergency lighting installation MEP building 6;
Design WP3C
DBC shall determine the load requirements and shall advise MEP building DBC (WP3)
on the optimum technical solution.
The design shall have minimum 40% spare capacity.
DBC shall prepare calculations for protection and proper fault discrimination between
protection equipment when detailed engineering will take place.
DBC shall be responsible for calculation of the actual short circuit level of the system
and shall supply the equipment in compliance with the actual calculated figures.
DBC shall make their connections on 400V Low Voltage level in the MEP building 6 for
all electrical consumers (including MOVs) locate in or near fuel farm area.
DBC shall make their connections on 400V Low Voltage level in other outside
transformer station and/or MEP building for hydrant system MOVs when locate >
250m from tank farm area. DBC shall make reservations in LV distribution panels.
The Low Voltage electrical power distribution system includes but is not limited to:
o LV distribution panels
o Variable speed drives (VSD)
o Uninterrupted Power System (UPS)
Voltage levels which shall be used on the fuel system are as follows:
o 400 V: Motors operating voltage LV-side, three-phase;
o 230 V: LV Electrical equipment (some control systems, lighting etc.), single-phaseneutral;
o Control Voltages: 110V DC (for switchboards) and 24V DC (for control devices) to
be confirmed during detail design.
Overall power factor: 0.95 or even higher.
Operating frequency: 50 Hz
In general, Total Harmonic Distortion of the phase to phase voltages shall be less than
5%.
DBC shall supply and install all electrical equipment including switchgear control
equipment, safety accessories, cabinets, auxiliary equipment, cabling.
DBCs scope of supply also includes all maintenance switches, including wiring and
cables near the motors. Make and type to be approved by the Employer.
Equipment shall be suitable for the local ambient temperatures and appropriate for the
prevailing climatic and operating conditions.
DBC shall provide all necessary cooling, heating and/or ventilating for proper
functioning of all equipment taking into consideration the external service conditions.
Electrical equipment including motors installed outdoors or in the plant shall have as a
minimum fully weather proof enclosures (at least IP55). Electrical equipment installed
in a dusty environment shall have as a minimum IP65. Switchboards/cabinets installed
in electrical rooms shall have as a minimum protection IP41.
Electrical equipment installed in hazardous areas (zone 1, gas group IIB, temperature
class T4) should be according IEC 60079.
Particular attention shall be given to the weatherproofing and corrosion protection of all
electrical equipment located outdoors, having due regard for the specified industrial
site conditions.
BC5286-G-13360-001
For Comments
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10 March 2014
Equipment provided with louvers or openings for ventilation shall also be fitted with
vermin screens.
DBC shall supply a complete set of special tools, templates, operating handles and any
devices necessary for the erection, operation, testing and maintenance of the
equipment. The tools and devices shall be housed in a separate lockable box or on a
suitable tool rack in the electrical room(s).
A handling truck/lifting arrangement shall be provided where required to facilitate
maintenance of switchgear and control gear.
The commissioning spares shall include fuse links, lamps, etc. and those items
considered consumable or from experience, likely to require replacement during
installation and commissioning of the equipment.
A Factory Acceptance Tests (FAT), witnessed by the Employer shall be performed at
DBCs or his sub-DBCs premises prior to shipment; the FAT-protocol shall be sent to
the Employer for approval at least one month before FAT.
DBC shall provide inspection and test reports after installation according to applicable
standards.
6.9.2
6.9.2.1
LV distribution panels and VSD

LV Distribution panels
LV Distribution panels shall be configured and specified to be the extensible type to
enable future expansion at either end of the panel assembly without disturbing existing
steelwork of busbars.
Incoming feeders, section breakers and outgoing feeders shall be equipped with
auxiliary contacts for provision of interlock functions.
All incoming feeders shall be equipped with incoming voltage monitoring, 3-phase
Amp. measurement / meter, voltage measurement / meter.
Voltage measurement / meter with change over switch for busbar voltages, phasephase and phase-neutral.
Amp. meters shall have max-indication.
LED-type lamps shall be applied. Colours shall be according to the instructions of the
Employer.
Exact amount of 400V/230V outgoing circuits to be determined by DBC during detailed
engineering.
Metal clad, type tested and factory made industrial type LV Distribution panels. Frame
parts of prefabricated galvanised steel.
As the LV Distribution panels shall feed both building installations and machine
installations the design standard EN60439-1 shall be applied. The LV Distribution
panels shall be designed for operation by an unskilled person.
Freestanding type with base frame and separate compartments for components, cable
termination and busbars.
Separate sections for incoming and out-going feeders.
Full automatic power factor compensating equipment shall be installed.
Spare space and appropriate terminal design for termination of a number of parallel big
heavy-duty power cables. 0.8m distance (from bottom to cable terminals) and free
space per compartment/unit shall be envisaged for this purpose.
Busbar current rating and incoming breaker rating shall be equal or larger than the
incoming feeder safety device. The LV Distribution panels shall be designed for
natural ventilation.
Feeders larger than 250A shall be equipped with circuit breakers; for feeders to and
including 250A both circuit breakers and fuse-load switch combinations are allowed.
Each feeder (400V three phase) shall be placed in a separated compartment of the
switchboard.
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For Comments
6.9.2.2
Main earthing bar shall be distributed through all sections and compartments.
All breakers, MCBs (mini circuit breakers) and disconnectors for power supply shall be
supplied with a padlock facility in order to ensure a de-energized machine / installation.
Energized parts of the bus bars, which can be exposed, shall be equipped with
covering made in clear plexiglass.
The opening of all hinged doors shall be based on the use of a tool.
Wiring of LV Distribution panels
Requirements:
Internal wiring shall be with halogen-free wires.
Cross-section of minimum 2,5mm2 for power circuits and 1,5mm2 for control circuits.
Wiring shall be in duct.
Screw-terminals shall be of type with disconnect- and test facility.
Only one wire may be terminated per terminal.
Multi-stranded wires shall be provided with terminal-tubes.
Colour marking according to IEC 60445 and 60446 and according to the instructions of
the Employer.
Logical grouped terminal row blocks.
Terminal raking of wire at the point of termination.
6.9.2.3
For the termination of cables the following conditions shall apply:

Cable mounting sections shall be vertical with an extent from bottom to top. The width
shall typically be 400-600mm with sufficient space for the cables and the cable
mounting work.
The whole bottom area shall be equipped with bottom plates. Also the cable section
shall be equipped with bottom plates.
Cable fixing to cable-mounting plate, in the cable section only.
Power cables with loads < 63A and control and monitoring cables, shall be terminated
in terminal row blocks in the cable section.
Power cables carrying loads > 63A shall be terminated in the cable section or directly
on the individual components. No terminals for cable connections must be located less
than 800mm from the bottom of the compartments.
Only one cable conductor per terminal.
Testing of LV Distribution panels
As a minimum the following tests shall be executed for the LV Distribution panels
Factory Acceptance Tests (FAT):
Mechanical visual check.
Control circuits check.
Signal and measurement check.
High voltage test.
Insulation measurement.
Marking, signs etc.
Special tools, auxiliaries.
Site Acceptance Tests (SAT):
Mechanical visual check.
Control circuits check.
Signal and measurement check.
High voltage test.
Insulation measurement.
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For Comments
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10 March 2014
Marking, signs etc.

Special tools, auxiliaries.
Connections to other equipment, for example control system.
Interlock test.
Phase sequence.
Check of settings.
Test of protections.
The following documents / drawing shall be delivered during detailed engineering:

Technical data specific for the LV Distribution panels.
Dimensional drawings.
Connection details and dimensional drawings of the power cable connection
compartments.
Drawings of the required supports for the LV Distribution panels.
Lay-out of the LV Distribution panels components including secondary circuits and all
numeration of contacts shall be included in a file (minimum size A4) which is fastened
at the inside of a door of the LV Distribution panels.
6.9.2.4
VSD
VSD Incoming feeder shall be 400V three phase 50Hz.
VSD outgoing feeder shall be 400V three phase
The VSD shall be metal clad, type tested and factory made industrial type VSD.
Frame parts shall be prefabricated galvanised steel.
VSD shall be a freestanding type with a base frame and with separate compartments
for components, cable termination and bus bars.
Bus bar current rating and incoming breaker rating shall be equal or larger than the
incoming feeder safety device. The VSD shall be designed for natural ventilation.
For VSD components see same requirements as described for LV distribution panels.
Each VSD shall be equipped with his own control panel in front of cabinet, I/O to be
worked out during detail design.
6.9.3
UPS
UPS Incoming feeder shall be 400V three phase 50Hz.
UPS outgoing feeder shall be 230/400V one phase/three phase neutral 50Hz.
The capacity of the UPC battery shall be enough for 60 minutes or more.
The UPS shall be metal clad, type tested and factory made industrial type UPS.
Frame parts shall be prefabricated galvanised steel.
UPS shall be a freestanding type with a base frame and with separate compartments
for components, cable termination and bus bars.
Bus bar current rating and incoming breaker rating shall be equal or larger than the
incoming feeder safety device. The UPS shall be designed for natural ventilation.
For UPS components see same requirements as described for LV distribution panels.
6.9.4
Grounding, lightning- and cathodic- protection

The Fuel System shall connect to grounding as protection against static electricity of
fuel supply facilities.
The open-air constructions shall be provided with a lightning protection system for
protection of all personnel and apparatus. Lightning shall not cause any disturbance in
the actual operation of the terminal.
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10 March 2014
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For Comments
All LV Distribution panels shall have over voltage protection installed.

All electronic equipment located outside a building shall be protected against over
voltage. If the equipment is connected to equipment inside the building, over voltage
protection shall be installed at both ends of the connection cable.
A grounding system shall be provided to ensure:
o Safety to Personnel.
o Touch and step voltage limitation
o Protection against static electricity
o Service grounding
All electric equipment shall be connected in a proper way to the grounding system. LV
Distribution panels, cabinets and cubicles containing electrical equipment, fences, and
metal structures shall be also connected to the grounding system.
A system for protective grounding and potential equalisation shall be provided for all
electrical equipment and metal structures according to the regulations.
The grounding system shall consist of a copper ring bar of sufficient cross section,
installed in switchgear rooms and connected by two wires or bars to grounding rods.
The housing of equipment and cubicles shall be connected by means of a single wire.
The grounding busbar in switchboards shall be connected at both ends.
Low rated equipment outside switchgear rooms shall be earthed by means of a
grounding wire or screen in the power supply cable. High rated equipment shall be
grounded by means of a separate grounding wire or bar.
Cable trays and steel structures shall be grounded.
All pipelines containing flammable gas shall be bonded to the grounding system.
Undesirable static electric shall be controlled.
Cable screens shall normally be earthed at both sides, except for control and signal
cables to the PCS, which shall be earthed at one side.
Underground lines and tanks should be equipped with adequate cathodic protection
provisions.
The grounding and lightning protection installation of the fuel system shall be
integrated with the overall grounding and lightning protection installation of the new
airport.
6.9.5
Electrical tracing
Electrical heat tracing shall be installed on some potable water lines for freeze
protection purpose.
Electrical tracing shall be of a self-regulating type.
Electrical tracing line-up shall be determined during the detail design phase.
6.9.6
6.9.6.1

