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CONTRACTORS STAMP:

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Tender Documents (Addendum) Tender Documents (Addendum) Tender Documents Draft Tender Documents DESCRIPTION

HESHAM HESHAM HESHAM HESHAM PREPARED

MAGDI MAGDI ALBAZ ALBAZ CHECKED

25.05.2010 25.04.2010 06.06.2009 25.04.2009 DATE

SALINE WATER CONVERSION CORPORATION KINGDOM OF SAUDI ARABIA

Mohamed Turki Mott MacDonald Engineering Consultancy

RAS ALZAURE HAFAR ALBATIN WATER TRANSMISSION SYSTEM

GENERAL SPECIFICATION G-02


LOCATION: TITLE:

RAS ALZAUR HAFAR ALBATIN


SCALE: SUBCONTRACTOR:

DESCRIPTION PF PROJECT AND WORKS


REV: 2 Sheet 1 of 193

Q A

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TABLE OF CONTENTS 1. INTRODUCTION...07 1.1 Scope of this general specification.07 1.2 Drawings 07 1.3 Definitions ..07 1.4 Abbreviations..08 2. GENERAL DESCRIPTION..14 2.1 Location......14 2.2 General....14 3 DESIGN DATA AND SERVICE CONDITIONS...17 3.1 General ....17 3.2 Design criteria of the pipeline..17 3.3 Design Criteria for Mechanical Works.30 3.4 Design Criteria for Electrical Equipment in Pumping Station..32 3.5 Design criteria for SCADA system ..37 3.6 Liquid Properties ......38 3.7 Water Quality Data.......38 3.8 System Capacities and Flow Rates .....39 3.9 Pipeline Segments and Lengths ..39 3.10. Station and Reservoirs Elevations ....41 3.11 Utilities...41 3.12 Climatologic Data ......42 3.13 Noise Levels ...45 4. DESIGN REQUIREMENTS.....46 4.1 General46 4.2 Civil Engineering ...49 4.3 Mechanical Engineering 50 4.4 Electrical and Control Engineering.52 4.5 Performance guarantee53 5 HYDRAULICS AND OPERATION.....57 5.1 Scope .57 5.2 Basic Design Principles .57 5.3 Philosophy of Operation 59 5.4 Modes of Operation ...59 5.5 Automatic System Operation Programs ....60 5.6 Safety Programs .....62 5.7 Station Safety Sequences (SSS) ...63 5.8 System and Station Control Regulation Loops64 5.9 Station Programs and Sequences..64 5.10 Operation with and without Telecontrol System68 5.11 Surge Protection Devices68 5.12 Basic Data for Hydraulic calculations and system design..68 5.13 Hydraulic Calculations to be performed by the Contractor71

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6 PIPES STATIC....73 6.1 General ...73 6.2 Computation Parameters 73 6.3 Computation Method .74 6.4 Minimum Cover and Backfill Compaction ....79 7. PIPELINE....80 7.1 Route Description...80 7.2 Right of Way.......81 7.3 Pipeline construction ..........82 7.4 Special Points......83 7.5 Pipe Material, Lining and Coating for main line and branches 85 8. PUMPING STATIONS......86 8.1 Reference Drawings.. .......86 8.2 Booster Pump Units......86 8.3 Main Pump Units......87 8.4 Cooling Water System .. ....87 8.5 Control Valves .....87 8.6 Station Piping System .. .....87 8.7 Electrical Works, Control and Instrumentation .... .88 8.8 Civil Works ..........88 9. RESERVOIR AND WATER TOWER AND FILLING STATIONS ..................89 9.1. General Requirements ... 89 9.2 Reservoir and Filling Station at Nuairiyah.......89 9.3 AlKafji Tap-off Station............91 9.4 Water Tower and Filling Station at Ibn Hethlain........ 91 9.5 Reservoir and Filling Station at Qaryat AlOliyah........93 9.6 Water Tower and Filling Station at Sairah.......94 9.7 Water Tower and Filling Station at Sadawi......96 9.8 Reservoir and Filling Station at AlQaysumah..97 9.9 Reservoirs and Filling Station at Hafar Al Batin......99 10. LINE VALVE, VENT AND DRAIN STATIONS......101 10.1 Line Valve ..101 10.2 Line Valve Stations ....101 10.3 Vent & Drain Stations........102 11. STATION BUILDINGS...104 11.1 General..........104 11.2 main & booster Pump House. ..105 11.3 Electrical Building for Pumping Station.........106 11.4 Cooling Equipment Shelter..........108 11.5 Electrical Buildings (For Reservoir Stations) ........108 11.6 Combined Electrical & Mechanical workshop building at AlHafar AlBatin terminal....109

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11.7 Chlorination Building at Hafar AlBatin Terminal............110 11.8 Water Quality Monitoring Building at Hafar AlBatin Terminal..........112 11.9 Staff Building at Hafar AlBatin terminal. and alnuairiyah ... 112 11.10 Service Building.........113 11.11 Security Guard Building for All stations........114 11.12 filling pump building 115 11.13 CAR Shade.......... 116 12 FINISHING WORKS AND BUILDING INSTALLATIONS..117 12.1 General....117 12.2 Main Buildings Works....117 12.3 Platforms Ladders and handrails.....120 12.4 Furniture......120 12.5 Electrical Building Installation...120 12.6 Fire Detection & Alarm system.....121 13 CIVIL WORKS AND CONCRETE RESERVOIRS.122 13.1 Earth Works....122 13.2 Roads and Traffic Areas.....122 13.3 Station Areas . ...123 13.4 Equipment Foundations and Shafts....123 13.5 Water Supply System .123 13.6 Sewage and Storm Water System...124 13.7 walls , Fences and Gates. ... 125 13.8 landscaping 125 13.8 Concrete Reservoir at qaryat aloliyah and alqaysumah 126 14 STEEL WATER STORAGE TANKS....127 14.1 Design and Construction of steel tanks .. ..127 14.2 Foundation for Steel Tanks 127 127 14.3 Steel Tanks at Nuairiyah and Hafar AlBatin 14.4 Steel Water Towers at Ibn Hethlain ,Sairah and Sadawi ... 128 15 MECHANICAL WORKS.129 15.1 General ..129 15.2 Station Piping ... 129 15.3 Station Valves ...132 15.4 Pumps ...138 15.5 Cooling Water Systems for the main pump.... 140 15.6 pressure Relief Systems at Hafar Albatin terminal station..142 15.7 Chlorination Equipment ... 143 15.8 Fuel Supply ...146 15.9 Fire Protection .....147 15.10 Air Conditioning and Ventilation .....148 15.11 Cranes .......154 15.12 Service Air ........155

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16 POWER SUPPLY AND ELECTRICAL WORKS156 16.1 Power Supply Configuration ....156 16.2 Medium Voltage Switchgears ..157 16.3 Electrical Motors .157 16.4 Motor Starter Equipment .158 16.5 Low Voltage Transformers ..158 16.6 Low Voltage Switchboards ..159 16.7 Emergency Generators .........159 16.8 UPS Equipment ....159 16.9 Cabling .....160 16.10 Earthing and Lightning Protection .....160 16.11 Outdoor Lighting....160 16.12 General Requirements for Power Supply Systems ...161 16.13 Power Supply for Remote Stations....162 16.14 Pump Station Power Calculations .....163 17 17.1 17.2 17.3 17.4 17.5 17.6 17.7 18 18.1 18.2 18.3 18.4 18.5 18.6 18.7 18.8 INSTRUMENTATION AND CONTROL ..164 General .......164 Overall Functions .......165 System Topology .......166 Water Pipeline Control Centre ......167 Station Control Systems (SCS ).....168 Field Instrumentation ....170 Fire & Gas Detection .....172 COMMUNICATION..175 General..175 Fibre Optic Cables ...175 Transmission System .......176 Backup Transmission .......177 Telephone System ....177 Network Management System (NMS)..178 Hotline System .........178 Office LAN ......178

19 CATHODIC PROTECTION179 19.1 General..179 19.2 Pipeline CPS.... 180 19.3 CPS for station piping... .. 181 19.4 CPS for Steel Storage Tanks... .181 19.5 CPS Monitoring ... .. 181 19.6 Temporary CPS . 182 19.7 Interference ..... 182 19.8 Installation and Commissioning ..183

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20 MAINTENANCE ORGANIZATION, EQUIPMENT AND SPARE PARTS.184 20.1 Responsibility of the Contractor ......184 20.2 Basic Information on the organization..... 185 20.3 Familiarisation of SWCC Personnel.....185 20.4 Policies and Procedures........185 20.5 Forms to be supplied.....186 20.6 Equipment and Special Tools.......187 20.7 List of Equipment and Special Tools.......187 CHAPTER (21) START-UP AND TESTS UPON COMPLETION..188 21.1 General..... 188 21.2 Check Out and Tests for Mechanical Completion.... 188 21.3 Line fill, Start-up and Tests on Completion..... 189 CHAPTER (22) FAMILIARIZATION OF EMPLOYERS PERSONNEL.191 22.1 Responsibility and Objective........191 22.2 Familiarization Program.......191 22.3 Special Requirements for the DCS/SCADA System... 192 CHAPTER (23) TRINING OF SWWC PERSONNEL 193

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CHAPTER (1) INTRODUCTION


1.1 Scope of this General specification Saline Water Conversion Corporation SWCC planned to construct new pipeline to transport potable water from Ras AlZaur new desalination plant to Hafar AlBatin supplying various cities and villages on the route. The objective of this general specification is to define the basic layout of Hafar AlBatin Pipeline System, the design and construction requirements, the performances to be guaranteed, and is listing the required key equipment including the main data and the necessary functions. 1.2 Drawings The drawings are intended to portray the basic layout of the Water Transmission System and to define the minimum requirements regarding dimension and quality according to the Specifications. The drawings cannot show exact final dimensions and requirements, which will depend upon the size and shape of the equipment selected by the Contractor. This is especially applicable to all drawings of buildings, which house equipment and, to a certain extent, to the station plot plans. In these cases the Contractor shall determine the locations, dimensions and internal arrangement of sites and buildings in such a way that they meet the design requirements and all applicable specifications. In case deviations are necessary with respect to the pipeline route, it will be the Contractors responsibility to conduct all necessary investigations concerning any possible impact to the cost of the construction works. The final approval of the pipeline route will be granted by the Corporation. The route maps issued by the Employer along with the Tender/Contract Documents shall only define the general route to be followed. 1.3 Definitions Corporation is the Saline Water Conversion Corporation (SWCC), also called Employer. Engineer refers to the Organization or Engineering Firm assigned by the Employer to verify the design and to supervise the implementation of the Contract and Works. Works shall mean all activities to be carried out by the Contractor to design, construct and complete the Project (Pipeline System) in line with the Contract Documents. Pipeline ,Project or Pipeline System shall mean the complete entity of the pipeline,

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including all the pipeline segments, the pumping station, the reservoir stations, the filling stations and the line valve, vent and drain stations. Stations or Filling stations shall mean all works for the Pipeline System related to special locations along the pipeline route. When referring to a station without specifying a certain part, this expression shall mean all installations at the given location. Mainline or Branch Line shall mean the pipeline segments (with all accessories like cathodic protection facilities, etc.), which connect the pumping station outlet with the terminal and other stations, which together with these stations form the backbone of the Pipeline System. Final Design shall mean the design to be performed by the Contractor in accordance with the requirements stipulated in the Contract Documents. Capacity shall mean the overall final design capacity of Ras AlZaur Hafar AlBatin Water Transmission System , including all Stations and the Mainline and/or Branch line. 1.4 Abbreviations 1.4.1 Company, Authority and System Abbreviations SWCC ARAMCO MOT MOWE SEC STC HCISS SRO Saline Water Conversion Corporation Saudi Arabian Oil Company (Saudi Aramco) Ministry of Transport Ministry of Water and Electricity Saudi Electric Company Saudi Telecom Company / other telecom companies High Commission for Industrial Security and Safety Saudi Railway Organization

1.4.2 Project Specific Abbreviations PSRH TFLN FLIH TFLQA FLS Pump Station at km 0 at Ras Al Zaur Tank and Filling station at Nuairiyah Water Tower and Filling station at Ibn Hethlain Tank and Filling station at Qaryat AlOliyah Water Tower and Filling station at Sairah

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FLSD TFLQ TFLHB 1.4.3 Units Km mlc barg bara C m/d m/h m/s masl dB(A)

Water Tower and Filling station at Sadawi Tank and Filling station at AlQaysumah Tank and Filling station at Hafar Al Batin

Length or chainage, kilometer Pressure, metres liquid column, according to Bernoulli formula Relative pressure, gauge pressure (= bar) Absolute pressure, including atmospheric pressure Temperature, degree Celsius Flow rate, cubic metres per day Flow rate, cubic metres per hour Flow rate, cubic metres per second Elevation, metres above sea level Decibel (A)

1.4.4 General Abbreviations CM CPS ELEV FBE KP LVS MAOP MOP MDF O&M PCCP PPL PS ROW SYS Cement Mortar Cathodic Protection System Elevation Fusion Bonded Epoxy Kilometre point (Pipeline) Line Valve Station Maximum Allowable Operating Pressure Maximum Operating Pressure Maximum Design Flow Rate Operation and Maintenance Prestressed Concrete Cylinder Pipes Pipeline Pumping Station Right of Way System

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WQM Elevations: FFL IL MSL Operation: Station Operator System Operator SYSAD

Water Quality Monitoring

Finished floor level station level, platform level in stations [m] Invert level in pipe [m] Mean Sea Level

Person receiving instructions from the System Operator responsible for the operation of a station Person in Central Control Room responsible for the operation of the pipeline system.

System Administrator. Person responsible for configuration and maintenance of control system

(adj. SYSAD) This symbol means that the indicated variable can be set or adjusted by the SYSAD

System Operator Person in Central Control Room (CCR) responsible for operation of the System, including the individual Pipelines WITC WOTC Operation with Telecontrol System, full data transfer between stations of a particular Pipeline System and the CC, all functions available Operation without Telecontrol System, no data transfer between stations of a particular Pipeline System and the CC, neither via the fibre optic cable communication system nor the backup communication system. Station/Unit Control Equipment and Function FLOW-PATH The FLOW PATH defines the segments and sections of a Pipeline System which are subject of the FLOW PATH supervision (unscheduled valve closure). LCON Local Control (for auxiliary systems such as surge vessel plants)including local control panel with indication and command devices and programmable logic controller (PLC) equipment with regulation and control sequences. Interface

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with process equipment, instrumentation and station control system. Situated either at the location of the auxiliary system or in the control room. REC SCS SSS STATCON Pump Recirculation Bypass (Pump Low Flow Protection) Station Control System, including STATCON, UNCON and LCON Station Safety Sequence Station Control including control console, station control cabinet with indication and monitoring devices, programmable logic controller (PLC) with regulation and control sequences. Interface with station process equipment, station instrumentation, unit and local control systems and tele-control system located in the control room of each individual station. UNCON Unit Control including unit control cabinet with logic indication and monitoring devices, programmable

controller (PLC) with control sequences, interface with unit process equipment, unit instrumentation and station control system located in the control room of each individual pumping station. Tele-control Equipment: TCF Tele-control Failure. In case that the fiber optic cable fails as a first measure the backup communication system will be automatically activated. The Tele-control Failure is defined as a double failure with interruption of both connection facilities. TCS Telecontrol System for data transfer as a whole package, including RTUs, operating on transmission channels of the telecommunication system. For data transfer a fiber optic

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cable and a backup communication system is available. Control Centre Equipment CC CCR LDS PCC WPCC Central Control System as a package, located in the central control room Central Control Room Leak Detection System Pipeline Control Center Water Pipeline Control Centre in Ras AlZaur - AlRiyadh pumping station (PS1) Central Control Building, containing the CCR and the CC. Other Equipment and Functions AV CV NRV ESD FC FCV FS LAH,LCH LAL,LCL LC LV PC PCV PRV PAHCH PAL,PCL PHFP PLFP Automatic Vacuum/De-Aeration Valve, Automatic Vent Control Valve Non-Return Valve Emergency Shut-Down Flow Control Flow Control Valve Flow Switch Level Alarm High, Level Control High Level Alarm Low, Level Control Low Level Control Line Valve Pressure Control Pressure Control Valve Pressure Relief Valve Pressure Alarm High, Pressure Control High Pressure Alarm Low, Pressure Control Low Pump High Flow Protection Pump Low Flow Protection

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SD TLS

Shut-Down Top Limit Switch (at valve)

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CHAPTER (2) GENERAL DESCRIPTION


2.1 Location Ras Al Zaur is located in the Eastern region, north of Al Jubail while Hafar Al Batin is located north west of Ras Al Zaur as shown in the following map. More detailed information regarding the route is made to QP10-U-1000 General Route Map.

2.2 General This chapter gives a summarized description of the Works to be part of the Ras Al Zaur-Hafar Al Batin Pipeline System. For the description of the individual stations see the chapters below. The pipeline shall transport the water from Ras Al Zaur new desalination plant to Hafar Al Batin and shall have the following final design capacity including an operating factor of 0.95: Qfinal =110,000 m/d = 4,583.3 m/h = 1.2731 m/s The new pipeline system consists of one hydraulic main pipeline from the Ras Al Zaur PSRH, up to the Hafar Al Batin terminal Station. The main components of pipeline system with length of 352.1 km can be summarized as follows:

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2.2.1. Pipeline The main pipeline starting from Ras AlZaur pumping station (PSRH) with a nominal diameter of 1100mm (44``) till the terminal reservoir at Hafar AlBatin. From Hafar AlBatin terminal station a pipeline 1100mm (44``) will transfer water from Hafar AlBatin Terminal Reservoir to the existing Hafar AlBatin MOWE Tanks for 7 Km by Gravity. The diameters of the branch pipelines range from 100 mm to 300 mm as mentioned in article 3.9 2.2.2. Pumping Station Ras Al Zaur Pumping Station PSRH of discharge 1.2731 m3/s and head =730m with main and Booster pump units and all related facilities. 2.2.3. Filling Stations, water towers and reservoirs Several filling stations, water towers and reservoirs will be constructed along the pipeline route with all related facilities as follows: Name Nuairiyah Ibn Hethlain Qaryat AlOliyah Sairah Sadawi AlQaysumah Hafar Al Batin Type of Construction Two steel reservoirs, filling station and all related facilities. One Steel Water Tower, filling station and all related facilities. One concrete reservoir divided into two champers, filling station and all related facilities. One Steel Water Tower, filling station and all related facilities. One Steel Water Tower, filling station and all related facilities. One concrete reservoir divided into two champers, filling station and all related facilities. Two steel reservoirs, filling station and all related facilities. Capacity Each 5,000 m3 300 m3 Each chamber 1,500 m3 1000 m3 300 m3 Each chamber 3,500 m3 Each 50,000 m3

2.2.4. Pipeline Valves The pipeline system will consists of different type of valves as follows: Mainline isolation valves will be provided to limit the length of pipeline that must be isolated, and also to limit spillage of water in the event of an emergency such as a pipeline rupture. The distance

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between the isolation valves shall be optimized as much as possible as indicated in pipeline route and system flow diagram drawings ( QP10-U-1000 and QP20-D-3000) respectively. Ball valves are suitable for use as isolation valves. The mainline isolation valves will be designed to have long closure time and will include a by pass valve leg. All isolation valves on the main and branch lines will be in accessible shafts and be provided with necessary accessories. Automatic vent valves will be installed at all defined high points which will be identified during detailed design stage by the contractor. Pressure control valves are located at the inlet of the branch pipes to reduce the pressure from the main line to the branches. To enable flushing of the line during the initial phase of operation and to empty sections of the line for repair and/or inspection purposes, drain stations will be provided. The drain stations will be located at distinctive low points of the line (i.e. At the lowest point between the two adjacent vent stations). Drain stations consist of a pipe connection to the invert of the mainline, two manually operated valves, and a blind flange. The drain pipes terminate in a drainage shaft, which is fitted with a lockable cover and a ladder. Mobile pumps are foreseen to empty the shaft and the pipe.

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CHAPTER (3)_DESIGN DATA AND SERVICE CONDITIONS


3.1. General The purpose of this chapter is to define the design data for the Pipeline System, the ambient conditions and climatologic data, etc. 3.2. Design criteria of the pipeline:Water demand shall be considered as significant criteria which will determine system pipelines sizes and assist selecting other viable options which shall create a long lasting water transmission system.

3.2.1 General The following design criteria shall be considered: Pipeline Route Excavation Bedding Backfilling Depth of Cover Pipe Materials Pipe Pressure Classes Fittings and Special pieces. Pipe Joints Operating Pressure Corrosion Protection. Line Valve Vent and Drain Stations Shafts Roadway Crossings Utility Crossings Railway Crossings Aramco Crossing Marking Hydraulic Design

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HAZOP Study

3.2.2 Pipeline Route An optimum pipeline alignment transmits water with the most direct routes possible at the lowest capital and operating expense. The routing and alignment shall carefully consider the following constraints. Conflicts with surface or subsurface facilities and structures Hydraulic constraints of the system Property values Paralleling existing roadways or rights-of-way Year-round accessibility Route geology, topography and soil chemistry Environmental sensitive areas

The route of the pipeline has been discussed with SWCC and the pipeline route has been approved by SWCC.Reference is made to Pipeline route drawings (QP10-U-1000).

3.2.3 Excavation Excavation must be conducted in accordance with the requirements established by the U.S Occupational Safety and Health Administration (OSHA). Shoring may be required at certain locations due to the depth of the excavation required for these pipes (more than 3.5 m to crown) and due to space constraints in some location along the pipeline route. Shoring design and trench safety will be the responsibility of the contractor. Selection of the protective system (shoring), and/or angle of excavated slopes shall be determined after considering applicable (OSHA) safety standards, regulations and the recommendations adapted from the geotechnical investigation. Pipeline construction efficiency is typically optimized where available space allows stringing pipe and stock piling pipe material, excavation of the trench, and storage of the excavated material shall be all within the available right-of-way. In general excavation shall be as per specification L01 Pipeline construction.

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3.2.4 Bedding & Padding Material used for bedding of pipes shall be of selected nature with properties which will not have any negative impact on the pipes, joints and coating. If no such selected material can be recovered directly from the excavation material, suitable material may be produced by sieving of excavation material or otherwise has to be imported. The padding material shall be placed around the pipes such that each pipe is embedded in an annulus of selected material not less than 200 mm in thickness. In principle the same material as specified for pipe bed preparation shall also be used for padding. In general Bedding and Padding shall comply with specification L01 Pipeline construction.

3.2.5 Backfill 3.2.5.1 Backfill Material Large rocks or stones, rubbish, vegetable growth or other material which is unsuitable for backfill, shall not be put back into the trench but shall be collected and disposed of. Any consequent deficiency in material shall be made good with suitable imported material. The remaining excavated material of suitable quality together with any imported material shall be returned to the trench. The backfill material may be heaped up along the trench line to leave a crown of approximately 300 mm above adjacent natural ground level to ensure a minimum of 1.30 m total pipe cover, unless otherwise specified or required by the Employer. Surplus excavated subsoil, if any, shall be removed from Site or spread over the right-of-way on exposed subsoil. Surplus subsoil shall not be spread on topsoil. 3.2.5.2 Compaction of Backfill Compaction of backfill material is only required at special sections as detailed below:

At inhabited areas At road areas, the crossings of roads or at areas involved by transit loads (trail desert areas, etc.) At the crossings of pipelines and cables At the areas where the pipeline is laid within the ROW of an existing or future road. crossings in

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For the remaining trench sections no compaction is foreseen or required. In the sections defined during detailed design the material put back into the trench up to natural ground (and above) shall be duly compacted with Proctor density of 95 % according to DIN 18127, or as required by the respective authority. Compaction at above mentioned locations shall be done according to the following procedure: Backfill materials up to a level 500 mm below the final ROW level shall be very gently and carefully compacted to avoid damage to the pipeline coating and internal lining. Only small compactors shall be allowed within this range. For the remaining backfill, medium size roller compactors may be used. Backfilling works shall be carried out as soon as possible after jointing and padding is complete in order to give the pipe a natural anchorage, avoiding harmful actions of adverse weather conditions and caving in of the trench walls. Backfilling of trenches opened at crossings of roadways, pavements or other public areas shall be carried out immediately after laying the pipeline in conformity with the request of the proponent authority, and all temporary and permanent surface restorations shall quickly be completed. Sections of ground with significant slope in which the upper part of the backfilling is likely to be eroded by rains, efficient drain ditches or other works suitable to prevent scouring shall be implemented. Moreover, dams consisting of earth bags or sand sacks, properly spaced, shall be bound and connected to the natural ground of the trench wall by adequate supports, where necessary. Diversionary furrows shall also be provided if necessary to direct the flow of water into natural drainage courses and away from the pipeline trench. Movement of fine graded particles within the trench shall be avoided by provision of geotextile on the back side of the sand bag barriers. During backfilling temporary markers, suitable for locating the axis of the pipeline shall be installed. These temporary markers shall later be replaced by final markers. In general Backfill shall be as per specification L01 Pipeline construction.

3.2.6 Depth of Cover The design depth of cover for the Project pipeline will generally be a minimum of (0.8-1.0) m to address the factors discussed below:

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External loadings from earth and superimposed loads (i.e., Traffic and farm machinery); Utility conflicts Future excavation for utilities Pipeline grading to avoid the need for extra air-vacuum or air release valves (as possible)

External Loadings: The pipe structure must be designed to handle the imposed earth loads and superimposed loads aboveground without damage to the pipe, its lining, or its protective surface coatings. Except in the case of very deep or relatively wide trenches, the internal pressures have typically controlled pipe design. The current OSHA standards will typically result in wider trenches and increased earth loads on the pipe. This needs to be considered as part of final design in order to optimize cost-effectiveness. Utility Conflicts: When other utilities are encountered on the pipeline grade, they must either be avoided or protected. Generally, this is accomplished by installing the proposed pipeline deeper, or relocating the other utility. Utilities, such as sewers, which must be maintained on grade, are difficult to relocate. In some instances, the water supply pipeline may have to be installed deeper with adequate separation (for avoiding contamination) or the alignment changed to avoid conflicts with known future utilities. Future Excavations: Future utility and other excavations in the vicinity of the buried pipeline have the potential of damaging the pipe. The proposed 0.8-1.0 m cover would place the pipe below most typical excavations. Pipeline locations will need to be identified, documented and signed where appropriate. Pipeline Grading: Pipeline grading to avoid installation of air-vacuum and air-release valves when small elevation changes are encountered (hummocks) must be traversed and may result in shallower or deeper cover in specific instances. In general depth of cover shall be as per specification L01 Pipeline construction.

3.2.7 Pipe Materials Steel pipeline with cement mortar lining and three layer polyethylene coating will be used for the project for main line and branch line. Steel pipe (ASTM, API 5L) is manufactured to a wide variety of sizes and wall thickness.

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3.2.8 Pipe Pressure Classes The pressure class or thickness of pipe will be determined based on the following Handling Internal Pressure External Loads Deflection & Deformation Buckling

The minimum thickness for handling of welded steel pipe shall be the nominal diameter divided by 130. In no case the steel cylinder thickness shall be less than 8.7mm for the main pipeline according to API 5L.For steel pipe except as otherwise indicated, materials, fabrication and shop testing of specials and fittings shall conform to the requirements stated above for pipe and shall conform to the dimensions of API 5L.

3.2.9 Operating Pressure The selected steel pipeline operating pressure shall be up to 73 bars.

3.2.10 Fittings & Special Pieces All fittings and special pieces shall be complying to AWWA C208 and as per SWCC specification M04 Factory Made Bends for Mainlines and M11 Special Fittings.

3.2.11 Pipe Joints Steel pipes joints inside the pump station shall be flanged type next to valve and pumps. Other joints shall be welded type. Steel pipe with welded joints will have zero tested leakage. Flanged joints at hydrostatic test shall have zero leakage. The requirements of this test shall be according to ASME Each length of pipe shall withstand, without leakage, an inspection hydrostatic test to at least the pressure specified in the standard test pressure tables given in AWWA Manual M11 (welded steel) and as per SWCC specifications

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3.2.12 Corrosion Protection Corrosion evaluation and mitigation measures will be considered during the design and development of the transmission pipeline system once the final pipeline alignment is selected. Various corrosion protection methods related to mortar linings and 3 layers polyethylene coating are required. All steel pipe joints will be electrically bonded. It is anticipated to use an impressed current system. The use of impressed current method for cathodic protection will depend on the results and recommendations of the onsite specific corrosion evaluation. Insulation flange kits will be provided at connections to structures and other pipelines and other pipe materials where applicable. Cathodic Protection shall be according to SWCC specifications E16.

3.2.13 Line Valves Line Valves will be provided to limit the length of pipeline that must be isolated and also to limit spillage of water in the event of an emergency such as a pipeline rupture. Isolation valves are recommended at the pump station and at interval spacing of 30-60 Km, optimum locations for the valves based on the route profile will be incorporated at other sites (crossings, siphons, etc) as necessary. Ball valves or other slow closing valves are suitable for use as isolation valves. All Line valves on the main and branch lines valves will be in accessible Shaft and be provided with necessary accessories (Piping instrument, Telephone, batteries, electrical .. etc.) Valves shall comply with SWCC specifications (M06 Valves for Water Projects)

3.2.14 Automatic Vent and Drain Stations Automatic vent valves will be installed at all defined high points which will be identified during detailed design by the contractor. These valves have a large orifice which will vent air from the pipeline during pipeline filling and admit air during draining operations to avoid negative internal pressures which could damage the pipeline. Air-vacuum and air-release valves will be equipped with isolation valves and will be installed in shafts. Screened standpipe(s) located above the ground also will be provided to allow for venting. Standpipe material will address site specific conditions. For example, if the standpipe is located in pasture land, it will be fenced or constructed of steel.

