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Contractor Job No.022028

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Project Title :INSTALLATION OF NEW COMPRESSORS AT GC-07, 08 AND 21

Company Doc No.42906-408-020-MAN-08516

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KOC Contract No42906

Document Title: RE-ROUTING TIE-IN PACKAGE KOC Doc No. Rev

Project NoEF-1769

Unit Description: Gathering Center - 08

RE-ROUTING TIE-INS PACKAGE GC-08

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INDEX

1.

INTRODUCTION................................................................................................................ 3

1.1. OBJECTIVE ....................................................................................................................... 3 2. DEFINITIONS AND ABBREVIATIONS............................................................................. 4

2.1. DEFINITIONS..................................................................................................................... 4 2.2. ABBREVIATIONS .............................................................................................................. 6

3. REFERENCE DOCUMENTATION.................................................................................... 7 3.1. CONTRACTUAL DOCUMENTS........................................................................................ 7 3.2. KOC REFERENCE DOCUMENTS.................................................................................... 7 3.3. PROJECT DOCUMENTS .................................................................................................. 7 3.4. OTHER STANDARDS & SPECIFICATION ....................................................................... 7

4. TIE-INS CHAPTER LIST ................................................................................................... 8 5. TIE-IN CHAPTER GC-08 TP R23 & R24 .......................................................................... 9 5.1. CONTENTS........................................................................................................................ 9 5.2. ISOLATION & DRAINING PROCEDURE FOR RE-ROUTING FH-67 (TP R23) & FH-74

(TP R24)........................................................................................................................... 10 5.2.1. SAFETY INSTRUCTIONS ............................................................................................... 10 5.2.2. PRELIMINARY ACTIVITIES PRIOR TO COMMENCING THE ISOLATION & DRAINING

ACTIVITIES...................................................................................................................... 11 5.2.3. PREPARATION ............................................................................................................... 11

5.3. LINE-UP AND EXECUTION ............................................................................................ 12 5.3.1. ATTACHMENTS .............................................................................................................. 13 6. ATTACHMENTS.............................................................................................................. 14

6.1. Attachment 1: Fire Water Layout GC-08 (Doc. 408-GB-A-64040) .................................. 14 6.2. Attachment 2: GC-08 Re-Routing Tie-In Schedule.......................................................... 14

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1. INTRODUCTION

The Scope of Work for the PROJECT “Installation of New compressors at GC-07, 08 and21 is to provide a single stage centrifugal compressor driven by a Variable Speed ElectricMotor (VSEM), a Suction Scrubber, a Discharge Cooler, a Discharge Scrubber and aSuction Scrubber Drain Seal Drum for GC – 07, 08 & 21 in the Burgan Fields, SouthKuwait.

1.1.OBJECTIVE

SAIPEM has been awarded the EPC contract for the installation of these newcompressors. As a part of the project the purpose of this document is to provide allinformation and necessary procedures to be applied for the Re-Routing of Fire Hydrantsduring the Re-Routing phase of GC-08. This involves Isolation and Draining of a section ofthe Fire Water ring inside GC-08.

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2. DEFINITIONS AND ABBREVIATIONS

2.1.DEFINITIONS

COMPANY KUWAIT OIL COMPANY (K.S.C.)A COMPANY registered in the State of Kuwait underRegister No. 21835, its legal successors and assignees.Any powers or discretions exercisable under theContract by the COMPANY shall, unless the context

otherwise requires, be exercisable by the Chairman orManaging Director of the COMPANY or by his appointeddelegate.

CONSTRUCTIONSUBCONTRACTOR

GULF SPICCOMPANY to whom construction works is sub-contracted by the CONTRACTOR in accordance withthe terms of the contract.

CONTRACTOR SAIPEM SpAIdentified as such in the Contract Agreement andincludes its successors and permitted assignees.

SUBCONTRACTOR Any person, firm, partnership, corporation orcombination thereof to whom any part of the works issub-contracted by the CONTRACTOR in accordancewith the terms of the contract, and for the avoidance ofthe doubt includes Vendors.