Normal lighting
The fuel system area shall have a lighting system in order to work safely for 24 hours per day.
In order to archive this operational requirement, DBC shall provide a completely functional
lighting installation which shall at least fulfil the requirements given in this chapter as well as
requirements arising from DBC detailed engineering.
The loading area should be provided with a permanent lighting system providing both area and
task specific lighting. Consideration should be given to facilitating electrical isolation of each
load island (6 rail cars, 2 tankers per gantry) individually whilst retaining general area lighting.
The lighting circuit for task and area lighting should preferably be fed from different supplies.
On larger sites the lighting supplies should be further divided to allow maintenance of discrete
areas whilst normal operations continue in other areas.
BC5286-G-13360-001
For Comments
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10 March 2014
6.9.6.2
Design of the lighting system shall be done according to the European Standard EN12464-1 and EN-12464-2 or equivalent.
DBC should verify the intensity of illumination with Employer and Polimeks.
All lighting fixtures with metal housing shall be grounded.
Emergency Lighting
For all accessible locations at fuel system area, DBC shall provide lighting fixtures for the
purpose of emergency lighting. These fixtures may be combined with the normal lighting
fixtures. The lighting fixtures shall have their own battery (decentral) or central battery via
UPS. The capacity of the battery shall be enough for 60 minutes or more. In case of power
failure emergency lighting shall switch on automatically and the illumination shall be sufficient
to leave or enter equipment or building in a safe way and/ or continuation of handling
operations.
Routes on site to assembly points shall be illuminated in such way that these points can be
reached in a safe way.
Connection of the emergency lighting fixtures on normal power or emergency power shall be
considered during detail design. The normal lighting will be fed from a distribution system with
UPS, DBC to determine additional requirements in relation to emergency lighting.
6.9.6.3
Socket outlets
Single phase socket outlets shall be of local type with two contacts plus earth.
As a general requirement, as much sockets shall be installed in a room or place as the
intended functions of this room or places requires. Specifically, at least two double
socket outlets shall be installed in every pump pit and at locations shown in P&IDs as
utility station.
Intended use of rooms or places shall be taken into account when determining fuse
levels. No fuses less than 16A shall be used.
Three phase socket outlets shall be of local type, with a capacity that fits the power
requirements of the equipment, for which it is intended, but at least 16A and 5 poles.
For each three-phase socket outlet the corresponding three-pole plug shall be
delivered, in order to ensure proper connection of local equipment.
6.9.7
Electrical cabling
Field cabling includes (but not limited to):
o Power cables to/from distribution panels and all equipment;
o Lighting cables to lighting fixtures and socket outlets;
o Control cables to all equipment;
o Cable ladder and/or cable tray;
o All other cables, junction boxes, fastening equipment and auxiliary materials to
install the cables in a proper way and to meet the intended purpose of the
installation;
o All works for digging and closing cable channels, if required.
DBC shall provide all cabling, junction boxes, fastening equipment, cable conduits and
other auxiliary aids to realise a good functioning and safe location. All cores, including
spare cores, of cables shall be connected to terminal blocks in the cabinets or junction
boxes.
All cables and wires shall be coded properly and shall be marked at both ends. This
also applies to internal wiring of cabinets, switchboards and junction/connection boxes.
The coding system is subject to approval by the Employer.
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For Comments
Insulation materials for wires and cables shall be PVC or XLPE. Outer sheaths of
cables shall be of type that does not propagate flames. Cables laid in trenches without
sleeves shall be of armoured type. In addition, all power distribution cables shall be of
the armoured type.
Connection of wires shall be well ordered and shall allow for non-destructive
unfastening.
Power cables shall have a minimum cross-section is 2,5mm2. The appropriate crosssection of the conductors shall be approved by calculations.
Control cables shall have a minimum cross-section of 1,5mm2.
6.9.8
Cable ladder / tray
DBC shall supply and install ladder-racks and cable trays as required to support the cabling,
together with all required accessories. The ladder-racks and cable trays shall meet the
following requirements:
The ladder-racks shall be used for the medium and larger cables (power and control);
the cable trays shall be used for smaller cables (signal).
Cable trays shall be perforated.
All ladder-racks and cable trays and all mounting and fastening materials shall be hot
dip galvanised (or better).
All ladder-racks and cable trays shall be grounded.
All ladder-racks and cable trays shall have 40% spare capacity
Cables, trays and conduits shall be installed such that obstruction of walkways and
walking routes is avoided.
Cabling installed on cable ladder or tray shall be fastened using metal ti-raps.
Cable trays shall have appropriate partitions to separate power and control wires.
Cable ladders entering the floors through holes shall have a steel protection sheet. This
protection sheet shall have a height of at least 1,2m.
To connect cables, metal junction boxes shall be used. Separate junction boxes have to be
used for control and data cabling. The use of junction boxes for power cable is subject to
approval of the Employer.
6.10
RAM requirements
RAM stands for Reliability, Availability and Maintainability.

6.10.1
Reliability
The design life is defined as the period, starting at hand-over, for which structural elements,
services, process equipment, drainage systems, etc. are to be used for their intended
purposes with acceptable maintenance, but without major repair and/or replacement being
necessary. Reliability shall be assured by predictable maintenance at sufficient long intervals
of at least one year between two maintenance periods.
At the end of the design life the structures shall comply with the design ultimate and
serviceability limit states. Due regard shall be given in design to any corrosion loss during the
design life.
Design life periods as listed in table 6.10A shall be adopted.
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For Comments
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10 March 2014
WBS
Subject
14-40
Civil works (main structural elements)
51-55
Static mechanical equipment
57-59
Rotating equipment and packaged units
60
Piping
70-79
Main instrumentation items
80-89
Main electrical items
Table 6.10A design life periods
6.10.2
Life time in years

50
50
30
50
20
30
Availability of main system
The design shall allow maintenance on parts with minor impact on the total functionality of the
Fuel System. This shall be reflected by the amount of parallel acting equipment. The reference
design is based on parallel equipment specified by the Principal. An impression is reflected in
table 6.10B.
From
TS-1 rail car
To
TS-1 buffer tank
parallel
1
TS-1 buffer tank
TS-1 storage
TS-1 storage
Headers to
hydrants
Hydrants
Headers
Remarks
On gravity, low PFD of pipe,
long intervals between use.
Long intervals between use.
Single manifold with low PFD.
Continuous in use. Single
manifold with low PFD.
Continuous in use.
Ring headers
Table 6.10B parallel systems

The abbreviation PFD in table 6.10 stands for Possibility of Failure on Demand. E.g. for pump
failure the PFD is 0,1 per year (or once in the 10 years). For pipe the PFD for a serious leak
(10% of cross area) is 0,001 per 100 m.
In case of modifications on a manifold, a parallel line-up shall be made to allow uninterrupted
operations. The design shall allow the possibility to install such a parallel line-up.
Another reason for parallel systems is the velocity in the lines, see paragraph 6.4.
Recommendations for the risks of parallel or single systems and for main spare parts on stock
shall be specified by DBC.
Spare parts shall have the same technical specifications and quality as applied for the installed
equipment and / or materials.
DBC shall supply all spare parts for the installation, testing, inspection and preliminary testing
of the equipment, including the following items as a minimum: Nuts and bolts: 10%, gaskets
100%.
6.10.3
Availability of utilities
Stand-by power supply (diesel-generator) shall be provided to cover half the capacity of the
main maximal power supply in case of power failure.
Stand-by instrument air supply shall be provided to cover half the capacity of the main maximal
instrument air supply in case of power or instrument air failure (if instrument air is applied).
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6.10.4
Maintainability
Design shall be maintenance friendly and shall allow adoption of best practice maintenance
techniques:
Provision of permanent structures to allow clear access to all locations where
maintenance of equipment, valves or instruments is required.
The design shall allow maintenance while other items remain in use.
Sufficient maintenance valves shall be provided to limit volumes to be drained in case
of maintenance. Vent and drains shall be provided for easy draining in case of
maintenance and for easy and safe venting in case of refilling of the maintained part of
the system.
Lifting provisions shall be provided associated with maintenance activities. Heavy parts
shall be easy accessible by fork lift truck or mobile crane. This shall be taken into
account for the design of the structures around and above equipment.
Easy replaceable wearing parts
6.11
6.11.1
HSSE requirements
General
The protection layers for Health, Safety and Environment are described in the Control and
Safeguarding Philosophy appendix 14. Fire alarms and firefighting are described in chapters
13 and 14.
The requirements for security are described in paragraph 6.11.11.
In addition the following requirements shall be taken into account for the design. The SBS
codes refer to par 2.3.2:
SBS 01) Wherever possible, entry to rail sidings should be laid on a falling gradient
from the main line. The gradient should not exceed 1 in 400.
SBS 01) In contrast with PFD 123_1.19_TX_0801_HK_0001 and _0002 surfaces of
loading and unloading areas should be graded so that any product spillage will not flow
under the railcars, and its spread will be limited. This may be achieved by installing an
impermeable membrane below the track ballast, and longitudinal drains for rail loading
and unloading areas.
SBS 01) Loading and unloading of railcars shall be carried out on a siding provided
with a number of connection points spaced to suit railcar dimensions. Therefore
standard railcar types shall be used as shown in Appendix 11.
SBS 01) Rail sidings for loading and unloading of rail cars should be provided with
insulating joints to isolate the track of the siding from the main line and to prevent stray
currents from electrified lines or railway signaling track circuits. The siding track should
also be independently earthed.
SBS 02) Drop pipes used in top loading should reach the bottom of the railcars without
difficulty.
SBS 01-06) Incombustible materials shall be applied. Loading and unloading areas
should be surfaced in substantially impervious materials resistant to damage by fire
and product spillage .
SBS 03) Materials in valves direct connected to tanks shall be fire resistant for at least
the specified time as per international standard.
SBS 03) Open trenches and ducting in which pipes with category 1 and 2 products
(B91/115, A-80 and A-95) are run are not recommended as they can allow flammable
vapour to collect, but where they are unavoidable they should have fire stops at
suitable intervals. For these products bridges should be used.
BC5286-G-13360-001
For Comments
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10 March 2014
SBS 03) Pumps should preferably be situated in open air, however in this case
canopies will be applied to protect the pumps against the severe climate conditions.
SBS 03) Pumps should preferably not be installed below ground level. An exception
will be made for the pumps near the buffer tank as shown on PFD
123_1.19_TX_0801_HK_0001. The containment volume shall be below the pump
elevation.
SBS 03) Pumps and pump manifolds should not be located within tank compounds.
Exceptions will be made for the TS-1 tank sample pumps shown on PFD
123_1.19_TX_0801_HK_0014.
SBS 05 and 06) The use of kerbs in the gantry area of connections on bottom loading
tankers should be avoided, to prevent a trip hazard for the operator
6.11.2
Prevent contamination
Dedicated systems shall be used for each product.

Contamination of fuel and oil products by water, sand or other fuel or oil products shall be
limited by design. Contamination limits are detailed in IATAs Guidance Material for Aviation
Turbine Fuels Specifications, 5th Edition, Part III Cleanliness and Handling.
Double block and bleed valves shall be applied for separation of the TS-1 storage tanks from
the connected fuel system.
The design shall allow easy emptying of systems for product change.
A monitoring system composed of spot and continuous testing shall be used to evaluate the
quality and cleanliness of the fuel and the efficiency of the defence system. Fuel shall be
sampled and tested regularly for both particulate matter and undissolved water contamination.
Fuel System Icing Inhibitor (FSII) may also serve to inhibit fungal and bacterial growth in
aircraft fuel systems, but may not do so reliably. Fuels containing FSII, which have not been
stored or handled properly, are susceptible to microbiological contamination.
6.11.3
Classification of flammable liquids
The classification of flammable liquids according the Globally Harmonized System of

Classification and Labelling of Chemicals (GHS) shall be applied. This classification is explained
in table 6.11A.
Flash point Tf
Initial boiling point Tb
Category
Tf < 23C
Tb 35C
1
Tf < 23C
35C < Tb
2
23C Tf < 60C
3
60C Tf 93C
4
Table 6.11A GHS classification of flammable liquids
Note that for this project the classification according GHS is governing over the IP2 table D.1
Petroleum Classes.
6.11.4
Area classification
The area classification of the reference design (appendix 18) shall be updated by DBC.
BC5286-G-13360-001
10 March 2014
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For Comments
6.11.5
ATEX
The risks for sparks shall be reduced to an acceptable level by application of suitable materials
at Ex classified areas. ATEX certified equipment, instruments and electrical components shall
be applied at Ex classified areas.
6.11.6
HAZOP, SIL, PSSR
A HAZOP review and SIL classification shall be performed by DBC. A P&ID log shall be
maintained to keep track of all changes after the HAZOP. Change HAZOP shall be applied if
required. A Pre Start-up Safety Review (PSSR) shall be applied before start-up of any part of
the system.
6.11.7
Noise reduction
The noise pressure levels shall be limited to 80 dB(A) at 1 m distance from any noise emitting
component taking the impact of other noise emitting components in the Fuel System into
account.
6.11.8
Emission reductions
Emissions of volatile products shall be limited by installing pressure vacuum valves (PVV) and
vapour return. The design shall be based on table 6.11.
Product
Vapour pressure
at 20 C [mbar]
xx
xx
PVV
Aviation fuel TS-1

no
Aviation
petrol
yes
B91/115
Automobile A-95
xx
yes
Automobile A-95
xx
yes
Diesel fuel
<1
no
Gasoline
techn. About 300
yes
Purpose
De-icing liquid
xx
no
Slops
Mix of products
no
Table 6.11B provisions for emission reduction
Vapour
return
no
no
Remarks
Space reservations for

vapour return in future
yes
yes
no
yes
no
no
Underground storage
TS-1 thermal relief valves shall discharge to the TS-1 recovery tank. Thermal relief valves for
all other products shall discharge to slops tanks.
6.11.9
Waste stream management
Waste minimization and management is required for proactively addressing of environmental

issues and opportunities to reduce waste as an integral part of the design process. DBC is
responsible for a stream by stream waste minimization analysis during design development to
reduce, or better yet, eliminate each waste stream source.
For the Fuel System there are two main effluents; rain effluent and process effluent.
The containments shall be on slope to a pit in order to centralize spills.
BC5286-G-13360-001
For Comments
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10 March 2014
Rain effluent can be discharged in a controlled way, within specifications, via a sewer valve
and an API separator provided with oil trap to the storm sewer. The API separator design shall
allow easy removal of oil.
Locations where spills may occur shall be provided with leak catching provisions with facilities
to drain to subject slops tank. The slops tank shall have sufficient volume for low frequency
(max. once a month) need for a vacuum truck to empty the slops tank.
6.11.10
Emergency provisions
Emergency routes shall be defined in the next design phase by DBC.