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For vacuum relief during pipe draining, the valve will be sized on the full pipeline design flow and a 0.35 bar allowable differential pressure. For air venting during pipeline filling, a flow corresponding to a filling rate of 0.3m/second and an allowable maximum differential pressure of 0.14 bar will be used. Smaller air release valves will be provided at high points and at sudden changes in slopes to release air accumulated during normal system operation. The sizing of small diameter air release valves will be based on 2.0 percent of the design flow and the system pressure. Drain piping will be provided to facilitate drainage of pipeline segments for maintenance and repair. Drain will generally be installed at low points in the pipeline profile. Drain size will allow a reasonable time-to- drain for tributary pipe segments; typical diameters for drain piping and valves will be approximately 20 percent of carrier pipe diameter. Where reasonable, Drain will be drained to an energy dissipater (riprap or soil cement) which will be provided where pipeline drainage may cause erosion. However, in most cases, will be below grade and it will be necessary to provide a standpipe so that a pump can be inserted to drain the pipeline. Water will be directed from the drain to appropriate drainage facilities. For most applications, plug, ball valves are proposed as drain valves depending on drain application. Number of drain stations shall be minimized. In general automatic vent and drain valves shall comply with SWCC specification M06 Valves for water projects.

3.2.15 Shafts Shafts will be used to house various project amenities discussed above. All meters, flow-control systems, mainline valves, major air-vacuum, air-release valves, turnouts; pressure Control valves will be installed in Shafts. Drain will also be installed in Shaft-type Shafts on the upstream side of mainline valves. To the extent practical, the various system components will be installed in common shafts. Shafts containing Supervisory Control and Data Acquisition (SCADA) system components, which would include all automated mainline valve Shafts and all flow control stations, would be equipped with appurtenances including:

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Hatch and ladder for access; Electrical power, lights, ventilation, sump pump (or drains), and unit space heaters; Communications, intrusion and entry alarms; Drain ways in floors; and A battery-powered emergency power supply for the SCADA and local control (DC system) system for use in the event of power line failure. (Power failure precautions shall be for 24 hour emergency operation).

Pre-cast and cast-in-place concrete Shafts, pipeline encasements, cut off walls and other structural concrete shall be 300Kg/cm2compressive strength. Buried Shafts shall be designed for an AASHTO HS-20 live load where applicable. Lateral pressures and bearing capacity shall be in accordance with the geotechnical report. In the very unlikely instance where Shafts would have to be placed in roadways, the top of Shafts shall be flush with the finished surface with highway rated openings. Outside roadways, Shafts shall extend at least one foot above grade or what is required to avoid surface flooding. Man way covers shall be of cast iron, at least 60 cm in diameter. Man way covers will be solid, no openings, and shall be sealed to prevent water from gaining access. Access to Shaft with large equipment and appurtenances will be provided by hatchways confined space safety requirements need to be considered. In general Shafts shall comply with SWCC Civil specification.

3.2.16 Roadway Crossing The Project pipeline may cross several major roadways. Pipeline installation within paved highway right-of-ways will require a cased crossing using boring, jacking, or appropriate tunneling methods. For other non-paved and low traffic roads, open cut crossings are expected to be generally allowed. In some cases, installation of a cased pipe in the open cut to avoid future roadway excavations for repair of the pipeline could be considered. As a rule, the minimum burial for either the pipeline or the casing would be subject to the approval of the Engineer and the owner of the roadway and to avoid pipeline damage from future utility excavations. Future utility installation plans, where known, will need to be

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accommodated. The Roadway crossing shall be in accordance with SWCC specifications L01 Pipeline construction.

3.2.17 Utility Crossings At roadway crossings, utilities which generally run parallel with the road may be encountered. These would typically be above the profile of the Project transmission pipeline, given the greater depth of the pipeline at roadway crossings. One exception may be any local existing sewer lines, which may have been installed deeper. Clearances between sewer lines and the water pipeline would be maintained at not less than 3 meters horizontal separation (where the lines are parallel) and 0.5m vertical separation at crossings. Wherever possible the water line shall be installed above the sewer pipeline. Where adequate separation is not possible, steel pipes would have welded joints and non-steel pipes would be encased in concrete to prevent contamination of the finished water due to exhilaration of the sewer line. Separation from other utilities shall be sufficient to protect the existing utility. For larger utilities, encroachment would be reviewed on a case-by-case basis. In some instances, it may be desirable to encroach and protect the pipeline from excavations for the interfering utility by installing a concrete cradle between the two utilities. We do not expect that the Project pipelines and existing sewer line interferences will be a significant problem, but it would need to be considered in selecting pipeline alignment through populated areas. The Utility crossing shall be in accordance with SWCC specifications L01 Pipeline construction.

3.2.18 Wadi Crossings Wadi crossings and Wadi sections shall be carried out in strict compliance with the standard drawings and design specification. However the minimum cover over the top of the pipe shall be two meters plus the estimated scouring depth. The pipes for wadi crossings and Wadi sections, when not otherwise specified in the individual design drawings, or not required by the Engineer during final design stage shall have the same class as the line.

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For the crossing between the two bends of the pipe section, a straight pipeline with a single gradient shall be provided. The elevation of the gradient shall be determined by the minimum burying depth required, referred to the lowest level of the natural bed. Backfilling shall be carried out by bringing the bed and the banks back to the conditions existing before starting the Works. Particular care shall be taken for the compaction of the banks, the restoration of the existing protective works or the execution of protection works of masonry, gabions, rip-raps, sand bags or concrete. The type of protection shall be designed in such a way that they form continuous structures connected to each other over a certain distance. If gabions should be proposed for the structures the Contractor shall lay a filtermat under or on the back-side, where necessary, in order to protect the fine material from being washed out. The construction and filling shall be in strict accordance to the specifications of the manufacturer. The Wadi crossing shall be in accordance with SWCC specifications L01 Pipeline construction.

3.2.19 Railway Crossings Casing pipes shall be used when crossing railways. For all railway crossings the Contractor shall give the Engineer adequate notice on the date the work is planned. The Contractor is obliged to make all necessary agreements with the competent Authority prior to starting of work. The Railway Crossings shall be in accordance with SWCC specifications L01 Pipeline construction.

3.2.20 ARAMCO Pipeline Crossings Non-Saudi Aramco piping crossing pipeline corridors shall pass under the pipelines in a manner such that the minimum vertical distance between the bottom of any Saudi Aramco pipeline and the top of the non-Saudi Aramco piping is 1.0 m. The non-Saudi Aramco piping shall have no servicing points within pipeline corridors. As a general rule for crossings between Aramco facilities and SWCC pipelines Aramco will prepare their facilities. It is the responsibility of the Contractor to obtain the detailed requirements from Aramco and follow all related instructions precisely. All relevant details such as construction time schedule, description of construction works, equipment used during different stages of the work etc. shall be coordinated with Aramco. The documents to be prepared for each crossing shall contain at least the following information:

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- Detailed route survey from the crossing point - Horizontal and vertical position of Aramco facilities related to the pipe to be installed. - Elevation of all facilities related to Aramco reference points - Crossing method (boring, open construction, bridge construction etc.) - Cathodic protection cross bonding - Working program and all other relevant information For ARAMCO crossing reference is made for SWCC specifications L01 Pipeline Construction.

3.2.21 Marking Major valves, air vacuum, air release valves, drain, and buried access Shafts will be identified with steel marker posts. In those locations where the pipeline does not parallel an existing roadway, marker posts will be placed at the centerline of the pipe or along a line offset (noted as constructed drawings) from the pipe. The offset distance shall be identified on the marker post. Generally the markers shall be installed at regular intervals as per the following guidelines: Spacing Maximum spacing of the markers shall not exceed 500 M. Inter-visibility From each marker, the markers immediately ahead, and immediately behind shall be clearly visible. Markers shall be installed close to all pipeline crossings with roads, railways, wadis, electrical lines etc. A marker shall be installed at the crossing of the pipeline with another pipeline system. A marker shall be installed at the beginning, middle, and end of every bend in the pipeline. One marker shall be installed at every cable joint. A marker shall be installed at every Cathodic protection station. A marker shall be installed at the point where the diameter of pipe changes or where the pipe wall thickness changes. The distance between the marker post and the center of the pipeline should be indicated on the marker plate. ROW demarcation markers shall be installed at intervals of 100 meters at each side of the permanent ROW along the complete pipeline route, except at the areas where the pipeline is routed within the ROW of the roads (MOT/ Municipality).

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Concrete monuments of 20 x 20 cm cross section, sufficiently long enough and with a concrete base shall be used. The Marking shall be in accordance with SWCC specifications L01 Pipeline construction.

3.2.22 Hydraulic Design Depending on the alternative selected, the total length of transmission pipeline equals 352.1 Km. Hydraulic design must not only account for the hydraulic construction issues involved in construction and operation, but for the economics of construction and operation as well. The design must optimize the total life-cycle cost for the system which is a function of the energy, operation and maintenance, and capital construction costs for the various pipe diameters throughout the system. Initial pipe sizes will be chosen to keep the velocities in the major trunk lines not to exceed 2.5 m/s. The initially design flow shall be based on average flows developed by delivering the required volume of water over a 24-hour period. The pipe diameter which meets the hydraulic constraints and also yields the lowest life-cycle costs will be chosen for service. For planning and conceptual design purposes, the minimum delivery pressure (turnout, reservoir, tank or other customer discharge) will be 20 m. The minimum hydraulic grade will be +6 meters at steady state conditions and not less than +3 meters during transient conditions at invert level of pipe. The contractor shall perform a surge analysis to determine the appurtenances required to contain transient pressures within the desired range. The desired range runs from a minimum of atmospheric pressure up to a maximum of 1.1 times the Maximum Allowable Operating Pressure (MAOP). The roughness coefficient in Darcy-Weisbachs Equation (required for both the simulation modeling and the life-cycle cost optimization) equals 0.1 mm in steady state condition and equals 0.005 mm in transient condition The pipeline lives span (nominal) equals 50 years.

3.2.23 HAZOP Study Hazard and Operability (HAZOP) study shall be performed by the contractor for t h e Water transmission system in order to investigate the design of all facilities to identify any potential hazard

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and operability problems which could arise particularly through deviations from the design intent. A set of lists of necessary actions and recommendations to improve and mitigate the consequences of the identified problems or hazards shall be recorded and presented in the forms of the HAZOP report. The Contractor shall engage the Employer and Engineer in the HAZOP review which is led by an independent consultant nominated by the Contractor at his cost. The HAZOP review is based on the following drawings and project documents as minimum requirements: Process flow diagrams Piping and Instrument Diagrams, including a key for the used symbols Operating procedures, including description of start-up and shut-down sequences Systems design philosophy and process description Design data sheets for all plant items, including vendors packages Schedule of alarm and trip settings, Cause and Effect charts and diagrams Design duties for all relief valves . Electrical single line diagrams Instrumentation philosophy Drawings showing interfaces /tie-in systems for existing equipment Drawings showing the specific area covered or viewed by each Fire and Gas Detector Others topics and detail design documents as required

3.3 Design Criteria for Mechanical Works Pumping station both (main and booster) pumps shall consist of 3 pumps (2 duty + 1 stand by). Pumps shall be operated in parallel arrangement. The power required shall be as per the following equation: Power required for one pump [kw] = [m3/s]

Qp 9.81 Hm

Where Qp = pump Discharge Hm= Manometric head [m] = pump efficiency

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Pump efficiency ranges between 87 to 90%. A typical value of 88% shall be used for power calculations. This value is based on preliminary pump selection from supplier published performance curves. However, final value shall be specified by Contractor based on the proposed pump performance. The pump driver power shall be assumed in excess of required pump power by 15 % Electric power required for pump station auxiliaries shall be estimated based on foreseen auxiliaries and basic loads. Velocities will be calculated as follows:Q = AV Where Q = discharge [m3/s] V = Velocity of flow inside pipes [m/s] A = Area of pipes [m] Velocity in pump suction line shall not be less than 1 m/s and not more than 2 m/s, Velocity in pump delivery line shall not be less than 1.5 m/s and not more than 3 m/s, those ranges are according to many pumps manufactures Handbook Main and Booster pumps design shall be in accordance with SWCC specifications M05 3.3.1 Fuel System: Fuel storage tank shall be installed to feed the standby diesel generators. The capacity of the fuel tank shall be calculated for 3 days of continuous operation.

3.3.2 System to be used to prevent Water Hammer:System to be used to protect the pipeline against water hammer effects shall be designed based on computational simulations using a specialized computer program for fluid transients in pipelines. Protection devices shall include Pressure relief valves At least one standby unit shall be specified.

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3.4 Design Criteria for Electrical Equipment in Pumping Station: Electric power to drive the pump motors shall be 13.8 kV. At PSRH electric power source shall be provided from Busbar of Ras AlZaur Riyadh WTS. Pumping station shall be equipped with two low voltage power transformers (13.8/0.4 kV) to feed station auxiliaries, lighting and other loads. Standby diesel generators shall be specified to cover the low voltage loads in case of emergency. 3.4.1. Cable Design: The selection of the specific type and size of power cable will be based on the following: 1. Technical requirements such as voltage level, current loading, ambient temperature, voltage regulation, fault current etc. 2. Installation requirements of existing or planned facilities such as ducts, direct burial, conduit, thrust bearing, directional drilling and thermal resistively of soil and backfilling material. 3. Economic requirements based on the selection of a suitable cable and required accessories (splices, terminations, and connectors) The process used in selecting and sizing a cable shall be as follows: 1. Selection of a cable construction based on its planned application and installation. 2. Selection of the conductor size based on current. 3. Increasing, if necessary, the conductor size selected in (A) based on voltage regulation. 4. Increasing, if necessary, the conductor size selected in (A) and (B) based on fault currents. Installation Data: 1.Length and profile of route. 2.Details of the laying arrangement (e.g. flat or trefoil arrangement) A.) Underground Cables

1.Details of installation conditions (e.g. direct burial, in ducts, in trenches covered with chequred plates or pre-cast concrete covers etc.) to enable decisions to be taken on composition of metallic sheath, type of armor (if required) and type of overall jacket, e.g. anti-corrosion, flame-retarding or ant termite.

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2.Depth of lying. 3.Thermal Resistivity and kinds of soil along the route (e.g. sand, clay, made-up ground), and whether this information is based on measurement and inspection or only assumed parameters. 4.Minimum, maximum and average ground temperature at the depth of burial. 5.Proximity of other load-carrying cables, or of other heat sources, with details. 6.Lengths of troughs, ducts or pipelines. With spacing of Shafts, if any. 7. Number of ducts or pipes. 8. Internal diameter of ducts or pipes. 9. Spacing between individual ducts or pipes, if more than one. 10. B.) Material of ducts or pipes. Cables in Air

1. Minimum, maximum and average ambient air temperature to be assured. 2.Details of ventilation (for cables indoors or in tunnels). 3. Whether exposed to direct sunlight. The following basic parameters will assist to further evaluate the ampacities and objectively calculate alternative ampacities for a cable to fulfill any load requirements: 1. Load MVA. 2. Load Factor (LF). 3. Thermal Resistivity of the Soil (RHO). 4. Ambient Temperature mean temperature of the soil or riser temperature at above ground (in air) terminals. 5. Short circuit values with finite information on time duration (affects sizing of copper in cable shield). 6. Dreading factors (multiplicity of circuits and tie formations). 7. Route location that might affect placement of splice bays / Shafts and terminations.

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Reference Codes and Standards: 1. 2. 3. IEC 60287 (Calculation of Continuous Current Rating of Cables 100% Load Factor) IEC 60853 (Calculations of the Cyclic and Emergency Current Rating of Cables) IEC 61059 (Economic Optimization of Cable Size)

And SWCC specifications E12 Cables and Cable Laying

3.4.2 Power Transformer Design: 1. The transformer shall be capable of delivering its rated power continuously with rated voltage on the secondary winding under the ambient temperature. 2. The power transformer shall be designed to meet the overloading requirements of the relevant IEC or IEEE Industry Standards adjusted to ambient conditions. 3. All transformer accessories (tap changer, bushings, CTs. etc.) shall be rated to carry 120% of the transformer current with tap changer on the extreme minus tap. 4. The transformer shall be rated for the following over fluxing requirements on any tap while carrying the rated current for the tap without exceeding the temperature rise associated with temperature rise test: Continuous 110% of rated volts/Hz 1 minute 125% of rated volts/Hz 10 seconds 140% of rated volts/Hz 5.The transformer shall be designed and constructed to withstand on any tapping without damage, the thermal and mechanical effects of short-circuit in accordance with IEC 60076 or ANSI C57.12.90 The following factors need to be taken into consideration while selecting the type of transformer. 1. Ambient temperature and temperature rise 2. Insulation levels 3. Percentage impedance 4. Method of cooling

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5.Vector group 6.Fault level 7.Tap changing arrangement 8.Location (Indoor / Outdoor) Reference Codes and Standards: 1.IEC 60076 Power Transformer 2.IEC 60214 Tap Changes applications Guide 3.IEC 60529 Degree of Protection Provided by Enclosures (IP Code) 4.IEC 60354 Requirements for Transformers 230kV and below And SWCC specifications E22 High Voltage Power Transformes

3.4.3 Earthing System Design: Substation grounding is for the following functions: 1. System Grounding a) To provide low fault impedance to the ground fault currents for prompt and consistent operation of protective devices during a ground fault, and to limit potential rise of substation equipment. b) To stabilize system neutral potential by grounding the neutrals of the equipment. 2. Safety Grounding a)To provide means to carry electric currents into the ground under normal and fault conditions without exceeding any operating and equipment limits or adversely affecting continuity of service. b) To assure that a person in the vicinity of grounded facilities is not exposed to the danger of critical electric shock. While designing the earthing system, it is necessary to obtain following information about the system. 1. 2. Maximum ground fault current Resistivity of soil at the station

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3. 4.

Area covered by the station Fault clearing time

Reference Codes and Standards: 1. NEC 70, National Electric Code 2. ANSI / IEEE Std. 80, IEEE Guide for Safety in Substation Grounding, And SWCC specifications E13 Earthing and Lighting Protection

3.4.4 Surge Control System Design: Surge arresters are the primary protection to make the circuit devices immune to different types of over voltages and spikes either atmospheric or switching. Surge arresters are designed to limit the voltage surges by discharging or bypassing surge current and automatically limiting the flow of system power current. 1.Rod Gap 2.Metal Oxide Surge Arrester The following needs to be considered during the selection of Surge Arrestor. 1. Determination of maximum continues operating voltage with respect to system highest operating voltage. 2. 3. 4. Determination of rated voltage with respect to temporary over voltages. Live discharge in switching surges. Coordination of protection level of arrester with equipment to be protected.

5. Selection of current requirements for the arrester with respect to system short circuit currents. The objective of the arrester selection is to select the lower rated Surge Arrester that will have a satisfactory service life on the power system while providing adequate protection of equipment insulation.

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Reference Codes and Standards: 1. ANSI C62.22, Guide for the Application of Metal Oxide Surge Arresters for Alternating Current Systems 2. IEC 60099-5, Surge Arresters-Part 5: Selection and Application Recommendations.

3.4.5 Outdoor Transmission Design: Outdoor feeders shall connect the pump station to the 13.8kV networks. This may be using Underground Cable . Depending on many factors, the selection is done to choose cables or overhead lines. For cables, the design criteria are generally same as listed out in 3.4.1. Reference shall be made to SWCC specifications

3.5 Design criteria for SCADA system In this project the SCADA system will be used for monitor and/or control the different parameter of the transmission pipe line (pumping station, all Water Towers and ground tanks, the Line valve chambers along the transmission line, filling station, the flow and the pressure across all the taping points through the line). Pumping station will be equipped with PLC (Programmable Logic Control) or DCS (Distributed Control System) & SCADA system (Supervisor Control and Data Acquisition) for local control / monitor and it will be connected to the main SCADA located at the monitoring centre of Ras Alzaur station. Also the transmission pipeline components (Line Valve , Filling Stations and Tanks ) will be equipped with local panels for local controlling and monitoring that will be connected to nearest station as shown in the drawing QP20-T- 5200 All data shall be transmitted to the monitoring center of Ras AlZaur Riyadh WPCC using FOC.

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3.6 Liquid Properties The viscosity of water has an effect on the friction head loss along a pipeline. The viscosity is dependent on the temperature of water. The following water properties were used in the hydraulic calculations: Temperature: 20.00 [C] Although the temperature of water may reach 45oC, it shall be taken as 20oC in the hydraulic calculations. This assumption is more conservative in calculating the residual pressure .This effect is minor in turbulent flow conditions. Water density : 998.2 [kg/m] [cSt]

Kinematic viscosity : 1 Vapor pressure

: 0.025 [bar]

3.7 Water Quality Data The product water for the new pipeline system will be supplied from Ras AlZaur SWCC Plant .The water quality data are shown in the following table: Parameter Temperature PH Calcium Bicarbonate Calcium Carbonate Chloride R. Chlorine Turbidity Boron TDS Langlier Saturation Index Symbol T PH Ca HCO3 CaCO3 Cl RCI B TDS LSI Unit o C mg/l mg/l mg/l mg/l mg/l NTU mg/l mg/l Specification 20-45 8.2-8.6 14-20 36-50 36-50 20 max 0.2-0.5 0-2 0.5 110 max 0.1-0.3

The chlorination of the desalinated water is part of the Ras AlZaur SWCC Plant, additional chlorination facilities are foreseen at the Hafar AlBatin terminal.

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The design and specification of all materials for the system, which shall be in contact with the product water, shall be suitable for the anticipated range of the above water quality specifications. The Contractor is responsible for the selection of suitable materials and/or the verification of the adequacy of the materials specified as well as for a quality upgrading whenever required.

3.8. System Capacities and Flow Rates In the following table the design capacities and flow rates for the Pipeline System are listed for every city/village. An operating factor of 0.95 has been considered.

City / village PSRH Nuairiyah Khafji Ibn Hethlain Qaryat AlOliyah Sairah Sadawi AlQaysumah Hafar Al Batin

Design flow rate Including operation Factor (m3/d) 110,000 10,000 50,000 300 2,800 1,170 280 6,450 89,000

3.9. Pipeline Segments and Lengths The following tables and diagrams below indicate the length of the mainline and branch line segments, the line diameter and the station locations for the Pipeline System. The figures are preliminary and need to be confirmed by the Contractor with the final survey. The following table indicates the length of the mainline segments as well as pipeline diameter.

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Segment No. #1 #2 #3 #4 #5 #6 #7 #8

From PSRH Nuairiyah station Ibn Hethlain Station Qaryat AlOliyah Station Tap-off Sairah Station Sadawi Satation AlQaysumah Satation Hafar AlBatin

TO Nuairiyah station Ibn Hethlain Station Qaryat AlOliyah Station Tap-off Sairah Station Sadawi Satation AlQaysumah Satation Hafar AlBatin Existing Hafar AlBatin belong to MOWE

Segment Length (Km) 78.2 11.2 66.1 31.4 85.3 65.7 7.2 7

Segment Diameter inch (mm) 44`` (1100) 44`` (1100) 44`` (1100) 44`` (1100) 44`` (1100) 44`` (1100) 44`` (1100) 44`` (1100)

Segment Flow Rate (m3/day) 110,000 100,000 99,700 96,900 95,730 95,450 89,000 89,000

The following table indicates the location and the length of the branch pipelines. Station Nuairiyah Ibn Hethlain Qaryat AlOliyah Sairah Sadawi AlQaysumah Hafar Al Batin Tie-in station to the existing Hafar AlBatin Tank KP (of main line) 78.2 89.4 155.5 186.9 272.2 337.9 345.1 352.1 BranchLine Length (m) 350 100 20,000 250 300 300 7000 Diameter of BranchPipeline (mm) 300 100 200 150 100 250 1100

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Entering the desired flow rate, the operator gets information on pumps and station status and gets standard pump arrangement which he can alter. The selected combination will be installed in STEP4. b) STEP2: Prestart of Pumps Pumps selected in STEP1 are prestarted. c) STEP3: Setpoint Ramping in Preparation of Pump Starts Setpoints will be ramped to predefined setpoints in order to avoid unscheduled shutdown during pump start. d) STEP4: Pump Starts Pumps selected in STEP1 are started. The sequence and the timepoint of the start of the pumps is to be optimized based on hydraulic conditions. e) STEP5: Final Setpoint Ramping Setpoints are ramped to preselected optimized final setpoints. 5.5.3 System Stop and Flow Decrease (QMINUS) The QMINUS program is the standard program for the shutdown of the system, stations, pumps and the reduction of the system flow rate. The program is comparable to the QPLUS software described in the item above. The program is basically divided in 4 steps: a) STEP1: Selection of Flow Rate and Pumps Entering the desired flowrate, the operator gets information on pumps and station status and gets standard pump arrangement which he can alter. The selected combination will be installed in STEP3. b) STEP2: Setpoint Ramping in Preparation of Pump Stops Setpoints will be ramped to predefined setpoints in order to avoid unscheduled shutdown during pump stop. c) STEP3: Pump Stops Pumps selected in STEP1 are stopped. The sequence and the timepoint of the stop of the pumps is to be optimized based on hydraulic conditions. d) STEP4: Final Setpoint Ramping Setpoints are ramped to preselected optimized final setpoints.

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5.5.4 Line Shut Down Program The line shut down program shall stop pumps and close valves (station off-line sequence). The sequence and the timepoint of pump stop, valve closure and setpoint change is to be hydraulically optimized during the final design. 5.6 Safety Programs 5.6.1 General The Safety Programs guarantee the safe operation of the system in case of upset conditions such as the power failure at the pumping stations, uncontrolled closure of valves and failure of the telecontrol system. The system is a closed system requiring continuous monitoring and automatic control of its important components and stations. Upset conditions in the system have to be recognized and counter measures have to be initiated within suitable time periods, in order to meet the requirement for operational safety and operation at the highest possible and reduced throughput rate. Safety monitoring and control is in general to be performed from the Control Centre (CC), where all information on the system, as transmitted by the telecontrol system is available. In the event of telecontrol failure, it is still possible to continue operation of the system by bringing the stations (still having TC connection) to a safe waiting position, while the stations which have lost TC to/from CC takes the actions required by their own logic. Safety monitoring and control makes use of the following hardware installations: CPUs and servers in CC Station logic controllers (PLCs) TC System The software required for safety monitoring and control must be subdivided into the packages as described below. 5.6.2 Safety Program at CC The safety program is installed in the CC logics, which continuously monitors the System and in case of defined upset conditions initiates the Station Safety Sequence and supervises its execution. The safety program also initiates the Line Shut Down Program. 5.6.3 Leak Detection Program at CC

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During steady state pipeline operation the mass balance in the pipeline system shall be calculated by special leak detection software (LDS). No automatic pipeline or station shut down shall be initiated by the LDS, but an alarm shall be given only. In addition the calculated location of the leak shall be shown to the operator. 5.7 Station Safety Sequences (SSS) In the event of telecontrol failure or upset conditions in a station, all stations are automatically brought to a hydraulically safe operating condition. The station safety sequence prevents the development of vapor pressures and overpressures in the system. Two levels of the Station Safety Sequence, namely SSS1 and SSS2, shall be executed in the pumping station , reservoir stations and terminal station dependent on the control mode and the seriousness of the upset conditions. SSS1: In case of ESD or SD of only one unit in the pumping station (Scheduled or unscheduled stop). SSS2: In case of the following: ii.ESD or SD of more than one unit in the pumping station with in 20 sec seconds (time adjustable and to be optimize). iii.Loss of telecontrol connection from CC for more than 10 sec. iv.Change from Station control mode (Station Central ) to any other station control modes. The station sequences are to be programmed into the station PLC and always executed by STATCON. The whole pipeline system is monitored by SYSCON, the stations are monitored by STATCON. In case the telecontrol system is in proper function SYSCON decides which SSS is selected. Either SSS1or SSS2 is initiated by SYSCON (from CC). SSS2 is initiated by STATCON in case of Telecontrol failure. The setpoints and parameters inside the safety sequences shall adjustable from CC. The SSS command effects switching from the slow to the fast ramp function in the station control. The Station Safety Sequences as a whole and the setpoints and ramps below are to be optimized during the detail design stage by the contractor.

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5.8 System and Station Control Regulation Loops 5.8.1 General The principal system and station control and regulation loops are shown in the System Flow Diagram and in the individual Station P&I Diagrams. In the following a brief description of the required loops is contained. In addition the actions from the automatic programs must be considered. Setpoints are set either by the Operator or the Software from CC or by the Station Safety Sequences at the Stations. To avoid control conflicts (PSRH flow controlled and Terminal flow controlled) the flow rate setpoints of the Terminal or Reservoir Stations must be set in such a way that the PCL becomes active. But the design flow rates of the different Terminal Station or Reservoirs shall not be exceeded. 5.8.2 Pumping Station PSRH Station Control Valve acting on: Condition: Flow control by the PSRH.FC set point Override 1: Discharge pressure controlled by the PSRH.PCH set point Override 2: High Flow Protection controlled by the PSRH.PHFP set point Override 3: Tank Level Low controlled by the PSRH.LCL set point Station Recirculation Control Valves ( Booster pumps and main pumps separate loop) acting on: Condition: Flow control by PSRH.BO.PLFP and PSRH.MAIN.PLFP set point 5.8.3 Reservoir Stations Station Control Valve acting on: Condition: Flow control by the xx.FC set point Override 1: Inlet Pressure controlled by the xx.PCL set point Override 2: Tank Level High controlled by xx.LCH setpoint 5.9 Station Programs and Sequences 5.9.1 General The following automatic programs and sequences must be provided at the individual stations. 5.9.2 Pump Start-up Sequence The start-up procedure for the different pump units consists of two steps:

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The first step, the pre-start, activates the auxiliary equipment of the pumps and opens the suction valve. The pump discharge valve is to be put to a closed, open or predetermined intermediate open position (e.g. 20 % of opening), according to the motor/ pump manufacturers instructions or the hydraulic requirements. The second step, pump start, starts the pump and initiates the pump discharge valve to open completely. The pump is to be recognized as a running unit by the station control when the pump motor is running and the discharge valve has opened up to 20 %. Each of the two steps for pump unit start-up can be initiated either by the operator or by a computer program from CC, or locally from the station. The most appropriate mechanical and electrical equipment shall be provided to make pump startup as simple as possible for the operator and the software. 5.9.3 Pump Unit Stop and SD Sequence The pump stop sequence stops the pump, closes the pump discharge valve and deactivates the auxiliary equipment according to pump manufacture instruction. 5.9.4 Pump Unit ESD Sequences The pump is shut down in this sequence, the auxiliary systems are deactivated, the pump valves (suction and discharge) are to be closed. The pump unit ESD command can be initialized locally from the units only, but not from CC. Each pump unit has one local ESD button close to the pump / motor unit motor circuit breaker in the pump hall. The ESD circuits shall be hardwired and will trip the motor circuit breaker. The valves and auxiliary equipment will be closed by the normal software function. 5.9.5 Station Pressure Switch Sequence Generally, the pumping stations are to be equipped with a high pressure switch (PSH) on the station discharge side (PSRH) and a low pressure switch on the station inlet side (PSRH). If this switch is touched, one running pump is shut down immediately. Only if the signal has not disappeared after an adjustable time (range 0.0 to 20.0 sec.), indicating that the pressure is still too high, the next pump is shut down, and the time delay is to be reset prior to a shut-down for the next pump. By proceeding this way, any unnecessary shut-down of pump units is avoided. The time delay must be adjustable.

