cng directive israel
DESCRIPTION
manualTRANSCRIPT
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State of Israel Ministry of National Infrastructure, Energy and Water
Natural Gas Authority
Compressed Natural Gas Directive
Prepared for Natural Gas Authority Qiryat Hamada 6 POB 45140 Jerusalem 90451 Prepared by Parsons Brinckerhoff Beit Bareket 1 Airport City POB 1032 Airport City 70100 Israel www.pbworld.com
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State of Israel
Ministry of National Infrastructure, Energy and Water Natural Gas Authority
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State of Israel
Ministry of National Infrastructure, Energy and Water Natural Gas Authority
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AUTHORISATION SHEET
Current
Revision:
P1
Status: ISSUE
Client: State of Israel, Ministry of National Infrastructure, Energy and Water,
Natural Gas Authority
Project: Compressed Natural Gas
Address: Qiryat Hamada 6, Har Hotzvim, Jerusalem
PREPARED BY
Name: David Hanley
Position: Chief Engineer. Oil & Gas Projects, UK
CHECKED BY
Name: Ronen Marko
Position: Engineering Manager, Oil & Gas Projects, Israel
APPROVED AND AUTHORISED FOR ISSUE
Name: Cobi Ben-Shetrit
Position: Country Manager, Israel
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State of Israel
Ministry of National Infrastructure, Energy and Water Natural Gas Authority
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Table of Contents
SECTION 1.0 INTRODUCTION ............................................................................................ 8
SECTION 2.0 GENERAL .................................................................................................... 10
SECTION 3.0 RELEVANT STATUTORY PLANS .............................................................. 13
SECTION 4.0 DESIGN OF THE SYSTEM .......................................................................... 14
SECTION 5.0 PROCUREMENT ......................................................................................... 24
SECTION 6.0 CONSTRUCTION ......................................................................................... 27
SECTION 7.0 REQUEST FOR GASSING UP .................................................................... 36
SECTION 8.0 OPERATIONS AND EMERGENCY............................................................. 40
SECTION 9.0 HEALTH SAFETY AND ENVIRONMENT PLAN ........................................ 43
SECTION 10.0 QA/QC SYSTEM QUALITY ASSURANCE AND CONTROL PLAN .......... 48
SECTION 11.0 INSPECTION AND MAINTENANCE PROGRAM ....................................... 49
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State of Israel
Ministry of National Infrastructure, Energy and Water Natural Gas Authority
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PREFACE
The State of Israel Natural Gas Authority (NGA) require all gas supply and
infrastructure systems to be safe, and operated within tolerable levels of individual
and societal risk, and to maintain the integrity and fitness for purpose of these
systems throughout their designated design and operational life.
All gas system Owners/Licensees must demonstrate their design, operational and
maintenance philosophy, procedures and safe systems of work, which must include
identification of all hazards that may impact on the system integrity or tolerable
individual and societal risk, risk assessment, mitigation measures and definition of
residual risk associated with the management of each risk mitigation strategy.
EXEMPTION OF THE STATE FROM LIABILITY
The Owner/Licensee bears the sole responsibility for the safe design, construction,
operation and maintenance of the system and shall implement the required
procedures, means and methods for assuring that the system integrity is maintained
throughout its design and operational life.
Approvals issued by the State of Israel to the Owner/Licensee do not impose any
liability on the State of Israel and/or its representatives and will not be used as cause
for prosecution or legal action against the State of Israel and/or its representatives by
the Owner/Licensee or a third party.
In the event that the State of Israel and/or its representatives are to compensate any
party due to any act or negligence by the Owner/Licensee, the Owner/Licensee shall
indemnify the State, and/or on its representatives, accordingly. The Owner/Licensee
will bear all legal and other expenses of the State, if any, with respect to such
indemnities.
For the avoidance of any doubt, it is hereby clarified that approvals issued by the
State of Israel do not affect the powers given to the Minister, the Natural Gas
Authority and the Safety Officer granted by law.
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State of Israel
Ministry of National Infrastructure, Energy and Water Natural Gas Authority
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Abbreviation/Definition List
ABD
ADR
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As Built Documentation
European Agreement Concerning the International Carriage of Dangerous Goods by Road
AGI - Above ground installation
ALARP - As Low As Reasonably Possible
CB/Certifying Body - An independent engineering body with the competencies and experience required to evaluate and certify the design. This body shall be approved by the NGA prior to the submission of the design package.