Emergency lighting see paragraph 6.9.6.
Combined emergency showers and eye washers are required near the following locations with
increased risk as indicated on the PFDs:
Between rail car (un)loading and TS-1 filters
At sample take locations
For filter exchange locations
At the gantry near the tankfarm
At the gantry near the aprons
The number of emergency showers and the requirements per station are in accordance with
ANSI Z 358.1-2004.
6.11.11
Security
A security fence shall be provided around the Landside part of the Fuel System area. The
north part of this security fence shall act as security line between Landside and Airside as well.
Closed Circuit Television (CCTV) shall be applied for the gates as well for safety in the areas
for rail car (un)loading, for storage and at the gantries.
A risk assessment should be carried out to determine what further level of security is
required.
6.12
HSSE during construction
6.12.1
HSSE philosophy of Asghabat International Airport
DBC shall apply the HSSE philosophy of Asghabat International Airport. A fence shall be
placed by DBC indicating the boundaries of the construction site. Authority for access for
labour to the construction site shall be controlled by DBC.
Some construction activities are to be executed at the Airside, e.g. for the fuel lines to the fuel
hydrants and at the gantry near the aprons. Access for labour to the Airside will be controlled
by Airport Security. Access and leave timing to and from the Airside should be communicated
in advance.
After finishing of the construction, the construction area fence shall be removed by DBC
leaving the new Security gate and fence at the north side of the tank farm as new security line
between Land- and Air side.
BC5286-G-13360-001
10 March 2014
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For Comments
6.12.2
General HSE requirements for construction
Hold
6.13
Operability
The Fuel System shall be automated to the highest extend and remote controlled from the
local control room near the Fuel Tankfarm. The Control and Safeguarding philosophy is
described in Appendix 14 - Control & Safeguarding Philosophy.
Local operators are required to provide the fuel connections to the rail cars and to the vehicles,
to take samples in the Fuel Tankfarm and to clean filters.
Rain water and slops are to be handled by operators. Containments are provided with main
valves in normal closed position. Rain water can be discharged from a containment to the
storm sewer when the quality is within acceptable limits by opening of a hand valve. Oil
compartment of API separators and slops tanks are to be emptied by local operators. Slops
tanks are to be emptied by an ATEX classified vacuum truck. Small amounts of oil from API
separators can be pumped to containers. Provisions are available for TS-1 recovery. Other
slops are to be recovered elsewhere.
Short access routes are required for the operators to enable efficient execution of their duties.
6.14
Constructability
Areas for construction facilities and temporary storage of construction parts are indicated in
the lay-out of the reference design.
DBC shall provide a description about the proposed construction methods. Specific attention is
required for:
Prefab or site fabrication
Main sequence of construction
Receiving of materials.
Erection of tanks and large vessels
6.15
General requirements during realization
DBC is responsible for execution of all the activities related to construction including the
following general requirements during realization:
Check for existing underground piping and cabling.
Avoidance of Interference with Ashgabat International Airport except for planned
interference.
Tuning of temporary access of personnel to the construction area and to Airside.
Suitability and availability of access routes to and on the construction area including
emergency routes.
Reasonable efforts shall be used, by proper use of appropriate vehicles and routes, to
prevent any existing facility being damaged by construction traffic.
Signs and directions along the temporary routes for construction traffic, including
permission from the relevant Authorities to do so.
6.16
Clear construction area, cleaning of Fuel System
DBC is responsible for a structured way of working, resulting in a clear construction area.
BC5286-G-13360-001
For Comments
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10 March 2014
Before commissioning, DBC provides all parts of the Fuel System thoroughly cleaned. This
means that all parts, including all concealed spaces, must be drained of water, mud, debris,
waste, dirt, cement and the like. This obligation includes properties of the Employer
contaminated by execution of the Work.
At least once in a week DBC shall clear the roads from sludge and sand. DBC shall keep the
roads in a good state to prevent unsafe situations.
6.17
Other general requirements
6.17.1
Welding
DBC shall provide welding procedures, procedure qualifications and welder's qualifications in
accordance with the relevant specifications to Employer. Prior to commencement of welding
work Employer shall approve all of DBC's welding procedures and welders qualifications.
Welding and related work shall include stamping, cutting, bevelling, threading and grinding of
the parts to be welded together, supply of all consumables and welding equipment and other
welded attachments or supports.
DBC shall perform all required pre, intermediate or post weld heat treatment in accordance
with the requirements set forth in the relevant specification.
DBC shall provide a "Welder Traceability Program".
All welding (including tack welding) shall be performed by certified welders. All testing and
welding performed in order to certify welders shall be for DBC's own account. All materials
required for qualification of welders and procedures shall be supplied by DBC. DBC shall
provide all qualified welders an identity card and personal welders identification/ classification
number and stamp.
6.17.2
Coating
The application of blasting, primer and finish painting for all coating shall be in accordance
with painting specifications. This includes touch-up paintwork where required. Paint, and all
consumables shall be supplied by the DBC.
All finishes must prove extremely hard-wearing against UV as well as against shocks,
scratches and discoloration in time and under heavy use. As much as possible prefab coating
shall be applied in sead of site coating and/or spraying.
All so called painted metal elements will present similar, even, and smooth surfaces in
texture, shades and colours, without any variations for all elements with a similar finish and
without any traces and marks of brushes or of any rollers at all.
All sharp edges must be rounded in accordance with conservation specification to ensure
sufficient thickness of the coating layer.
Local zinc coating of galvanized parts, which are welded to ungalvanized parts, must be
ground away. After welding the zinc layer shall be treated with zinc paint repair.
DBC must ensure that all surfaces exposed to corrosive and other weather conditions during
transport and at the construction site are adequately protected.
BC5286-G-13360-001
10 March 2014
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For Comments
6.17.3
Insulation
Installation of Insulation materials shall follow the requirements of international standards.

DBC shall supply all materials and install thermal, personnel protection and cold insulation in
accordance with the line list, isometrics and specifications.
DBC shall install removable and reusable insulation cladding/boxes after hydro testing.
Insulation adjacent to items which have removable insulation cladding/boxes shall have a
weatherproofed, sealed, termination so-that water cannot enter the remaining insulation when
the removable cladding is removed.
Piping adjacent to flanged connections to be insulated shall be totally finished, weatherproofed
and sealed regardless of whether the flanges are insulated or not.
6.17.4
Special tools
Special tools required to operate and maintain the Fuel System shall be listed with itemized
prices. Special tools shall be delivered including lockable cabinet.
BC5286-G-13360-001
For Comments
- 69 -
10 March 2014
RAIL CAR (UN)LOADING STATION SBS 01+02

7.1
Scope of subsystem
The Rail Car (Un-) loading Station is the source of the products. Offspec products can be
returned from the Tank Farm to rail cars. The Rail Car (Un-) loading Station scope SBS 01
concerns the railway and all related provisions. Scope SBS 02 concerns all the unloading and
loading provisions. The interfaces with other subsystems are shown in table 7.1A.
Interface
with
subsystem
SBS 03 Tank farm
other
Scope limit of
other
subsystem
Hoses connected to the
manifold for unloading of 4
railcars for B91/115, A-95,
A-80 and diesel
Table 7.1A interfaces with other subsystems
Scope limit of SBS 02

(Un)loading
connections
with rail cars and discharge
line to the buffer tank
BC5286-G-13360-001
10 March 2014
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For Comments
The Rail Car (Un)loading Station consists of the main components listed in table 7.1B. For
details see BOQ document in appendix 15, filter SBS 01 and SBS 02.
SBS
01.12
01.14
01.16
01.23
01.17
01.17
Description
Piling
Sewer & drainage
Foundation incl. earthing
Railway
Road to site & paving
See paragraph
6.6.2
6.6.3
6.6.6
6.6.4 + 6.6.10
7.2.2
7.2.3
02.17
02.26
Pipe sleeper
02.27
Containment for rail tank cars
02.30
Steel structure
02.36
Platform and access way
02.40
Wind proof sampling cabinets
02.51
Slops tank
02.55
Separator
02.57
Loading facilities
02.58
Pump
02.6x
Piping
02.7x
Instrumentation
02.8x
Electrical
Table 7.1B main components of SBS 01 and 02
7.2
6.6.xx
6.6.xx
7.2.4
6.6.7
6.6.xx + 8.2.7
7.2.4
8.2.5
8.2.5
7.2.6
8.2.6
6.7
6.8
6.9
7.2.1
Process
The rail car (un)loading station is intended for the following services:
SBS 01) railway and related provisions
Receipt, shunting, fixations and removal of rail cars with standard sizes as indicated in
appendix 11.
Rail road crossings
SBS 02) unloading and loading provisions
Grounding
Sampling
Unloading of TS-1
Unloading of other products
Loading
Vapor return
These services are described below with reference to SBS codes of other subsystems.
7.2.1.1
Receipt, shunting, fixations and removal of rail cars
A new railway track for the new fuel tank farm system of the new Ashgabat International
Airport will be branched off from the existing main railway track passing south of the Ashgabat
International Airport. The location of this branch is not yet known and will be determined during
basic design phase.
The railroad shall be designed to receive 22 rail tank cars with TS-1 and 4 rail tank cars with
other products on two parallel railway tracks in a the fenced area of the new Fuel System.
BC5286-G-13360-001
For Comments
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10 March 2014
In addition one railway track shall be available for loading and unloading of 1 rail car with
aviation packaging materials (SBS 07).
7.2.1.2
Rail road crossings
Movements on the railway shall be according procedures at low speed with sufficient operator
attention.
7.2.1.3
Grounding
A grounding connection shall be made to each rail tank car before any other activity on the rail
tank car can be executed.
7.2.1.4
Sampling
Sampling can be executed on the rail tank car by means of a sample valve on the unloading
nozzle and via the top of the rail tank car. These samples can be taken before connection of
the rail tank car to the unloading line.
Sampling waste can be dumped in a funnel near the rail cars. In total there will be 26 funnels
available at the loading and unloading bays to collect liquid sampling waste from all the rail
tank car locations. Via a header the waste can be discharged to an underground slops tank. A
dedicated TS-1 slops system is required apart from a system for the other products.
7.2.1.5
Unloading of TS-1
All the TS-1 rail cars can be emptied at the same time. After approval of samples, each rail car
with TS-1 aviation fuel can be connected to the piping system with a flexible hose. Selective
couplings, dedicated for the use of TS-1 only, will be used to avoid contamination with other
fuel liquids. When connected, the valve to the collecting system will be opened and the rail car
will be emptied by gravity.
Collecting headers for TS-1 aviation fuel shall run on slope to the buffer tank (SBS 03). The
level in the buffer tank is low when starting with the first rail car unloading. The flow to the
buffer tank will increase when more rail cars become connected to the header, until the stand
pipe on the buffer tank will become filled. This stand pipe has an atmospheric outlet located
higher than the highest elevation of the TS-1 rail cars. In that way all connected rail cars and
the buffer tank will act as communicating vessels. The liquid will level out between all these
connected rail cars and the atmospheric buffer tank.
7.2.1.6 Unloading of other products
Other products can be unloaded via a one to one connection of a rail car with a pump
discharging to a storage tank (SBS 03). Selective couplings, dedicated for the specific product,
are to be used. The rail car type will be identical to the type used for TS-1.
7.2.1.7
Loading
Facilities are required to return offspec products (SBS 03). Loading arms will be installed for
two TS-1 locations and for the four rail tank car locations for other products. Loading arms will
act via the top connection. The pipe shall end close to the bottom of the tank to prevent
splashing of the liquid. The tank opening shall be covered by a Chinese hood to minimize
rain or sand to enter the tank opening.
BC5286-G-13360-001
10 March 2014
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For Comments
7.2.1.8
Vapor balance
Facilities are required for vapor return from the storage tanks (SBS 03) of the gasoline grades
(A-80, A-95 and technical purpose). The vapor balance can be used during unloading of these
products or during loading of offspec.
7.2.2
Railway tracks
One new main railway track will be required to the new fuel tank farm system of the new
Ashgabat International Airport.
The new main railway track for the new fuel tank farm system of the new Ashgabat
International Airport will be branched off from the existing main railway track located at the
south of the Ashgabat International Airport. The location of this branch is not yet known and
will be determined during basic design phase.
At the new fuel tank farm system the new main railway track will be divided into 3 separate
railway tracks. One railway track will be for loading and unloading of a rail car with aviation
packaging materials. The two other railway tracks will be for loading and unloading of aviation
fuels, automobile fuels and de-icing fluid.
The end of a railway track shall be equipped with stopping bars. According SNIP 2.11.03-93,
the end of the railway track should be at least 30 meters from the loading and unloading spot.
This is required to be able to move a rail car to an empty area in case of a fire.
7.2.3
Access to site by road
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 and trucks and should be suitable for both driving directions.
7.2.4
Containment
The containment shall be on slope, keeping a pool fire apart from the rail tank cars.
7.2.5
Platforms and access ways
Platforms are required on to reach the top level of the rail tank cars for top loading, vapour
return, level measurement and top sampling of products and on the lower line for unloading
and bottom sample connections.
A typical rail car shall be used having a standard length and top elevation; see doc xx.
A railroad overpass for access to top level platforms for 26 rail tank car locations shall be
provided. The overpass shall be equipped with sufficient staircases for escape routes to the
area around the loading and unloading bays and for access to the lower platforms in between
the loading and unloading bays.
For representative sampling it is necessary to provide windproof cabinets at the railroad
overpass. Such cabinets shall be mounted to the tilt-able access platforms to each rail tank car
top nozzle.
BC5286-G-13360-001
For Comments
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10 March 2014
7.2.6
(Un)loading facilities and vapour return connections
(Un)loading facilities and vapour return connections shall be easy operable. Drips catching
shall be provided by design.
BC5286-G-13360-001
10 March 2014
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For Comments
TANK FARM SBS 03