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5.9.6 Station SD and ESD Sequences In the pumping stations two sequences are to be prepared: The SD sequence stops the running pumps adopting a cascade mode with a time interval of 0.0 to 30 sec. (adjustable). The station ESD sequence stops the pumps in cascade with adjustable time delay. The individual unit ESD stops the particular unit immediately. The SD sequence can be started locally or via telecontrol system from CC by operator or computer program. The ESD sequence can be initiated locally from the pumping station only. The separate station ESD button (in the control room and on escape ways) will initiate the individual unit ESDs (hard wired), additional valve closure will be executed with the normal software. 5.9.7 Station On-line / Off-line Sequence This sequence shall prevent the closing of the last open way within the Stations at the running pipeline. Pump start shall be possible only with Station On-line, the Station Off-line will initiate the station shut down sequence. 5.9.8 Flow Path Monitoring Before start of operation the flow path within each station must be monitored and verified, depending on the selected way of operation. In case the last open way in one active station starts closing the shut down sequence will be initiated. 5.9.9 Station Flow Computer In the pumping stations pertinent electronic equipment is to be provided to compute the flow setpoints for the station control closed loops. The following values are to be considered: Low flow rate limit for each running pump High flow rate of each running pump Maximum low flow limit for all running pumps, considering the number of running pumps in the pumping station. Minimum high flow limit of all running pumps, considering the number of running pumps in the pumping station.

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The calculated value controls the Pump Low Flow (PLFP) and Pump High Flow Protection (PHFP) of the pumps. The pump is set to running status, when it has hydraulically started operation. The pump is set to the not running status, when the pump is hydraulically stopped. PS.PLFP Setpoint = QMIN * n [m3/h] PS.PHFP Setpoint = QMAX * n [m3/h] QMIN (=MDF/2*0.7) and QMAX (=MDF/2*1.2) represents the minimum and maximum continuous flow rate for a single pump, to be defined during final design. n represents the number of running pumps. n is to be considered in pumping stations with parallel pumps. Alarms in the Station Flow Computer signal if the present flow conditions are beyond the allowable range (tolerance or + 5 % of defined setpoints). An automatic start-up of the pumps is not foreseen. Any pump start is subject to the Operators responsibility. The present pipeline flow rate is measured by the station flowmeters at the pump stations. 5.9.10 Pump Low Flow Protection (PLFP) A low flow condition occurs if too many pumps are running for the actual pumping station flow rate. The pumps operate on the left hand side of the allowable operating range of the pump characteristics. The low flow condition disappears if pumps are shut down or the flow rate is increased. The pump station recirculation control valve shall be opened automatically on the PLFP signal and closed if the signal disappears. The Pump Low Flow Protection triggers an alarm and if this alarm does not disappear automatically within 180 sec (adj.SYSAD), the first running pump is shut down, using the PUMPSTOP sequence. If the alarm persists, the next pump is shut down after a time lapse of 180 sec (adj.SYSAD), etc. until all pumps are shut down. The Pump Low Flow Protection is suppressed during and after pump start for 60 sec (adj.SYSAD). 5.9.11 Pump High Flow Protection (PHFP) A high flow condition for the pumps occurs if the number of running pumps is insufficient for the actual pumping station flow rate. The pumps operate on the right hand side of the allowable operating range of the pump characteristics. Cavitation in the pumps may occur and the motors could be shut down by over-current. The high flow condition disappears if additional pumps are started or if the flow rate is reduced.

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The PHFP Setpoint is an override setpoint for the Outlet Control Valve Loop. The flow rate in the PS is reduced to the allowable limit by closing the outlet control valve at the Pumping Station. The Pump High Flow Protection is suppressed during and after pump start for 60 sec (adj.SYSAD). Note: Due to the installation of fixed speed pumps, the pump high flow protection is a very important protection equipment for the pumps. During start and stop of pumps, and after tripping of single pumps high flow may occur. 5.10 Operation with and without Telecontrol System For operation with the maximum design flow rate the telecontrol system is necessary. The telecontrol system provides surge protection system measures (initiation of Station Safety Sequences). Operation without telecontrol system shall be possible at maximum flow rates. Details must be verified and calculated by the Contractor during final design. 5.11 Surge Protection Devices The major hydraulic load cases are the power failure at the Pumping Stations and the unscheduled closure of control valves at the Terminal Station. Surge protection equipment is the pressure relief valves at Hafar Albatin Terminal . The Station Safety Sequences in the individual stations are also important for surge protection. An unscheduled closure of the line valves has to be prohibited (valves have to be set locked open). 5.12 Basic Data for Hydraulic Calculations and System Design Reference is made to the Hydraulic Study Report, QP50-J-001. Both steady and unsteady flow conditions were calculated using a computer software suitable for a realistic simulation of the pipeline system. The transient analyses were simulated by using KY pipe program SURGE 2000, v 2.107 and Bentely Hammer V8. The following information only includes data which are of importance for the hydraulic behavior and the safety of the system. The data are envisaged to be used as the basis for computations and examinations by the Contractor, if necessary.

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5.12.1 Stations, Elevations and Water levels Reference is made to chapter 3.10.All pressure data are relative pressure data (= barg, without atmospheric pressure) and are to be seen in connection with the stations and elevations which are used in the entire hydraulic analysis. The station location given under chapter 3.9 corresponds with the horizontal lengths in the hydraulic profile. 5.12.2 Design flow rate The following design flow rates have been considered in the Hydraulic Calculations: City / village PSRH Nuairiyah Ibn Hethlain Qaryat AlOliyah Sairah Sadawi AlQaysumah Hafar Al Batin The above figures include an operating factor of 95 %. 5.12.3 Liquid Properties The following water properties were used in the hydraulic calculations: Temperature Water density : 20.00 [C] : 998.2 [kg/m] [cSt] Design flow rate Including operation Factor (m3/d) 110,000 10,000 300 2,800 1,170 280 6,450 89,000

Kinematic viscosity : 1

5.12.4 Pipe Data Steel pipes with CM lining will be used. Steel grades, wall thickness and minimum yield strength is indicated in the Hydraulic Profile, Draw. No. QP50- D-1000.

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5.12.5 Allowable Pressures acc. To ASME Classes The allowable pressures are defined in chapter 15.2.1 Sizing of Station Piping. 5.12.6 Allowable Pressures for Operation and Transient Conditions The allowable pressures of the different pipe materials, diameters and wall thicknesses are summarized in chapter 6 Pipe Static. The maximum allowable operating pressure (= MAOP) and the over pressure are also defined there. 5.12.7 Pipe Diameters The hydraulic calculations are to be performed with the actual inner pipe diameter. For steel pipes the inner pipe diameter is equal to the outer diameter minus 2* wall thickness (nominal), minus 2* thickness of CM lining. Tolerances in steel wall thickness and CM lining are not to be considered. 5.12.8 Pipe Roughness The actual roughness of the CM lining depends on the fabrication process and can only be defined by measurements during performance tests. For hydraulic design purposes the absolute roughness was assumed as follows: - Maximum pipe roughness: ks = 0.1 [mm] - Minimum pipe roughness: ks = 0.005 [mm] Head loss calculations have been performed using the hydraulic friction loss formulas valid for straight pipes. The maximum pipe roughness is used for the steady state analysis and the layout of equipment (e.g. pumps). The minimum pipe roughness is used for surge analyses and the dimensioning of the surge protection equipment. 5.12.9 Station Equipment Any equipment not generally mentioned for any particular location, station, or pipeline section, is generally to be considered for all necessary locations.

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5.13 Hydraulic Calculations to be performed by the Contractor 5.13.1 Steady Flow Conditions In the Hydraulic Profiles the gradients for the maximum design capacities (MDF) are shown for with cement mortar lining with ks = 0.100 mm(according to Prandtl-Colebrook Formulae) In addition to the flow rates shown in the Hydraulic Profiles, other steady flow conditions are possible. It is the duty of the Contractor to perform a detailed hydraulic study to determine which pump configurations and flow rates will be the most economical with respect to the power consumption. The most economical operation flow rates are to be defined by means of optimization. After pipeline start-up the true pipe roughness is to be found by means of tests and relevant computations. The system set points are to be checked and adjusted, if necessary. The maximum possible flow rate without telecontrol system is to be defined and supported by the hydraulic calculations. Flow rates, set points and Station Safety Sequences are to be optimized. 5.13.2 Transient Flow Conditions Using the Bently HammerV8 computer program for the calculation of transient flow conditions, a reasonable number of cases were checked on the basis of a mathematical model. The simulation program was made according to Pandtl Colebrook formulae and with pipe surface roughness = 0.005 mm. The computations performed on the basis of the assumed data show that a safe operation will be possible (see Hydraulic Report). The 10% overpressure line will not be exceeded, nor will vapor pressure occur, if some restrictions and precautions in the systems (e.g. pressure relief etc.) are taken into account. Because some of the data used for the computations were only assumed (pump characteristics, valve characteristics, etc.), it will be necessary to study the transient flow conditions in detail after the equipment to be installed has been selected. These final computations are part of the Contractors scope of work during final design. The minimum closing time of all valves and control valves in the system shall be selected and optimized within the hydraulic calculations. The optimization has to regard overpressure and minimum pressure conditions as well the greatest operating efficiency. Detailed mathematical models are to serve as the basis for the Contractors computations; the behavior of the different components of equipment is to be simulated in a realistic way.

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Load cases are to be studied in detail for scheduled and unscheduled shut down/ start-up of pumps and other critical load cases, starting with various steady flow conditions. Various flow rates with different pump arrangements are to be studied. System set points (pressure switches, etc.) and sequences in stations shall be defined on the basis of these detailed calculations. The hydraulic design necessary for the System requires programming by highly qualified experts, since the higher the quality of design, the less problems will arise during start-up and operation. This work shall therefore be done under the responsibility of an independent expert (to be nominated by the Contractor) with at least 10 (ten) years of practice and experience in projects of equivalent nature and proportion. The choice of this specialist shall be subject to approval of the engineer and client (SWCC).

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CHAPTER (6) PIPE STATIC


6.1 General This chapter defines the pipe design requirements for the main pipeline, consisting of straight buried steel pipes. It contains the necessary computation method regarding pipe stresses against internal pressure, the empty pipes stability (buckling) and the deformations of the pipes. The design standards to be used for these calculations are the relevant DIN, AWWA and ASME Codes. 6.2 Computation Parameters 6.2.1 Pipe Data The Mainlines and Branchlines shall be made out of welded steel pipes with internal Cement Mortar lining in accordance with the Specification M01 Steel Pipes for Mainlines and Specification M03 Shop applied cement Mortar Lining. For the preliminary hydraulic layout the following pipe data have been used. Pipe type and length thereof is indicated in the Hydraulic Profile drawing QP50-D-1000:
Pipe Material Wall Thickness (mm) Steel Grade

No.

Diameter Inch

Diameter mm

Length Km

1 2 3 4 5 6 7 8 9 10 11 12

44 44 44 44 44 44 44 44 44 44 44 44

1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 1100 TOTAL

Steel:12.7 ; X65 Steel: 11.9 ; X65 Steel: 11.1 ; X65 Steel:10.3 ; X65 Steel: 9.5 ; X65 Steel: 8.7 ; X65 Steel: 8.7 ; X60 Steel: 8.7 ; X56 Steel: 8.7 ; X52 Steel: 8.7 ; X46 Steel: 8.7 ; X42 Steel: 8.7 ; B

20.92 29.37 13.74 32.11 6.31 18.08 6.83 7.78 12.65 8.71 36.17 159.43 352.1

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6.2.2 Loads The main pipeline shall be made out of welded steel pipes with internal cement mortar lining. For the preliminary hydraulic layout the following loads data have been used for the System: a) Pressure The maximum internal pressure is indicated in the Hydraulic Profile at every single location along the pipeline. The minimum internal pressure, the vacuum pressure, is -0.09 N/mm (13.04 psi). b) Earth Fill The weight of earth (backfill) material is assumed to be 20 kN/m (0.0723 lb/cu in.). This corresponds to medium compacted well graded gravels and gravel sand mixtures , as per AWWA M11 c) Weight of Water The weight of water is 10 kN/m (0.0361 lb/cu in.). Groundwater above top of pipe is not considered. d) Traffic Loads For pipes outside of right of way of existing or known future roads, crossings and the uninhabited areas the traffic load (= live load), on the basis of AWWA M11, 4th Edition, is a HS-20 Truck acc. to AASHTO. An impact factor of 50% is included in the values in Table 6-3 in AWWA M11, 4th Edition. Where the pipeline is laid in the right of way of existing or known future roads and highways and at crossings thereof the traffic load of a Heavy Truck 60 t (SWL 600 acc. to DIN 1072) shall be adopted. The impact factor of 1.20 (=20%) shall be applied. 6.3 Computation Method 6.3.1 Straight Pipe under Internal Pressure The pipeline components shall be designed on the operating internal pressure following the guidelines of ASME B31.4 code. The internal pressure design thickness t in mm is calculated using the following equation:
t= Pi D 20 S

Where Pi is the internal operating pressure in bar D is the outside diameter of pipe in mm S is the applicable allowable stress of pipe material in MPa (=0.72 x E x SMYS) SMYS is the specified minimum yield strength of pipe material 0.72 is factor of safety

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is Welding factor (=1)

Table 6.1 lists the adopted allowable stress for different grades available for manufacturing steel pipes either by electric resistant or submerged arc welding methods: Table 6.1 Allowable stresses for different steel grades used for pipe material Steel Grade B X42 X46 X52 X56 X60 X65 Specified Minimum Yield Allowable Stress Value (S) Strength (SMYS) MPa 241 290 317 359 386 414 448 MPa 174 208 228 258 279 297 322

As per ASME B31.4 code no corrosion allowance is required if cathodic protection or other method of corrosion control are applied to protect the pipeline against corrosion. The pipe thickness shall be selected according to the standard thickness ts listed in pipe tables in API 5-L. (table 6C). The selected thickness shall be greater or equal to the calculated nominal thickness. The selected pipe thickness (ts) shall be used to calculate the maximum allowable operating pressure using the following formula: MAOP =

20S t s D

The allowable surge pressure shall be 10 % higher than the MAOP as per ASME BS 31.4 (Para 402.2.4) 6.3.2 Application to Ras AlZaur - Hafar Al Batin Pipeline Thickness Calculation Based on Internal Pressure The pipeline includes one pumping station. The pumping station PSRH is located in Ras AlZaur. The pipeline starts with a diameter of 1100mm (44) till the end at Hafar AlBatin terminal station with total length of 352.1 Km.

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The design pressure of the pipeline shall be based on the maximum allowable operating pressures. These pressures are indicated in the hydraulic profile Drawing QP50-D-1000. The maximum steady state pressure occurs very close to the pump station. Along the pipeline, the operating pressures become less than the maximum pressure near the pump station. In some cases where the pipeline elevation decreases away from the pump station the operating pressures at the lowest part of the pipeline increases. Economical design of the pipeline should respect the variations in operating and maximum pressures and the appropriate pipe thickness must be selected. Table 6.2 shows the standard pipe thickness for nominal pipe diameters of and 1100 mm (44``) (API 5L) for different material grades and the associated maximum allowable operating pressure. The table was used to specify the material grade and pipe thickness for different parts of the pipeline. The shaded bold cells show the used steel grade and thickness in the project as indicated in the hydraulic profile and Table 6.1 above. Table 6.2 Maximum Allowable Operating Pressure for 1100 mm (44``) pipes , Do = 1117.6 mm ts 12.7 11.9 11.1 10.3 9.5 8.7 X65 73.16 68.55 63.94 59.33 54.72 50.11 X60 67.48 63.23 58.97 54.72 50.47 46.22 X56 63.39 59.39 55.40 51.41 47.42 43.42 MAOP X52 58.62 54.92 51.23 47.54 43.85 40.15 X46 51.80 48.54 45.27 42.01 38.75 35.48 X42 47.26 44.28 41.30 38.33 35.35 32.37 B 39.53 37.04 34.55 32.06 29.57 27.08

6.3.3 Buckling The empty pipes are subjected either to external loads like the weight of the backfill material and traffic loads and internal vapour pressure. The calculations for this type of loading shall be done according to AWWA M11, 4th Edition, for normal pipe installation. Acc. to clause Buckling of this code the following loading conditions are to be applied: Internal vacuum pressure Live load (= traffic load) These calculations shall be done during the detailed design phase by the Contractor.

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Simultaneous application of internal vacuum pressure and live load need not normally be considered. The calculation of safety against buckling is independent of the yield strength of the material. Only the modulus of elasticity comes into application. As a result of this the calculations are valid for all steel grades. qa = 1 . (32.Rw.B`.E`. El )1/2 FS D Where: qa FS Rw hw h B H allowable buckling pressure (psi) design factor = 2.0 water buoyancy factor = 1-0.33 (hw/h), 0 <hw <h height of water surface above top of pipe (in.) height of ground surface above top of pipe (in) empirical coefficient of elastic support (dimensionless) = 1/(1 + 4e(-0.065H)) height of fill above pipe (ft)

For determination of external loads in normal pipe installations, the following equation shall be used:

.hw + Rw . Wc + Pv qa
D Where: hw w Pv Wc height of water above conduit (in.) specific weight of water (0.0361 lb/cu in.) internal vacuum pressure (psi) vertical soil load on pipe per unit length (lb/in.)

If only live loads are considered, the buckling requirement is satisfied by:

.hw + Rw . Wc + WL qa
D D Where: WL live load on the conduit (lb/linear in. of pipe) These calculations shall be done during the detailed design phase by the Contractor.

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6.3.4 Deformation The pipe deformations due to external loadings like weight of the backfill material and traffic loads such as: HS-20 truck at free pipeline routes and SWL 600 in the right of way of existing or known future roads and highways with at least 95% Proctor density backfill compaction shall be calculated acc. to AWWA M11, 4th Edition. The calculation of the deformations of the pipes is independent of the yield strength of the material. Only the modulus of elasticity comes into application. As a result of this, the calculations are valid for all steel grades. These calculations shall be done during the detailed design phase by the Contractor. The interaction between the deformed pipe and the surrounding soil is considered by using the modulus E of the backfill. For cement mortar lined pipes with an external elastic coating this deformation is limited to 3% of pipe diameter (see clause Deflection Determination in AWWA M11, 4th Edition). = Dr . ( K.W. r3 ) . El + 0.061 .E`.r3

Where: x DI K W r EI E I E horizontal deflection of pipe (in.) deflection lag factor (1.0 1.5) bedding constant (0.1) load per unit of pipe length (lb/linear in. of pipe) radius (in.) pipe wall stiffness (in.-lb) modulus of elasticity (30,000,000 psi for steel) transverse moment of inertia per unit length of pipe wall modulus of reaction (lb/in.)

6.4 Minimum Cover and Backfill Compaction For pipes located outside of right of way of existing or known future roads, crossings and also in uninhabited areas where a HS-20 Truck acc. to AASHTO shall be applied as traffic load no compaction of the backfill material is required.

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Where the pipe is laid in the right of way of existing or future roads and crossings a traffic load of Heavy Truck 60 t (SLW 600 acc. DIN 1072) shall be adopted. The backfill compaction shall be at least 90% Standard AASHTO relative compaction acc. to Table 6-1, AWWA M11, and 4th Edition. The minimum pipe cover shall not be less than 1.2 meter. The maximum pipe cover shall be calculated by the Contractor during final design.

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CHAPTER (7) PIPELINE


7.1 Pipeline Route Description The pipeline route is shown in the General Route Map (QP10-U-1000) , QP10-U-1001 to 1020 and also in details in the survey drawings from ( ZP00-D-001 ) to ( ZP00-D-552 ). The route description contained in the following sub chapters is based on the routing performed by the Engineer. This description shall be considered as preliminary and shall not relief the Contractor to perform the detailed route selection and verification during his final design activities. 7.1.1 Route Description: The selected route will utilize the new service road to be constructed for the new pipeline from RasAlzaur to Riyadh, the first part of this route will be intersected with Highway to Nairiia at 6 Km west of Abu Hedria. The proposed pipeline will be constructed from Ras Al Zaur to AlNuairiyah alongside the new pipeline from Ras Alzaur to Riyadh , then it will follow the highway from Abu Hidria to AlNuairiyah. 7.1.2 Section 1 This section starts from Ras Al Zaur up to The intersection with the highway to Abu Hedria at coordinate (N 3030991 E297341) , in this section the new pipeline will be constructed alongside the new pipeline to Riyadh . Length of this section is : 28.6 Km. The route is clear from any properties and obstacles. The route will pass near to some ARAMCO properties, but it will be far from it with more than 100 meter. 7.1.3 Section 2 - This section starts from The intersection with the highway to Abu Hedria at coordinate (N 3030991 E297341) up to The intersection with the highway to Nairiia at coordinate (N 3021305.00 E294320.00). - Total length of this section is 10.2 Km. - The route in this section will also be alongside the new pipeline to Riyadh

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- The proposed route will pass near to ARAMCO property, the right of way of the pipeline in this point will be 65 m . 7.1.4 Section 3 - This section starts from The intersection with the highway to AlNuairiyah at coordinate (N 3021305.00 E294320.00). - Total length of this section is 313.3 Km. - The route will be alongside the highway from Abu Hedria to Hafar AlBatin. 7.2 Right of Way In principle, the ROW should be in SWCC's possession or should be procured by the Employer and put at the Contractor's disposal. Whenever the pipeline is laid within the ROW of MOT or the Municipality, then the ROW boundaries of MOT and/or municipality should also be the limit of the ROW provided by SWCC. However, experience has shown that at some occasions it will be necessary to negotiate and buy land servitudes for sections of the permanent ROW during construction. Such producers are especially necessary when crossing private land. The contractor is to make available his own survey team for this purpose at his own expense. This survey team will have the following duties: - Surveying of certain pieces of land for right of way negotiations. - Preparation of all subsequently necessary drawings and calculations. - Preparation of inventory report for SWCC. - Preparation of a video recording of the complete ROW before and after the construction works for documentation. The Right of way negotiations with the land owners will be done by SWCC. It is the Tenderers obligation during the tendering stage to acquaint himself with the site and visit all the organizations involved in the planning of the area (Ministry of Trasport, Ministry of Agricluture, Municipalities, SEC, STC, ARAMCO, SRO and any other authorities) to account for any changes required along the route during the implementation of the works (road crossings, railway crossing, foreign line crossings , etc..)

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7.3 Pipeline Construction The supplies and works given below are to be performed by the Contractor based on the appropriate Specifications. This list does not claim to be complete: - Obtaining all authorizations and permits for the performance of the works. - Provision of a "survey team" during construction for land expropriation. - Surveying the pipeline route. - Determination of the number and type of bends including procurement, lining and coating of all bends. - Preparation, staking out and grading of the working strip. - Construction of access roads from public roads to pipe storage areas. - Performance of all survey works necessary in connection with the earthworks and pipe laying. - Locating of the existing facilities. - Determination of the location of valve, vent and drain stations. - Excavation of trench. - External coating and internal lining of the bare pipes, provided by SWCC, depending on used lining method. - Internal Lining of the mainline shall be (CML) and for station piping shall be FBE. - Transport and laying of the pipes and performance of all required non-destructive tests. - Installation of the entire equipment. - Keeping of a pipe log (pipe record/book). - Supply and installation of protection conduits for the communication cable in accordance with the specifications. - Installation of the temporary and permanent cathodic protection system as mentioned later in chapter 19 and according to SWCC specification E16. - Application of lining at welding seams and repair of damaged lining. - Coating of welding seams, Tee - pieces and fittings, repair of damaged coating and insulation testing. - Performance of hydrostatic pressure tests. - Backfilling of trenches, restoration of working strip and all access roads. - Construction of access roads to valve-, drain and vent stations and to all feed-in stations for cathodic protection, as far as required.

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- The road for construction vehicles and for pipe stringing shall be performed by the contractor and Employer will not pay for constructing this road at any case. It is the obligation of the contractor to use appropriate materials for construction road. - Stabilisation of top and embankments of pipeline berm, as far as required - Installation of pipeline markers. - Maintaining the water quality in the pipes from the time of the hydrostatic test to the commencement of commissioning/start up. - Provision of required as-built documentation. 7.4 Special Points 7.4.1 General Aspects The construction of the mainline also includes all special constructions, such as: - Laying of the pipeline within road or traffic areas - Road crossings - Railway crossings - Water course and wadi crossings - Crossings with pipelines - Cable crossings - Valve, vent and drain stations In general, for all special points the following procedure is valid: - For all works close to existing or foreign facilities, the Contractor has to apply for and obtain work permits from the pertinent owner and/or authorities. However, the Contractor will still be liable for damage. - The Contractor has to make a detailed field survey with staking of the exact alignment of the pipeline to be constructed and exact determination of the location of existing facilities such as crossings of existing facilities, or laying of the new line parallel to existing pipelines, power lines, or within roads. - The Contractor has to investigate the soil conditions at the complete route, but especially at the above mentioned locations (crossings, etc.) in order to determine the appropriate work methods. - The Contractor is to prepare a detailed design for each individual crossing or special point in accordance with the typical drawings and the Specifications. The design must include the traffic load and additional requirements at areas where the line is laid within the existing or future roads or other

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third party corridors. These detailed designs shall be submitted to the Engineer. After a preliminary check by the Engineer, the design is to be approved by the pertinent owner and authorities and subsequently submitted to the Engineer for final approval. In addition to the above-mentioned special points, the Contractor has to provide proper drainage of surface water along the complete pipeline route but especially at all points where runoff channels are already foreseen at the road running parallel to the pipeline. The Contractor is also responsible for removing the excavation material in populated areas if required by the authorities. Detailed investigations concerning the exact number and nature of crossings to be performed are the Tenderers/Contractors responsibility. Box culvert for Railway crossings will be the responsibility of the Saudi Railway's contractor and it will not be part of the scope of work of this project. However the contractor is responsible to lay the pipeline inside the box culvert constructed by Saudi Railway's contractor. The box culvert shall be based on the drawing no. QP10-U-4161 , all other drawings regarding the Railway crossing are not applicable in this particular project. 7.4.2 Road , Railway and Aramco Crossing The following table shows the road crossing points along the pipeline, the list of crossing and special points listed below do not claim as complete it is only as indication. Sr. 1 2 3 4 5 6 7 Type of Crossing Road Crossing Road Crossing Road Crossing Road Crossing Railway Crossing Railway Crossing Railway Crossing Crossing Pipeline Diameter 1100 mm (44) 300 mm (12) 200 mm (8) 1100 mm (44) 1100 mm (44) 1100 mm (44) 1100 mm (44) Location AboHedria Khafgi Highway Nuairiyah Hafar AlBatin Highway Nuairiyah Hafar AlBatin Highway Nuairiyah Hafar AlBatin Highway Ras AlZaur RasAlZaur Nuairiyah Hafar AlBatin Highway Coordinates Zone39 N 3030991 E297341 Zone 39 N3038698 E256550 Zone 38 N3068163 E777761 Zone 38 N3133399 E608481 Zone39 N3039227 E311001 Zone39 N3034299 E302189 Zone39 N3025887 E284296

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8 9 10 11

Railway Crossing Aramco Crossing Aramco Crossing Aramco Crossing

250 mm (10) 1100 mm (44) 300 mm (12) 1100 mm (44)

Qaryat AlOliyah In Ras AlZaur Nuairiyah Hafar AlBatin Highway Nuairiyah Hafar AlBatin Highway

Zone38 N3067656 E777598 Zone 39 N3033717 E301608 Zone 38 N3068005 E777793 Zone 38 N3133074 E609881

7.5 Pipe Material, Lining and Coating for main line and Branches Steel pipes for all pipelines (including mainlines, branch lines and interconnection lines) of the Water Transmission System. The steel pipes shall be outside coated with a three (3) layer High Density Polyethylene (HDPE) system. The internal lining of the pipes shall be cement mortar (CM).

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CHAPTER (8) PUMPING STATION


Ras AlZaur Hafar AlBatin Water transmission system consisit of one pump station (PSRH) located in Ras AlZaur.(Reference drawing Ras AlZaur Hafar AlBatin Pipeline Routa QP10-U-1000). The pump station will be designed for flow rate of 110,000 m3/day, this chapter describe the main component of the pump station.

8.1 Reference Drawings For reference see the following drawings: QP20-D-1100 Booster Pumping Station - P&ID QP20-D-1105 Main Pumping Station - P&ID For size and layout refer to the following drawings :
QP10-Q-3110 QP10-Q-3120 QP10-Q-3130 QP10-Q-3140 QP10-Q-3150 QP10-Q-3160 QP10-Q-3210 QP10-Q-3220 QP10-Q-3230 QP10-Q-3240 QP10-Q-3250 QP10-Q-3260 Booster Pump Building Plan View Booster Pump Building Pumps House Plan Booster Pump Building Section Booster Pump Building Elevation (3,4) Booster Pump Building Mechanical Drawing (Sec Plan) Booster Pump Building Mechanical Drawing (Sec Elevation) Main Pump Building Plan View Main Pump Building Pumps House Plan Main Pump Building Section Main Pump Building Elevation (3,4) Main Pump Building Mechanical Drawing (Sec Plan) Main Pump Building Mechanical Drawing (Sec Elevation)

8.2 Booster Pump Units Consisting of three (3) booster pump units in parallel arrangement have to be installed, two (2) units normally in operation and one (1) in stand-by. The data for the booster pump units are defined in chapter 15 & 16. The pump units are connected on the suction side to the flange of delivery pipeline of Ras Alzaur AlRiyadh booster pumps unit as shown in drawing no.QP10-Q-1500. Normally all valves are open, pool operation of all storage tanks is foreseen. In case of problems in one header, the operation with one header only shall be possible.