PROJECT Installation of New Compressors at GC – 07, 08 and 21SITE Gathering centres GC-07, GC-08 and GC-21 at South of

KuwaitVENDOR Any manufacturer or supplier approved by the

COMPANY in accordance with the contract.

WORKS All those things to be done or provided by theCONTRACTOR in connection with the design,engineering, procurement, reinstatement, dismantling,demolition, construction, installation, testing, pre-commissioning, commissioning and assistance withperformance testing of the Facilities together withTemporary Works and all other obligations andresponsibilities of the CONTRACTOR under and

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MECHANICALCOMPLETION

The transfer of responsibility for the care, custody, andcontrol of a System from Contractor to Company. It isapplicable to a Subsystem as well.

DECOMMISSIONINGPHASE

All the activities relevant to execute demolition phase ofthe existing TV Compressors and relevant ancillaries insafe conditions.

DEMOLITION PHASE All the activities relevant to dismantling/demolition of theexisting TV Compressors and relevant ancillaries.

RE-ROUTING PHASE All the activities relevant to dismantling / demolition / modification of the existing facilities in order to allow theconstruction of the new TV Compressors and relevantancillaries.

CONSTRUCTION PHASE All the activities relevant to the construction of the newfacilities without affecting the existing facilities.

REVAMPINGCONSTRUCTION PHASE

All the activities relevant to dismantling/demolition of theexisting facilities in order to connect the new TVCompressor and relevant ancillaries to the existingplant.

PRE-COMMISSIONINGPHASE (1)

A series of verifications and activities executed beforeintroduction of process fluids into any Portion or thewhole Facilities.

COMMISSIONING PHASE(1)

The first introduction of process fluids into any Portion orthe whole Facilities. It is the Initial Start-up of andoperation of any Portion or the whole Facilities, carriedout by COMPANY/CONTRACTOR, specialist staff andVendor’s representatives.

SYSTEM TURNOVER The transfer of responsibility for the care, custody, andcontrol of a System from Contractor to Company.

Note (1) Pre-commissioning and commissioning phase are relevant to all the activitiesincluded in Demolition, Re-routing and Revamping Construction Phases.

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2.2. ABBREVIATIONS

CRU CONDENSATE RECOVERY UNIT

GC GATHERING CENTRE

KOC KUWAIT OIL COMPANY (K.S.C.)

JSA JOB SAFETY ANALYSIS

RA RISK ANALYSIS

TP TIE-IN

TV TANK VAPOUR

VSEM VARIABLE SPEED ELECTRIC MOTOR

BA BREATHING APPARATUS

FH FIRE HYDRANT

VP VALVE PIT

TP TIE-IN POINT

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3. REFERENCE DOCUMENTATION

3.1. CONTRACTUAL DOCUMENTS

1) Contract No. 42906, Installation of New Compressors at GC – 07, 08 & 21

3.2. KOC REFERENCE DOCUMENTS

1) KOC.SA.023 - Demolition Work Procedure2) KOC-G-015 Part 1 - Procedure for Plant Shutdown-Gathering Centre

3) KOC.EV.008 - Waste Management Procedure4) KOC.SA.029 -Safety Requirements for Lifting-Shifting and Material Handling5) KOC.SA.027 -Electrical Work Safety Procedure6) KOC.SA.024 - Job Safety Analysis.7) KOC.SA.016 - Driving Procedure.8) KOC.SA.014 - Portable Battery & Electrically Operated Tools & Equipment.9) KOC.SA.013 - Temporary Mobile Equipment.10) KOC.SA.010 - Protective Clothing and Equipment11) KOC.SA.007 – Procedure for Confined Space Entry12) KOC.SA.004 - Permit to Work Procedure.