8.1
Scope of subsystem
The Tank Farm is the buffer between fuel supply by rail tank cars and airport consumers. The
Tank Farm scope SBS 03 concerns all the fuel containing tanks and vessels including pumps,
separators and related components. The interfaces with other subsystems are shown in table
8.1A.
Interface with other
subsystem
SBS 02 Rail car
(un)loading
Scope limit of other

subsystem
(Un)loading connections
with rail cars and discharge
line to the buffer tank
SBS 04 Fuel distr. Network

incl. hydrants
SBS 05 Gantry and petrol
station near tankfarm
SBS 15 Fire fighting
Fuel headers to fuel

hydrants
Petrol counters,
containment
Foam and cooling water
supply lines

Hoses connected to the
manifold for unloading of 4
railcars for B91/115, A-95,
A-80 and diesel
Manifold in tankfarm
Hoses and lines to fuel
stations
Risers and provisions on
top of tanks
The Tank Farm consists of the main components listed in table 8.1B. For details see BOQ
document xx, filter SBS 03.
SBS
Description
03.12
03.14
Piling
03.16
Sewer & drainage
03.17
Roads & paving
03.23
Concrete foundation
03.24
Trench and pipe trace
03.26
Concrete pipe sleeper
03.27
Containment
03.30
Pipe rack
03.36
Platform and access way
03.40
Canopy and sun sheds on tanks
03.51
Horizontal tanks and vessels
03.54
Vertical storage tanks for TS-1
03.55
Tank bottom leak detector
03.55
Separator
03.58
Pump
03.6x
Piping
03.65
Sampling provision on tank
03.7x
Instrumentation
03.8x
Electrical
Table 8.1B main components of SBS 03
See paragraph
6.6.2
6.6.3
6.6.6
6.6.9
6.6.4 + 8.2.3
6.6.2
6.6.4
8.2.3 + 8.2.6
6.6.7
6.6.8 + 8.2.7
6.6.7 + 8.2.5
8.2.5
8.2.4
8.2.3
8.2.5
8.2.6
6.7
8.2.1
6.8
6.9
BC5286-G-13360-001
For Comments
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10 March 2014
8.2
8.2.1
Process
The tank farm is intended for the following services:

Buffer and transfer of fuels
Recovery of TS-1
Monitoring of fuel quality
Vapor balancing
Low suction, offspec
Additives
8.2.1.1
Buffer and transfer of fuels
TS-1 fuels are received from rail tank cars in a buffer tank (SBS 02). The use of an
atmospheric buffer tank will give a smooth operation of the TS-1 unloading pumps due to a
stable supply and pressure of TS-1 aviation fuel. Also will it prevent air intrusion from the rail
cars into the piping system.
TS-1 fuels are transferred via a manifold to the TS-1 storage tanks. The contents of a rail car is
about 80 m3. The total contents of 22 railcars is 1760 m3. Based on a total pump capacity of 4
x 120 m3 / h this amount can be transferred to storage within 4 hours.
After transfer the TS-1 storage tank will be separated from the system by means of closing the
double block and bleed valve. TS-1 should remain in a storage tank for settlement and
approval of quality before it can be distributed. No simultaneous filling and emptying of a TS-1
storage tank is allowed. A separate tank outlet is connected to a floater to collect TS-1 from the
surface of the tank contents.
TS-1 from storage tanks can be distributed via manifolds and two underground headers to the
fuel hydrants at the aprons (SBS 04). The headers shall be kept pressurized by return of the
minimum pump flow to the source tank. A smooth switch from one approved source tank to the
next shall be possible.
TS-1 distribution to the gantry near the tankfarm (SBS 05) is possible via a manifold separated
from the manifold to the hydrant headers. Via the pump discharge manifold a branch is made
for offspec product to rail cars (SBS 02).
The other products (see 123_1.19_GE-LST_002) are direct transferred from rail tank cars
(SBS 02) to storage tanks. The products can be transferred from the storage tanks to the
gantry and petrol stations near the tankfarm (SBS 05). In addition offspec products can be
returned to rail cars (SBS 02).
8.2.1.2
Recovery of TS-1
Sedimentation, fouling and water will be collected at the bottom sump of the TS-1 storage
tanks. This waste can be drained to slops tanks. TS-1 coming from the TS-1 storage sampling
system and the TS-1 thermal relief valves can be drained to the slops tanks. Any TS-1 liquid in
the slops tanks can be pumped from the slops tanks to TS-1 recovery tanks. The recovered
TS-1 can be pumped back to the TS-1 storage tanks.
BC5286-G-13360-001
10 March 2014
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For Comments
8.2.1.3
Monitoring of fuel quality
Monitoring of the transfers described in the previous chapters is listed in table 8.2A.
Product
From
To
microfilter
TS-1
Buffer
tank
storage
storage
Yes
TS-1
TS-1
Other
fuels
storage
storage
Rail car
aprons
gantry
storage
Other
fuels
storage
De-icing
Rail car
Gantry
or petrol
station
gantry
Recovered
TS-1
Recovery
tank
TS-1
Filter/water
separator
yes
Millipore
filter
connection
Approval
before
transfer
yes
yes
Bulb on
storage
tank
Yes
connection
connection
Sample
point
yes
From
different
levels incl.
recirculation
yes
yes
On storage
tank
Yes
Bulb on
storage
tank
yes
storage
On storage
tank
From
different
levels incl.
recirculation
Table 8.2A monitoring of fuel quality

All filter/water separators will have a drain connection to a slops tank. TS-1 slops are kept
separate from slops related to other products.
The micro filter, filter/water separator, connection for millipore filter and flow meter will all be
located in a spill containment to protect the surroundings in case of a spill. The discharge of
the spill containment will be connected to an API oil separator. The discharge of the API oil
separator will be connected to the storm sewer.
8.2.1.4
Vapor balancing
Vapor balancing shall be applied for the products indicated in table 6.11B as shown on the
Process Flow Schemes. No Vapor Recovery Unit is required.
8.2.1.5
Low suction, offspec
Sedimentation and water will be collected at the bottom sump of the TS-1 storage tanks. This
waste can be drained to a slops tank via a low suction connection of a storage tank. TS-1
liquid in the slops tanks can be pumped from the slops tanks to recovery tanks. The recovered
TS-1 can be pumped back to the TS-1 storage tanks.
A 2nd low suction is for draining of TS-1 with sufficient quality to another tank when a tank has
to be emptied.
Offspec TS-1 can be returned via the storage tank outlet to rail cars (SBS 02).
BC5286-G-13360-001
For Comments
- 77 -
10 March 2014
The tanks for other products and filter / water liquid separators are each provided with a bulb
for removal of water and sedimentation. The most bulb drains are connected to slops tanks.
The bulb of the storage tanks for other fuels can be connected to the top loading of a rail car
(SBS 02) for offspec return. The bulb of the storage tank for de-icing is provided with a drain
only. Offspec to rail car can be returned via the normal outlet.
8.2.1.6
Additives
In general the TS-1 aviation fuel will be supplied from the supplier including the required
additives. Nevertheless the design will include an optional design for a dosing system for antistatic additive. This optional anti-static dosing system will be located in the TS-1 pump spill
containment.
8.2.2
Buffer capacity
The buffer capacity for each product shall be sufficient for the maximal supply interval at
maximal demand.
8.2.3
8.2.3.1
Containment and tank foundations

Containments general
The soil shall be protected by containments at all locations where large spills might occur.
The floor of each containment should be of concrete of minimum concrete grade C28/35 with
at least 2.0% steel reinforcement of steel grade B500B. Special care needs to be taken to
ensure liquid tightness at the junction of tank foundations and floor Prepufe 300R (or
equivalent) adhesively bonded HDPE membranes should be pre-applied to the entire top
surface of 50mm blinding concrete before placement of the concrete for the raft slab, tank
foundation and containment bunds. Special care needs to be taken to ensure liquid tightness
at the anchoring of tank skid and pump platforms to the floor to ensure that the slab is not
punctured through-and-through.
Containments shall be bunded with a continuous reinforced concrete retaining wall to provide
secondary containment in case of spillage or rupture of a tank. The tank farm will consist of
several separate tank pits each surrounded by its own containment bund meeting the
requirements of I.P. Code Part 19 "Fire Precautions at Petroleum Refineries and Bulk Storage
Installations" The foundation raft of the concrete bund shall be at a minimum depth of 900mm
below final ground level outside the tank pit. Fire-retardant joints shall be used at the bunds.
The bunds shall be of reinforced concrete of minimum concrete grade C28/35 with at least
5.0% steel reinforcement of steel grade B500B. The bunds shall have adequate corrosion
resistance, adequate strength and durability (in total : sufficient quality) as soil protection
against the stored products
As per current design the minimum required bund heights are:
Tank pit TS 1: 1600mm
Tank-pit Other Fuels: 600mm
DBC contractor shall check the minimum bund height requirements according I.P. Code Part
19.
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For Comments
The containments shall have rainwater drains which drain into a contained and enclosed
collection sump in the base, requiring manual action for discharge into a drain. There shall be
no pipework that penetrates through the bund floor as far as reasonably practicable, otherwise
it shall be with adequate sealing and support.
8.2.3.2
Containment for TS-1 tanks
The TS-1 containment shall be provided with a threshold to separate the containment in two
parts to limit the area of pool fire.
8.2.3.3
TS-1 tank foundations
Vertical storage tanks for TS-1 shall be supported on a concrete foundation ring beam in-filled
with sand. At the base of each tank will be 5cm sand lined with bitumen sand, which will be
underlain with 10cm bitumen and gravel. A perforated steel pipe will pass beneath this layer
within a layer of gravel and sand. Any leakages will be collected by the pipe and detected at
the outlet. Beneath the pipeline a bentonite seal layer will serve to prevent leakages entering
the soil.
The footprint of the containing ring beam shall be hexagonal for vertical cylindrical tanks and
rectangular for horizontal tanks. The reinforced concrete shall be of minimum concrete grade
C28/35 with at least 2.0% steel reinforcement of steel grade B500B.
Horizontal storage tanks will be supported on raised steel skids of adequately designed
capacity, and will rest on a (minimum) 200mm thick reinforced concrete continuous raft slab.
The raft slab shall be bounded by a continuous concrete curb of minimum height of 500mm.
Steps for entry and exit from this curbed/bunded area, shall be provided in at least 3 locations.
The steel skids shall be anchored to the concrete slab using appropriately designed anchor
bolts as per specified standards.
The TS-1 tank foundation shall be provided with a tank bottom leak detector giving a visual
indication (e.g. by means of a floater) that liquid is entering the space between tank bottom
and foundation.
The TS-1 tank foundations shall be approved by DBC before start with the construction of the
tanks is allowed.
8.2.3.4
Containment for vacuum truck
Slops tanks can be emptied by using a vacuum truck. Near every slops tank a liquid tight area
with connection to the contaminated water drain system shall be provided to locate the vacuum
truck during emptying of a slops tank.
8.2.4
Tanks with conical roof
The TS-1 aviation fuel storage tanks shall be designed according International Design Codes
and International Aviation Codes.
Each TS-1 storage tank shall include the items listed below:
Atmospheric cylindrical vertical tank
Material carbon steel with coating (internal and external)
Conical roof
Conical down bottom with central sump
Floating suction line including sampling at 3 elevations
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For Comments
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Goose neck protected with mesh for open vent