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The booster pump units are located in the Booster Pump Building near to the Booster Pump building related to Ras AlZaur Riyadh pipeline. 8.3 Main Pump Units Consisting of three (3) main pump units in parallel arrangement have to be installed, two (2) units normally in operation and one (1) in stand-by. The data for the main pump units are defined in chapter 15 & 16. The main pump units are located in the Main Pump Building, near to the Main Pump building related to Ras AlZaur Riyadh pipeline. 8.4 Cooling Water System A cooling water plant shall be provided for the main pump motor units. The cooling water system plant will be under shade near the Pump House. The description of the cooling water plant is part of chapter 15 of this general specification. 8.5 Control Valves Control valves have to be provided for the re-circulation bypass of the pumping units and at the station outlet. The flow control valves shall be provided with upstream and downstream isolation valves. Each control valve group will be located in a separate shaft. 8.6 Station Piping System The pump station piping system to be implemented consists of the following components:

The inlet, outlet and drainage piping for the pumping station including valves, fittings, etc. The interconnection of the product water header between the booster pump station and the delivery flange at the suction header of Ras AlZaur - AlRiyadh WTS (including reducer from 96" to 44").

Flow measuring facilities. The 1100 mm (44``)diameter discharge header piping with fittings and valves. Any other piping not listed above but shown on the drawings and as necessary for proper function of the plant.

For size of piping and pressure class reference is made to the respective P & I Diagrams.

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8.7 Electrical Works, Control and Instrumentation The electrical works to be implemented under this project comprise:

The 13.8 KV medium voltage cable circuits from Ras AlZaur Riyadh WTS bus bar. Booster pump motors. Main pump motors Motor starter equipment Medium voltage switchgears and low voltage switchboards, including DC and UPS . Emergency diesel generator. All power supply installations associated with valves and auxiliary process systems such as, cooling water plant, control valves, valves, HVAC equipment and building installations, etc. All necessary instruments to measure flow, pressure, level, temperature, etc. All PLC controllers. All communication equipment multiplexer, switch, LAN, F.O.C, etc.

The detailed requirements for electrical works can be found in chapter 16 and for requirements associated with instrumentation and control works reference is made to chapter 17 of this general specification. 8.8 Civil Works The civil works to be performed consist of:

The Pump Station Buildings to house the pumps (Booster and Main pumps) and motors with all related piping, valves and associated process equipment. The Electrical Building. Shafts for all underground equipment such as valves, control valves, and other subsystems Civil infrastructure such as paving, drainage system, cable ducts, lighting, fire fighting, etc. Cooling water foundation.

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CHAPTER (9) RESERVOIR, WATER TOWER , FILLING STATIONS and TIE-IN STATION
9.1. General Requirements There are seven consumer points along the pipeline. Three points (Nuairiyah, Qaryat AlOliyah and AlQaysumah) shall have reservoirs and filling stations for water truck loading and for local water supply purposes. The other three points (Ibn Hethlain , Sairah and Sadawi) shall have water towers and filling stations for water truck loading and for local water supply purposes. Finally terminal reservoir and filling station at the end of the pipeline is located at Hafar AlBatin. In addition to the tie-in station at the existing Hafar AlBatin tanks belong to the MOWE. Each station reservoir station and filling station will be surrounded by a separate fence with fence lighting in accordance with the HCISS requirements. The hall land area of each station as shown in the location drawings shall be surrounded by security fence. Access road to the next public road is foreseen as part of the contract as indicated in the respective general layouts. 9.2 Reservoir and Filling Station at Nuairiyah Two steel reservoirs (of capacity 5000 m3 each) are required to feed Nuairiyah with water. A location of area 40000 m2 (square of dimensions= 200 m*200 m) laying on the left side of the road from Abu Hedria to Nuairiyah before Nuairiyah with about 500 m) was suggested for reservoirs as shown in Drawing QP10-Q-9010. The works to be implemented at this station comprise of : a) Station Piping The inlet facilities will comprise the piping, valves, control valves and the flow meter facilities. In addition to connection point for a mobile chlorination unit. Also an outlet connection for future requirement shall be foreseen. b) Steel Tanks Two steel tanks of capacity of 5,000 m each shall be constructed including inlet, outlet, overflow and drain line connections and output flange for future connections. c) Filling Station

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A filling station near the reservoir station with four (4) filling arms shall be constructed. Each arm shall be designed for a flow rate of 75 m/h so that the operation time of filling station shall be 8 hours. Filling station will be connected to the outlet piping of the reservoir; the operation of the filling station shall be by using filling pumps. The required space for the filling station is approx. 50 x 60 m. d) Electrical Works, Control and Instrumentation The electrical works to be implemented at this station comprise:

The power supply feeder with distribution transformer The low voltage switchboards The UPS with distribution board All power supply installations associated with valves, control valves and auxiliary process systems such as building installations, outdoor lighting, etc. All necessary instruments to measure flow, pressure, level, temperature, etc. All PLC controllers. All communication equipment multiplexer, switch, LAN , F.O.C , etc.

The detailed requirements for electrical works can be found in chapter 16 and for requirements associated with instrumentation and control works reference is made to chapter 17 of this general specification.

e) Civil Works The civil works to be performed will consist of:

The foundations for the steel tanks The electrical building The guard house at the entrance of filling station and at the entrance of the tank. Shafts for all underground equipment such as valves, control valves, flow meter and other subsystems. One (1) staff building.

Civil infrastructure such as roads, paving, drainage system, fence, overflow disposal to safe run off or dry pits, etc.

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Reference Drawings: - Location of Nuairiah station QP10-Q-9010 - Nuairiyah station General Layout QP10-Q-1910 - Nuairiyah 5,000 m3 Steel Tank QP10-Q-2210 - Nuairiyah station P&I diagram QP20-D-1110 - Filling Station- Four (4) Arms P & I Diagrams QP20-D-1250 (Type 2) 9.3 Water Tower and Filling Station at Ibn Hethlain A filling station of capacity 300 m3 is required at Ibn Hethlain.The suggested filling station requires a water tower (capacity 300 m3) to store the quantity of water required. A location of area 15000 m2 (100*150) m lying at the right side of the high way road was suggested to construct the required tank as shown in Drawing QP10-Q-9020. The works to be implemented at this station are summarized below: a) Station Piping The inlet facilities will comprise the piping, valves, control valves and the flow meter facilities. Also a connection point for a mobile chlorination unit shall be foreseen. b) Water Tower One steel water tower of capacity 300 m have to be constructed including inlet, outlet, overflow and drain line connections and output flange for the local supply. c) Filling Station A filling station near the water tower station with two (2) filling arms shall be constructed. Each arm shall be designed for a flow rate of 75m/h so that the operation time of filling station shall be 8 hours. The filling station will be connected to the outlet piping of the water tower, to allow operation by gravity flow. The required space for the filling station is approx. 50 x 60 m. d) Electrical Works, Control and Instrumentation The electrical works to be implemented under this project comprise:

The power supply feeder with distribution transformer The low voltage switchboards

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The UPS with distribution board All power supply installations associated with valves, control valves and auxiliary process systems such as building installations, outdoor lighting, etc. All necessary instruments to measure flow, pressure, level, temperature, etc. All PLC controllers. All communication equipment multiplexer, switch, LAN , F.O.C , etc.

The detailed requirements for electrical works can be found in chapter 16 and for requirements associated with instrumentation and control works reference is made to chapter 17 of this general specification.

e) Civil Works The civil works to be performed will consist of:

The foundation for the water tower The electrical building The guard house at the entrance to the filling station and at the entrance of the water tower. Shafts for all underground equipment such as valves, control valves, flow meter and other Civil infrastructure such as roads, paving, drainage system, fence, etc.

subsystems

Reference Drawings: - Location of Ibn Hethlain station QP10-Q-9020 - Ibn Hethlain station General Layout QP10-Q-1920 - Ibn Hethlain 300 m3 Steel water tower QP10-Q-2220 - Ibn Hethlain station and line valve LV2 & LV3- P&I diagram QP20-D-1130 9.4 Reservoir and Filling Station at Qaryat AlOliyah One concrete reservoir is required to feed Qaryat AlOliyah with water. The tank will be divided into two chambers; capacity of each 1500 m3. A location of area =33000 m2 laying on the right side of the road from Qaryat AlOliyah to Riyadh was proposed to construct the required tanks as shown in Drawing QP10-Q-9030. The works to be implemented at this station comprise:

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a) Station Piping The inlet facilities will comprise the piping, valves, control valves and the flow meter facilities. In addition the tank shall include a connection point for a mobile chlorination. Also an outlet connection to the existing tank belong to MOWE shall be foreseen. b) Concrete Tanks One concrete tank with two chambers of capacity of 1,500m each shall be constructed including inlet, outlet, overflow and drain line connections. c) Filling Station A filling station near the tank station with four (4) filling arms shall be constructed. Each arm shall be designed for a flow rate of 75 m/h so that the operation time of filling station shall be 8 hours. The filling station will be connected to the outlet piping of the reservoir; the operation of the filling station shall be throw using filling pumps. The required space for the filling station is approx. 50 x 60 m. d) Electrical Works, Control and Instrumentation The electrical works to be implemented at this station comprise:

The power supply feeder with distribution transformer The low voltage switchboards The UPS with distribution board All power supply installations associated with valves, control valves and auxiliary process systems such as building installations, outdoor lighting, etc. All necessary instruments to measure flow, pressure, level, temperature, etc. All PLC controllers. All communication equipment multiplexer, switch, LAN , F.O.C , etc.

The detailed requirements for electrical works can be found in chapter 16 and for requirements associated with instrumentation and control works reference is made to chapter 17 of this general specification. e) Civil Works

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The civil works to be performed will consist of:

The construction of the tank. The electrical building The guard house at the entrance of the filling station and at the entrance of the tank. Shafts for all underground equipment such as valves, control valves, flow meter and other subsystems.

Civil infrastructure such as roads, paving, drainage system, fence, etc Reference Drawings: - Location of Qaryat AlOliyah station QP10-Q-9030 - Qaryat AlOliyah station General Layout QP10-Q-1930 - Qaryat AlOliyah 3000 m3 Concrete Tank QP10-Q-2230 - Qaryat AlOliyah station- P&I diagram QP20-D-1140 9.5 Water Tower and Filling Station at Sairah A filling station of capacity 1170 m3 is required at Sairah. The suggested filling station requires one (1) water tower of capacity 1000 m3 to store the quantity of water required. A location of area =10000 m2 (square of dimensions= (100*100) m) lying on the right side of the road leading to Hafar Al Batin was suggested to construct the required water towers as shown in Drawing QP10-Q-9040. The works to be implemented at this station are summarized below: a) Station Inlet Piping The inlet facilities will comprise the piping, valves, control valves and the flow meter facilities. Also a connection point for a mobile chlorination unit shall be foreseen. b) Water Tower One steel water tower divded into two chambers of capacity 500m each will have to be constructed including inlet, outlet, overflow and drain line connections and output flange for the local supply. c) Filling Station A filling station near the water tower station with two (2) filling arms shall be constructed. Each arm shall be designed for a flow rate of 75m/h so that the operation time of filling station shall be

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8 hours. The filling station will be connected to the outlet piping of the water tower, to allow operation by gravity flow. The required space for the filling station is approx. 50 x 60 m. d) Electrical Works, Control and Instrumentation The electrical works to be implemented under this project comprise:

The power supply feeder with distribution transformer The low voltage switchboards The UPS with distribution board All power supply installations associated with valves, control valves and auxiliary process All necessary instruments to measure flow, pressure, level, temperature, etc. All PLC controllers. All communication equipment multiplexer, switch, LAN , F.O.C , etc.

systems such as building installations, outdoor lighting, etc.

The detailed requirements for electrical works can be found in chapter 16 and for requirements associated with instrumentation and control works reference is made to chapter 17 of this general specification. e) Civil Works The civil works to be performed will consist of:

The foundation for the water tower The electrical building The guard house at the entrance to the filling station and at the entrance of the water tower. Shafts for all underground equipment such as valves, control valves, flow meter and other
subsystems

Civil infrastructure such as roads, paving, drainage system, fence, etc.


Reference Drawings: - Location of Sairah water tower and filling station QP10-Q-9040 - Sairah station General Layout QP10-Q-1940 - Sairah 1000 m3 Steel water tower QP10-Q-2240 - Sairah filling station and line valve LV4 & LV5- P&I diagram QP20-D-1150

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9.6 Water Tower and Filling Station at Sadawi A filling station of capacity 280 m3 is required at Sadawi. The suggested filling station requires a water tower (capacity 300 m3) to store the quantity of water required. A location of area 10000 m2 (square of dimensions= (100*100) m) laying south of the existing water treatment plant and on the right side of the road leading to Hafar Al Batin was suggested to construct the required tank in it as shown in Drawing QP10-Q-9050. The works to be implemented at this station are summarized below: a) Station Piping The inlet facilities will comprise the piping, valves, control valves and the flow meter facilities. Also a connection point for a mobile chlorination unit shall be foreseen. b) Water Tower One steel water tower of capacity 300 m will have to be constructed including inlet, outlet, overflow and drain line connections and output flange for the local supply. c) Filling Station A filling station near the water tower station with two (2) filling arms shall be constructed. Each arm shall be designed for a flow rate of 75 m/h so that the operation time of filling station shall be 8 hours. The filling station will be connected to the outlet piping of the water tower, to allow operation by gravity flow. The required space for the filling station is approx. 50 x 60 m. d) Electrical Works, Control and Instrumentation The electrical works to be implemented under this project comprise:

The power supply feeder with distribution transformer The low voltage switchboards The UPS with distribution board All power supply installations associated with valves, control valves and auxiliary process systems such as building installations, outdoor lighting, etc. All necessary instruments to measure flow, pressure, level, temperature, etc. All PLC controllers. All communication equipment multiplexer, switch, LAN , F.O.C , etc.

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The detailed requirements for electrical works can be found in chapter 16 and for requirements associated with instrumentation and control works reference is made to chapter 17 of this general specification. e) Civil Works The civil works to be performed will consist of:

The foundation for the water tower The electrical building The guard house at the entrance to the filling station and at the entrance of the water tower. Shafts for all underground equipment such as valves, control valves, flow meter and other subsystems Civil infrastructure such as roads, paving, drainage system, fence, etc.

Reference Drawings: - Location of Sadawi water tower and filling staiotn QP10-Q-9050 - Sadawi station General Layout QP10-Q-1950 - Sadawi 300 m3 Steel water tower QP10-Q-2250 - Sadawi filling station and line valve LV6- P&I diagram QP20-D-1160 9.7 Reservoir and Filling Station at AlQaysumah One concrete reservoir is required to feed AlQaysumah with water. The tank will be divided into two chambers; each of capacity 3500 m3. A location of area =90000 m2 (square of dimensions= (300*300) m) laying on the left side of the road leading to Hafar Al Batin opposite to Aramco tanks farm was suggested to construct the required reservoir in it as shown in Drawing QP10-Q-9060. The works to be implemented at this station comprise of: a) Station Piping The inlet facilities will comprise the piping, valves, control valves and the flow meter facilities. Also a connection point for a mobile chlorination unit shall be foreseen. b) Concrete Tanks One concrete tank divided into two chambers of capacity of 3,500 m each , shall be constructed including inlet, outlet, overflow ,drain line connections and outlet flange to local supply.

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c) Filling Station A filling station near the water tower station with four (4) filling arms shall be constructed. Each arm shall be designed for a flow rate of 75 m/h so that the operation time of filling station shall be 8 hours. The filling station will be connected to the outlet piping of the reservoir,the operation of the filling station shall be through using filling pumps. The required space for the filling station is approx. 50 x 60 m. d) Electrical Works, Control and Instrumentation The electrical works to be implemented at this station comprise:

The power supply feeder with distribution transformer The low voltage switchboards The UPS with distribution board All power supply installations associated with valves, control valves and auxiliary process systems such as building installations, outdoor lighting, etc.

The detailed requirements for electrical works can be found in chapter 16 and for requirements associated with instrumentation and control works reference is made to chapter 17 of this general specification.

e) Civil Works The civil works to be performed will consist of:

The construction of the tank. The electrical building The guard house at the entrance of the filling station and at the entrance of the tank. Shafts for all underground equipment such as valves, control valves, flow meter and other subsystems. Civil infrastructure such as roads, paving, drainage system, fence, etc

Reference Drawings: - Location of AlQaysumah station QP10-Q-9060 - AlQaysumah station General Layout QP10-Q-1960 - AlQaysumah 7000 m3 Concrete Tank QP10-Q-2260 - AlQaysumah tank station and line valve LV7- P&I diagram QP20-D-1170

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9.8 Terminal Reservoir and filling Station at Hafar Al Batin Two steel reservoirs (each of capacity 50,000 m3) are required to feed Hafar Al Batin city with water. A location of dimensions (300 m*300 m), about 500 m away from the road 7.2 km after AlQaysumah reservoir station. The proposed tanks shown in Drawing QP10-Q-9070. The works to be implemented at this station comprise the following : a) Station Piping This will comprise the piping, valves, check valves, control valves and the flow meter facilities as shown in the respective drawings. Also a connection for chlorination unit shall be foreseen and WQM. b) Steel Tanks Two steel tanks of capacity of 50,000 m each shall be constructed including inlet, outlet, overflow , drain line connections and outlet connection line to Hafar AlBatin existing tanks belong to MOWE. c) Filling Station A filling station near the tank station with eight (8) filling arms shall be constructed. Each arm shall be designed for a flow rate of 75 m/h so that the operation time of filling station shall be 8 hours. The filling station will be connected to the outlet piping of the reservoir; the operation of the filling station shall be by using filling pumps. The required space for the filling station is approx. 100m x 60 m. d) Electrical Works The electrical works to be implemented at this station comprise:

The power supply feeder with distribution transformer The low voltage switchboards The UPS with distribution board All power supply installations associated with valves, control valves and auxiliary process systems such as building installations, outdoor lighting, etc. All necessary instruments to measure flow, pressure, level, temperature, etc. All PLC controllers. All communication equipment multiplexer, switch, LAN , F.O.C , etc.

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The detailed requirements for electrical works can be found in chapter 16 and for requirements associated with instrumentation and control works reference is made to chapter 17 of this general specification.

e) Civil Works The civil works to be performed will consist of:

The foundations for the steel tanks The electrical building The guard house at the entrance of the filling station and at the entrance of the tank. Shafts for all underground equipment such as valves, control valves, flow meter and other subsystems. Civil infrastructure such as roads, paving, drainage system, fence, etc. Chlorination building. One (1) Staff building. WQM building. Combined electrical mechanical workshop.

Reference Drawings: - Location of Hafar Al Batin Terminal station QP10-Q-9070 - Hafar Al Batin station General Layout QP10-Q-1970 - Hafar Al Batin 50,000 m3 Steel Tank QP10-Q-2270 - Hafar Al Batin terminal station P&I diagram QP20-D-1180

9.9 Tie-in station to the existing Hafar AlBatin Tanks Military base tie-in station is located at KP 352.1 at elevation of 335 masl . The existing water tanks belong to the MOWE will be the terminal point for the 1100 mm gravity pipeline coming from Hafar AlBatin terminal station at Kp 345.1 The works to be implemented at this station are summarized below: a) Station Inlet Piping The inlet facilities will comprise the piping, valves, control valves , flow meter facilities and Tee connections to feed the new tank belong to MOWE as per Drawing# QP10-Q- 1970.

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b) Electrical Works, Control and Instrumentation The electrical works to be implemented under this project comprise:

The power supply feeder with distribution transformer The low voltage switchboards The UPS with distribution board All power supply installations associated with valves, control valves and auxiliary process All necessary instruments to measure flow, pressure, level, temperature, etc. All PLC controllers. All communication equipment multiplexer, switch, LAN , F.O.C , etc.

systems such as building installations, outdoor lighting, etc.

The detailed requirements for electrical works can be found in chapter 15 and for requirements associated with instrumentation and control works reference is made to chapter 16 of this general specification c) Civil Works The civil works to be performed will consist of:

Shafts for all underground equipment such as valves, control valves, flow meter and other Civil infrastructure such as roads, paving, drainage system, fence, etc. Electrical building.

subsystems

The proposed arrangement of the station is shown in the following drawings: HAFAR ALBATIN TIE-IN STATION P&I DIAGRAM , Drawing QP20-D-1190

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CHAPTER (10)
10.1 Line Valve

LINE VALVE, VENT AND DRAIN STATIONS

The Line Valves are required to allow separation of the pipeline into sections and to limit the volume of water which will have to be drained in case of maintenance and/or inspection activities. Also, limit the outflow of water in case of a leak is also an important safety aspect. Access shafts with blind flange have to be located upstream and downstream of the line valve. The line valves shall be locked open and must be closed locally by the operator. Since the pipeline diameter is larger than 600mm then all the line valves in the system will have electric actuator. For the electrical power supply and instrumentation and control reference is made to chapter 16 and 17. The electrical switchboard and the instrumentation cabinet (including the RTU and the FOC connection) shall be located within the valve shaft. 10.2 Line Valve Stations The following table shows the distance for each line valve in the project as follows: Description LV 1 LV 2 LV 3 LV 4 LV 5 LV 6 LV 7 Distance from Start point of the pipeline (KM) Kp 38.8 km Kp 89.4 km Kp 146 km Kp 202.6 km Kp 248.1 km Kp 296.6 km Kp 337.9 km

The valve station to be implemented shall consist of a filling by-pass and drainage facilities, one (1) main line valve with electric actuator and the tap-off valve. The principle arrangement of the Line valve shall include the mainline valve, the by-pass-, tap-off- (As required in LV2 ,LV4 and LV7) and

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drainage valves Reference drawings:

Typical Line Valve Station (QP10-Q-4117) Typical Tap-Off Station (QP10-Q-4119) Ibn Hethlain station and line valve LV 2 & LV3 P&I( QP20-D-1130) Sairah station and LV4 & LV5 P&I ( QP20-D-1150) Sadawi station and LV6 P&I ( QP20-D-1160) AlQaysumah station and LV7 P&I ( QP20-D-1170)

10.3 Vent and Drain Stations 10.3.1 General Requirements During final design the Pipeline Contractor must perform the necessary calculations based on the approved design criteria, to define the required number, location, type and size of vent and drain valves. The installation of manual vents shall be limited as much as possible. The hydraulic requirements will be provided by the Contractor. The specification for the vent and drain valves, including the definition of the location, purchasing and installation, including all related piping and civil works, is part of the scope of work of the Contractor. 10.3.2 Vent Stations Automatic Vent Stations shall be installed at distinct highpoints of the pipeline profile in average distance of approx. 5 km. The automatic vents shall be designed for automatic aeration and de-aeration, in addition they shall serve as access opening to the pipelines to perform joint lining and lining inspection during the construction phase and to enable later maintenance and/or inspection. A typical automatic vent station consists of a tee connection to the pipeline (mainline or branch line) with a flange/blind flange assembly. On top of the blind flange the isolation valve and the aeration/deaeration valve will be constructed. The vent station equipment will be located within concrete shafts with removable cover, vent chambers shall be made of precast concrete elements in case the water level is below bottom elevation of the shaft.The use of manual vent shall be limited as much as possible. The general layout and arrangement s shown in the following drawings:

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Typical Vent Station ( QP10-Q-4118) Typical Vent And Drain Station-P&I Diagram QP20-D-1210

10.3.3 Drain Stations To enable flushing of the pipelines during the initial phase of operation and to empty pipe segments and sections of the pipelines for repair and/or inspection purpose, the installation of drain stations is necessary. Such drain stations have to be located at distinctive low points of the pipeline profile (i.e. at the lowest point between two adjacent vent stations). Drain stations consist of a pipe connection to the invert of the pipeline, two manually operated valves and a blind flange. The drain pipes will terminate in a drainage shaft, which is fitted with a lockable cover land a ladder. Mobile sump pumps shall be foreseen to empty the drain shaft and the pipe. Drain chambers shall be made of precast concrete elements in case the water level is below bottom elevation of the shafts. Permanent valve stem extensions shall be installed at drain valves in case the shaft depth is exceeding 3.50 m. The general layout and arrangement is shown in the following drawings:

Typical Drain Station ( QP10-Q-4114) and ( QP10-Q-4115) Typical Vent And Drain Station-P&I Diagram QP20-D-1210

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CHAPTER (11)
11.1 General:-

STATIONS BUILDINGS

This chapter describes the layout and construction requirements for all buildings to be erected at The various Stations of Ras AlZaur - Hafar AlBatin Water Transmission System. The arrangement of the buildings within the Stations is shown on the General Layout drawings of the respective Stations. As a general rule the design of the buildings shall be identical for all Stations, if not specified otherwise. The size of the buildings, including the height and the structural grid represents the proposed dimensioning. Actual size of buildings is subject to final design depending on the selected equipment. The fence around layout shall be a steel column grid four (4) inches in diameter with spacing of 4 m. All platforms shall be made interlock tiles shall be 6 cm thickness All roads shall be covered with asphalt except the Truck loading area in filling stations shall be covered with concrete, Grass green areas are among platforms. This table shows the buildings that will be constructed in (PSRH ,Hafar AlBatin Terminal And Reservoir Stations) As Follows : Buildings Main Pump House Booster Pump House Electrical Building Cooling Water Equipment Shelter Electrical Building (for reservoir stations) Combined Mechanical and Electrical Workshop Chlorination building Water Quality Monitoring Building Staff Building Security Guard Building Service Building Filling pumps Building Car Shade PSRH Hafar AlBatin Terminal Reservoir Stations


At Nuairiyah only

Nuairiyah, Qaryat AlOliyah,AlQaysumah and Hafar AlBatin

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11.2 Main & Booster Pump House :General Description:The buildings are to house pumps and drive motors as well as all piping, Valves and subsystems required for operation of the pumps. In addition a lay down area is provided at one end of the building. At the pumping Station, the Pump Houses (Booster pump house and Main pump house) are one story building with one cable duct and two pipe ducts. The finished floor level of the building is 30 cm above the station elevation. The pump houses have a total height of 9.00 m above station elevation Reference drawings numbers:
QP10-Q-3110 QP10-Q-3120 QP10-Q-3130 QP10-Q-3140 QP10-Q-3150 QP10-Q-3160 QP10-Q-3210 QP10-Q-3220 QP10-Q-3230 QP10-Q-3240 QP10-Q-3250 QP10-Q-3260 Booster Pump Building Plan View Booster Pump Building Pumps House Plan Booster Pump Building Section Booster Pump Building Elevation (3,4) Booster Pump Building Mechanical Drawing (Sec Plan) Main Pump Building Mechanical Drawing (Sec Elevation) Main Pump Building Plan View Main Pump Building Pumps House Plan Main Pump Building Section Main Pump Building Elevation (3,4) Main Pump Building Mechanical Drawing (Sec Plan) Main Pump Building Mechanical Drawing (Sec Elevation)

Foundations:The building foundations shall be reinforced concrete foundation slab, individual footings for pump/motor units and supports for pipes and valves. Load bearing Structure:-

Below ground: Reinforced concrete walls and column. Above ground: columns, trusses and longitudinal girders, cantilevering crane runway girder and
shoulders for crane beams as well as wind bracings made of steel. Walls:-

Below ground: Reinforced concrete walls, water tight. Above ground: Precast concrete sandwich panels with thermal insulation of min. 60 mm, visible
aggregate surface on the outside, painted inside.

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Roof:Flat roof with concrete hollow core slabs with inverted roof construction with layers of bituminous felt, thermal insulation of min. 100 mm and concrete tiles. Roof drainage by means of down pipe reservoirs and down pipes on one longitudinal side. Smoke escapes in sufficient number have to be provided as well as access to the roof (e.g. mounted ladders). Floor:Cement screed, partly covered by hot dip galvanized gratings for maintenance and for ventilation of ducts. The cable duct is covered with precast concrete slabs. Floor drains in sufficient number have to be provided in accordance with the drawings. Windows:Window strips on both longitudinal sides, sashes opening to the inside. Sun screens of aluminium outside Doors:Electrically driven sectional doors of steel with thermally insulated panels. Sinks and hose connections in sufficient number have to be provided. The main and booster pump house shall have a forced ventilation system. 11.3 Electrical Building for Pumping Station :General Description:The electrical buildings are one storey structures and will house the control installations for pumping station control as well as offices, social and sanitary rooms, the electrical switchgears, the motor starters of the pumps, the DC and UPS equipment, etc. The floor plan is rectangular and the buildings are set up in structural steel grid, the height of the building is 6.45 m above station elevation. Reference drawings numbers:
QP 10-Q-3310 QP 10-Q-3320 Electrical Building Plan View Electrical Building Plan Elevation (1),(2),(3),(4) & Section

Foundation:Reinforced concrete slab. Load bearing Structure:-

Below ground: Columns and walls made of reinforced concrete, watertight. Above ground: Frame construction of steel sections with longitudinal steel girders and wind

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bracing Roof : Flat roof with precast reinforced concrete slabs with inverted roof construction with layers of bituminous felt, thermal insulation of min. 100 mm and concrete tiles. Roof drainage by means of down pipe reservoirs and down pipes on the longitudinal sides of the building. Access to the roof (e.g. mounted ladders) shall be provided in sufficient numbers. Interior walls:-

Cable cellar: Reinforced concrete walls or hollow concrete block work covered with plaster. Above ground: Hollow concrete block work plastered and painted Sanitary rooms tiled (room
high). External walls: Pre-cast concrete sandwich panels with thermal insulation of 60 mm, visible aggregate surface on the outside. Ceilings:Cable cellar: Reinforced concrete fair faced. Above ground: Frame construction of steel sections with longitudinal steel girders and wind bracing Stairs

Stairs and pedestal made of reinforced concrete fair faced ramps made of reinforced concrete fair faced

Ramps:Windows:Window strips on both longitudinal sides, sashes opening to the inside. In habitable rooms, sashes partly side- and partly bottom hung. Doors:Exterior doors shall be either Rolling and double leaf doors or single doors of Steel . Interior doors shall be either double leaf doors or single doors. Material and Finishing is described in chapter 12 of this General Specification. Sanitary installations:Water connections and sanitary equipment in the kitchen, lavatories, washrooms and ablution have to be provided in accordance with the drawings and the room book. Finishing works and building installations are described in chapter 12 of this General Specification.