CAR - Corrective action report. Issued to close out a specific NCR
Contractor - The body performing works. Deemed as the 1st party in this document
CNG - Compressed Natural Gas
CP - Cathodic Protection
CS - Carbon Steel
CTOD - Crack Tip Opening Displacement
Deviation - Deviation from the code requirements
EMP - Environmental Management Plan
HAZ - Heat Affected Zone
HAZID - Hazard Identification Study
HAZOP - Hazard & Operability
HSE - Health, Safety & Environment
IGID - Industrial Gas Installation Directive
ITP - Inspection and Test Plan
LD - Lead Designer
NB/Notified Body -
A body which has been notified by the European Union that it fulfills the relevant requirements and has been designated to carry out conformity assessments in according to a directive.
NCR - Nonconformance report detailing a non-conformity to the design requirement or a procedure.
NDT - Non Destructive Testing
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NGA - Natural Gas Authority- Israel
NGV - Natural Gas Vehicles
OPM - Operating Manual
Owner/Licensee - May be the Owner/Licensee and/or operator and is deemed as the 2nd party in in this document
P&ID - Process and instrumentation diagram
PFD - Process flow diagram
PIT - Pressure Indicator Transmitter
(W)PQR - (welding) Procedure qualification record
QA/QC - Quality Assurance / Quality Control
QP - Quality Plan
QRA Quantitative Risk Assessment. A formalized specialist method for calculating numerical individual, societal, (employee and public) risk level values for comparison with regulatory risk criteria.
SCADA - Supervisory Control And Data Acquisition
Shall - Indicates a mandatory requirement
Should - Indicates best practice and is the strongly recommended/preferred option
SIL - Safety Integrity Level
SMS - Safety Management System
TABA - City Wide Outline Plan for Natural Gas
Statutory Plans - TABAs, VATAL's, Building Permits etc.
TIT - Temperature Indicator Transmitter
TPI - Third Party Inspection Body. Deemed as the 3rd party supervision body in this directive
WPS - Welding procedure specification
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State of Israel
Ministry of National Infrastructure, Energy and Water Natural Gas Authority
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SECTION 1.0 INTRODUCTION
This document shall be known as the Compressed Natural Gas Directive, hereinafter
entitled the CNGD. The purpose of this directive is to provide guidelines for
Owner/Licensees, designers and operators who wish to utilize Compressed Natural
Gas (CNG) in order to ensure system integrity is maintained throughout both the
design and operational life of the system.
The main intended use of CNG technology in the industry is as an alternative fuel for
vehicles (NGV's). Additionally, where potential natural gas consumers are currently
remote from the natural gas transmission and distribution piping networks, and wish
to be connected to the natural gas distribution network, CNG supplies may offer a
temporary solution for bridging the gap in the non-availability of the piped supply of
natural gas to the local distribution network.
It shall however be emphasized, that the preferred option is to connect new
industrial consumers to either the transmission or distribution piped natural
gas networks.
The scope of this Directive includes NGV Vehicle Filling Stations, CNG Compression
Stations, CNG Trailers, Decompression Stations and all other associated auxiliary
systems. The decision regarding whether the NGA or the Ministry of Transport is
responsible for the CNG trailers is currently under review by the government and was
not yet determined.
Concerning the transport of dangerous goods by road in industrial CNG applications
or mother-daughter, it is incumbent on CNG license Owner/Licensees, designers and
operators of CNG assets to demonstrate documented evidence of full compliance
with Israeli Law and ADR requirements.
The CNG Trailers and the routes of the specific installation shall be approved
by the Israeli Ministry of Transport as required by Israeli law.
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The segments of this Directive which are related to Decompression stations are
further based on letters from the CEN and NEN technical committees.
Currently, The State of Israel CNG Safety Decree (2010) requires that the main
applicable design standards to be utilized for CNG Compression and Decompression
installations are the European standards; prEN13638 and the EN12186, respectively.