TS-1 supply at the bottom (dedicated nozzles required)
2 low suction connections at the bottom
Manholes, each provided with a David (lifting device)
Nozzles for all connections and instruments including 2 spare
Dip hatches
3 vertical conduit 2 pipes over the full height of the tank to protect instrument cables
and cable for lighting to the top
Provisions to mount lighting
M16 earthing bolt
External riser lines from flange near tank bottom to foam chambers at top of cylindrical
tank wall.
External riser lines from flange near tank bottom to cooling provisions on top and at
sides of the tank.
Top platform including handrails
Access and escape routes shall be determined in an integral way for all the TS-1 tanks
resulting in sufficient spiral stairways and cage ladders on the tanks and inter connecting
bridges between the tanks.
All tanks shall be designed as low-pressure tanks unless the TS-1 tanks are free venting. This
may allow future application of pressure vacuum valves. It is not required to design the bottom
of the tank for the design vacuum. During normal operation there will be always a layer of
product present in the tank. If the tank is emptied further, roof nozzles shall be opened to
prevent vacuum.
The required ventilation and venting capacity shall be based on gravitational discharge of a full
tank contents through the tank outlet nozzle. The calculation must be performed in accordance
with ISO28300. The amount of vent nozzles shall be based on the probability of failure of one
of the (future) vacuum valves leaving sufficient vent capacity via the other nozzles.
The level measurement and sampling point shall be centrally placed on the roof. All roof
nozzles should be accessible from the top platform.
The bolt holes of the flanges connected to the tank shall be straddle to the center lines of the
nozzles.
The earthing bolt shall be M16.
The bottom of the tanks shall be executed as "cone - down" with a slope of 1:120 with in the
center a bottom sump, 600 mm internally. The bottom sump top shall be welded below the
bottom plate level in order to ensure good drainage.
The tank wall shall be welded inside flush to the bottom plates.
The minimum thickness for wall, bottom and top plates is 8 mm.
The batch numbers of soil and annular plates must be visible at the top. The batch number of
the wall panels shall be visible on the inside of the tank wall.
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For Comments
8.2.5
Tanks with dome heads and separators
Tank with dome heads will be used for all other applications. Those tanks can be designed
according local Design Codes.
Each tank with dome heads for fuels shall include the items listed below:
Aboveground horizontal tanks
Bottom sump
Design pressure based on application of pressure vacuum valve and vapor balancing
line.
Shed on top of each tank to protect for solar radiation
The bottom of the riser shall be provided with a restriction, dampening the level increasing
speed and preventing overflow via the vent.
The de-icing storage tank shall include the items listed below:
Aboveground horizontal tank
Bottom sump
The TS-1 recovery tank shall include the items listed below:
Aboveground horizontal tank
Floating suction line including sampling at 3 elevations
All the storage and recovery tanks with dome heads, including free venting tanks, shall be
designed at least as low-pressure tanks. This may allow future application of pressure vacuum
valves for the tanks.
The slops tank shall include the items listed below:
Underground horizontal tank
Cathode protection
Manholes
Dip pipe for discharge by vacuum
Nozzle for piping to aboveground open vent
The number of slops tanks is de pending on the locations where slops are to be gathered from
and the available level differences for sufficient slope to the slops tanks.
The filter/water separator shall include the items listed below:
Aboveground horizontal tank designed for stalling pressure of the upstream pump.
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For Comments
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The specification limit of the fuel outlet is 30ppm (parts per million) free water
Bottom sump
The micro filters shall include the items listed below:

Aboveground filter housing designed for stalling pressure of the upstream pump.
Bottom drain
Easy removable top for filter cleaning / filter exchange, provided with a David (lifting
device) if weights of components to be handled exceed 25 kg per component.
Nozzles for all connections and instruments
Filter opening 25-30 micron
Strainers shall include the items listed below:
Aboveground strainer housing designed for maximal suction pressure of the
downstream pump.
Bottom drain
Easy filter cleaning / filter exchange.
Nozzles for in-line connections
Coarse filter opening to protect the downstream pump.
The bolt holes of the flanges connected to the tank or separator shall be straddle to the center
lines of the nozzles.
Each tank or separator shall be provided with a M16 earthing bolt.
8.2.6
Pumps
The most pumps can be executed as centrifugal pumps each direct driven by a fixed speed
electric motor.
The elevation of each pump in relation to the suction vessel shall be sufficient to prevent the
need for priming. Exceptions can be made for self-priming pumps required for underground
suction vessel or for emptying the sump for the TS-1 buffer tank.
In general all pumps will be located in containments separated from the tank containments. An
exception can be made for the pumps in the containment for the TS-1 buffer tank. The design
for that containment shall be based on pump elevations below the buffer tank bottom and a
connection on slope to a remote containment, apart from the pumps, where major spills can be
gathered.
The remote containment for the buffer tank shall be provided with a submergible pump for
discharge to the slops tank (small spills) or to an ATEX certified vacuum car (large spills).
The six large TS-1 pumps pressurizing the headers to the fuel hydrants at the aprons will be
provided with variable speed drive systems enabling lower start currents and easy adjustment
of the supply to the fuel demand.
Each fuel pump shall be executed with a seal leak detection.
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For Comments
The suction line of each pump should be equipped with a strainer to protect the pump. The
discharge line of each TS-1 unloading pump should also contain a spool piece to be able to
install an additional filter if required.
Pump platforms will consist of continuous reinforced concrete slabs of depth and reinforcement
designed as per the footprint and weight of the pump skids. The reinforced concrete shall be of
minimum concrete grade C28/35 with at least 2.0% steel reinforcement of steel grade B500B.
8.2.7
Access
Sufficient provisions shall be made for easy routine access and for emergency routes.
In the Tank Farm specific attention is required for:
Bund wall crossings
Crossings with pipe routes
Access to tank roofs including interconnecting bridges between vertical tanks
Access to relief valves and other provisions on top of tanks
Access for operation and maintenance; specific for pulling of internals
Readability of all local instrument indications
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For Comments
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10 March 2014
FUEL DISTRIBUTION NETWORK INCL HYDRANTS SBS 04

9.1
Scope of subsystem
The Fuel Distribution Network (Incl. Hydrants) is supplying the fuel from the Tank Farm to the
Airport consumers. The Fuel Distribution Network (Incl. Hydrants) scope SBS 04 concerns all
Fuel hydrant lines, valve pits, hydrants and related components.
The interfaces with other subsystems are shown in table 9.1A.
Interface
with
subsystem
SBS 03 Tank farm
other
Scope limit of
other
subsystem
Manifold in tank farm
SBS 06 Gantry and petrol Hoses and line to gantry

station near apron

Fuel headers
hydrants
Fuel header
hydrants
to
Fuel
to
Fuel
The Tank Farm consists of the main components listed in table 9.1B. For details see BOQ
appendix 15, filter SBS 04.
SBS
Description
04.12
04.6x
Piping
04.23
Foundation
04.24
Table 9.1B main components of SBS 04
9.2
9.2.1
Process
See paragraph
6.6.2
6.7
6.6.xx
6.6.xx
This part concerns an entire new underground fuel supply system at the airside of the Airport.
The Fuel Distribution network is intended for the following services:
Transfer and delivery of TS-1 fuel
Flushing of the system back towards TS-1 storage tanks
Pigging
9.2.1.1
Transfer and delivery of TS-1 fuel
TS-1 fuels are pumped from the TS-1 hydrant pumps (SBS 03), with a flow up to approx. 1500
m3/h, to the aprons and gantry (SBS 06) via a, mostly, underground Piping network.
Two (2) main headers will transfer the fuel from the Fuel Farm towards the main valve
chamber VP1.
To protect the buried lines from corrosion, cathodic protection shall be applied. The buried
lines shall be electrically separated from other metallic structures to protect chemical
(re)action.
In order to allow maintenance and regular leak testing sectional valve chambers are foreseen.
To increase the hydrant system availability the network will be designed as a looped system,
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For Comments
meaning that two separate lines are foreseen between all adjacent valve chambers. This will
allow parallel maintenance and operation.
The valve chambers will be underground installed with enough provisions for maintenance and
easy access by stairway and/or ladder.
To limit the amount of fuel during a spill and safety reasons a valve chamber has been
foreseen every approx. 200 m3 (single line volume) or at the end of a distribution loop.
At each apron 2 Fuel Hydrants will be available, each connected to a separate header.
The hydrant pit valves function is to facilitate aircraft refueling at all aprons by connecting
between the underground hydrant system and dispenser, as well as safely control the flow of
fuel into the aircraft. The design of the pit shall minimize the ingress of ground water and
egress of spills and/or leaked fuel.
Nozzles, hydrant couplers and hydrant pits shall have dust covers in place when not in use.
The dispensers shall be provided with metering, filtration and control valves to allow safe
control of the flow into the aircraft in combination with pressure control.
At every apron, at minimum, one emergency shutdown (ESD) button shall be provided. When
pressed, the hydrant will be zoned. The system shutdown will be restricted to that vicinity.
9.2.1.2
Flushing of the system back towards TS-1 storage tanks
Although a sufficiently high velocity should be maintained in the lines at all times to reduce
sedimentation, it cannot be prevented.
The flushing of the system shall be accomplished by pumping TS-1 from one of the operating
tanks (SBS 03) through the TS-1 fuel lines, back towards a different tank until the quality of the
returning TS-1 is within the acceptable limits as defined by Employer.
9.2.1.3
Pigging
Provisions are in place to enable pigging

1.19_GP_0802_HK_0003_0 (appendix 6).
9.2.2
of
the
main
lines
as
indicated
in
Design considerations/requirements
The Fuel System shall be designed and sized to accommodate a peak flow of 26.7 m3/min.
The current preliminary design ensures a minimum pressure of 8.5 barg at all hydrants, which
is sufficient.
Preliminary calculations and line sizing has been performed based upon the following
requirements:
A low pipe roughness (Coated pipe).
Velocities in the line shall be 3 m/s at a maximum.
Minimum / Maximum / supply pressure at the beginning of the Fuel System (directly
after the control valve at the pumps) shall be 10.5 barg.
On each line, between two independent valve chambers, fuel is withdrawn.
Depending on the maximum plane size the withdrawal is at the same apron or two
aprons as far apart as possible.
During peak flow no withdrawal shall take place at the Gantry.
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For Comments
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Fuelling of VIP and parked planes will be done outside of peak hours.
The system shall still be able to accommodate a flow of 26.7 m3/min and maintain sufficient
supply pressure of 8.5 barg at all hydrants, within all requirements, when one of the main
headers (From Fuel Farm to Valve Chamber VP1) is out of service.
Preliminary calculation results are given in Appendix 22. Based on these calculations the
preliminary line sizes are stated in 1.19_GP_0802_HK_0003_0 Plot plan fuel hydrant system
(Appendix 6).
The DBC is responsible for an adequate and safe system, which complies with all
requirements, and must check if the sizing, as stated in Appendix 6, is still applicable when the
final design is available.
All lines above and including 14 shall be suitable for pigging. Pigging shall be performed by a
third party. Provisions for attaching pigging installations shall be provided by the DBC.
During normal operation the velocity in the lines will be (very) low. In order to prevent the
accompanying problems it is advised to feed the loops from one side instead of two. The
system shall be designed to accommodate this.
The DBC shall design and install provisions to allow (partial) flushing of the system back to the
Fuel Farm.
9.2.3
Piping under runway/taxiways
Due to the location of the Fuel Farm in relation to the aprons, it is required to pass under the
runway and taxiways. When crossing, the shortest possible route shall be selected.
The lines shall pass at sufficient depth to avoid excessive external forces on the pipe.
9.2.4
Water hammer
DBC shall check the requirement for provisions to reduce the effects of water hammer. The
large diameter of piping in combination with the velocity, especially during peak hour operation
with one header, will result in very high pressures (>30 barg). The accompanying forces might
result in loss of pipe integrity and/or damage to the coating.
9.2.5
Underground obstructions
DBC shall check for existing structures, underground piping, cables or other obstructions.
Appendix 6: 20140211_123_2.XX_GP_00013_1_AV -infra total shows the Masterplan with all
existing or future structures, cables or piping. It is the responsibility of DBC to make a design
based on this interfaces. Depending on overall Construction planning DBC can examine when
other structure, cables or other will be constructed by others.
9.2.6
Excavation of trenches for pipe installation
The pipe trenches as described in the General section shall be excavated up to a max. depth
of 0.5m beneath the planned pipeline. The trench depth and bottom width are specified in
more detail for each pipe section.
It is to be assumed that the average depth of the pipelines is 8 meters below surface.
See Appendix 5: Std. Earthwork activities with drainage
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For Comments
See Appendix 15: Bill Of Quantity