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Floor:Cement screed and ceramic tiles. The building will have a central HVAC system. A transformer box for two (2) Transformers is located in front of one of the longitudinal sides of the building. The box is constructed of reinforced concrete with visible aggregate surface. The double door is constructed of Aluminum or steel profiles with wire mesh. 11.4 Cooling Equipment Shelter:Reference Drawing:QP 10-Q-3350 QP 10-Q-3360 Cooling Equipment Shelter plan Cooling Equipment Shelter Section & Elevation

General Description :The cooling equipment shelter will protect the cooling equipment from adverse weather conditions and direct solar radiation. The shelter consists of a concrete slab and a steel structure with roofing and afacia made out of cladding material. Size and layout can be deduced from the above mentioned drawing. 11.5 Electrical Buildings (For Reservoir Stations) Reference Drawings
QP10-Q-2320 Typical Electrical Building For Reservoir Stations

General Description :This building is provided to accommodate the electrical and control equipment. Foundation;Reinforced concrete foundation slab with skirting. Load bearing structure:
Columns and trusses made of reinforced concrete.

External Walls:Recast concrete sandwich panels with thermal insulation, fair faced inside and visible aggregate surface outside. Internal Walls:Hollow concrete blockwork plastered and painted. Lavatory room tiled (room high). Roof :-

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Identical construction as for electrical buildings. Ceiling:Plastered and painted. Floor:Electrical rooms, Control room: Double floor with synthetic floor covering (antistatic) Battery room: Porcelain stone ware tiles, acid resistant. Doors:Exterior doors shall be either double leaf doors or single doors. Material and finishing works are described in chapter 12 of this General Specification. Windows: Windows with sashes opening to the inside. In habitable rooms, sashes partly side- and partly bottom hung. Sanitary installations: Water connections and sanitary equipment in the lavatory has to be provided. The Electrical Building shall have a split A/C unit.

11.6 Combined Electrical & Mechanical workshop building at Hafar AlBatin terminal Reference drawings:
QP 10-Q-2481 QP 10-Q-2482 QP 10-Q-2483 QP 10-Q-2484 Electrical & Mech. Workshop First Floor Plan Electrical & Mech. Workshop Ground Plan Electrical & Mech. Workshop Elevation ( 1& 3 ) Electrical & Mech. Workshop Elevation (2 & 4) & Section (A - A)

General Description: Electrical & Mechanical storage with storage area for electronic components and a small office Workshop for Electrical and storage area. Workshop for instrumentation, telecommunication and storage area. Workshop for Mechanical and storage area. Social rooms as locker room, pray room ,wash room, lavatories, kitchen with storage, lounge etc.

3 Offices for the maintenance personnel.


Foundation:Reinforced concrete slab with skirting Load bearing structure:Frame construction of steel sections with longitudinal steel girders and wind bracing, cantilever crane runway girders and shoulders for crane beam.

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External walls:Pre-cast concrete sandwich panels with thermal insulation of 60 mm, visible aggregate surface on the outside. Internal walls:Reinforced concrete, fair faced or hollow concrete block work, plastered. Ceilings:In technical rooms fair faced concrete and painted, in habitable rooms suspended aluminium panels. Roof :Identical construction as described for the electrical building. Smoke escapes and access to the roof (e.g. mounted ladders) have to be provided. Floor:Mechanical rooms, storage: Cement screed with top coating Electrical room: Synthetic floor covering (antistatic) Offices, Lavatory: Porcelain stone ware tiles Windows:Window strips on both longitudinal sides, sashes opening to the inside. In habitable rooms, sashes partly side- and partly bottom hung. Doors:ALL Exterior doors shall be either Rolling and double leaf doors or single doors of Steel . Interior doors shall be either double or single leaf doors. Material and finishing Is described in chapter 12 of this General Specification. Sanitary installations:Water connections in accordance with the drawings and room book. Hose connections for cleaning purposes. Finishing works and building installations are described in chapter 12 of this General Specification. The building will have a central HVAC system. 11.7 Chlorination Building at Hafar AlBatin Terminal Reference Drawings :QP10-Q-2421 QP10-Q-2422 Hafar AlBatin terminal station - Chlorination Building Plan View Hafar AlBatin terminal station - Chlorination Building Elevations ( 1 - 2 )

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Hafar AlBatin terminal station - Chlorination Building Elevations ( 3 - 4 ) Hafar AlBatin terminal station - Chlorination Building Sections

General Description:The building is to house the chlorination equipment, a drum storage room, control room and HVAC room.The chlorination building is a one story building and has a rectangular floor plan. The size is 20.85 m x 15.20 m and a clear height of 8.75 m. Foundations:Reinforced concrete foundation slab with skirting and two ducts for pipes and cables of reinforced concrete. Load bearing structure :Columns and beams made of reinforced concrete and shoulders for crane beam (5 kN). External walls:Pre-cast concrete sandwich panels, inside fair faced, outside with visible aggregate surface and thermal insulation of 60 mm. Internal walls :Reinforced concrete or concrete block work, both sides plastered and gastight Roof:Flat roof with pre-cast or in situ reinforced concrete slab(s) with inverted roof construction with layers of bituminous felt, thermal insulation of min. 100 mm, gravel and concrete tiles. Roof drainage by means of down pipe reservoirs and down pipes on the longitudinal sides of the building. Access to the roof shall be provided. Floor:Cement screed and ceramic tiles For Cl2 Storage and Dosing Room anti acid ceramic tiles shall be used. Windows:Window strips on both longitudinal sides. sashes opening to the inside Doors:All Exterior doors shall be either Rolling and double leaf doors or single doors of Steel . Interior doors shall be either double or single leaf doors. Material and finishing Is described in chapter 12 of this General Specification. Sanitary installations :Water connections in the dosing room, for the eye wash sink and the laboratory equipment in the

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control room. The building shall be equipped with a central HVAC plant. 11.8 Water Quality Monitoring Building at Hafar AlBatin Terminal a) Reference Drawing
QP 10-Q-2451 Water Quality Monitoring Building Floor Plan, Sections, Elevations

b) General Description The building houses the water quality monitoring equipment. For layout and size reference is made to the above mentioned drawing. Foundations: Reinforced concrete foundation slab with skirting and one duct of reinforced concrete. Walls: The walls are made of precast concrete sandwich panels with thermal insulation of 60 mm, visible aggregate surface on the outside. Roof: The roof construction shall be similar to the electrical building. Floor: Cement screed and floor tiles, concrete duct covered with galvanized steel plates. 11.9 Staff Building at Hafar AlBatin terminal and AlNuairiyah. Reference Drawings
QP 10-Q-2461 QP10-Q-2330 Hafar AlBatin terminal station -Staff Building Plan& Elevation &Section Nuairiyah station -Staff Building Plan& Elevation &Section

General Description :The building is located at the entrance to the station area. The design of the building must comply to the HCISS Standard SSD 17. Layout and size can be seen at the above Mentioned drawings. With a small W.C.& kitchen With a total size of 7.20 m x 6.00 m and a clear height of 4.35m. Foundation;Reinforced concrete slab with skirting of reinforced concrete. Walls:In-situ reinforced concrete with thermal insulation, inside and outside plastered and painted. Lavatory tiled (room high). Roof :-

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The roof construction shall be similar to the electrical building. Ceiling:Plastered and painted. Floor:Cement screed and ceramic tiles Doors and Windows :Made of aluminum frames with double glazing (thermal insulated). The building shall have a HVAC split unit Electrical operated gate barriers are to be provided for each road lane (entrance and exit) in accordance with the applicable security standard.

11.10 Service Building Reference Drawing :QP 10-Q-2491 QP 10-Q-2492 QP 10-Q-2493 Hafar AlBatin terminal station - Service Building Floor Plan Hafar AlBatin terminal station - Service Building Elevation ( 2 ), ( 4 ) Hafar AlBatin terminal station - Service Building Elevation ( 1 ),( 3 ) & Section

General Description The building contains the following rooms:

Storage (oil, grease, etc.) pump room for fire fighting pump room for station water supply

The typical service building is a one storey building and is set up in 5.00 m x 5.00 m structural grid. The size of the building is 10.90 m x 11.00 m, the height is 6.0 m above station elevation. Foundations:Reinforced concrete foundation slab with skirting. Load bearing structure:Frame construction of steel sections with longitudinal steel girders, cantilevering crane runway girders and shoulders for crane beam (2 TON) and wind bracing. External walls :Pre-cast sandwich panels with thermal insulation of min. 60 mm in between, fair faced inside and

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outside. Internal walls:Reinforced concrete or concrete hollow block work, plastered Roof:Flat roof with pre-cast reinforced concrete slabs with inverted roof construction with layers of bituminous felt, thermal insulation of min. 100 mm, intermediate layer, gravel and concrete tiles. Roof drainage by means down pipe reservoirs and down pipes on the longitudinal sides of the building. Access to the roof shall be provided. Floors:-

Generator room and oil storage: Cement screed, with top coating (oil resistant). Pump rooms: Ceramic tiles, Floor drains for pump room(s).

Windows:Window strip of thermally insulated aluminum frames with thermally insulated glass, dustproof. Sashes opening to the inside. Doors:All Exterior doors shall be either Rolling and double leaf doors or single doors of Steel . Sanitary Installations:Hose connection and sink for pump room(s). Ventilation system(s) as per actual requirement and in accordance to the specifications.

11.11 Security Guard Building for All stations Reference Drawings


QP10-Q-2411 QP10-Q-2310 Guard House Hafar AlBatin Terminal Plan& Elevation & Section Typical Security Guard Room For Reservoir and filling Station plan , elevation and section

General Description :The building is located at the entrance to the station area. The design of the building must Comply to the HCISS Standard SSD 17. Layout and size can be seen at the above Mentioned drawing.. The security guard building is a one storey structure consisting of a guard room with a small W.C. With a total size of 4.20 m x 3.40 m and a clear height of 3.60 m. Foundation;Reinforced concrete slab with skirting of reinforced concrete.

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Walls:In-situ reinforced concrete with thermal insulation, inside and outside plastered and painted. Lavatory tiled (room high). Roof :Same construction as described for the electrical building. Ceiling:Plastered and painted. Floor:Cement screed and ceramic tiles Doors and Windows :Made of aluminum frames with double glazing (thermal insulated). The building shall have a HVAC window type unit. Electrical operated gate barriers are to be provided for each road lane (entrance and exit) in accordance with the applicable security standard. 11.12 Filling Pumps Building Reference Drawing :QP10-Q-2340 Filling pumps building

General Description The building contains one room for filling pumps The filling pumps building is a one storey building. Foundations:Reinforced concrete foundation slab with skirting. Load bearing structure:Frame construction of steel sections with longitudinal steel girders, cantilevering crane runway girders and shoulders for crane beam (2 TON) and wind bracing. External walls :Pre-cast sandwich panels with thermal insulation of min. 60 mm in between, fair faced inside and outside. Internal walls:Reinforced concrete or concrete hollow block work, plastered

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Roof:Flat roof with pre-cast reinforced concrete slabs with inverted roof construction with layers of bituminous felt, thermal insulation of min. 100 mm, intermediate layer, gravel and concrete tiles. Roof drainage by means down pipe reservoirs and down pipes on the longitudinal sides of the building. Access to the roof shall be provided. Floors:-

Generator room and oil storage: Cement screed, with top coating (oil resistant). Pump rooms: Ceramic tiles, Floor drains for pump room(s).

Windows:Window strip of thermally insulated aluminum frames with thermally insulated glass, dustproof. Sashes opening to the inside. Doors:All Exterior doors shall be either Rolling and double leaf doors or single doors of Steel. 11.13 CAR Shade:Reference Drawing:Pumping Station PSRH and Hafar AlBatin terminal
QP10-Q-2431 QP10-Q-2370 Car shade Hafar AlBatin Terminal station Plan & Section & Elevation Car Shade Plan & Section & Elevation

General Description :This shade is a standard steel structure and comprises parking areas for six (6) cars. The lay out is based on a structural grid of 5.20 x 6.00 m. The total height is about 3.20 m. Foundations:Single reinforced concrete foundations Load bearing structure:Columns of steel profiles with cantilever galvanized steel frames above Roof:Tensioned membranes (composite material) resistant to degration from UV rays, to erosion, color changes etc. Floor:Asphalt lay on sub grade and sub base material.

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CHAPTER (12) FINISHING WORKS AND BUILDING INSTALLATIONS


12.1 General The scope and extent of the various requirements pertaining to finishing works and building installations is described in this chapter as well as in the pertinent specifications. The information provided therein is intended to supplement each other. Special attention must be given to ensure that all foundations, concrete floor slabs and the perimeter walls of all underground structures are watertight. In general, this applies to all underground concrete works, and is, therefore, not limited to buildings, but is rather equally valid for retaining walls, valve shafts, etc. All buried concrete surfaces shall in addition be protected against any attack of harmful substances through the application of tanking membrane. All architectural and finishing materials shall be of highest quality specification. 12.2 Master Builders Works 12.2.1 Walls External walls shall be made of precast concrete sandwich panels inside fair faced outside visible aggregate surface. The thickness of the sandwich panels shall be min. 30 cm and is mainly depending on the panel length and the necessary cover layer on the reinforcement. The external surface finishing of the precast sandwich elements (e.g. structure, color etc.) have to be approved by the Engineer. External walls out of reinforced concrete shall be plastered and painted. Internal walls of reinforced concrete or hollow block work shall be plastered and painted. Room high porcelain stone ware tiling in wet rooms. 12.2.2 Ceilings Below ground:- Reinforced concrete fair faced and painted (e.g. cable cellar). Ground floor:- Reinforced concrete and precast reinforced concrete slab fair faced and painted. In habitable rooms suspended ceiling with aluminum panels. 12.2.3 Floors Below Ground :- (Cable cellar, Cable ducts):

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Cement screed Ground Floor: Pump Halls, Generator Rooms, Workshops, Storage Buildings and Oil Storage: Cement screed with top coating (heavy duty). Electrical rooms, HVAC room: Synthetic floor covering (antistatic), if no cable cellar installed (e.g. Electrical Buildings at the Reservoir Stations) double false floors have to be foreseen. Emergency Diesel Generator and oil storage: Cement screed with top coating (oil resistant). Cooling Water system shelter: Cement screed with top coating Offices , Control room and corridors :Porcelain stone ware tiles, carpets Battery room: Porcelain stone ware tiles, acid resistant Office, Control rooms, Corridors: Marble tiles with standard size. In case of false floor, antistatic synthetic floor covering elements Prayer room:Porcelain stone ware tiles, carpets Wet rooms:Porcelain stone ware tiles Chlorination Building and other technical rooms (e.g. pump rooms):Acid resistant ceramic tiles Staircase:Ceramic tiles Stairs, Ramps external:Fair faced concrete Cable ducts:Covering with heavy duty precast concrete slabs Pipe chambers and shafts:-

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Hot-dip galvanized gratings or grooved plates. All screed surfaces shall receive a durable heavy duty PVC coating, if not protected otherwise. For the walkways to all the access doors of the buildings and structures, to the manholes of the shafts and around the buildings (min. width of 1.60 m) interlocked concrete tiles with a thickness of min. 6 cm shall be used. The colour and shape has to be approved by the Engineer. The walkways shall be surrounded by curb stones (40 x 20 cm, 30 cm height) on both sides. 12.2.4 Windows All window frames shall be of aluminum, insulated construction. Upper window strip with insulated glass, partly stationary, partly bottom-hung sashes. All easily operable by hand, sand and dustproof. In habitable rooms, sashes partly side- and partly bottom-hung. All with glass panes and special sand and dustproof. Aluminum surfaces anodized or coated. Special sand resistant. 12.2.5 Doors All exterior doors shall be either sectional doors, double leaf doors or single leaf doors of steel construction, insulated, alum-sheet panelled or with glass panes. Some of the doors have an upper window strip of unbreakable, insulated glass panes. Sectional doors: Electrical driven, steel construction with thermally insulated panels and acryl glass panes. One section with pedestrian door. All exterior doors shall be sand- and dustproof. Interior doors to offices consist of steel frames with wood veneer panels, room high with fan light. Doors to technical rooms consist of steel frames and aluminum panels. Doors to corridors consist of steel frames and aluminum panels with glass panes. Fire proof steel doors in fire walls.Aluminum surfaces anodized or coated. Steel surfaces coated. Cylinder locks for all doors. 12.2.6 Sun Shades

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For control rooms, offices and habitable rooms adjustable sunscreens (e.g. made of aluminum) have to be foreseen. 12.2.7 Miscellaneous All paints and colours are subject to approval and must be coordinated with SWCC. Key system shall be implemented for all lockable facilities (gates, doors, shafts etc.) according to the approved key lock system. 12.2.8 Insulation Thermal insulation External walls minimum 60 mm insulation with vapour barrier, for roof insulation of min. 100 mm thickness. Acoustic Insulation Acoustically insulated windows or doors for rooms with high noise level, according to the requirements of work safety and local standards, made of acoustic panel systems. 12.3 Platforms Ladders and handrails Ladders, platforms, gratings, steps and handrails of steel (hot-dip galvanized) profile sections shall be provided for all pump units, valves and other equipment to which access is required for operation and maintenance. All handrails have to be removable. 12.4 Furniture Furnishing and equipment of the highest quality applies for all furniture, kitchen facilities (including all utensils), washrooms and toilet equipment, etc. to make the buildings ready for use. For additional information reference is made to the pertinent specification. All furnishing and equipment is subject to SWCC approval. 12.5 Electrical Building Installation The buildings shall be provided with appropriate electrical installation, mainly consisting of: Lighting system fed from the low voltage switchboards via sub distribution boards Escape way lighting with built-in batteries

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Socket outlets fed from the low voltage switchboards via sub distribution boards Sub distribution boards, junction boxes, switches, conduits, wires, cables for the above mentioned equipment and for all other auxiliary equipment like cranes, ventilators, etc. Conduit system for telephone Conduit system for office LAN (if applicable) Conduit system for fire & gas alarm system (if applicable) Lightning protection system for all buildings and high structures Grounding system and connections to the station earthing system belonging to the electrical installation and as far as not part of the station earthing system covered under chapter 16 of this general specification. Shafts inside of stations shall also be equipped with an appropriate electrical installation, mainly consisting of distribution boards, lighting fixtures, socket outlets, junction boxes, cables and accessories. The electrical installation of shafts shall be supplied either via common boards for a group of shafts or via sub distribution boards for other buildings. For details and technical requirements reference is made to the Specification E14 Electrical Installation of Buildings, Doc. No. QC10-H-094. 12.6 Fire detection and Alarm system The fire detection and alarm system for the buildings is described in chapter 17 of this document. For technical requirements reference is made to the Specification S10 Fire Detection and Alarm System, Doc. No. QC10-H-130.

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CHAPTER (13) CIVIL WORKS AND CONCRETE RESERVOIRS


13.1 Earth Works Along with the earthworks soil explorations are to be carried out. The reconnaissance works are to be conducted in such a manner that the structure of the subsoil is known completely. In the area of the pump houses, steel tanks, concrete reservoirs and other station buildings a sufficient number of boreholes with dynamic subsoil explorations is to be carried out. Accordingly, a number of boreholes have been carried out and the results of these investigations were submitted under separate documents. The contractor shall be obligated to carry out a detailed soil investigation under the contract conditions. The earthworks to be performed subsequently are to be carried out in accordance with the specifications, paying particular attention to sufficient compaction of the subsoil. All backfilled or cut slopes at the Pumping Stations, the Reservoir Stations, the Line Valve, Vent and Drain Stations shall be protected against washouts or erosion by a layer of riprap. The earthworks shall also include all landscaping works and the restoration works required. The Contractor shall be also responsible to provide adequate flood prevention measures in and around the stations. The preparation of pipe trenches at stations took into account the outside coating of the pipes. Size of trench, bedding, padding and backfilling shall avoid the damage of the coating. The material surrounding the pipes must consist of sieved excavation material or sand according the previously mentioned design criteria and has to be approved by the engineer. 13.2 Roads and Traffic Areas All paved areas, access roads as well as the internal roads of the stations shall be constructed according to the plot plan, contract specifications and the general specifications for road and bridge construction issued by the Ministry of Transport (MOT). In addition to the works mentioned above all the existing roads, paved areas and sidewalks which are damaged during the construction works have to be repaired. At the border line between new roads and station area, curb stones shall be installed and sidewalks shall be envisaged at frequently used locations. The use and location of temporary access roads for construction have to be discussed and approved by SWCC and/or MOT operation department. Construction roads are contractor responsibility.

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Rainwater will run off as a result of the longitudinal slope or cross fall of the roads and shall be drained off via road gullies or trapezoid channels. In some cases a bituminous rim is to be constructed in order to prevent the surface runoff from flowing to open areas.

13.3 Station Areas The station areas, which are not protected by any other means, shall be covered by a layer of 5 cm of crushed gravel, size 5 - 20 mm. Prior to the application of the gravel the station areas should be graded to ensure surface water run-off.

13.4 Equipment Foundations and Shafts Reinforced concrete foundations for equipment located at the various stations shall be designed by the Contractor according to the static requirements and considering the prevailing soil conditions. Shafts shall be of reinforced concrete in various thickness (min. 25 cm), watertight, according the typical drawings and the pertinent specifications. Shafts are required for valves, metering equipment etc. at the pumping station area, for the line valve stations, Hafar Al Batin Reservoir and the other various reservoir stations and in addition for the drain and vent stations. The shafts shall be covered with removable (e.g. Lifting lugs) concrete slabs and equipped with watertight access shafts (No. depends on the size of the shaft), lockable type, with a ladder and removable supporting handle. A ventilation system for the shaft (aeration pipes) is to be foreseen. For easy access of the concrete cover slab a ladder shall be foreseen, if the difference in elevation exceeds 600 mm. All pipe penetrations through the shaft walls shall be provided with proper watertight maintenancefree pipe wall ducts - link seal or equivalent. All shafts located within road areas of stations or within existing or future highways along the pipeline shall not be higher than the adjacent road area. The shaft cover shall be laid out for a bearing capacity of SLW 600. Ventilation pipes of shafts located within road areas shall be routed outside the road area (edge of ROW of the road). All shafts shall have a pump sump.

13.5 Water Supply System The purpose of the station water supply system is to distribute drinking and utility water inside the

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Pumping and the Reservoir Stations building. For the station water supply system the following main works shall be performed:

All piping and equipment between the take-off point of the water from the main piping and the feeding points to the water installations of buildings, such as wash basins, hose connections for cleaning purposes are to be installed by the Contractor. At the Pumping Station the water shall be taken from the suction headers. At the Reservoir Stations the water supply shall be taken from the reservoirs.

It likewise includes the supply and installation of all drinking and utility water piping within the station area, including all valves within the drinking and utility water distribution network. Pressure supplying equipment such as pumps, compressors, instrumentation etc. which make automatic operation possible shall be part of the works to be provided. Cooled drinking water shall be made available to the people passing any of SWCC stations. the taps for drinking water shall be preferably be located at station entrance.

For the underground water supply system outside the buildings HDPE pipes and for the water supply (distribution) inside the buildings polypropylene pipes shall be used. 13.6 Sewage and Storm Water System The purpose of the station sewage system for the Pumping Station and Reservoir Stations is the collection, removal and treatment of sewage and domestic waste water. The following main work items are listed below; however the works are not given in detail:

Complete

external

sewage

lines

including

maintenance

shafts,

the

internal

installations within buildings are part of the building. At the deepest point of the sewerage system a lift station shall be provided, equipped with all installations and equipment for automatic operation. At Ras AlZaur pumping station (PSRH) transfer lines shall be constructed to the sewage treatment plant belongs to Ras AlZaur Riyadh WTS including all necessary lifting stations.

At Reservoir stations including terminal station the sewage system shall be led to a septic tank if there is no sewage network available. Otherwise the station sewage system shall be connected to the existing installation.

The above work items shall include all mechanical and electrical equipment (pumps, valves

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etc.) required for the proper function of the system.

Particular attention shall be paid to the requirement that no storm water shall enter the sewage system. For the pump houses separators for light liquids according the pertinent specifications have to be installed and connected to the sewage system afterwards. In addition to the sewage system a storm water drainage system with maintenance shafts shall be installed. The rainwater shall be led via road gullies and maintenance shafts from the area of the roads and paved areas and via gutters from the roof into the storm water system.

If no other means of storm water drainage are possible (e.g. disposal into natural outfall channel), an evaporation pond of adequate size has to be implemented. This pond must be dimensioned to also accommodate the overflow and/or drainage volume from the over flow from reservoir. At the Terminal Stations the storm water drainage system of the new station area shall be connected to the existing drainage facilities, if feasible, otherwise an evaporation pond has to be constructed. For the sewage system vitrified clay pipes shall be used. The piping for storm water drainage shall consist of concrete pipes.

13.7 Walls, Fences and Gates The station area of the Pumping Stations and the Terminal Stations shall be surrounded by a fence. In addition at all Line Valve Stations, which are located outside of roads or highways, a station fence shall be constructed. The hall land area of each station as shown in the location drawings shall be surrounded by a security fence. All fences and gates shall be designed to meet the relevant requirements of the High Commission for Industrial Security and Safety (HCISS). These guide-lines shall also be mandatory for the distance of buildings (structures) from the fence and the lighting of fence and station area. For construction works which will take place within existing Terminal Stations, damages on the existing boundary walls or fencing and fence lighting etc. have to be repaired by the Contractor after completion of the installation works.

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13.8 Landscaping For the Pumping Stations , terminal station and reservoir stations , it is required to provide and install suitable landscaping (plants, trees, etc.). Type and layout of the landscaping is part of detailed design and is subject to SWCC approval. 13.9 Concrete reservoir Qaryat AlOliyah and AlQaysumah

One Concrete tank with two chambers shall be constructed at Qaryat AlOliyah (capacity of each
chamber 1,500 m3 ).

One Concrete tank with two chambers shall be constructed at AlQaysumah(capacity of each
chamber 3,500 m3 ).

The proposed arrangement and layout of the station is shown in the following drawings:
- Qaryat AlOliyah Concrete reservoir 3,000 m3 , Drawing : QP10-Q-2230 - AlQaysumah Concrete reservoir 7,000 m3, Drawing : QP10-Q-2260

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CHAPTER (14) STEEL WATER STORAGE TANKS


14.1 Design and Construction of Steel Tanks The water storage tanks to be erected at Ras Al Zaur-Hafar Al Batin water transmission system shall be flat bottom welded steel tanks. The tanks shall be designed and constructed in accordance with specifications M09 Steel Tanks which is based on API.

14.2 Foundation for Steel Tanks The shell of the water storage steel tanks shall rest on a ring beam of reinforced concrete of adequate width. The bottom plate of the tanks shall be laid on a layer of 300 mm of clean washed sand. Below the sand a layer of well compacted road base material of approx 500 mm thickness shall be placed. The road base material is supported by subsoil which has to be compacted to 98% proctor density. Prior to commencement of the backfilling works soil exploration activities have to be carried out to ensure that soil conditions at the tank area will be suitable for expected loads. In case of unsuitable bearing conditions, the existing ground conditions shall be improved by a suitable improvement method. The tanks embankment has to be safeguarded against erosion by Rip-Rap or concrete retaining walls. 14.3 Steel Tanks at Nuairiyah and Hafar AlBatin

Two steel tanks with a capacity of 5,000 m3 each shall be constructed at Nuairiyah. Two steel tanks with a capacity of 50,000 m3 each shall be constructed at Hafar Al Batin.

The following main inlet and outlet nozzles shall be foreseen for each tank as follows: - Nuairiyah Tank : Inlet 1 pipe DN 300 (12``)

Outlet 2 pipes DN 300 (12``) Overflow Piping with adequate size. Drain piping with adequate size. Nozzles for inspection and instrumentation are required as per specifications.

The proposed arrangement and layout of these station shown in Nuairiyah Steel Reservoir 5,000m3, Drawing : QP10-Q-2210

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- Hafar Al Batin Tank :

Inlet 1 pipe DN 1100 (44``) Outlet 2 pipes DN 1100 (44``) Overflow Piping with adequate size. Drain piping with adequate size. Nozzles for inspection and instrumentation are required as per specifications.

The proposed arrangement and layout of these station shown in the following drawing Hafar Al Batin Steel Reservoir 50,000 m3 , Drawing : QP10-Q-2270 14.4 Steel Water Towers at Ibn Hethlain ,Sairah and Sadawi For some small reservoir stations steel water towers with one day storage capacity shall be constructed. The water towers have to provide the necessary pressure for the connected filling stations. List of water towers at the Consumer Reservoir Stations Location Ibn Hethlain Sairah Sadawi No. of tanks 1 1 1 Volume m/tank 300 1000 300 Tank Diameter (m) 8.75 12 8.75

The proposed arrangement and layout of the stations is shown in the following drawings: - Ibn Hethlain Steel water tower 300 m3 , Drawing : QP10-Q-2220 - Sairah Steel water tower 1000 m3 , Drawing : QP10-Q-2240 - Sadawi Steel water tower 300 m3 , Drawing : QP10-Q-2250

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15 MECHANICAL WORKS
15.1 General This chapter describes the main construction requirements for mechanical works at all stations of the Pipeline System. As a general rule the design of the mechanical components, mechanical systems and materials shall be identical for all stations, if not otherwise specified. 15.2 Station Piping 15.2.1 Sizing of Station Piping System The pipe sizes to be used are indicated in the P&IDs of the pipeline system and shall be considered minimum requirements. In general the flow velocities shall not exceed

2 m/s for pump suction headers, pump suction pipes and overflows, 3 m/s for pump discharge pipes and headers and all other station water pipes and drain lines.