13) KOC.SA.003 - Manual Handling of Loads.14) KOC.SA.002 - Control and Use of Scaffolding.15) KOC.SA.001 - Control and Use of Ladders and Stepladders.16) KOC.HE.001 - Hydrogen Sulphide17) KOC.HE.003 - Gas Testing and Gas Test Standards18) KOC.HE.013 - Food Handling and Distribution Procedure.19) KOC.HE.011 - Vibration Exposure Control and Management Procedure.20) KOC.HE.006 - Noise Exposure Control and Management Procedure.21) KOC.EV.007 - Transport, Storage and Handling of Hazardous Material.22) KOC.MP.031 Part 2 - Gaskets for Pipe Flanges

23) KOC.015-AH-1003 - System Isolation

3.3. PROJECT DOCUMENTS

1) Site survey Report – GC 07, 08 and 21 (Mechanical, Piping, Civil, LOSPE) 000-GA-E-62012

2) Revamping Methodology, Doc. 000-ZA-E-085003) C t ti Ti i Li t GC 21 D 408 GA E 65200

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4. TIE-INS CHAPTER LIST

The following tie-ins will be performed during the Re-Routing Phase:

GC-08 TP R23 & GC-08 TP R24

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5. TIE-IN CHAPTER GC-08 TP R23 & R24

5.1. CONTENTS

This Tie-in chapter includes the following documents:

1. Drawings

2. Isolation & Draining Procedure

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5.2. ISOLATION & DRAINING PROCEDURE FOR RE-ROUTING FH-67 (TP R23) &FH-74 (TP R24)

5.2.1. SAFETY INSTRUCTIONS

The Construction team responsible for the site activities, through sub-contractors willensure the following actions is put in place at site,

Obtain dedicated work permit.

Barricade off the system at a safe distance.

Ensure back-up Water Tankers are available to cover the areas where the FireHydrants will be affected / inactive.

Post adequate signs around the barricaded area such as,

USE PROPER PPE

NO ENTRY TO UNAUTHORIZED PERSONNEL

Carry out a tool box meeting before starting the activity.

Ensure the calibration validity of the intrinsically safe Gas Detector. All readings

will be taken in the presence of the Company representatives Prior to commencement of operations, the Contractor / Subcontractor supervisor

shall ensure that the safety equipments have been identified and provided i.e.Breathing Apparatus (BA), Hoses from non-affected Fire Hydrants, Equipmentsto pump out the water from the valve pits if the Isolation valves are passing.

Verify that all people involved in the activity wear appropriate Personal ProtectiveEquipments (PPE).

All lifting equipments and operators certificates will be made available at site for

verification prior to commencing the job.

All lifting gear and tackles used will have the current inspection status and willhave the current colour code.

The existing windsock will be used to observe the Wind direction.

At the end of the FH Relocation works, remove all materials (e.g. temporary pipe,drums hoses etc) from the area and the Company site representative informed

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5.2.2. PRELIMINARY ACTIVITIES PRIOR TO COMMENCING THE ISOLATION & DRAININGACTIVITIES

The Isolation / Depressurization / Draining / Tie-In works will be performed in thepresence of Company personnel The pipe spools fabricated for the Re-routing works will be prepared and stringed

as per the pre-defined routing in the drawings, Section Isolation will be done only for draining and rotating the existing

underground tee piece by 90 degree located at TP R23 and TP R24 andconnecting to the newly laid re-routed FW pipes.

Inspect the system verifying that all mitigation measures are put in place.

The work area will be checked and cleared from any obstruction to perform thetask safely without any hindrance.

Sufficient numbers of Portable Fire Extinguishers will be made available to meetany Emergency.

Contractor/Sub-contractor will inform the Control Room before commencing the

actual work at site and obtain the requisite clearance from Company Siterepresentative.

5.2.3. PREPARATION

Lift Pump will be available to pump out water from the valve pit VP2 located

north side the existing Substation F12 near by the Plant Fence. Excavation willbe carried out for the below mentioned Fire Hydrants showing their respectiveTie-In point numbers.

The isolations for the Re-routing of FH-67 and FH-74 will be carried out as perthe attached marked up P&ID 408-GD-B-85182 showing the Isolation to carry

out the FW Re-Routing works.