9.2.7
Excavation for valve chambers and other structure installations
The construction pits installed in an open excavation must be excavated as described in the
General section up to a maximum depth of 0.5m below the concrete structures with pipes that
are to be built or installed and in addition set a distance of 1.0m from the structures, measured
from the underside.
See Appendix 5: Std. Earthwork activities with drainage
9.2.8
Valve Chambers
Valve chambers will be constructed in order to house hydrant isolation valves. The chambers
will be constructed using reinforced concrete. The valve chambers will be located outside of
taxiways / service roads and shall be installed flush to finished ground level. Pit covers shall be
suitable for the passage of road vehicles to a maximum weight of 70T. Sumps shall be
provided in each chamber. The valve chambers should be designed for seismic loads.
There are several groups of valves indicated on the KKIA Exhibit G Addendum 1 Part B2
Drawings, these valves will be located in a by DBC to construct reinforced concrete chamber.
Concrete for cast-in-place structures shall be according to standard, with a nominal minimum
28-day compressive strength of 30 MPa and should be designed to be able to resist seismic
loads.
The valve chambers will be underground installed with enough provisions for maintenance and
easy access by stairway and/or ladder.
9.2.9
Drain and Vent Points
Drain and vent points will be located at high and low points on the new hydrant system. The
valves shall be mounted above groundlevel.
9.2.10
Hydrant Pit Assemblies
The hydrant pits will be located directly above the hydrant pipeline at positions suitable for the
refueling of heavy aircraft. A hydrant point shall be provided to cater for each wing i.e. right and
left of the aircraft center-line. It shall consist of a reinforced concrete casing of as per the
dimensions of the Environmental Pit Box for hydrant isolation valves. The hydrant pits should
be designed for seismic loads.
9.2.11
Hydrant Pipeline Installation
9.2.11.1 Surveying and Setting Out

Horizontal Control Stations
Horizontal survey control stations shall be established around the site, consisting of a number
of permanent ground markers (PGM). PGMs shall be coordinated on the airport grid by
established surveying techniques, using DGPS electronic total stations and levels as
appropriate absolute relative to height. The positional accuracy of the PGMs shall be:
Horizontal
10mm absolute
3mm relative to neighboring stations
Vertical
3mm absolute
1.5mm relative to height
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For Comments
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DBC shall propose a suitable construction arrangement of the PGMs for the Employers
approval. All survey works shall be tied to the PGM network.
9.2.11.2 Location and Protection of Control Stations
DBC shall co-ordinate the location of PGMs and Bench Marks with the
Employer and other involved parties to ensure that the locations selected will not be in conflict
with other temporary and permanent works being constructed by others on the site. In the
event that conflict arises necessitating relocation of any of the PGMs, relocation shall be
carried out by DBC at his own cost and the new PGM shall be coordinated and levelled into
the control system and the reference drawings shall be updated accordingly and re-issued.
Reference drawings of the survey control system shall be prepared by DBC and issued to the
Employer.
PGMs shall be protected throughout the duration of the works and shall be subject to checks
for co-ordinate and level accuracy at intervals to be agreed with the Employer. DBC shall be
held responsible for any errors detected in coordinates and levels and for any corrective
measures required to line and level of the hydrant pipelines resulting there from.
PGMs are expected to remain in position after completion; however this will be subject to the
Employers agreement. In the event that any or all PGMs are required to be removed, DBC
shall do so at no additional cost.
9.2.11.3 Setting Out of the Pipeline Routes
DBC shall set out the routes of the pipelines in accordance with the Drawings.
Using the survey control system, the pipelines shall be set out to accuracies of:
Horizontal: +10mm
Vertical: + 3mm
DBC shall allow 2 working days for the Employer to check the setting out before the routes are
fixed. Minor adjustments and realignment may be required to facilitate construction and shall, if
required, be made at DBCs cost.
9.2.11.4 Trenching
General Excavation
The pipe trench shall be carefully excavated to a depth of 200mm deeper than the invert levels
specified in the Drawings. The trench bottom contour shall be such as to obtain a smooth
profile for the pipeline and to obviate field bending. All excavation shall be by hand or
mechanical equipment subject to proximity of other services.
The pipe trench shall be excavated along the staked alignment but where there is a change in
direction, the trench shall be cut so as to accommodate the specified radius of pipe bend. A
clearance shall be maintained between the bend and the trench walls to conform to the trench
dimension requirements.
The finished trench shall be free from stones, rocks or other hard objects which may damage
the pipe or pipe coating. Provision shall be made for dewatering if required. Where the trench
has been over-excavated to a depth greater than that specified above, DBC shall refill the
trench to the specified depth with suitable excavated material and consolidate.
Trench Dimensions and Pipe Cover
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The pipe trench shall be excavated as specified above. The trench width shall not be more
than 1200mm greater than the outside diameter of the coated pipe. At locations where work on
the installed pipe is to be performed later, such as at tie-ins, sufficient extra excavation shall be
made so that welding and other work can be performed satisfactorily around the pipe in the
trench. The depth of cover shall be 1.5m or otherwise advised on the Drawings.
Limitation of Open Trench
In order to reduce the hazard of long lengths of open trench excavation and to avoid the risk of
problems and additional work caused by earth slips and falls in rainy weather, DBC shall plan
his construction programme and excavating operations so that the trench remains open for as
short a period as practicable. Protective measures to be adopted at open trenches. The
maximum length of trench permitted to be open at any one time is 300 metres.
Note Intermediate tie-in welds to be left exposed until hydrotest satisfactory completed with
suitable fencing barriers in place.
Earth Spoil Bank
The bank of earth spoil produced by pipe trench excavation shall not be contaminated by
organic and other foreign materials that would produce an unsatisfactory back-fill. DBC shall
make gaps in the spoil bank so that rainfall will not cause water to accumulate and flood
adjacent areas. Where insufficient land is available to accommodate the excavated material, it
shall be removed from site for temporary storage and if suitable, returned for the back-filling
operation.
Timbering and Supports
When ground conditions are such that the sides of the trench are unstable or where the depth
of the excavation exceeds 1.5 metres, DBC shall provide timbering, sheet piling and supports
to retain the trench side walls to the satisfaction of the Employer. DBC shall be responsible for
selecting the most suitable type of support system based on prevailing ground conditions.
Water Removal and Disposal
Open trenches shall be kept free from water at all times. DBC shall submit to the Employer his
proposed methods for trench dewatering, including equipment to be used. Inlet filters shall be
fitted and used on all pumps used for dewatering. The deposition of silt in ditches, water
courses or drains due to disposal of water from the Works shall as far as possible be avoided,
but if so caused, shall be cleared out by DBC.
Access
Where access is to be provided across the pipeline route, DBC shall provide safe access
across the trench. Such access shall be provided at reasonable intervals for third parties
where directed by the Employer.
Existing Services
DBC shall follow the approved proposals for support and protection of existing underground
services. Excavation around existing services shall be carried out by hand with such care as is
necessary to avoid damage to the services.
Bedding Material
Where required DBC shall import and lay bedding to the invert of the trench, after excavation
of the trench. Should DBC not have excavated the trench to sufficient depth to accept imported
bedding, which would result in the laid pipe not having sufficient cover, then DBC shall reexcavate or lower the bottom of the trench by an approved method.
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Imported material used for bedding shall be sand and shall be clean and salt free and shall not
contain clay, roots, stones or other material which is likely to cause damage to the pipe
coating. DBC shall, prior to any imported material being used for pipe bedding, submit samples
of the proposed materials for the approval of the Employers representative, and shall satisfy
the that sufficient quantities of suitable materials are readily available for use in the pipeline
trench.
Pipeline Surround Material
Where suitable material free from sharp stones or flints, perishable matter or other materials
likely to cause damage to the pipe coating, other than the surface top soil material, can be
selected / obtained from the excavated material adjacent to the point of backfilling, same shall
be used to provide intimate backfill for the pipeline.
The material shall be carefully placed over and around the pipe and shall not be dropped
directly onto the pipe from a height above the pipe exceeding 500mm. The material shall be
worked around and under the pipe by either mechanical or hand held machines or tools, to fill
any voids which exist. Within the constraints of safe working practices, the material shall be
rammed around the pipe in layers not exceeding 150mm using suitable tools ensuring that no
damage is caused to the pipeline coating. Such suitable material shall be used up to a level of
at least 150mm above the crown of the pipe.
Intimate Back-fill
Pipeline intimate back-fill shall be sand of an equal specification to that of trench padding. The
material shall be carefully placed over and around the pipe and shall not be dropped directly
onto the pipe from a height above the pipe exceeding 500mm. The material shall be worked
around the pipe to fill any voids which exist. Within the constraints of safe working practices,
the material shall be hand rammed around the pipe in layers not exceeding 150mm thick using
wooden tampers or other tools ensuring that no damage is caused to the pipeline coating.
Such sand back-fill shall be used up to a level of 300mm above the crown of the pipe.
General Back-filling and Compacting
The remaining excavated material shall be returned to the trench in layers not exceeding
300mm and compacted. Compaction shall be undertaken in accordance with an approved
procedure using mechanical equipment. The procedure shall state a method and degree of
compaction adequate to preclude any further settlement.
DBC shall establish by field tests the type of compacting plant and number of passes to be
used taking into account the cohesiveness and the moisture content of the back-fill. Such a
procedure shall be reviewed whenever the soil type and conditions show significant variation.
DBC shall consider reducing the excavated material to a suitable size and texture, and
supplying and adding water to obtain optimum moisture content.
DBC shall commission an approved testing house to carry out regular compaction tests at
various levels of the compacted back-fill material to verify the degree of compaction achieved.
The density of the compacted back-fill shall not be less than 95% of the adjacent undisturbed
soil at the same depth.
Imported General Back-fill
Should the Employer consider that the excavated material cannot be used for general back-fill
material for whatever reason he will instruct DBC to remove the unsuitable material from the
site and dispose of it at a licensed tip. Under such circumstances DBC will be instructed to
import suitable general back-fill material from an approved source. The material shall be either
granular or cohesive and be free from any material or chemicals which may be detrimental to
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For Comments
the integrity of the pipeline or incompatible with the native soil conditions. DBC shall submit
samples of materials he proposes to use for this purpose for approval by the Employer.
Back-filling of Vertical Pipe
Risers and any other vertical sections of hydrant piping shall be surrounded by a minimum
150mm layer of intimate backfill. During back-filling, the riser shall be laterally supported by
temporary timber or other approved restraints.
Removal of Surplus Excavated Material
Surplus excavated material displaced by the pipelines and the presence of imported material
shall be removed from the site and disposed of by DBC. DBC shall ensure that the material
actually removed from site is the material from the part of the trench excavation which has
been replaced by the pipe and imported material.
Reinstatement
Unless otherwise directed, DBC shall permanently reinstate all areas disturbed by the Work, or
as a result of the construction of the Work, including surfaces, structures and features to a
condition equivalent to that existing before the commencement of the Work and shall provide
all materials required.
DBC shall maintain the reinstatement, and make good the surface of the trench, all sinkages,
scouring, erosion or other defects until the Final Acceptance of the Work. Reinstatement shall
be carried out as soon as practicable after completion of backfilling.
The material used in soil reinstatement shall be the excavated material from the upper levels of
the pipe trench and shall match the soil in the surrounding area. DBC shall remove all surplus
excavated material.
9.2.11.5 Pipeline installation under Aprons and Taxiways
The design of the hydrant pipeline under taxiways shall consider requirements for future
maintenance, i.e. alternative pipe surround other than encasement in concrete. Where the
trench is in any area designated for development of airport aprons, taxiways or roads, foam
concrete shall be used as the backfilling material up to a level of 700mm below the planned
future finished ground level. The foam concrete shall be laid strictly in accordance with the
manufacturers instructions. The level above the foam concrete shall be reinstated in
accordance with the relevant Directorate General of Civil Aviation (DGCA) specifications.
9.2.11.6 Pipeline Warning Tape
During back-filling of the trench pipeline warning tape shall be introduced above
the pipeline on top of the intimate backfill. Pipeline warning tape shall be high strength
metallic/polyethylene material, yellow in color, carrying the repeated wording FUEL PIPELINE
BELOW in English. The tape shall be detectable by industry standard cable locating devices.
The width of the tape shall be 150mm minimum. Samples of the proposed tape shall be
submitted for the Employers approval. The tape shall be run in continuous parallel lengths
above the width of the pipeline diameter.
DBC shall ensure that sufficient lengths of pipe are left exposed to allow for any tie-in work to
proceed without stressing the pipe and that excavation and bell holes are suitably aligned to
ensure vertical and lateral line up without the use of force.
9.2.11.7 Pipeline Markers
Temporary and permanent pipeline markers shall be installed as follows.
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Temporary Markers
Temporary pipeline markers shall be installed at exposed hydrant risers following construction
of pipeline sections where risk of third party interference from other construction activities is
deemed to be increased. Temporary markers shall be of a design approved by the Employer
and shall be left in place until such time as all construction has been completed.
Permanent Markers
Permanent pipeline markers shall be installed where indicated on the Drawings. Pipeline
markers design and inscription shall be agreed by the Employer.
9.2.12
External coating of piping and appurtenances in valve pits
DBC shall apply, test and inspect external coating of steel piping and appurtenances in
accordance with this requisition and its Appendices. This requisition covers external spayed
Zinc coating on piping, valves and instrumentation in valve pits.
9.2.13
Installing and compacting pipe bedding material.