Higher velocities are acceptable at special sections such as control valves, flow meters, etc. the suction requirements of the pumps with respect to NPSH (Net Positive Suction Head) and flow pattern shall be checked based on actual pump data and if necessary lower velocities shall be selected. For the pressure design of the piping system the highest possible pressures occurring in the individual piping sections, taking into account all steady and unsteady state conditions shall be calculated. The pressure rating of the fittings and equipment shall then be selected in accordance with the next higher rating in accordance with ASME B 16.5. Based on the design temperature of 45 C of water and the table of pressure-temperature ratings given in the standard ASME B16.5 the following pressures have been calculated by doing a linear interpolation of ratings: Design Pressure [barg] Piping Pressure [ASME B16.5] 19.4 Class Class 150 50.4 Class 300 67.4 Class 400 100.8 Class 600

The required minimum wall thickness for the station piping shall be calculated using the equation stated in the design code ASME B 31.4. Because the station piping is internally protected, no corrosion allowance is required.

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After the minimum wall thickness has been determined, the appropriate nominal wall thickness from standard API 5L or ASME B 36.19 shall be selected. The standard manufacturing tolerances shall be checked to confirm that the tolerance will not reduce the nominal wall thickness below the minimum required as calculated. 15.2.2 Materials for Station Piping The material of station piping shall be steel , the design code ASME B 31.4 shows a table for recommended materials used for liquid transportation systems. The detailed specification of the material used in station piping is given in SWCC Specifications M08 Piping Material for Stations Doc. No. QC10-H-0048. 15.2.3 Internal Lining of Station Piping To avoid internal corrosion, the piping and piping components shall be protected. The internal lining of pipes, fittings, flanges and other piping components shall be done with fusion bonded epoxy. The detailed specification lining is given in SWCC Specifications M20 Fusion Bonded Epoxy Lining Doc. No QC10-H-0060. 15.2.4 External Coating of Station Piping Depending on how the piping is laid, above ground or buried, the station piping shall be painted or coated with polyethylene (PE). Method and material for Polyethylene coating are defined in SWCC Specification M02 Polyethylene PE Coating. Doc. No. QC10-H-0042. The painting procedure and material shall be as per M21 Painting of Piping, Equipment and Structural Steel Work Doc. No. QC10-H-0061 15.2.5 Piping Layout The piping layout in stations with existing equipment and piping shall be done in such a way as to avoid interference with the existing piping systems, structural steel and concrete, electrical cable trays and conduits etc. 15.2.6 Access for Inspection and Repair For inspection/repair of internal lining and for maintenance works permanent access points to enter the main headers shall be provided with blind flanges in concrete shafts.

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15.2.7 Piping Flexibility The piping shall be designed with sufficient flexibility to prevent expansion or contraction from causing excessive stresses in the piping material, excessive bending moments at joints, or excessive forces or moments at points of connection to equipment or at anchorage or guide points. This shall be achieved by using piping arrangement such as L-shaped, U-shaped or Z-Shaped configurations in the normal routing of any piping system. The aboveground piping shall be laid on pipe supports. Supports shall be designed to support the pipe without causing excessive local stress in the pipe and keep the desired freedom of movement. A pipe stress analysis shall be part of the final design proving that stresses for piping and equipment are kept within the allowable limits. 15.2.8 Dismantling Pieces and Flange Adaptors These components, which are not depicted in the P&IDs and other drawings, shall be used in the piping to facilitate assembly and disassembly of equipment and valves for maintenance and repair. Dismantling pieces or flange adaptors shall generally be used at valves, flow meters and other equipment installed in straight pipe runs equal or larger than 24 (DN 600) in size. For smaller sizes it shall be decided during final design and depending on the piping configuration where dismantling pieces/flange adaptors shall be installed. Flange adaptors shall only be used where no axial forces have to be transmitted. Dismantling pieces and flange adaptors shall comply with specification M11 Special Fittings, Doc. No. QC10-H-051. 15.2.9 Pump Suction Piping For the pump suction piping in addition to the stress calculation, the Contractor, in close co-operation with the pump manufacturer, shall carefully check the piping arrangement and the suction pipe lengths with respect to velocity distribution at the pump inlet which shall meet the requirements of the pumps for proper operation. The design shown in the drawings is deemed to satisfy these requirements for the pump types under consideration, however, if necessary measures for straightening the flow (e.g. elbows with straightening vanes, flow straightness in straight pipes, special fittings) shall be foreseen.

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15.2.10 Strainers Strainers shall be installed at the suction side of Booster pumps , as shown in drawing QP20-D-1100 Booster pumps P&ID Diagram. The strainers shall be of conical type with a mesh size of approx. 8-10 mm, with differential pressure monitoring and drain down facilities. The strainer mesh shall be of rigid design and its thickness shall be determined with sufficient safety against deformation taking into account that foreign matters have accumulated in the strainer. 15.2.11 Filling and Drainage For filling and drainage of station piping it is necessary to provide suitable filling bypass valves, drain valves and vent valves. The drain valves shall be at low points and the vent at high points. Filling by pass valves shall be designed to handle the possible different pressure, if necessary pressure throttling devisees (Pressure reducing valves, cages, etc.) 15.2.12 Installation of station piping For fabrication and installation of station piping the Specification M19 Station Piping, Doc. No. QC10-H-059 shall be followed. 15.3 Station Valves 15.3.1 General Design Requirements This subchapter refers to the different valve types to be installed in the station piping, such as isolation valves, check valves, control valves, pressure safety valves, etc. Valves shall comply with the Specification M06 Valves for Water Service Projects, Doc. No. QC10H-046. The design pressure of the station valves shall be according to the piping class of the connected pipe work. Where a change of the pressure class coincides with the location of a valve, this valve shall belong to the higher pressure class. Valve design shall also take the hydrostatic test pressure into account.

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The valve materials shall be carefully selected with respect to suitability and corrosion resistance for the use under the specific operating conditions, especially with respect to the water quality. Heavy valves shall be adequately supported independently of the pipes to which they are connected in order to prevent the pipe having to bear the weight. 15.3.2 Control Valves Control valves are required at various locations as follows (reference is made to the relevant P&I Diagrams):

In the Booster pump re-circulation by-pass line. In the Main pump re-circulation by-pass line. At the outlet of pumping station. At the station inlet side of water towers and reservoir stations

Special attention shall be paid that each control valve will meet its specific performance requirements and will be suitable for continuous operation without cavitation damage. Piston type control valves with suitably designed throttling elements shall be used. The control valves shall be equipped with an electro-hydraulic actuator, because operation (fail safe closing or opening) shall also be possible when no external power supply is available. In order to minimize energy losses the control valves to be installed into the main stream and therefore permanently flown through shall be designed for minimum losses in open position which shall not be more than 3 m at maximum design flow rate. The numbers, locations and sizes of these valves are shown on the relevant P&IDs. However, final calculations shall be made by the Contractor during the final design stage. a) Station Outlet Control Valve, Main Control at PSRH Location : Purpose : Number of valves Max. flow rate Min. flow rate (1 parallel pump 70%) Total closing time Station outlet piping . flow and discharge pressure control, high flow Protection (FC, PCH, PHFP) 2 (1 duty +1 standby) 4,583 x 1.1 = 5,041 [m/h] = 458 [m/h] 4,583 /2 x 0.7 = 1,607 [m/h] 3 10 (adjustable) [sec]

Pipeline filling rate (approx. 10% of MDF) 4,583 x 0.1

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Total opening time Fail safe position Max. losses in open position Pressure rating

3 10 (adjustable) [sec] closed 3.0 (assumed value) [m] ASME 600#

b) Booster pumps recirculation control valve Location Purpose Number of valves Max. flow rate (1 parallel pump 120%) Min. flow rate Total closing time Total opening time Fail safe position Pressure Rating Min. losses in open position recirculation line of booster pumps low flow protection (PLFP) 1 4,583 / 2 x 1.20 = 2,750 [m/h] down to zero [m/h] 3 10 (adjustable) [sec] 3 10 (adjustable) [sec] Opened ASME 150# approx. 40 [m]achieved by control valve itself or additional down stream equipment (e.g.cage,orifice, etc.). d) Main pumps recirculation control valve Location Purpose Number of valves Max. flow rate (1 parallel pump 120%) Min. flow rate Total closing time Total opening time Fail safe position Pressure Rating Min. losses in open position recirculation line of main pumps low flow protection (PLFP) 1 4,583 / 2 x 1.20 = 2,750 [m/h] down to zero [m/h] 3 10 (adjustable) [sec] 3 10 (adjustable) [sec] Opened ASME 600# approx. 300 [m]achieved by control valve itself or additional downstream equipment (e.g.cage,orifice,etc.) e) Control valve at Nuairiyah reservoir and Filling station

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Location Purpose Number of valves Max. flow rate (station) Min. flow rate (30%) Total closing time Total opening time Fail safe position Pressure Rating Max. losses in open position

Station inlet piping inlet pressure control 2 (1 duty +1 standby) 417 x 1.1 = 458 [m/h] 417 x 0.3 = 125 [m/h] 30 [sec] 30 [sec] closed ASME 400# approx. 3 [m]

f) Control valve at Ibn Hethlain Water tower and Filling station Location Purpose Number of valves Max. flow rate (station) Min. flow rate (30%) Total closing time Total opening time Fail safe position Pressure Rating Max. losses in open position

Station inlet piping inlet pressure control 2 (1 duty +1 standby) 12.5 x 1.1 = 14 [m/h] 12.5 x 0.3 = 3.8 [m/h] 30 [sec] 30 [sec] closed ASME 400# approx. 3 [m]

g) Control valve at Qaryat AlOliyah Water tower and Filling station Location Purpose Number of valves Max. flow rate (station) Min. flow rate (30%) Total closing time Total opening time Fail safe position Station inlet piping inlet pressure control 2 (1 duty +1 standby) 117 x 1.1 = 129 [m/h] 117 x 0.3 = 35 [m/h] 30 [sec] 30 [sec] closed

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Pressure Rating Max. losses in open position Location Purpose Number of valves Max. flow rate (station) Min. flow rate (30%) Total closing time Total opening time Fail safe position Pressure Rating Max. losses in open position

ASME 300# approx. 3 [m] Station inlet piping inlet pressure control 2 (1 duty +1 standby) 49 x 1.1 = 54 [m/h] 49 x 0.3 = 15 [m/h] 30 [sec] 30 [sec] closed ASME 300# approx. 3 [m]

h) Control valve at Sairah Water tower and Filling station

i) Control valve at Sadawi Water tower and Filling station Location Purpose Number of valves Max. flow rate (station) Min. flow rate (30%) Total closing time Total opening time Fail safe position Pressure Rating Max. losses in open position

Station inlet piping inlet pressure control 2 (1 duty +1 standby) 12 x 1.1 = 13.2 [m/h] 12 x 0.3 = 4 [m/h] 30 [sec] 30 [sec] closed ASME 150# approx. 3 [m]

j) Control valve at AlQaysumah Reservoir station Location Purpose Number of valves Max. flow rate (station) Min. flow rate (30%) Station inlet piping inlet pressure control 2 (1 duty +1 standby) 269 x 1.1 = 296 [m/h] 269 x 0.3 = 81 [m/h]

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Total closing time Total opening time Fail safe position Pressure Rating Max. losses in open position

30 [sec] 30 [sec] closed ASME 150# approx. 3 [m]

k) Control valve at Hafar AlBatin terminal station Location Purpose Number of valves Max. flow rate (station) Min. flow rate (30%) Total closing time Total opening time Fail safe position Pressure Rating Max. losses in open position 15.3.3 Line Valves The Line valves for the Ras AlZaur Hafar AlBatin pipeline system shall be of reduced bore or butterfly valves. Ball valves with sizes of 24 and above shall be of the top entry design. 15.3.4 Pressure Relief Valves Pressure relief valve group install at the inlet piping of Hafar AlBatin terminal station shall be of Pneumatic acting diaphragm or pilot operated surge relief valves type. Refer to SWCC specifications M06. 15.3.5 Other Valves Isolation valves shall be used to shut off sections of the station piping from each other for switching operations during normal operation, but also for maintenance and repair purposes. Generally the shut off valves in the station piping system shall be butterfly and /or ball valves. Butterfly valves and ball valves shall generally have flanged ends. Ball valves may have welded ends

Station inlet piping inlet pressure control 2 (1 duty +1 standby) 3,708 x 1.1 = 4,079 [m/h] 3,708 x 0.3 = 1,112 [m/h] 300 [sec] 300 [sec] closed ASME 150# approx. 3 [m]

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provided they are of the top entry design. The valves located adjacent to the pumps shall have flanged ends. The pump discharge valves, which are involved in the starting sequence of the pumps, shall be ball valves. All balls valves 24 and above shall be top entry type. The check valves at the discharge side of the main and booster pumps as well as at the pumping station outlet downstream of the control valves shall be of the non-slam piston type. For check valves at other locations or installed in other than the product water system swing check valves may be used. In order to avoid unallowable pressures due to temperature rise those sections of the station piping which may remain isolated shall be equipped with spring type pressure safety valves. Set pressure shall be selected in such a way that at design relief capacity the pressure corresponding to the pressure class of the pipe in which they are installed will not be exceeded. Valves to be installed in the filling bypass around mainline valves and valves to be used as drain valves may require special designs which avoid cavitation damage and/or vibrations when in operation. Selection of suitable valve types and characteristics shall be subject to final design. 15.4 Pumps 15.4.1 General All high pressure pumps shall be of the horizontal centrifugal type and shall comply with specification M-05 Centrifugal Pumps for Water Service, Doc. No. QC10-H-045. The performance data listed below are based on the hydraulic calculations carried out during preparation of the tender design and Contractor shall verify with his own calculations. Pumps with best available efficiency shall be selected without, however, violating their performance and lifetime requirements. Pumps efficiency shall not be less than 87%. They shall preferably be selected out of the manufacturers standard production range. Special attention shall be paid to the material selection for all wetted parts regarding their suitability for the quality of the pumped water. The coupling hubs on the shafts shall be designed for easy maintenance. A coupling design with high pressure removal and shrink fit hubs is not permitted. The lube oil drainage piping shall be constructed from the lube oil tank to the outside shaft with suitable facilities to dispose the lube oil. An air vent shall be provided on the top of the casing of each pump unit. The seal flush piping and vent piping shall be manufactured of corrosion resistant stainless steel.

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Pumps and electrical motors shall preferably be mounted on a common base plate. The drivers of all pumps have been designed with fixed speed. The electric motors are described in chapter 16 Power Supply and Electrical Works hereinafter. 15.4.2 Design and Performance Requirements The suction conditions for all pumps shall be carefully determined for the rated conditions as well as for any other operational cases the pumps will ever be subjected to according to the operating philosophy. NPSH available shall be provided with sufficient safety margin over NPSH required taking into account the properties of the pumped water and the selected pump type as well. Pump manufacturers requirements in this respect shall be fully observed. Where booster pumps are specified to generate the necessary suction pressure to satisfy the NPSH requirements of the downstream main pumps the differential heads of booster and main pumps as given below are not mandatory. The optimum head distribution between booster and main pumps adding up to the total station differential head shall be selected during final design considering the NPSH requirements, overall efficiency and operation. Not mandatory are also the number of stages, the impeller arrangement, the pump speed or whether a single or double suction design will be used. The pumping stations shall be equipped with all means required to ensure that the pumps are only operating between their minimum and maximum allowable continuous operating capacity. Design of the adjacent pipe work and of the pumps shall be such that the allowable forces and moments on the pump nozzles are not exceeded under any circumstances. Pump casing design pressure and flange rating shall be according to the next higher ASME rating above the maximum pressure occurring during operation. This pressure is the maximum suction pressure plus the shut off head of the pump, or the maximum pressure during surges and other transient conditions, whatever is higher. Maximum tank levels and shut off heads of pumps arranged in series (including booster pumps) shall be considered when determining the maximum pressure. Within the following subchapters pump configurations and pump types are listed which have been selected taking into consideration pump characteristic data, such as pump specific speed, estimated suction specific speeds and efficiencies.

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15.4.3 Pumping Station Equipment The pumping equipment must be suitable to meet the following pumping station performance requirements: PSRH: Booster Pumps Station differential heads is 13 bar g at flow rate of 1.2731 m3/s PSRH: Main Pumps Station differential heads is 60 bar g at flow rate of 1.2731 m3/s The following pumps have been selected for the final performance requirements: PSRH Booster Pumps Number of pumps: 2 + 1 Arrangement: parallel Rated flow/pump: 0.6365 m3/s Rated head: 130 meter NPSHA: 8.1 m PSRH Main Pumps Number of pumps: 2 + 1 Arrangement: parallel Rated flow: 0. 6365 m3/s Rated head: 600 meter The NPSHA of the main pumps is generated by the Booster pumps. 15.5 Cooling Water System for the main pump 15.5.1 General Description and Design Requirements This chapter describes the design and the material selection requirements for the cooling system to be provided for the main pumps/motor sets of the Pumping Station of the Pipeline System. a) General Description Product water shall be used as prime cooling medium. It will be taken from the main product water line as shown in the P&IDs. It will be pumped through the primary circuit (1+1 circulation pump) to a double plate heat exchanger which will cool down the water of the secondary circuit. All equipment of the primary circuit including pumps and piping and also the heat exchanger shall be provided for with 100% stand-by capacity. The heated water of the primary circuit will be returned into the same line

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from where it was taken at a location downstream of the take-off point. So the primary circuit is an open circuit. The secondary circuit shall be operated by means of 1+1 circulation pumps to feed the cooling circuits of pump motors. The secondary circuit is a closed circuit. b) Design Requirements The cooling water system capacity shall be designed in such a way that under the worst conditions 110% of the heat load produced by the pump motors in the ultimate stage of the pump units can be dissipated. The heat load shall be determined on basis of all installed pump units in a group, i.e. running units and stand-by units included. The temperature difference between the heat exchanger entering and the heat exchanger leaving water temperature shall be approximately 5 K. c) Cooling Water Quality The water used for the primary circuit is the pumped product water. The water quality requirements for the secondary circuit shall be carefully determined taking into consideration the quality of the untreated water available, the materials of the installed and the connected equipment and the fact that it is a closed circuit. Adequate stationary treatment is to be provided including appropriate agents against fouling and corrosion which allows for continuous dosing into the make-up water flow. 15.5.2 Description of the Cooling Equipment a) Plate Heat Exchanger Water/Water Due to the high requirements on the quality of potable water feeding the primary circuit, in any heat exchanger the occurrence of water contamination needs to be avoided. This shall be accomplished by the use of stainless steel, double-wall plate heat exchangers. This type differs from conventional plate heat exchangers in a way that instead of a single plate between the two media, pairs consisting of two identical plates are stacked on top of each other and welded around the portholes. The design shall be such that in the event of leakage, one of the two media will always appear externally. Should a failure occur, whether it is related to the plates, gaskets or welds, the released fluid must be led to the outside and thus become visible. Leakage shall be detected by means of leakage switch. The plate heat exchanger shall be designed and manufactured in accordance to ASME standards. A filter with automatic flushing system has to be installed in the primary circuit, to protect the heat exchanger against pollution.

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b) Circulation Pumps, Valves, Piping Regarding these components reference is made to Specification M06 Valves for Water Projects, Doc. No. QC10-H-046, Specification M07 Auxiliary Pumps, Doc No. QC10-H- 047, Specification M08 Piping Materials for Stations, Doc. No. QC10-H-048 and the standards and documents referenced therein. c) Membrane Expansion Vessel The expansion vessel shall be built according to DIN 4807-1 to 3 and approved according to DIN 4807-5 with a replaceable membrane, a pressure gauge in the gaseous phase and support construction suitable for fixation in vertical position. d) Piping All cooling pipe above ground shall be hot dip galvanized, external painted and show the direction of flow. e) Instrumentation and Controls The cooling systems shall be equipped with all necessary instrumentation and controls required for the proper operation and shall be provided with a unit control which will be connected to the station control system. Automatic and manual operation shall be possible. Operation of the cooling system shall be a start-up precondition for the pumps. 15.6 Pressure Relief System at Hafar AlBatin Terminal station As a result of the hydraulic calculations a pressure relief system is required at the inlet piping of the Hafar AlBatin Terminal station. The relief valves shall comply with Specification M06 Valves for Water Service, Doc.-No. QC10-H-046.The valves materials shall be carefully selected with respect to suitability and corrosion resistance for the use under the specific operating conditions, especially with respect to the water quality. The following relief valves types are considered technically feasible solutions: a) Pneumatic acting diaphragm surge relief valves including air or nitrogen supply, control system, instrumentation, etc. b) Pilot operated surge relief valves, self actuated or with suitable actuator, including all local control, instrumentation, etc.

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The final number of valves will depend on the selected types which shall be taken from manufacturers standard production range and shall be subject to the approval of the Engineer. In any case one (1) stand-by valve shall be installed. For maintenance and repair purposes a shut-off valve shall be installed up- and downstream of each surge relief valve. The relieved quantities of water shall be piped into Hafar AlBatin Terminal Reservoir. Reference is made to the relevant P&I Diagrams and station layout drawings. According to the preliminary design the following main equipment is required . Location Purpose Number of valves Max. flow rate Set pressure Max. opening pressure above set pressure Min. closing pressure below set pressure Max. overpressure above set pressure Opening time to full capacity Pressure rating Reference drawings : QP10-Q-2170 Typical Relief Shaft and Typical Shed for Pressure Relief System Station inlet Pressure protection of pipeline and station To be optimized (+1 spare unit) 4,080 [m/h] 8 [barg] 1 [barg] 1 [barg] 5 [%] 0.2 [sec] ASME 300#

The spare unit is out of operation only for maintenance or repair.

15.7 Chlorination Equipment 15.7.1 System Description At the inlet of Hafar AlBatin reservoir , a stationary chlorination system based on chlorine gas will be installed in the Chlorination Building. The water shall be treated by means of solution feed chlorination. Water is taken from the mainline and passed through a vacuum generating injector, dissolving Cl2 with water. The chlorine solution of the side stream shall be fed back into the mainline utilising a suitable type of distribution nozzle. The Cl2 side stream water pump will stop in case of no flow in the main water line. The amount of gas to be dissolved shall be delivered by a chlorinator with an automatic feed rate adjuster. Both, chlorination and injection unit shall be arranged with configuration one unit on duty and one standby.

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The chlorine shall be stored in the liquid state in 907 kg drums. The chlorine will be withdrawn in the gaseous phase. All equipment shall be corrosion-resistant to chlorine gas and solution. The injection unit shall operate fully automatic in order to maintain a certain, manually preset value in the range of 0.1 to 0.5 ppm of residual chlorine in the water of the product line for costumer usage. Automatic adjustment in proportion to the water flow rate shall be achieved by means of a flow meter and a Cl2-residual analyzer downstream of the injection point. Both act directly on the system control unit. It shall be possible to run both, the duty and stand-by system, simultaneously in case of a temporary high chlorine concentration of 1 ppm requirement. The injection point shall be located upstream of the storage tanks. The chlorination equipment shall be according to specification M16 Chlorination Equipment QC10-H056 15.7.2 Design Data The design data of the chlorination system are as follows: Design water flow rate: Cl2-Dosage: 1 month storage capacity: No. of 907 kg drums: 3,708 m/h 0.5 ppm 1335 kg (2 chlorine vessel per month) 2 connected plus 4 for storage

Cl2 system design capacity: 1.85 kg/h

15.7.3 Description of Cl2-Equipment Chlorine Drums The liquid chlorine shall be provided by 907 kg drums. The drums shall be supported by a proper balance (electrical load cell) in order to determine the chlorine content. For each dosing line one drum shall be arranged as one duty and two stand-by, i.e. 3 drums are connected in total. The header shall be connected to the gaseous flanges of the drums. Chlorinator (Dosing Unit) The chlorinator shall be also arranged as 1 duty and 1 stand-by, shall be installed in the dosing room and shall be designed to control and meter the rate of flow of chlorine gas under automatic and/or manual control. The capacity of each chlorinator shall be variable between 0.5 to 1.85 kg/hr. All the

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gas beyond the chlorinator shall be in the vacuum condition. The chlorinator shall comply in general to the requirements of DIN 19606. Pumps Two centrifugal pumps (1 duty and 1 stand-by) for each dosing line shall be installed in the water supply pipe work prior to the chlorine injectors. Pump and electric motor driver shall be skid mounted. Pumps shall be in accordance to the specifications M07 Auxiliary pumps. Injector The chlorine injector shall be operated by the pressure and flow delivered by the pump. The injector shall operate by water passing through the centre orifice at high velocity, producing a vacuum at the side port. Distribution Nozzle The injection point into the main line a distribution nozzle of proper design shall be installed ensuring a fast distribution of solution in the mainline product water. 15.7.4 Neutralization The chlorination treatment building shall include neutralization system for chlorine gas leakage. The system shall consist of air blowers to withdraw the Cl2 gas leakage from both the storage room and equipment room to neutralization tower. In addition the system shall include Soda Ash tank and recalculation pump. The neutralization system shall be in accordance to the SWCC specification M16. 15.7.5 Mobile Chlorination Unit For the use at different locations one (1) mobile chlorination unit, complete skid mounted in a container including a trailer shall be provided. The mobile unit shall contain chlorine gas storage bottles, the dosing train for automatic/manual injection, the electrical and control cabinet, as well as all required connection hoses, cables, etc. The mobile unit shall be designed for a standard dosing rate of 0-0.5 ppm and shall have a capacity of 0.5 kg/h.

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15.8 Fuel Supply For the emergency generator (EMG) and for diesel driven firefighting pump, day fuel tanks are required. The day fuel tanks shall be re-filled out of underground diesel storage tanks which shall be buried near to the generator room. The following requirements for underground diesel storage tanks shall apply:

The volume of the underground diesel storage tank shall be sufficient for three (3) days operation of the generator at full capacity, but minimum shall be 5 m3. Design, manufacture, installation and testing of the storage tanks shall be in accordance with EN 12285 P1 or equivalent. Tanks shall be equipped with a submerged pump, which can be manually switched on/off from the EMG control room and with automatic on/off switching when the supplied day tank reaches low/high level.

Tanks shall be within a concrete shaft. Dome and filling shall be located in roofed over positions. In addition to proper outside coating the tank bottom shall be internally protected against corrosion by a suitable synthetic coating covering at least 25% of the tank internal surface. Local level indicator shall be provided at a position to be easily read during re-filling by tanker truck. High/low level switches shall be installed for monitoring and alarm indication. Tanks shall be further equipped with: o Vent pipe with vermin screen. o Outlet pipe and connection pipe with valves to the day fuel tank. o Filling pipe work including fittings, isolation valve, and end cap of non-sparking material and inscription for fuel type o Drain pipe with valve and end cap o Earthing.

Provisions shall be made at the filling point to avoid any spilled fuel may get into the soil. The fuel pump control system, including the level and leak detection monitoring of the underground storage tank shall be installed in the EMG and/or control room. Selected status and alarm signals shall be made available for remote indication in the station control room.

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The pumps shall be protected by adequate means to prevent them from running dry and from running against closed valve.