Ensure the prefabricated line to be connected has been inspected and cleared

Section Isolation FH / VP TP

1 FH-67 R23

1 FH-74 R24

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5.3. LINE-UP AND EXECUTION

STEP 1 – Isolation / Depressurizing / Draining Procedure

The activities will be performed during the Sectional Shutdown of theFire Water system. The Section Isolation (refer to P&ID 407-GD-B-85182) will be depressurized and drained prior to Contractor activities.

The Fire Hydrants which will be inactive by the temporary SectionIsolation are as below

1. FH-67 (To be Re-routed)

2. FH-71

3. FH-72

4. FH-73

5. FH-43

6. XV 4003 (Deluge System to Test Tank 08-TK-1178)

7. FH-74 (To be Re-routed)

The Section Isolation 1 will be achieved by closing the valves in thefollowing Valve Pits:

1. VP1

2. VP2

3. VP3

The Fire Hydrants will be depressurized by opening the ¾” valve on its

respective riser and their 6” above ground valves are in open position.

Loose the bolts on the VP2 valve in order to drain the entire Section 1by pumping out water outside the Plant (Substation F12 – North side).

After completion of the draining works switch off the pump and checkthe level in the VP2 i.e. if the level is increasing in the existing VP2would mean that the Valve Pit valves involved in Section Isolation 1 are

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STEP 3 – Re-instatement and Service Test

Remove the spades installed, tighten the flanges and replace gaskets

as required. VP1, VP2 & VP3 valves will be slowly opened in sequence and the

system pressurized again.

Visual inspection will be carried out to verify for any flange leaks on thenew pipes.

In the case of any leaks, the system will be depressurized and systemtightened again.

All tools and equipments mobilized for the works will be removed fromsite after the works are completed and the re-routed line will bebackfilled.

5.3.1. ATTACHMENTS

Marked-Up P&ID 408-GD-B-85182 (Isolation 1)

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6. ATTACHMENTS

6.1. Attachment 1: Fire Water Layout GC-08 (Doc. 408-GB-A-64040)

6.2. Attachment 2: GC-08 Re-Routing Tie-In Schedule

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Saipem INSTALLATION OF NEW COMPRESSORS AT GC-07, 08 AND 21 KOC

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p ,

FW RE-ROUTING TIE-IN SCHEDULE GC-08

ATTACHMENT 6.2

KOC

ACTIVITY IDREF. ACTIVITY

Lev.4ACTIVITY DESCRIPTION START

DURATION

(Calendar

Days)

END

Ref. Activity RE-ROUTING TIE-IN SCHEDULE R23 & R24 2-Oct-10 90 30-Dec-10

1.0 RR-08-1700 Avai labi lity of P ipes, Fi ttings and other materials 2-Oct-10 1 2-Oct-10

2.0 RR-08-1710 Availability of approved Drawings 2-Oct-10 1 2-Oct-10

3.0 RR-08-1720 Prefabrication of new pipes 22-Nov-10 14 5-Dec-10

4.0 RR-08-1730 Testing 6-Dec-10 2 7-Dec-10

5.0 RR-08-1740 Internal Coating 8-Dec-10 7 14-Dec-10

6.0 RR-08-1750 External Painting 15-Dec-10 7 21-Dec-10

7.0 RR-08-1760 Field Installation 22-Dec-10 5 26-Dec-10

8.0 RR-08-1770 Wrapping , Coating & Flange joints 27-Dec-10 4 30-Dec-10

Note: System Isolation Test will be carried out prior to commencing the actual works at site.

FW RE-ROUTING TIE-IN PHASE GC-08

Availability of Materials

Availability of approved dwgs

Prefabrication of new pipes

Testing

Internal Coating

External Painting

Field Installation

Wrapping / Coating of flanged joints

29-Sep-10 5-Oct-10 11-Oct-10 17-Oct-10 23-Oct-10 29-Oct-10 4-Nov-10 10-Nov-10 16-Nov-10 22-Nov-10 28-Nov-10 4-Dec-10 10-Dec-10 16-Dec-10 22-Dec-10 28-Dec-10 3-Jan-11

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