Installing and compacting backfill material. Testing of compaction and providing test
reports for all compaction performed. All necessary backfill with compaction shall be
performed in dry conditions with the aid of drainage, as described in specification.
Various stages in the backfilling of the excavations may be distinguished:

sand with a maximum layer thickness of 0.5m beneath the pipelines;
at least 0.3m of sand on top of the pipelines after the latter have been laid;
further sand backfill to the underside of the future foundations for paving;
further sandy soil backfill up to ground level in unpaved terrain.
The sand beneath the pipes must be well drained.
The backfill material shall be placed in position in layers 0.3m thick and compacted with a
vibrating plate in a minimum of four passes, criss-cross and overlapping. The subgrade of
0.5m shall be compacted in a single layer with a suitable vibrating weight. Where it is not
possible to vibrate beside the pipes at right angles to the direction of the run, extra compaction
should be made in two passes. The weight of the vibrating plate must be at least 3.5 kN and
must also be geared to the thickness of the layer to be compacted, while it must also be able
to function optimally. Other vibrating equipment shall require the express consent of the
management.
The optimal compaction degree shall be determined with the aid of a Proctor test for each pass
of sand and if the composition of the sand so justifies.
In the case of control measurements and in situ cone penetration testing, the values found
shall be recorded on the relevant forms, unless the equipment is self-recording.
The locations in respect of fixed measurement points or lines shall also be recorded.
See Appendix 5: Std. Sand backfill with compaction
See Appendix 15: Bill Of Quantity
9.2.14
Design and install a cathodic protection system
Provide a temporary sacrificial anode cathodic protection system to protect the pipe until the
complete piping system is installed. See Appendix 5: Std. Cathodic protection
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For Comments
9.2.15
Specific standards
Appendix 5: Std. Cathodic protection
Appendix 5: Std. Earthwork activities with drainage
Appendix 5: Std. External coating of piping and appurtenances in valve pits
Appendix 5: Std. Fabrication and Installation of Welded Pipework for Air Fuel systems
Appendix 5: Std. Sand backfill with compaction
Appendix 5: Std. ATEX zone typical valve pits and hydrants.docx
API 1540
Interface with International Airport personnel/staff
Interference with aviation system shall be estimated/taken into account (roads have to
be free for normal airport activities during construction)
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10
GANTRY AND PETROL STATION SBS 05 + 06

10.1
Scope of subsystem
The Gantry and Petrol Station, located at the Fuel Farm as well as the Aprons, are used for
supplying airport vehicles with various automobile fuels and as filling station for bowsers with
TS-1 and Avgas.
The Gantry and Petrol Station scope SBS 05\06 concerns all Petrol Station dispensers,
vessels and related components.
The interfaces for SBS 05 and SBS 06 with other subsystems are shown in table 10.1A or B
respectively.
Interface
with
subsystem
SBS 03 Tank farm
other
Scope limit of
other
subsystem
stations
Interface
with
subsystem
SBS 03 Tank farm
other
Scope limit of
other
subsystem
stations
Manifold at Gantry
SBS 04 Fuel distr. Network

incl. hydrants
Table 10.1B interfaces with other subsystems
Petrol
containment
Petrol
containment
Petrol
containment
counters,
counters,
counters,
The Tank Farm consists of the main components listed in table 10.1C. For details see BOQ
appendix 15, filter SBS 05/06.
SBS
Description
05/06.12
05/06.16
Sewer and drainage
05/06.17
Road to site & paving
05/06.23
Foundation
05/06.24
05/06.27
Containment
05/06.51
Horizontal tanks and vessels
05/06.58
Pump
05/06.6x
Piping
05/06.7x
Instrumentation
Table 10.1C main components of SBS 05/06
10.2
10.2.1
Process
See paragraph
6.6.2
6.6.6
6.6.9
6.6.xx
6.6.xx
8.2.4 + 8.2.6
8.2.5
8.2.6
6.7
6.8
The Gantry and Petrol Station is intended for the following services:
Refueling of airport vehicles
(Un)Loading of bowsers
Parking of bowsers
Testing of relief valves (Test rig)
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For Comments
10.2.1.1 Refueling of airport vehicles
All airport vehicles require some sort of fuel. As refueling outside the airport perimeter is
impractical, refueling should be done on site.
Each type of fuel will get a dedicated dispenser.
The gantries and petrol stations shall be covered by a canopy.
To minimize runway crossings a second petrol station is foreseen close to the aprons. The
underground storage tanks at this petrol station are refilled using a bowser. When (practically)
possible the airport vehicles should refuel at the petrol station at the Fuel Farm.
10.2.1.2 (Un)loading of bowsers
Bowsers will be loaded with TS-1 and/or other fuels at the gantry near the Tank Farm. No
unloading of TS-1 and/or other fuels will take place at the gantry.
Bowsers carrying other fuels will be unloaded at the gantry near the aprons. These fuels are
mainly for the airport vehicles refueling. No unloading of TS-1 will take place at the gantry near
the aprons. Bowsers can be loaded with TS-1 at the gantry near the aprons.
10.2.1.3 Vapor balance
Facilities are required for vapor return from the dispensers and bowsers towards the storage
tanks (SBS 03) of the gasoline grades (A-80, A-95 and technical purpose). The vapor balance
can be used during (un)loading of these products.
10.2.1.4 Parking of bowsers
It is to be expected that the bowsers will not be in operation constantly. Parking areas shall be
available for bowsers which are idle.
To minimize runway crossings, parking will be possible at the Fuel Farm as well as close to the
aprons.
10.2.1.5 Testing of relief valves (Test rig)
A TS-1 branch from the Fuel hydrant pumps (SBS 03) is connected to keep the test rig at the
gantry near the tankfarm (SBS 05) pressurized. The test rig shall be designed for testing of
relief valves at full relief flow related to the maximal hydrant capacity to an airplane.
The test rig will be covered by a canopy.
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11
HANDLING AND STORAGE OF PACKAGED MATERIALS SBS 07 HOLD
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12
UTILITY SUPPLY SBS 11

LATER
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13
GAS AND FIRE ALARM SYSTEM SBS12

The purpose of the fire and gas (F&G) detection system is to detect fires or gas leakages on
the Fuel System site and alarm operators in the field control room, at the gantry and at the rail
tank car (un)loading platform, officers in the main guard house and flight controllers in the
AOC.
The F&G detection system shall consist of F&G detectors, local call points, an F&G detection
rack, F&G alarm panels, beacons and a mimic panel. The fire detectors can be infra-red (IR)
and/or ultra-violet (UV) type positioned on strategic locations on the Fuel System site. The gas
detectors can be open path detection type with a light source and a reflector bridging critical
areas. The manual call points shall be break-glass type located at entrances and exits of
buildings. The F&G detection rack can contain a small signal processor and shall be located in
the cabinet room of MEP building 6. The F&G detection alarm panels shall be a panel with a
map of the Fuel System site with a number of LED indicators. The beacons shall be poles with
a hooter and a flash light erected on road corners. The mimic panel shall be a panel at the
main gate showing the local fire brigade the way to the fire.
The F&G detectors and local call points shall be connected to the F&G detection rack. If there
is a fire or a gas leak, this rack shall send alarm(s) to the F&G detection alarm panels in the
field control room and the main guard house, activate the beacons at the gantry and the rail
tank car (un)loading platform and animate the mimic panel at the main gate. The F&G
detection rack shall also be connected to a F&G monitoring station in the AOC by a redundant
fibre optic network of proprietary design.
The F&G detection system shall not automatically trigger the fire-fighting system. Initiation of
the fire-fighting system shall be a manual operation controlled either from the field control room
or the main guard house.
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14
FIRE FIGHTING SBS 13

14.1
General Fire Protection Capabilities
Fire protection capabilities are required for the fuel farm and at the terminals where fuel will be
loaded on the airplanes. This will consist of both active and passive fire protection, as well as
early warning of toxic/explosive gas release.
Active fire protection shall consist of various installed firefighting equipment, fixed and portable,
to be used in emergency events in conjunction with various gas, flame, heat and smoke
detection systems.
To provide effective support to these active fire protection systems on the fuel farm, passive
fire protection shall be used where appropriate. This consists of utilising fire resistant coatings
on walls and ceilings, and the use of fire resistant fibres on flooring. The objective of these
measures is to impede the spread of fire.
The objectives of the active and passive fire protection systems are to prevent or mitigate the
serious consequences from a fire, explosion or toxic gas release, such as to:
Prevent escalation of fire from one area to an adjacent area,
Ensure the temporary refuge is intact for the time necessary,
Protect personnel from the fire (heat and smoke) and make escape or evacuation
possible,
Protect personnel from the poisonous/toxic/explosive environments through early
detection and warning of the potential threat,
Protect systems and equipment of essential importance for safety,
Maintain structural integrity for the required period of time.
14.2
Objectives of Fire Protection system
The primary objective of any firefighting system is the protection of human life. Secondary
objectives are the protection of property and the environment. In order to protect human life,
the crude oil transfer equipment, the jetty structure and moored vessels within the port, the
following shall be considered:
Identification, analysis, assessment of fire and explosion hazards,

Reduction of residual risks or hazards to personnel associated with potential fire and
explosion scenarios to a level that is deemed acceptable,
Fire detection, protection and response measures should be provided to a level that
commensurate with the hazards and risks within the jetty area, with the order of priority
being:
o Avoiding the occurrence of fires,
o Protecting personnel against the immediate effects of gas/vapour/heat,
o Protecting all personnel against the immediate effects of fires,
o Removing personnel from the danger zone presented by potential escalation of
the initial incident through the use of identifiable escape routes to known
muster points.
14.3
14.3.1
Fire Fighting philosophy Objectives