15.9 Fire Protection To protect lives and properties fixed and portable fire fighting systems and equipment shall be installed in the pumping station of the pipeline system. The technical requirements for the fire fighting equipment are laid down in Specification M14 Fire Fighting Equipment, Doc. No. QC10-H-054. Reference is also made to the following specifications: M06 Valves for Water Service, Doc. No. QC10-H-046 M07 Auxiliary Pumps, Doc. No. QC10-H-047 M08 Piping Material for Stations, Doc. No. QC10-H-048 M09 Steel Tanks , Doc. No. QC10-H-049 15.9.1 Fire Water Hydrant Systems A fire water hydrant system shall be installed at PSRH and Hafar AlBatin station. In general a fire hydrant system shall consist of an underground ring system in accordance with NFPA 24.The ring mains shall be subdivided by hand operated isolation valves which shall be placed in such a way that when a section is shut off for repair or maintenance the other parts of the main ring will remain in service. Hydrants shall be spaced that fire water can be delivered to all buildings including their roofs and to all exterior structures. Spacing shall not exceed 50 m. The fire water main ring shall also supply the water spray fixed systems as specified below. For determination of the required water quantities a minimum duration of fire attack of 30 min. shall be taken into account. At Ras AlZaur Pumping Station the hydrant ring system shall be connected to the Ras AlZaur AlRiyadh WTS system. At Hafar AlBatin Termianl station and other reservoirs , in order to supply the necessary quantities for the new water based fire protection systems (hydrant systems, water spray systems), the installation of a fire pump station is required, consisting of one electrically and one diesel engine driven fire pump unit in the relevant section of the emergency generator building. A connection from the station water supply system will be made which shall keep the system under pressure. Water supply shall be effected directly from the station suction main headers. The fire water

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pumps shall be fully instrumented and automatically controlled. The diesel engine shall be equipped with a day tank of adequate size. 15.9.2 FM-200 Fire Suppression Systems The electrical buildings at all stations shall be equipped with FM-200 fire suppression systems according to NFPA standard 2001 to protect the control room, the switchgear room, the battery room, the motor starter room, the instrumentation room and the cable cellars. Each system shall be connected to the fire alarm system in the corresponding station. 15.9.3 Dry Chemical Extinguishing System The emergency generator room shall be equipped with dry chemical fire extinguishing system in accordance with NFPA 17. 15.9.4 Portable and Wheel Mounted Extinguishers Two each wheeled ABC dry powder extinguishers 50 kg shall be provided at all pump buildings. Portable 12 kg multipurpose powder extinguishers in sufficient number shall be foreseen at Hafar AlBatin workshop, car shed, stores, fuel tank filling points, building corridors, etc. Portable Carbon-dioxide 6 kg extinguishers shall be provided for : LV and MV switchgear rooms Starter equipment room Any rooms housing electronic or data processing equipment Battery room Approximate spacing: within 10 m of the special hazard but at least one extinguisher at the entrance to the protected area. Portable extinguishers shall comply with NFPA 10. All extinguishers shall be placed where they can be easily seen and where they are not endangered to be hidden, blocked or damaged. Marking and signs shall be used to direct attention to their locations. 15.10 Air Conditioning and Ventilation 15.10.1 General Requirements, Room Conditions Depending on the individual design of the various stations of the project, different buildings are foreseen. The required buildings are defined at Chapter (11) station buildings. The buildings and

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rooms shall be equipped with air conditioning and ventilation systems, which shall provide the conditions as specified in the following table as a minimum:
Internal Conditions Summer Room Types Electrical Building Office Control Room Temperature [C] 24 +/-2K 24 +/-2K 24 +/-2K Instrument Room < 30 MV Switchgear Room < 30 Motor Starter Room < 30 LV & UPS Room Room temperature < 5 C above ambient temperature Emergency Generator Room Kitchen Lounge Meeting Room Lavatory Room Battery Room Cable Cellar not controlled 50 +/-10 not controlled not controlled not controlled 50 +/-10 not controlled not controlled < 80 >5 < 80 < 80 >5 < 80 < 80 >5 < 80 Humidity [%] 50 +/-10 50 +/-10 50 +/-10 Winter Temperature [C] 21 +/-2K 21 +/-2K 21 +/-2K Humidity [%] 50 +/-10 50 +/-10 50 +/-10 Minimum Air Changes per hour 4 4 Dependent on heat emission into room Dependent on heat emission into room Dependent on heat emission into room Dependent on heat emission into room Dependent on heat emission into room 4 6 6 8 1 Dependent on heat emission into room 2
Maximum Noise Level by HVAC equipment [dB(A)]

40 40 45

65

65

65

110

27 +/-2K 24 +/-2K 27 +/-2K > 16

21 +/-2K 21 +/-2K 23 +/-2K > 16

60 40 45 45 65

Room temperature < 5 C above ambient temperature

Room temperature < 5 C above ambient temperature HVAC Room Corridor Entrance Staircase 27 +/-2K not controlled 21 +/-2K not controlled

80

65

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2 65

Store

27 +/-2K

not controlled

21 +/-2K

Pump House

Room temperature < 5 C above ambient temperature

Water quality monitoring building

26 +/- 4 K

Dependent on heat emission into room Dependent on heat emission into room 6

95

65

Security Guard Building Combined Mechanical / Electrical Workshop Mechanical Workshop room

24 +/-2K

not controlled

21 +/-2K

not controlled

45

24 +/-2K

50 +/-5

21 +/-2K

50 +/-5

6 Dependent on heat emission into room 4 6 Dependent on heat emission into room 6

65

24 +/-2K Storage Room Office Lavatory Room 24 +/-2K 27

not controlled 50 +/-5 not controlled

21 +/-2K 21 +/-2K 24

not controlled 50 +/-5 not controlled

65 40 45

25 E-Room Electrical Workshop Room Workshop Room for Comm. Workshop Room for Instrum. Prayer room 24 +/-2K

50 +/- 5

20

50 +/- 5

65

50 +/-5

21 +/-2K

50 +/-5

65

24 +/-2K

50 +/-5

21 +/-2K

50 +/-5

65

24 +/-2K

50 +/-5

21 +/-2K

50 +/-5

65

24 +/-2K

50 +/-5

21 +/-2K

50 +/-5

45

Electrical Storage Room

24 +/-2K

50 +/-5

21 +/-2K

50 +/-5

Dependent on heat emission into room

65

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4 6 4 Dependent on heat emission into room Dependent on heat emission into room 6 6 Dependent on heat emission into room 4 Refer to subchapter 15.10.4 40 40 60

24 +/-2K 24 +/-2K 24 +/-2K

50 +/-5 50 +/-5 50 +/-5

21 +/-2K 21 +/-2K 21 +/-2K

Kitchen Staff Building

25

not controlled

20

not controlled

60

Kitchen

25

not controlled not controlled 50 +/-5

20

not controlled not controlled 50 +/-5

60

Lavatory Room Living Room

27 24 +/-2K

24 22 +/-2K

45 40

Service building

Room temperature < 5 C above ambient temperature

95

Chlorination Building Control room Cl2 dosing room / Cl2 storage room 24 <27 Not controlled Not controlled 21 <20 Not controlled Not controlled 40 80

For rooms which are not covered in the above list, the condition of similar room with equal application shall be considered. The following air velocities shall not be exceeded: Equipment Outside air inlet Outside air outlet Dry filters (face velocity) Bag filters (face velocity) Coils (free velocity Main ducts) Main Ducts Branch Ducts Velocity range [m/s] <3 <7 1.5 2.8 1.5 2.5 2.0 2.8 7.0 9.0 3.0 - 7.0

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Further requirements: - All equipment shall comply with Specification M15 HVAC Equipment, Doc.No. QC10-H-055. - All equipment shall be designed for high humidity and saline environment. - Air conditioning loads shall include all electric or mechanical equipment losses, lightning, fan motor losses, personnel, solar and infiltration air gains. - Heating loads, in general, shall be based upon night time conditions with no credit for equipment or personal loads. -The supply air temperature to rooms and areas to be air-conditioned shall not be less than 10C below room temperature. Specific requirements for the different HVAC systems are given in the following subchapters. 15.10.2 Electrical Building The air conditioning system for the electrical buildings shall be provided with two independent working air handling units, one of them on duty, the other one providing 100 % standby. Each system is fully equipped with fans, sand trap louvers, a filter system, refrigeration and heating set (DX), heat exchanger, humidifier and sound attenuators. The ductwork shall be equipped with all necessary equipment to guarantee a silent and proper air distribution such as to hold a room temperature and/or the room humidity within the tolerance as described above. The rooms within the building shall have a slight positive pressure to avoid the ingress of sand and dust. The pressurization shall be achieved by a 5% imbalance between the supply and return/exhaust air quantities. However, care shall be taken that the pressure inside is not too high to prevent easy opening of the doors (30 Pa). Outside air is mixed with a part of return air coming from the return air ventilation in the mixing chamber and after that the mixing air is cleaned and cooled by a bag type filter and air cooler. The supply air ventilator transports the cleaned and cooled supply air through the heat insulated ductwork system into the rooms. Exhaust air, which is not be used for mixing with the outside air get released to the outside. Specific fire sections have to be provided with fire release dampers. From the battery room no return air shall be taken back into the building, which means there shall be 100 % exhaust. The room ventilation shall be designed with a slight under pressure in order that no explosive gas can escape in to other occupied rooms. If lead batteries are used then the ventilation equipment shall be explosion proof. The supply air of the battery rooms shall enter the room at a low level. 50 % of the exhaust air shall leave at a low level and the other 50 % at high level of the battery

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room (according to EN 50272-2). From kitchens, lavatories and ablutions no return air shall be taken back into the building, which means there shall be 100 % exhaust. Supply air is entering from the corridor or adjacent rooms. The exhaust air shall be discharged by roof fans. The cable cellar and generator room shall have an own ventilation system. 15.10.3 Pump House Booster and Main pump house shall be equipped with several single fan/filter units (at least one for each motor/pump-unit) to be mounted to the inner side of the building wall. Moved by its higher pressure within the building the heated up exhaust air will be discharged via motor operated multi leaf dampers mounted in the opposite wall to outdoors. The building shall be slightly pressurized to prevent the ingress of sand and dust, however, care shall be taken that the pressure inside is not too high to prevent easy opening of the doors. In order to provide redundancy each unit shall be designed in such a way that in case of a failure of one unit the remaining units are able to cover the necessary design air flow. The maximum noise level outside the building shall not be exceeded (sound attenuators.) 15.10.4 Chlorination Building at Hafar AlBatin Terminal The chlorination building shall be provided with two split units one of them on duty, the other one providing 100 % standby. Each system is fully equipped with a fan, a filter system, heat exchanger, refrigeration and heating set and sound attenuators. Both systems shall be equipped with an automatic changeover panel. Specific fire sections have to be provided with fire release dampers. In normal operation the unit will ventilate the CL2 Storage and Dosing Room with an air exchange rate of 8 per hour. No return air will be taken back into the building. In case of an emergency (major leakage of chlorine gas) the air exchange rate shall be increased to 15 per hour through a special scrubbing system. In this case the normal ventilation system shall be stopped. 15.10.5 Security Guard building The building shall be provided with one air-conditioning window unit.

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15.10.6 Combined Workshop Building The air conditioning system for this building shall be provided with split units for the rooms inside the workshop building. The HVAC system of this building shall be designed according HVAC description Electrical Building within this chapter. Each system is fully equipped with a fan, a filter system and sound attenuators. 15.11.7 Electrical Building for reservoir stations The building shall be provided with two air-conditioning split units. 15.10.8 Water Quality Monitoring Building The building shall be provided with one air-conditioning split units. 15.10.9 Staff Building The building shall be provided with two air-conditioning split units. 15.11 Cranes 15.11.1 General For material handling, for maintenance purposes and to allow for disassembly/assembly of equipment requiring overhaul or repair cranes shall be installed within various buildings of the different pumping stations. The lifting capacity of the cranes shall be such that the heaviest object, which cannot be dismantled further in situ, can be safely lifted and transported. All cranes shall be overhead travelling cranes. The cranes may not be used for construction purposes. Exact capacity shall be verified based on the selected equipment and adapted accordingly. Cranes shall comply with Specification M13 Cranes and Hoists, document no. QC10-H-053. 15.11.2 Summary of cranes Cranes shall be installed in the following buildings:

Booster Pump House for 100 kN Main Pump House 200 kN Chlorination Building 20 kN

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Combined Workshop Building at Hafar AlBatin 80 kN

15.12 Service Air For Booster and Main Pump buildings and combined workshop a compressed air system shall be installed for maintenance and cleaning purposes. Each system shall consist of Industrial type workshop air compressor 500 l/min., 10 bar Air receiver approx. 100 lit Inlet filter Outlet filter, water separator Instrumentation All internal controls and cabling Noise protection cabinet with integrated unit control panel Air distribution piping with condensate traps, manual valves and outlet with coupling close to each pump unit Air hoses with couplings on both ends.

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CHAPTER (16) POWER SUPPLY AND ELECTRICAL WORKS


16.1 Power Supply Configuration This combined pumping station is located in Ras Al Zaur Riyadh Pumping Station and includes reserved space for the pumping station equipment for Ras AlZaur - Hafar Al Batin Pipeline as well. The electrical power supply will be provided from the pump station facilities of medium voltage switch gear. Two (2) separate 13.8 kV feeder cable circuits shall be supplied and installed up to the 13.8 kV medium voltage switchgear of the electrical building of the pumping station. If each feeder cable circuit shall be suitable for the full station load. All provisions (current transformers, converters, relays, pilot cables, etc.) for the differential protection of the transformers shall be provided as part of the contract, including the necessary relay coordination study and protective schedule calculations. An estimated power requirement of this pumping station is approximately 13,666 kVA. Power supply to pump station auxiliary systems shall be provided from the auxiliary transformer. Given below is the table-1 which gives power source for the filling station , line valve station these data indicative values , and contractor shall conduct his own study to verify ammend neccessary.
Sr. 1 2 3 4 5 6 7 8 9 10 Description Pumping Station PSRH Line Valve Station LV-1 NUIRIAH Station Ibn Hethlain Station & Line Valve-2 Line Valve Station LV-3 Qaryat Al-Oliyah Station Sairiah Station Line Valve Station-4 Line Valve Station-5 Load (Kw) 12,300 0.5 50 15 0.5 0.5 20 15 0.5 0.5 Electrical Power Source 13.8KV from RasAlZaur-AlRiyadh WTS electrical building. Solar Cell 13.8 KV from SEC grid 13.8 KV from SEC grid LV From Ibn Hethlain Station Solar Cell 13.8 KV from SEC grid 13.8 KV from SEC grid Solar Cell Solar Cell Distance (Meters) 100 500 -100 100 200 200 200 500 --

where

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500 500 600 200 700

Sadawi Station Line Valve Station-6 Al-Qaysumah Station Line Valve-7 Hafar Al

13.8 KV from SEC grid Solar Cell 13.8 KV from SEC grid From AlQaysumah station 13.8 KV from SEC grid

Reservoir

16.2 Medium Voltage Switchgears The 13.8 kV medium voltage switchgear of the pumping station shall be located in the MV room extension of the Electrical Building. The switchgear shall contain in general two (2) bus bar sections, each supplied via one (1) feeder breaker and connected with normally open bus-tie breaker. Each feeder circuit is to be designed for the total station load connected to both bus bar sections. The number of feeders and the general layout is shown in the Medium Voltage Single Line Diagrams. The shown short circuit capacities in these drawings are indicative only and must be confirmed based on short circuit study. 16.3 Electrical Motors 16.3.1 General The motor size indicated in the various documents and drawings are preliminary only, and shall be verified by the Contractor during final design on basis of the actual survey, the hydraulic calculation and the final number, type and size of the selected pumps.

16.3.2 Pump Motors The main pumps for pumping station PSRH shall be driven by fixed speed 13.8 kV medium voltage motors, each with the following preliminary rated motor power: PSRH Booster Pumps: 1100 kW PSRH Main Pumps: 5000 kW

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Asynchronous squirrel cage induction motors with air/water heat exchanger shall be used for main pump cooling. Air fans shall be used for booster pump cooling. The proposed number of pump units is shown in the P&I diagrams. 16.4 Motor Starter Equipment Each medium voltage motor for main pump shall have compact motor starting equipment, consisting of:

One (1) dry type autotransformer By-pass contactor or circuit breaker Star-point contactor or circuit breaker Control, protection and monitoring devices

All together shall be factory assembled in steel sheet cabinets and installed in the separate MV starter room within the relevant Electrical Building. With the use of motor starters the starting current shall be limited to maximum 2.5 times the rated motor current. The starters must be designed for the application, considering the actual network data, the pump characteristic and the start-up procedure. The Contractor shall be responsible to perform the necessary coordination between the equipment suppliers. For low voltage motors the starting method must be defined separately, either DOL, star-delta starters or soft starters shall be provided, depending on the application, the motor size and the network conditions. 16.5 Low Voltage Transformers The initial pumping station at Ras Al Zaur will be supplied by 13.8KV medium voltage via power transformers supplied and installed by contractor, the following transformer data are assumed, subject to confirmation. Station Auxiliaries Transformer data 13.8KV/0.4KV 300 KVA Oil Sealed Each transformer shall be designed for the full station load to serve all auxiliaries required. The 400V secondary voltage will be connected via XLPE cable circuits Number 2

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16.6 Low Voltage Switchboards 16.6.1 General Requirements The power supply for the low voltage consumers within pumping station shall be performed with the use of the following type of low voltage switchboards: a)Auxiliary service board (ASB) / panel A consists of 2 bus-bar section with two (2) bus-tie breakers with automatic change over logic given in the table of drawing no. QP20-T-5100. b) Auxiliary service board (ASB) / panel B for all essential loads consists of 3 incomers without Bus Tie with automatic change over logic given in the table of drawing no. QP20-T-5100.

16.6.2 Principle Configuration The principle configuration of the low voltage switchboards required for each station, including basic definition of consumers connected to each type of switchboard shall include lighting and auxiliaries such as ventilation, lifting equipment and control equipment. 16.7 UPS Equipment For a continuous and uninterrupted power supply of the selected instrumentation, control and communication equipment the installation of redundant UPS with battery back-up and 230 VAC, 60 Hz output power supply and distribution board shall be specified for pumping station. The UPSs will be installed in the LV room of the respective electrical/control building, for the batteries a separate battery room is foreseen at each location. For the generation of the 24 V DC and all other lower voltage levels, which may required for the various control and communication devices, separate power supply units located in the control cabinets are to be provided. These power supply units shall be fed from the UPS by 230 V AC. 16.8 Emergency Generators

For power supply of the essential station consumers, connected to the ASB of each individual station, a diesel driven low voltage emergency generator (EMG) unit is recommended, especially for the stations which are located along the pipeline route.

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For the pumping station these EMG units together with all auxiliary facilities shall be placed in separate EMG building, for the Smaller stations the incorporation in the small Electrical buildings is possible. The detailed power demand calculation for all stations Is part of the final design .The proposed size of new EMG units for the pumping station shall be 50 KW ,subject to calculation and confirmation during final design. The EMG units shall be designed to supply the full load of the consumers connected to the ASB. In case of total power failure at the PCB level the automatic start and switch-over is foreseen , with synchronization and switch over to normal supply without any interruption if the power returns. For the technical requirement of the EMG reference is made to the specification E08 Emergency Diesel Generators , Doc No QC10-H-088 with the corresponding data sheets . 16.9 Cabling The connection of the entire electrical equipment with the power supply source shall be generally done by cables laid either in the cable cellar or in cable ducts on trays, in cable conduits and for auxiliary cable routes also in direct buried trenches. The same applies in general to the entire instrumentation and control equipment. The necessary field junction boxes, required for collection of individual sensor or signal cables on machinery or package units are part of the cabling works. Direct buried electrical power and control cables shall be avoided. Cable conduits with pulling shafts shall be foreseen for process related equipment cabling. Auxiliary cables (e.g. for outdoor lighting) shall be installed direct buried. In general, conduits must be used for all road crossings or pipe crossings. 16.10 Earthing and Lightning Protection For the entire station areas an equi-potentially meshed grounding network shall be specified. Each new building and high structure within the stations shall have lightning protection facilities. For stations in hilly areas respectively rocky locations, it is required to install special earth pits with filling of conductive concrete in accordance with the approved specification. 16.11 Outdoor Lighting The outdoor lighting for each station shall contain the following subsystems: Road lighting,

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Area lighting including structures ,valve and flow meter shafts ,platforms and other working places of areas outside of buildings, Fence lighting. For the technical requirement of outdoor lighting reference is made to specification E15 outdoor Lighting ,Doc NO.QC10-H-095.for fence lighting of the pumping station and Hafar AlBatin Terminal ,the requirement of the HCISS standards (security and safety Directives) must be fulfilled . For the new stations areas at the existing RWC stations and at the strategic reservoir stations the existing lighting must be partly removed to allow stations extension .the re-installation and incorporation into the existing power supply and control circuits is required a as part of the contract . For such existing stations ,as well as for the Hafar AlBatin Terminal station the outdoor lighting must be co-ordinate with the existing installations in order to provide uniform type and layout of lighting fixtures 16.12 General Requirements for Power Supply Systems The following general requirements shall be considered for the final design of the power supply systems, in addition to the technical specifications: a) The 13.8 kV network within the SWCC stations shall have preferably low resistance earthing. This shall be coordinated with SWCC and Ras AlZaur Riyadh WTS and depending on the final agreement the earthing grid including all protective devices have to be designed and installed accordingly. If necessary, separate earthing transformers must be provided and a separate earthing grid will have to be introduced and connected to the neutral of these earthing transformers. b) All MV motors above 2,000 kW rated output power shall have starting transformer equipment. c) All MV motors between 2,000 kW to 5,000 kW rated output power shall have economical differential protection in line with approved specification. d) The selected short circuit rating of bus bars must be based on the detailed short circuit study calculations. f) Electrical energy metering shall be provided at the 13.8 kV incoming lines at the SWCC end at each station. g) In general for all stations with high inductive loads the necessary power factor compensation equipment shall be provided if the overall power factor of the installed equipment is lower than 0.90 during normal operations. The requirements of SEC shall be obtained and considered.

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i) Electrical power cables shall have fire protection paint at entry and exit points of cable ducts and cable cellars within buildings, at the recommended distance along the length in cable trays. Approved paint material shall be used in accordance with SWCC standard specification. 16.13 Power Supply for Remote Stations For remote stations along the transmission pipeline route, e.g. Line Valve Stations or CPS T/R Stations the use of permanent SEC network supply is the preferred solution. However, depending on location of such stations it may not be possible to provide reasonable connections to the local power supply network. As a general rule it shall be noted that if within a distance of approx. 5 km no local MV/LV network is available, the use of alternative power supply sources is admissible. In such case the use of Solar panel units will be the alternative. One of the most important requirement for such remote stations is to optimize the installed equipment, to have as less as possible power demand. Normally the power demand for the Line Valve Stations is very low, because only instrumentation, control and communication equipment must be supplied. For the CPS T/R Stations the load demand is higher, but due to the high quality of pipe coating and with proper selection of the T/R station spacing, also the load demand can be kept less. In any case the installation of suitable storage batteries is required to provide uninterrupted power supply for such stations in case the prime feeder is out of operation As part of the contract the most reasonable solution shall be investigated and proposed. The finally selected power supply configuration is subject to approval. For technical requirements of solar panel units reference is made to the Specification E10 Solar Panel Units, Doc. No. QC10-H-090. For the installation of the batteries, as well as the control and distribution cabinets the equipment shall be installed within ventilated underground shafts. For technical requirements of the passive cooling shelters reference is made to the Specification E17 Line Valve Station Containers, Doc. No. QC10-H-097. In case the Stations will receive permanent electrical power, the switchboard and control cabinets shall be also installed within the above mentioned shelters, or in the below ground shafts.

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16.14 Pump Station Power Calculations Booster Pumps No of pumps Working pumps Stand by pumps Total Flow q pump hm efficiency Required Power Motor power Total Power for Pumps Main Pumps No of pumps Working pumps Stand by pumps Total Flow q pump hm efficiency Required Power Motor power Total Power

3 2 1 1.2731 0.6365 130 0.88 922 1,100

m3/s m3/s m KW KW

3 2 1 1.2731 0.6365 600 0.88 4,258 5,000

m3/s m3/s m KW KW

2,200 KW KW

10,000 KW

Auxiliary Power 100 Total Station power requirements Power Factor Total Power Demand

12,300 KW 0.9 13,666 KVA

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CHAPTER (17) INSTRUMENTATION AND CONTROL


17.1 General The pipeline systems with all relevant stations are to be designed for remote control and monitoring from the Water Pipeline Control Center (WPCC) at Ras AlZaur Pumping Station (PSRH), with local monitor & control system for line valve station connecting to the master control center in the (WPCC). The system will consist of following main components : a) PCC Pipeline Control Center: - Monitoring and control of the main process of the pipeline, the PCC itself and all relevant systems at any station , including the monitoring of the communication system. - Optimization , pipline management and leak detection system. - Safety functions b) SCS Station Control System at the Pumping Station , Reservoir stations and terminal station: - Station local control (LCC) with HMI for monitoring and control of the process within the station (eg. STATCON , ESD , UNCONs) - STATCON with HMI for monitoring and control of the process within the stations and all relevant UNCONs. - UNCONs with HMI for local monitoring and control of the appropriate subsystems. - ESD system - Safety functions (SSS) LVCS (RTU) Station Control at the line valve stations: - RTU with HMI for monitoring of the entire valve station.

c)

The following basic control modes for the operation of the different parts of station equipment shall be possible:

Central automatic / manual operation from WPCC. Station automatic / manual operation from Station Control System (SCS). Unit manual mode from the SCS equipment provided at the local station control room from the unit of the particular station.

The instrumentation and control system shall be designed to allow these basic modes of operation, all the necessary hardware and software, including the human-machine interface devices are part of the scope of work. For detailed requirements reference is made to the following standard specifications: S01 Design and Construction of I&C Systems , Doc. No. QC10-H-121 S04 Distribution Control System , Doc. No. QC10-H-124

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S05 Central Control Hardware and Standard Software , Doc. No. QC10-H-125 S06 SCADA and Plant Software , Doc. No. QC10-H-126 The main objective of the control and monitoring system is to achieve safe and reliable transport of water, with the support of state-of-the-art control and monitoring facilities. The control system shall be designed in such a way that the responsibility for safety will be as much as possible transferred from the operating personnel to the mechanical and/or electronic equipment. Furthermore the operation must be clearly structured, simple and economic to reduce the number of highly qualified personnel, required to operate the System, to a minimum. The Station Control System for a Line Valve Station shall be combined (interconnected) with the Station Control System of the nearest Reservoir Station, Water Tower Station, Filling Station, etc. 17.2 Overall Functions 17.2.1 General The dominating overall function of the instrumentation and control equipment is to guarantee a continuous water flow throughout the Pipeline System. This means that the technological process for operating the pipeline has to be considered as one entire unit over the complete distance, from the supply tank/reservoirs up to the end point tanks/reservoirs, including pumping station, line valve stations and intermediate reservoir stations. Therefore the objective of the pipeline control centre is not only reduced to monitoring and control of the several stations, it also has to handle the following overall function: Start up / shut down of the pipeline as a sequence of start up / shut down / flow increase / flow decrease sequence of the several stations and units. Monitoring and control of the pipeline flow rate depending on the levels of the tanks and reservoirs. Leak detection and leak location. Operation optimization. Station Safety System (SSS) functions. Emergency shut down (ESD) functions. Cathodic protection system monitoring Electrical power supply and power consumption monitoring The main control functions, regulation loops and sequences for the pipelines and the stations are described in the chapter 5 Hydraulics and Operation of this general specification.All other control functions, regulation loops and sequences for the main process or any auxiliary system and/or package unit, which are not described in detail, but necessary to fulfill the

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overall

philosophy

of central control and remote monitoring, shall form part of the

instrumentation and control works.

17.2.1 Station Safety System (SSS) Function Depending on hydraulic requirements station safety systems (SSS) shall be implemented to bring the pipeline and/or a station automatically into a safe waiting position in case of any abnormal conditions or loss of telecommunication. For detalies reference is made to chapter 5 Hydraulics and Operation of this general specification and the requirements define in the hydraulic calculations, which must be performed as part of the contract. 17.2.2 Emergency Shut Down (ESD) Functions An ESD can only be initialized by emergency push buttons, which are installed close to the pumps, at the operator working place of the SCS and at defined escape way location within pump houses. All these ESD push buttons shall be connected hardwired to the MV motor circuit breakers of the booster and main pumps. In case an ESD push button of a single pump is activated the respective pump has to stop without any time delay. All other necessary steps and sequences shall be handled by the Station/Unit Control and if necessary also by the operator at WPCC. In case the ESD push button for the station is activated for the pump station, all pumps have to stop in a defined cascade with an adjustable time. The station subsystems shall be shut down by the Station Control. With a shut down of one of the stations along the pipeline a pipeline shut down sequence shall be initialized by the Main control system at WPCC. For the implementation of the ESD functions a separate ESD panel shall be provided at each station with interface to the Station/Unit Control System. 17.3 System Topology The overall system comprises the following main components: a) WPCC - Water Pipeline Control Centre b) SCS - Station Control Systems for Pumping Station c) RTU Remote Terminal Unit for Reservoir Stations and Valve Chambers.

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17.4

Water Pipeline Control Centre The entire system shall be controlled and monitored from the WPCC. The WPCC shall consist at least of the following subsystems:

Interface to the existing Ras Al-Zaur - AlRiyadh MIMIC Screen as central display for
all Pipeline Systems, inclusive video control unit (server) and software.

Operator Station. Engineering Station. Redundant Database Server for central part of the SCADA software. Alarm Printer and Report Printer.
Network components

Operating Main PLC for controlling the pumping station and pipeline network. Hot Standby PLC. Router for redundant communication link using Public Switching Telephone Network
(PSTN).

Use the existing GPS server of Ras AlZaur AlRiyadh for synchronization of all control
system of Ras AlZaur-Hafar AlBatin. All process specific and non process specific displays shall be available for the Dynamic MIMIC Screen as well as for the Operator/Engineering Stations. This includes at least the following displays: Level 1 Displays

Common Overview Display of the process of all pipeline systems within one or more
displays.

All Common Non Process Displays (e.g. Index, Fire and Gas Alarms, Communication
System) for the entire system Level 2 Displays

All Pipeline System Overview Displays of the process for each separate pumping station. All Pipeline Non Process Displays (e.g. Index, Fire and Gas Alarms) for each separate

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pumping station. Level 3 Displays

All Station Overview Displays of the process for each station within a pipeline system. All Station Non Process Displays for each separate pumping station including
electrical systems. Level 4 Displays

All Unit Displays of a sub system process (e.g. for a Pump Unit, etc.) All Component Displays for a individual equipment (e.g. Valve, etc.)

17.5
17.5.1

Station Control Systems (SCS)


Station Control System at Pumping Station (PSRH)

a) Station Control System including:

One (1) Operator / One (1) Engineering working place for monitoring and control of the
station, two (2) TFT 21 monitors, two network interfaces for connection to the redundant station LAN,incl. necessary Software

One (1) Line printer (monochrome, A4) with two network interfaces Redundant and independent station LANs (switches) with connections to the
communication system (redundant router for the connection to the transmission system and the back-up communication link) b) Redundant STATCON for the station overall functions including all required network interfaces for connection to the redundant LAN. c) UNCON, unit control systems of package units or subsystems (station utility systems), including Local Control Panels, which are connected to the STATCON via station plant bus system, such as:

UNCON for each pump Dual UNCON for the cooling water systems UNCON for the fire detection system UNCON for the MV/LV switchgear

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d) Sub-systems status to be transferred to the STATCON, such as:

Cathodic Protection Electrical Power Supply


e) Several additional plant bus systems, as required f) Marshalling racks with connections to the power supply, the cathodic protection, the field I/Os and/or field buses, F&G equipment and over voltage protection g) Remote I/Os as required h) Communication interfaces to third party equipment 17.5.2 Reservoirs ,Water towers and Filling stations The Station Control System of shall at least consist of: a) Station Control system including: Redundant and independent station LANs (switches) with connections to the communication system b) Redundant STATCON for the station overall function including all required network interfaces for connection to the redundant station LAN. d) Sub-systems status to be transferred to the STATCON, such as:

Cathodic Protection Electrical Power Supply


e) Marshalling racks with connections to the power supply, the cathodic protection, the field I/Os and/or field buses, fire detection equipment and over voltage protection f) Remote I/Os, as required g) Communication interfaces to third party equipment 17.5.3 Hafar Albatin Terminal Station The Station Control System of Hafar AlBatin terminal shall at least consist of: a) Station Control System including:

One (1) Operator working place for monitoring and control of the independent station, Two (2) TFT 21 monitors, two network interfaces for connection to the redundant station LAN, incl. necessary Software.

One (1) Line printer (monochrome, A4) with two network interfaces.

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Redundant and independent station LANs (switches) with connections to the communication system (redundant router for the connection to the transmission system and the back-up communication link).

b) Redundant STATCON for the station overall function including all required network interfaces for connection to the redundant station LAN c) UNCON, unit control systems of package units or subsystems (station utility systems), including Local Control Panels, which are connected to station plant bus system:

UNCON for the chlorination system including water quality monitoring UNCON for the fire detection system
d) Sub-systems status to be transferred to the STATCON, such as:

Cathodic Protection Electrical Power Supply


e) Several additional plant bus systems, as required f) Marshalling racks with connections to the power supply, the cathodic protection, the field I/Os and/or field buses, F&G equipment and over voltage protection g) Remote I/Os, as required h) Communication interfaces to third party equipment 17.5.4 Line Valve Stations The Station Control System of the line valve stations (LV1 to LV7) shall at least consist of: a) Redundant STATCON for the gathering station process data with Local Monitoring Panel and two network interface connection to the communication system. b) Several additional plant bus systems c) Marshalling racks with connections to the power supply, the cathodic protection, the field I/Os and/or field buses, fire detection equipment and over voltage protection.