Fire Prevention Philosophy
The philosophy of prevention of fire shall be under constant review throughout the design
process and during operations in order to prevent fires occurring. The basic fire prevention
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philosophy shall incorporate the requirements of all relevant parties in the design and
operation of this facility. These are envisaged to include the following, but not limited to:
Authority Having Jurisdiction (AHJ),
Airport Employer,
Civil Defence,
Authority.
It is recommended these parties shall constantly review the risks within the Airport and update
the Airports normal operating procedures and design to mitigate against risks throughout the
design process. The above-mentioned parties should create criteria from which risks, hazards
and mitigation measures that can be continuously assessed. The criteria should set out
acceptable limits of risk and therefore should form an integral part of the risk assessment
process.
Fire prevention philosophy requires preventative measures to be considered and put in place
to prevent fires and explosions occurring. The preventative measures are listed below:
Approved engineering design standards for equipment and systems,
Classification of hazardous areas, linked to requirements for all certified equipment
installed or used in these areas,
Maintenance of asset integrity including inspection work and change control,
The Permit To Work system for control of maintenance and engineering activities,
Procedure based control of major activities (drilling, construction, painting),
Proper organisation and maintenance of all facilities (good fire safety practice) ,
Safety audits, with follow-ups,
Timely detection of process upsets and corrective action,
Effective shutdown process,
Operator patrols of all areas,
Operator and fire team leader/member incident response training,
Smoking control,
Specification and on-going monitoring of furnishings and structure finishes reducing
ignition and fire spread probabilities.
14.3.2
Fire Detection Philosophy
The purpose of the fire and gas detection is to provide alarms to enable subsequent rapid
responses to minimize the risks to life and equipment. The automatic detection system
consists of sensory devices installed to detect environmental changes created by fire or by the
presence of toxic or combustible gases.
14.3.3
Fire Protection and Response Philosophy
The firefighting protection philosophy for this fuel farm shall include the following:
Escape routes, mustering of people, evacuation of people, personal protection, etc.,
Means of rescue of people within a defined time scale,
Means of evacuation of people from the facilities within a defined time scale,
Means of minimising escalation of fire must be provided,
Means of communication on who should be involved, and who is responsible for
different items of firefighting and rescue etc.
The firefighting response philosophy shall be to ensure that the protection of human life is the
priority. The response to a fire event, and the subsequent weight of attack on the fire(s), shall
be appropriate in terms of equipment and manpower available and shall be based on an
analysis of likely fire scenarios.
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For Comments
14.4
Firewater Supply
Firewater is to be supplied from firewater pump station by a firewater header over the fuel farm
plot. On the fuel farm a firewater ring main will be provided. The supply of this water shall be
automatically delivered, when a hydrant or monitor, or other firewater dependent device is
turned on. The system shall detect the pressure drop in the fire water mains and thereby
causing the main fire pump to start..
14.5
Foam supply
Foam is to be supplied from a mobile firefighting truck with foam generator. The mobile foam
generator will take water out of the firewater supply system.
Foam is used to kill a tank fire inside the tank. Each vertical storage tank has foam chambers
that will create foam. The foam-water solution to the foam chambers is supplied by a single
line per vertical storage tank. Each riser is part of the tank scope, see 8.2.5.
The single line per tank will start and the outside of the bundwall, where the mobile foam
generator can make the supply connection, and will go all the way up to the top of the storage
tank to the foam chambers.
Amount of foam chambers and foam flow needed is depending on measurements of the
storage tank and to be defined and / or confirmed by DBC.
If other equipments as pumps, concrete slaps, horizontal tanks, rail cars or other are on fire,
the fire will be killed with foam by mobile foam generating and directing equipment.
14.6
Cooling
If a fire occurs the area and objects within the 10 kW contour around the fire needs to be
cooled to prevent fire escalation.
The cooling water will be supplied by the firewater supply system.
Amount of cooling water need for worst case scenario and cooling water flow needed is to be
defined and / or confirmed by DBC.
At the fuel farm plot following cooling equipments will be present:
Vertical storage tanks: stationary sprinklers rings per tank on roof and wall. Ring and
riser are part of the tank scope, see 8.2.5.
Horizontal storage tanks covered: stationary sprinklers lines above the storage tanks
and under the cover
Pumps slaps: stationary monitors and extinguishers
Railcar (un)loading, not covered: stationary monitors and extinguishers
Truck loading, covered: stationary sprinklers lines above and under the cover
Maintenance building, workshop, lab: stationary sprinkler installation within the building
Office building: hoses and extinguishers
Gate control offices: extinguishers
Rules and regulations as per NFPA.
14.7
General Alarms both Visual and Audible
Appropriate annunciation systems, both audible and visual shall be available to ensure that all
the alarms generated, both, audio and visual are reported to the installation personnel at local
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and remote control panels. The alarms both, audio and visual shall be repeated at additional
locations, for example the control rooms, to ensure corrective action is taken.
The alarm and signalling system, on the jetty, must perform four significant functions. It should:
Rapidly transmit an alarm or signal to indicate the detection of fire before there is
significant damage,
Initiate a sequence of events to evacuate personnel in the vicinity of fire,
Transmit an alarm or signal to notify responsible parties or initiate an automatic
extinguishing system,
Have the capability to automatically self-test and warn of malfunction.
14.8
Escape routes and Muster areas
14.8.1
Escape routes
Escape routes shall be clearly marked and lit.

14.8.2
Muster areas
Muster areas should be protected against gas, fire and smoke risks, based on technical
assessments. The ability of muster areas to continue in operation for as long as is necessary
to achieve safe evacuation of all non-essential personnel during foreseeable fires should be
evaluated and appropriate measures taken for protection against fire spread, impingement of
thermal radiation and prevention of smoke and gas ingress.
14.9
General Electrical Considerations
Electrical Equipment shall be carefully considered to ensure that there are no possibilities of
stray currents, or potential sparks. Special attention shall be afforded to the lighting installation
to ensure that it complies with the requirements of NFPA 70, being vapour proof, of low
surface operating temperature and well protected from mechanical damage.
As far as practicable, lightning should be discouraged from striking on the storage tanks. All
steelwork, loading facilities etc. should be bonded to earth.
14.9.1
Communications and Alarm
Communications between the fuel farm and the main fire control at the Airport shall be
provided by automated signal transfer by fiber optic.
A separate fire only telephones or a priority dialling fire system shall be located at strategic
points within the facility.
14.10
Emergency RESPONSE FROM landbased fire department
The Fuel farm shall be covered by an emergency response plan that should take account of
the following:
Firefighting equipment,
Firefighting and rescue responsibilities,
Command and control responsibilities.
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14.10.1
Firefighting equipment
Firefighting equipment should be provided in accordance with this philosophy. Location plans
for firefighting equipment should be displayed at access points and copies included in the
emergency response plans.
14.10.2
Firefighting and Rescue
Protection of life is the primary objective in all circumstances. No attempt to fight a fire should
be made if this involves exposing fire-fighting personnel to the risk of fire escalation.
For rescue operations conflicts may arise between preservation of the rescuers lives and
preservation of the trapped/injured personnel lives. In such circumstances, extremely hard
decisions may be necessary. All such decisions are envisaged to be responsibility of the OnScene Commander, who must decide whether and when the rescue attempt should go ahead.
Inputs to this decision should include, but not limited to:
Knowledge about the numbers and condition of trapped / injured personnel,
Generic knowledge of fire characteristics, thermal radiation levels and effects, smoke
exposure effects,
Understanding of fire escalation particularly with respect to time elapsed,
Knowledge about the fire and the status of engulfed or impinged targets (elapsed time
of engulfment,
Knowledge about the security of firewater supply if this is required for the rescue
operation,
Alternative rescue approaches or methods.
14.10.3
Command and Control
It is envisaged that a qualified On-Scene Commander (OSC) should be available at all fuel
farm whenever personnel are present and production is in progress. OSC training should
include major fire and explosion scenarios for the fuel farm.
Command and control of fires and other safety issues require that all alarms shall provide a
signal to all control rooms. Once the alarm occurs on the fuel farm, the Central Control Room
shall provide the command and control for this event. If an event occurs on the fuel farm it is
envisaged again the command control shall initially start at Central Control Room.
If fire or release of toxic gas does occur in both these locations, all command and control
functions in terms of firefighting, or controlling toxic gas release shall have the capability of
being transferred to the breakwater control room. This is necessary, since it may become
unsafe for personnel to remain on the fuel farm, or that they may be overwhelmed by fire.
These command and control functions not only include personnel but the firefighting
capabilities, such as remote control of the monitors. It shall also be possible to transfer these
capabilities back to the Central Control Room.
Command and control philosophy within the Airport should over regular periods be revaluated
to ensure that any changing conditions, or lessons learned from training exercises, or
assumptions that have been made initially do not affect the firefighting philosophy within the
International Airport of Ashgabat.
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15
SECURITY PROVISIONS
15.1
Airport security
The security fence around Airside of Ashgabat International Airport will be adjusted by third
parties. A part of the new airport security fence will be installed as security border between the
new tankfarm and Airside. This part at the tankfarm border will be a part of the DBC scope.
The gate between tankfarm and Airside shall be designed as Main Airside Entrance gate for
vehicles (passes in two directions) and personnel. The gate shall include a guard house in the
middle.
15.2
Tankfarm security
A fence is required around the tankfarm as indicated in the plot plan of appendix 2.
Entrance/exit gates will be required for the new main railway track and for the new access
road. These gates will separate the new Fuel System from the public area.
A guard house will be required at each main gate. Additional emergency gates are required to
assure sufficient escape routes.
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16
BUILDING FACILITIES HOLD

16.1
HVAC
16.2
Laboratory
16.3
Office buildings incl. technical classrooms
16.4
Warehouses
16.5
Sheds for automobiles
16.6
Repairing shops
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17
DELIVERABLES
17.1
Document control (input and deliverables)
During project execution the DBC shall maintain document control.
17.2
Applicable software
The DBC shall specify the applicable software in his bid for approval.
17.3
As Built documentation
DBC shall submit the as-built record documentation of the Fuel System as digital files and as
paper files in 3-fold, before at latest 2 months after commissioning.
Al least the following data shall be included in the as-built report:
Actual document list showing the full Fuel System documentation
Actual permit request dossier
Updated HAZOP dossier
Actual calculations and 3-D model
As-built drawings with as-built location information.
Verification and validation reports and certificates
Equipment catalogue data in maintenance and operation manuals.
All drawings except for UFD, P&IDs, Plotplan, equipment list, line list, shall be made As-Built
by DBC on native files.
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18
APPENDICES
LIST)
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LIST)
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ASHGABAT INTERNATIONAL AIRPORT

A company of Royal HaskoningDHV

HaskoningDHV Nederland B.V.

Ashgabat International Airport

Document short title

Design & Build

Ashgabat International Airport

APPLICABLE INPUT DOCUMENTS

Control & safeguarding

RAIL CAR (UN)LOADING STATION SBS 01+02

TANK FARM SBS 03

FUEL DISTRIBUTION NETWORK INCL HYDRANTS SBS 04

GANTRY AND PETROL STATION SBS 05 + 06

HANDLING AND STORAGE OF PACKAGED MATERIALS SBS 07 HOLD

UTILITY SUPPLY SBS 11

GAS AND FIRE ALARM SYSTEM SBS12

FIRE FIGHTING SBS 13

BUILDING FACILITIES HOLD

Sheds for automobiles

APPENDIX 1 - SYSTEM AND WORK BREAKDOWN STRUCTURE

APPENDIX 2 - FUEL FARM LAYOUT

APPENDIX 3 - FENCING AIR LAND SIDE

APPENDIX 4 - ARCHITECTURAL SYSTEMS CONFIGURATION

APPENDIX 5 - STANDARDS FUEL HYDRANT SYSTEM

APPENDIX 6 - LAYOUT FUEL HYDRANT SYSTEM

APPENDIX 7 - TYPICAL VALVE PITS

APPENDIX 8 - METHOD OF MEASUREMENT

APPENDIX 9 - PFD SHOWING PIPING DIAMATERS FOR BOQ

APPENDIX 10 - PROPOSED PIPING AND E&I ROUTES

APPENDIX 11 - STANDARD RAIL CAR

APPENDIX 12 SITE AND MAIN INTERFACE CONDITIONS

APPENDIX 13 DOCUMENT CONTROL LIST

APPENDIX 14 CONTROL & SAFEGUARDING PHILOSOPHY

APPENDIX 15 - BILL OF QUANTITY

APPENDIX 16 - EQUIPMENT LIST

APPENDIX 17 - HOLD LIST

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

APPENDIX 20 - ELECTRICAL LOAD LIST

APPENDIX 22 - FUEL HYDRANT SYSTEM LINE SIZING

APPENDIX 23 - G124 ANNEX 8

Contract Specification (based on FIDIC yellow book)

Main outline in this System Specification:

Overall project scope is defined in chapter 2.

Considerations, main parties

Risk management during design, construction and life time

Risk analysis matrix shall be updated along the project.

Risk description with cause and effect;

Reference design and governing documents

A concept reference design is made. The functionality described in this specification is

Project location and security requirements

Existing Fuel System.

Scope for New Fuel System

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

Fuel System general provisions

Utility supply (incl. safety showers)

Demolishing of existing tankfarm

Excluded from scope

Scope limits and main interfaces

WP-1B Airside systems

WP-1B Airside systems

WP-1B Airside systems

Connections to rail tank

WP-1A Airside Infra

WP-3 Main power feed