17.6

Field Instrumentation

17.6.1 General Requirements The field instrumentation is required for continuous measurement and monitoring of the process equipments during all possible modes of operation. Electrical remote transmitters are required, additionally; local indication at the source of measurement is to be foreseen.

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The main instrumentation, including the main control and regulation loops, are shown in the System Flow Diagrams and in the basic P&I Diagrams. For detailed technical equipments reference is made to the following specifications: S01 Design and Construction of I&C Systems , Doc. No. QC10-H-121 S02 Field Instrumentation , Doc. No. QC10-H-122 S03 Installation and Start-up of Field Instrumentation , Doc. No. QC10-H-123 In general it is in the contractors responsibility to design and select the field instrumentation depending on the required purpose , the application and environmental conditions in line with these specifications. The field instrumentation for the main process pipeline equipment is necessary for the following major tasks: a) Pipeline monitoring and control Flow, pressure and level measurements are the main parameters that are used for the pipeline control and regulation loops as shown in the P&IDs. b) Leak detection The same parameters as listed under a above shall be used, additionally the water temperature is required for this purpose. If necessary due to accuracy requirements, separate instrumentation shall be provided for leak detection purpose. c) Water quality monitoring At Hafar AlBatin Terminal station, the delivered water quality shall be monitored. The parameters residual chlorine, conductivity, PH value and temperature shall be measured. The residual chlorine value shall be used for the control of the chlorine injection as well. 17.6.2 Pumping Stations Reference is made to the following P&I Diagrams:
QP20-D- 1100 Main Pumping Station - P& I Diagram QP20-D-1105 Booster Pumping Station - P & I Diagram

The field instrumentation for the pumping station shall include the following main items:

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Pressure measurement with pressure gauge, pressure transmitters and pressure switches. Flow indicator , flow transmitter with /without totalizer. Level transmitter and switches. Temperature sensors, transmitters and monitoring devices for machinery Vibration sensors, transmitters and monitoring devices for machinery
17.6.3 Reservoir Stations and Terminal Station

Reference is made to the following P&I diagram


QP20-D-1110 QP20-D-1130 QP20-D-1140 QP20-D-1150 QP20-D-1160 QP20-D-1170 QP20-D-1180 Nuairiyah Station P& I Diagram Ibn Hethlain Filling Station and Line Valve LV2 & LV3 P& I Diagram Qaryat Aloliyah Tank P&I Diagram Sairah Filling Station and Line Valves LV4 and LV5P& I Diagram Sadawi Station and Line Valve LV6 P&I Diagram Alqaysumah station and Line Valve LV7 P & I Diagram Hafar AlBatin terminal station P & I Diagram

Depending on station location the field instrumentation consists of the following main parts:

Pressure measurement with pressure gauge, pressure transmitters and pressure switches. Flow indicator , flow transmitter with /without totalizer. Level transmitter and switches. Water quality sensors, transmitters and monitoring devices including water sampling points. Flow switches.

17.6.4 Line Valve stations LV1 to LV7 Depending on the location the field instrumentation consists of the following main parts : - Pressure measurements with pressure gauge and pressure transmitter. - Flow Switch. 17.7 Fire & Gas Detection

All relevant buildings in the Stations shall be equipped with appropriate detectors for fire and gas detection. The fire detection and alarm system of the new buildings consists mainly of:

Fire alarm central control panel (UNCON) Automatic fire detectors (smoke, fire, heat)

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Automatic gas detectors (chlorination building only) Manual call points Audio-visual fire alarm Necessary cabling, installation and wiring Interfaces to the related systems like HVAC, ventilation

For detailed technical requirements reference is made to the Specifications S10 Fire Alarm System, Doc. No. QC10-H-130 . The signalization of the fire alarms for each fire zone to the central control should be transmitted to the station control system, at least consisting of:

Pre-alarm (one detector) Fire alarm (min. two detectors or one manual call point activated) Failure fire alarm system to SCS Failure power supply of the fire alarm system to SCS

Summary alarm signal shall be transmitted to security guard room. The fire and gas detection system shall be installed at the following stations/buildings: a) Pumping Station (PSRH) - Booster Pump House - Main Pump House - Electrical Building b) Nuairiyah Reservoirs and Filling station - Electrical Building - Security Guard Buildings c) Ibn Hethlain Water tower and Filling station - Electrical Building - Security Guard Buildings d) Qaryat AlOliyah Reservoirs and Filling station - Electrical Building - Security Guard Buildings e) Sairah Water tower and Filling station - Electrical Building - Security Guard Buildings

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f) Sadawi Water tower and Filling station - Electrical Building - Security Guard Buildings g) AlQaysumah Water tower and Filling station - Electrical Building - Security Guard Buildings h) Hafar AlBatin terminal reservoir - Electrical Building - Chlorination Building, incl. gas detection - Quality Monitoring Building - Security Guard Building - Combined Electrical / Mechanical Workshop i) Line Valve Stations (LV1 LV7) - Shaft

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CHAPTER (18) COMMUNICATION


18.1 General For the Ras AlaZaur Hafar AlBatin WTS adequate communication facilities shall be installed, that allow the safe and reliable communication between the various stations along the transmission pipeline. The communication system includes the following sub-systems: a) Transmission System Redundant internal data communication between the WPCC and all other stations along the pipeline system including back-up communication links b) Telephone System Independent voice communication system between all stations, to the PABX and to the PSTN c) Network Management System Monitoring and control of all communication components d) Office WAN A new FOC shall be laid along the pipelines to interconnect all respective stations of the new transmission system. The communication network shall be used for process data transfer and voice communication. Details of the proposed system configuration, the technical requirements and the structure of the communication network are described in the subchapters below.

18.2 Fiber Optic Cables 18.2.1 FOC along the Transmission Pipeline System Along the Ras AlZaur Hafar AlBatin Transmission Pipeline System one (1) FOC shall be laid from PSRH up to the existing Hafar AlBatin Tanks. This FOC shall have at least 24 fibers and shall be laid within the pipe trench between the pipelines in a suitable protection conduit. The FOC shall be terminated at all stations in the telecommunication cabinets (Optical Distribution Frames).

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The design, laying, test and commissioning of the FOC shall be performed according to the following specifications: S07 Fibre Optic Cables for Pipelines, Doc. No. QC10-H-127 S08 Fibre Optic Cables Conduit and FOC Installation, Doc. No. QC10-H-128

18.2.2 FOC within Stations For the interconnections within the various Stations all required FOC shall be supplied and installed in compliance with the technical requirements as defined in the specification S07, see chapter 18.2.1 above. Cable laying shall be performed within cable cellars on cable trays, in cable ducts, or within cable conduits, depending on location.

18.3 Transmission System For Ras AlZaur Hafar AlBatin WTS the Contractor shall provide a Transmission System in compliance with the technical requirements defined in the Specification S09 Communication System, Doc. No. QC10-H-129.The transmission system of Ras AlZaur Hafar AlBatin WTS is shown in the drawing SCADA and Communication Block Diagram QP20-T-5200. The transmission system shall provide the following objectives:

100 Mbps data connection between WPCC and all other pipeline stations. 10 Mbps internal voice communication (VoIP) between the PABX at PSRH and the telephones
at the pipeline stations.

>= 2 Mbps data and voice communication between the WPCC, pipeline stations and LVs
In any case, failures or other malfunctions within the voice communication shall not have any influence to the process data transmission (separate channel, VLAN). The equipment at all Stations, except for the Line Valve Stations, shall be redundant as shown in the reference Block Diagram.

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For the set-up of the transmission system of the Line Valve Stations preferably optical modem should be used. The process data interface as well as the communication integration between Ras AlZaur Water pipe line control center and (PSRH) transmission system (Hardware, Software, License, etc.) shall be part of the Scope of Work. During modification work of the existing transmission system , Routers should be installed for connection of the control system, PABX and Office LANs with the transmission system.

18.4 Backup Transmission For backup cases a stand-by connections over the Public Switched Telephone Network (PSTN) shall be established at the following locations possible:

At Ras Alzaur pumping station (PSRH). At Hafar AlBatin Reservoir Station.

Since these Stations, which are located within cities or at least villages, it shall be possible to get suitable (at least ISDN 128 kbps) telephone connections over there. The necessary coordination with the STC shall be performed by the Contractor, final agreement for the PSTN services and/or leased channels shall be signed by SWCC.

18.5 Telephone System For voice communication a VoIP PABX incl. gateway to PSTN shall be installed at PSRH Electrical Building. This PABX shall handle all calls between the telephones installed in

PSRH, at least 10 telephones LVSs, 1 telephone each All reservoir stations 5 telephone for each Hafar AlBatin Terminal station 10 telephone. Hafar AlBatin Exisiting MOWE tanks 2 telephone.

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The subscriber numbers of the new telephones shall be integrated into the existing numbering scheme of SWCC. The necessary investigation and coordination works are part of the contract. At the PABX node located in WPCC all PABX networks of the water transmission systems located in the region should be interconnected with the new PABX, network of the Ras AlZaur Hafar AlBatin and the existing PABX network at Ras AlZaur WPCC. All required works, including the commissioning of the integrated telephone network are part of the Scope of Work. For voice communication a separate connection to the PSTN at the Pumping stations shall be foreseen. Details are subject to final design.

18.6 Network Management System (NMS) The NMS for monitoring and control of the entire transmission system, routers and switches shall be installed within the control room or communication room of the PSRH Water pipe line Control Center.

18.7 Hotline System A hotline system should be installed between the following Stations:(including telephone sets)

Ras ALzaur to PSRH. PSRH to Hafar AlBatin reservoir.


This should be a point to point voice communication via the transmission system and PABX. The link should automatically be established by picking up the listener (no dialing required). 18.8 Office LAN At PSRH and at Hafar AlBatin Terminal Station a switch to implement an Office LAN is to be provided and connected to the redundant network. The switch should have at minimum 48 ports and should be state of the art type. All required work to install, set-up and commissioning the office LANs according to SWCC requirements are part of the Scope of Work.

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CHAPTER (19) 19.1 General

CATHODIC PROTECTION

In addition to the good passive corrosion protection and coating of all buried metallic pipes and structures, the pipeline and the station piping shall have an active corrosion protection by means of cathodic protection for technical requirements reference is made to E16 cathodic protection. Special care is required to avoid any negative influence from CP installations to other existing pipes or foreign installations and vice versa. Also the possible high voltage interference from overhead lines, power cables or other HV installations in the vicinity of the pipe and structures must be considered and limited. The pipeline cathodic protection system (CPS) shall be separated from the Pumping Station , reservoir stations and the terminal reservoir by means of isolation coupling. The Line Valve Stations are an integrated part of the pipeline CPS. There are two common systems for the CP, they are Sacrificial Anodes and Impressed Current. Sacrificial Anodes, is a metallic anode used in CP where it is intended to be dissolved to protect other metallic components. Also, a sacrificial anode can be defined as a metal that is more easily oxidized than the protected metal. Electrons are stripped from the anode and conducted to the protected metal, which becomes the cathode. Impressed current, for large structures galvanic anodes can not economically deliver enough current to complete protection. This system use Anodes, a DC power source, Rectifier. Anodes for IC system are tubular and solid rod shapes or continuous ribbons of various specialized materials. The number of CPS feeder stations along the pipelines shall be optimized under consideration of low ground resistance for the anode bends and availability of electrical power supply connections. The necessary site investigation and detailed survey is part of the contract. The CPS shall be equipped with a remote monitoring system via the CPS feeder stations (T/R stations) and selected potential measuring points with monitoring relays. The measurement and alarm signals shall be transferred to the SCADA system. In case the T/R stations will be installed outside areas of direct FOC interface (e.g. Pumping Station, Line Valve Stations, Reservoir stations etc.) the respective interface to the FOC communication system shall be provided as part of the contract. Design and installation of CPS shall be performed by well experienced and approved companies only. Detailed site survey and investigation of existing facilities is mandatory and part of the contract.

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19.2

Pipeline CPS

19.2.1 Pipeline The individual pipes of the new pipeline are welded together, the pipes are equipped with factory applied 3-layer HDPE coating, the welding seam will be coated on site after welding. The pipes are internally lined with cement mortar (CM). Cathodic protection of the steel pipeline will be achieved by an impressed current cathodic protection system consisting of transformer/ rectifier (T/R) stations, anode ground beds, pipe to soil test points and pipe to foreign installations test points installed along the pipeline . The number of T/R stations, type and number of anodes and number of test points depends on the final route, the soil resistively survey, the number of crossings, foreign installations, availability of low voltage power, etc. 19.2.2 Line Valve Stations The Line Valve Stations will not have separate local CPS provisions because these stations are not directly buried but installed in underground shafts. The piping system of such stations will be connected with the earthing system in order to avoid dangerous touch voltage due to HV interference. These grounding connections shall be performed via special AC voltage limitation devices avoiding direct low-ohmic earthing connections of the pipes. Any additional grounding connections via AC voltage limitation devices along the pipeline route and within the LVS shafts must be defined by the HV interference calculation, which is part of the final design. Bonding cables across each line valve station shaft, to interconnect the upstream and downstream pipeline must be foreseen. 19.2.3 Crossings or parallel routing with other Pipelines For crossings and parallel routing with existing SWCC water pipelines or other foreign pipelines (e.g. oil, gas or water pipelines) the particular protection requirements and crossing conditions must be observed and considered. The co-ordination with the Owner's of the pipelines to be crossed or routed in parallel must be performed as part of the contract. The necessary bond boxes, cable connections, shunts, etc. must be supplied and installed.

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19.3

CPS for Station piping

All buried steel pipes and all other underground metallic structures , the steel tank bottom plate and reinforced concrete foundations at the Pumping Station and reservoir Stations shall be protected by implementation of a suitably designed impressed current local cathodic protection system. Details on the number, type and size of T/R stations, anodes and test points depends on the final station layout. Any existing CP installations shall be considered and incorporated. The Contractor shall work out the final design for layout of the local CPS, considering the actual soil resistivity and all other effects influencing the good performance of the CPS. The station CPS will operate independently and fully separated from the pipeline CPS. 19.4 CPS for Steel Storage Tanks 19.4.1 Protection of Tank Bottom For each above ground steel storage tank a separate cathodic protection system for the tank bottom shall be provided. The impressed current system with rectifier and buried impressed current anodes shall be used. Depending on construction of the tank foundation and the soil conditions, the anodes shall be either distributed around the tank (preferred solution) and/or installed underneath the tank bottom. For technical requirements reference is made to the Specification E16 Cathodic Protection, 19.4.2 Tank Internal Protection In addition to the cathodic protection of the tank bottom, each steel storage tank shall have separate internal cathodic protection with impressed current rectifier and anodes installed within the tank. For technical requirements reference is made to the Specification M09 Steel Tanks, Doc.No. QC10H049 and the Specification E16 Cathodic Protection, Doc.No. QC10-H-096. 19.5 CPS Monitoring For the continuous effectiveness supervision of the CPS for the pipeline and the stations, the installation of a remote monitoring system is required. At least the following parameters must be continuously measured at various locations, transmitted to the CC and recorded:

Pipe to soil protection potential at the drain points (On/Off potential)

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Pipe to soil protection potential at starting and endpoints of each pipeline and at intermediate
points (e.g. Line Valve Station) with access to communication system.

Protection current Anode current Rectifier DC output potential and current Rectifier supervisory signals (supply voltage, alarm)
The remote controlled and synchronized on/off switching of the T/R stations shall be possible. For data transmission the FOC communication system, which will be installed along the pipeline, shall be used. Data interface is to be coordinated by the Contractor. If it is not possible to provide reasonable access to the FOC communication system at the location of the CPS rectifiers and/or monitoring stations, the installation of wireless hubs or separate cables to the next possible FOC station shall be foreseen as part of the contract. The CPS Subcontractor shall work out a proposal for the complete CPS monitoring system, which is subject of approval. 19.6 Temporary CPS

The temporary cathodic protection shall be performed with sacrificial anodes of suitable number and size, terminated on the test points. For temporary CP of the pipeline the sacrificial anodes are to be placed in distances of not more than 10 km; preferably at locations of potential measuring points. Prior to commissioning of the permanent CP all temporary anodes must be disconnected. The temporary CP is not necessary, if the steel pipes will be without permanent CP for less than one (1) month. The Contractor shall work out a respective detail procedure to ensure, that no segment of pipeline will be in the ground without any CP (temporary or permanent) for more than the above mentioned time. 19.7 Interference

Special measures are required to limit the admissible touch voltage for personnel safety along the entire pipeline system. In addition all negative effects on the pipeline CPS due to HV interference and stray current influence

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from/to existing CPS installations or foreign lines must be considered and the appropriate counter measures must be implemented. Detailed measurements, investigations and calculations are necessary as part of the final design, where interference due to HV installations is likely. The counter measures and/or provisions, which are necessary, shall be supplied and installed as part of the contract. It is the obligation of the Contractor to obtain all required information and data from any of the foreign installations as well as from SEC, ARAMCO, etc. 19.8 Installation and Commissioning

The installation and commissioning of CPS, including all necessary site survey and field measurements must be performed in accordance with the requirements contained in the Specification E16 Cathodic Protection, Doc. No. QC10-H-096.

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CHAPTER (20) MAINTENANCE ORGANIZATION, EQUIPMENT AND SPARE PARTS 20.1 Responsibility of the Contractor Within the scope of work for the construction of the Ras AlZaur Hafar AlBatin Water Transmission System, the Contractor shall be responsible for setting up of an efficient maintenance organization in order to fulfill the following key requirements: - To maintain all equipment up to the highest feasible standard of system reliability. - To minimize shut downs. - To keep maintenance costs within reasonable limits. The preconditions to reach the above objectives are as follows: - Sufficiently qualified personnel. - Well designed (layout) and well equipped (equipment, tools) workshops and proper transportation facilities. - Clear and well defined policies and procedures for maintenance and store keeping. Based on the general descriptions in the Tender Documents the work concerning the setting up of the maintenance organization shall include but shall not be limited to: a) Elaboration of an organizational scheme for the operation & maintenance of Ras AlZaur Hafar AlBatin Water Transmission System. b) Definition of policies and procedures for maintenance & operation. c) Preparation of qualification requirements and job descriptions for all personnel. d) Elaboration of a familiarization program for the maintenance personnel and operating staff including a detailed time schedule. e) Preparation of detailed lists of equipment and tools for the workshops and the storage building as well as lists for all transportation facilities. f) Elaboration of a program concerning the intervals and scope of preventive maintenance measures and overhauls required for the equipment provided under the contract. g) Submission of the documents mentioned in a) through f) above in form of a proposal, which is subject to approval by the Engineer. h) Integrate the approved version of the maintenance organization proposal into the final design of the buildings for the workshops, spare part storage and garage. i) Elaboration of a maintenance manual based on the approved maintenance procedures and list of tools.

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j) Supply of all special tools following the approved proposal, familiarization of the personnel and supply of all forms according to the approved procedure in sufficient numbers for a two years operation period. 20.2 Basic Information on the organization The maintenance center with related workshops, carshed and ware house for spare parts will be located at Ras AlZaur-AlRiyadh (PS1). Small workshop will be installed at Hafar AlBatin terminal. It is foreseen not to divide the operation and maintenance functions at the station level. The maintenance organization will be split as follows: - The staff located at the stations will be responsible for all daily routine maintenance activities at their location of assignment. - For special maintenance works, repairs and overhaul of equipment at reservoir stations , crews with equipment and tools will be sent from the maintenance center. The maintenance organisation will be directed by the chief maintenance engineer, who reports to the manager of the Water Transmission System. The building for maintenance purpose is described in chapter 11 of this general specification 20.3 Familiarization of SWCC Personnel Based on the Contractors approved proposal SWCC will delegate the staff foreseen for familiarization. Following the approved familiarization program the Contractor shall organize and conduct familiarization sessions for operation and maintenance, explaining in detail all the requirements and procedures. Such sessions shall be held for personnel who will later on execute the work as well as for the supervising staff. The scope of work concerning the familiarization of the Employers personnel is described in chapter 22 of this general specification. 20.4 Policies and Procedures 21.4.1 Maintenance Policies In general the activities proposed by the Contractor shall comply to the existing practice of SWCC at other comparable installations. In addition, the Contractor shall define the maintenance policies based on the objectives listed under 20.1. These policies shall cover such items as:

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- Classification of maintenance activities and maintenance objects - Planning of preventive maintenance defining the work to be performed and the corresponding frequency of intervention. - Planning of shut-downs and overhauls - Emergency procedures - Accounting and budgeting for maintenance works - Updating of as built records - Reporting and ordering of spare parts Based on the above requirements the Contractor shall prepare and submit maintenance procedures for all equipment provided and all works performed within the Contract for the construction of the Ras AlZaur Hafar AlBatin Water Transmission System. 20.4.2 Spare Parts The Contractor shall submit suitable policies for: - Classification of spare parts including code system for computer application (MESC Code) - Level of spare part storing, considering the Suppliers recommendations and the average procurement time in Saudi Arabia - Method of preservation and storage requirements - Material control and recording system Spare part interchangeability record sheets (SPIR forms) have to be provided by the Contractor after completion of equipment design. These forms shall be filled for two (2) years wear and tear parts and five (5) years spare parts. The SPIR forms to be used, including the filling in procedure, are enclosed in the SWCC project procedure manual. 20.5 Forms to be supplied A stock of bilingual forms resulting from the maintenance procedures mentioned above shall be supplied by the Contractor and shall include but not be limited to the following: a) Schedules for periodical maintenance work Check lists for - Pipeline and station equipment - Mechanical and electrical function tests

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- Cathodic protection - Lining and coating control - Instrumentation - Communication - Periodical tests for pressure vessels, air compressors, auxiliary systems, etc. The number, content and layout of these forms shall be coordinated with the head of the SWCC operation and maintenance organization. 20.6 Equipment and Special Tools During the warranty period the Contractor shall replace all equipment items and special tools that prove to be improper and do not meet the requirements for effective maintenance works. Tools, equipment and other facilities/items provided under this Contract shall not be used in any way for the purpose of construction. 20.7 List of Equipment and Special Tools Combined workshop at Hafar AlBatin terminal: No. 1 2 3 4 5 6 7 8 9 10 Description Center Lathe (1000 mm) with complete accessories & full range of relevant tools Power Saw, motor driven multi-speed (metal cutting saw) Double ended heavy duty pedestal grinder (motor driven) Pillar type multi-speed motor driven drilling machine, capacity up to 25 mm (drilling) Electric welding machine, comprising oil immersed is welding. Transformer with double winding & elding current regulator. At least welding capacity 90 up to 400 amps. Battery charger Air compressor, electric motor driven Mobile electric generating set (diesel engine driven) 15 kVA with distribution sockets & fuses 4 Wheel hand trolly to handling materials Ladders folding type, 10 feet Quantity 1 1 1 1 1 1 1 1 1 1

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CHAPTER (21) START-UP AND TESTS UPON COMPLETION


21.1 General This Chapter describes in general terms the activities the Contractor has to perform with regard to start-up and completion tests. For the entire procedure, starting with the check-out tests required for Mechanical Completion up to and including the Reliability Test, the Contractor has to prepare and submit for approval detailed procedures and programs including, but not limited to: - Time schedule for the entire period and for the individual tests - Detailed descriptions of test procedures and modalities - Manpower details - Lists and specifications of measuring and control devices intended to be used for the tests - Method and calculation for evaluation of test results - Definition of activities which will be performed by the Contractor himself and which are to be carried out by the Subcontractors/Suppliers under the Contractors supervision - List of the Contractors personnel authorised to perform and/or witness and certify the tests - Sample forms for the documentation of test results - Detailed testing instructions The activities shall be covered by the following detailed specifications: 1. Pipeline Tests 2. Check-Out, and Tests for Mechanical Completion 3. Line Fill, Start-Up, and Tests on Completion The documentation, test forms and procedures prepared by the Contractor must be in full compliance with the SWCC Project Procedure Manual. 21.2 Check Out and Tests for Mechanical Completion These activities have to be performed by the Contractor before issuing of the MechanicalCompletion Notice and shall be a precondition for the Mechanical Completion Certificate to be obtained. The main purpose of the check-outs and the tests is to prove that the pipeline and its components, subsystems, individual functional groups, and the equipment installed at the Project are in compliance with the specifications, are complete and functionally operable.

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The precondition for any test performed on site is the availability of the shop test certificate for each individual component or subsystem, which therefore shall be held in evidence by the Contractor and a copy of which shall form part of the test documentation. The check-outs and the tests shall aim at having the components and subsystems in the condition ready for start-up. Therefore the tests shall also include operational tests and trial runs of the machinery and equipment. However, the performance of tests requiring electric medium voltage power and/or product water to be provided by SWCC or others (i.e. running of booster and main pumps) shall not be a precondition for issuing of the Mechanical Completion Certificate. All the tests required for the pipeline such as initial sterilization, etc. shall form part of these activities, but shall be described in a separate specification. 21.3 Line fill, Start-up and Tests on Completion 21.3.1 Preconditions The following activities must be performed and successfully completed prior to commencement of line fill: - Initial sterilisation of pipeline as part of the hydrostatic testing - Mechanical Completion Certificates available for the pipeline and the stations - Energizing of power supply feeders. In addition the permanent CPS for the pipeline and stations must be completed and in operation. 21.3.2 Line Fill Line fill shall mean the first filling of the pipeline segments with product water from the Ras AlZaur tank farm with the water being pumped by the systems own booster and main pump units (no auxiliary pumps). The operation shall include flushing and sterilisation of the mainline as well as the piping of the stations, which will for the first time be in contact with the product water, so that after line fill the complete system will be filled with clean fresh product water. The sterilization of the pipelines shall be performed in compliance to the requirements and guidelines detailed in the standard ANSI/AWWA C651-99. 21.3.3 Start-Up Start-up shall mean that the operation of the Pipeline System is commenced under the same conditions as prevailing during commercial operation.

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21.3.4 Tests on Completion The Tests on Completion consisting of the Performance Tests and the Reliability Test shall be carried out as required in chapter 4.5 (Performance Guarantees) of this general specification. A detailed procedure will have to be established by the Contractor in accordance with the Conditions of Contract, taking into account the final design data and the equipment actually installed. It is mandatory to perform the tests on completion for the complete Pipeline System at the same time. The detailed test program must be co-ordinated with SWCC and shall consider the vailability of electrical power and product water at the Plant side and along the pipeline route, especially for the Pumping Station , as well as the completion and availability of the Reservoir Stations.

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CHAPTER (22) FAMILIARIZATION OF EMPLOYERS PERSONNEL 22.1 Responsibility and Objective The Contractor is responsible for the familiarization of the Employers O&M personnel for all disciplines. In addition the particular training requirements regarding operation and maintenance of the SCADA System, which will be supplied under this Contract, are part of the contract. The objective of familiarization is to prepare the Employers O&M personnel to manage, operate and maintain the System, which include among the other components especially the aspects of instrumentation, control and communication works, as well as safety installations. The familiarization shall be performed on the actual plant equipment and shall be organized and structured in such a way, that due allowance is made for the phased assignment of O&M staff in accordance with the hand-over program of the individual sections of the Works. The Contractor shall also instruct, advise and supervise the SWCC personnel in the correct application of procedures and practices of operation and maintaining the system during the entire warranty period. The Contractor shall observe regularly the activities of the designated personnel, evaluate their performance, give them technical advice and conduct special tutorial sessions, if deemed necessary. 22.2 Familiarization Program To accomplish this objective, the Contractor shall prepare a detailed familiarization program, which shall consider the following: a) The minimum familiarization period shall be three (3) months and shall be completed before issuing the Preliminary Acceptance Certificate (PAC). b) In preparing the familiarization plan the Contractor shall refer to the already established SWCC O&M organization set up for other pipeline systems (e.g. RWTS, etc.). c) The number of O&M personnel, to be assigned by SWCC for the familiarization must be considered. d) The personnel shall be divided into the two groups, operation including engineering and maintenance, which shall undergo a supervised, task- and performance oriented on-the-job training. e) The Contractors O&M Manuals shall be the basis for the familiarization, brief handouts in Arabic and English according to each position shall be prepared. f) The familiarization program, including the time schedule, the procedures and handouts are subject to SWCC approval.

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22.3 Special Requirements for the DCS/SCADA System The familiarization and training program for the DCS/SCADA equipment and instrumentation shall be performed on site and in the manufacturers premises and shall last at minimum three (3) months (45 days on site and 45 days outside KSA). The familiarization and training program shall include at least the following: a) General: Brief introduction of the pipeline system. System structure and modes of operation, incl. e.g.:

Handling of command power and change over Automatic and Manual mode Documentation Introduction structure of the documentation Operation Manual Maintenance Manual Drawings Introduction for all software packages Graphics, control functions, changing of parameters of all software packages Control of the entire pipeline system, of a pipeline section, of the pumping stations and the Terminal station. Operating systems, access control, accounts Practices on the basis of all possible scenarios Alarm handling, protocols, history handling, Parameterisation Modification of functions and graphics General recommendation (e.g. of the manufactures) Periodic inspection (time periods, content) Instruction for each instrument Maintenance of DCS equipment Maintenance of CC equipment, incl. plasma screens

b) For the Operation and Engineering group:

c) For the Maintenance group:

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CHAPTER (23) TRAINING OF SWCC PERSONNEL The Contractor shall arrange the following training programs for SWCC personnel on all the supplied systems separately. 1- On-site training for (24) operators for (6) weeks on Central Control operation. 2- Factory training for (24) operators for (6) weeks on Central Control operation. 3- On-site training for (12) maintenance personnel on all systems for (6) weeks. 4- Factory training for (12) maintenance personnel on all systems for (6) weeks. 5- Overseas detailed system training for (10) engineers for (6) months. 6- Contractor shall bear the cost of travel, boarding and lodging of the trainees.