European standard prEN13638 is currently still at draft stage and the current scope
of this standard covers the design, manufacturing, assembling, installation and
testing of CNG vehicle filling stations for filling of natural gas fuelled vehicle tanks up
to a delivery pressure of 200 barg at 15o C. As such, the NGA considers that for the
design of CNG Compression installations, this standard may only be used as a
guideline, and additionally requires these designs to encompass best engineering
practices.
The scope of European standard EN12186 limits the maximum inlet operating
pressure of natural gas pressure reduction and metering stations (PRMSs) to 100
Barg. This European standard states that For higher maximum inlet operating
pressures, this standard should be used as a guideline. As such, the NGA requires
that the design of PRMSs at pressures exceeding 100 Barg shall additionally be in
accordance with best engineering practices and best available techniques.
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State of Israel
Ministry of National Infrastructure, Energy and Water Natural Gas Authority
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SECTION 2.0 GENERAL
2.1. The scope of this document takes into consideration the upstream boundary
limits from the upstream natural gas supplier, for both NGV filling station and
Compression Stations, as the isolating valve downstream of the supplier
meter. The downstream boundary limits are the fuelling nozzle to the NGV's
in Vehicle Filling Stations and the last isolating valve downstream of the
PRMS in the decompression station in industrial applications e.g. the
connection to the factory.
2.2. Potential CNG Facilities Owner/Licensee shall provide the NGA with a full
system Master Plan which would detail the number of expected installations,
their type and specific location.
The Master Plan shall be provided in advance of commencing any facility
design, procurement or construction activities. It is incumbent on these parties
to ensure sufficient lead time is available to allow the NGA to review the
Master Plans and comment accordingly.
2.3. The CNGD shall be supplementary to the relevant statutory plans (TAMA 18,
TABAs, Building Permits etc.), the Natural Gas Law, Safety Decree and other
relevant regulations, and shall be read in conjunction with them.
2.4. The relevant statutory plans shall be in place and sanctioned independent of
the CNGD. The CNGD provides more detailed specifications concerning the
requested information necessary to obtain NGA approval for the design,
fabrication, installation and operation for the CNG system concerned.
2.5. The precedent codes relevant to the CNGD are the following:
Compression and Decompression Stations: The Pressure Equipment
Directive 97/23/EC (PED) and all other applicable EU directives or
ASME B31.3 and all other referenced ASME standards.
NGV Filling Stations: SI-6236 and SI-6119.
It shall be emphasized that regardless of the station type or
purpose, once a design path is chosen by the Owner/Licensee
and Designer, it shall be followed and implemented consistently
throughout the design using the normative references found in
either the EU directives or the ASME suite of standards.
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Ministry of National Infrastructure, Energy and Water Natural Gas Authority
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2.6. NGV Filling Stations and CNG Decompression Stations providing gas to
industrial consumers are to comply with the Weights and Measures
Ordinance (1947) and the Weights and Measures Regulations (1963). This
will be in accordance with the guidelines and under the supervision of the
Israeli supervisor on weights and measures, with the involvement of an
approved laboratory which would include including the following but not
limited to:
General audit and review.
Type approval verification.
Accuracy verification testing.
Periodic re-validation of the accuracy tests.
2.7. The CNGD is applicable to the planning, design, fabrication, construction,
operation and maintenance of CNG systems, however, it does not address
local and regional permitting.
2.8. The system Owner/Licensee shall be in full compliance with the CNGD. When
in full compliance with the requirements of the CNGD and all other specific
requirements made by the NGA in all other applicable directives, the NGA will
submit written confirmation of compliance to the required Regional Planning
Committee.
2.9. Once written confirmation has been submitted by the NGA to the Regional
Planning Authorities, the Owner/Licensee may continue to apply for the
required building permits ( ).
2.10. The Owner/Licensees compliance with the CNGD shall be verified with the
NGA through the ongoing process, as described below. Only upon completion
of this process will written approval be submitted.
2.11. The Owner/Licensee shall bear all costs associated with Owner/Licensees
compliance with the CNGD and application for permits. The NGA shall not
bear any commercial or other responsibility related to the Owner/Licensees
successful or unsuccessful compliance with the CNGD and application for
permits.
2.12. The NGA shall be the custodian of the CNGD. The Owner/Licensee shall be
obliged to obtain the latest version of the CNGD, inclusive of all its
supplements, addendums, etc., from the NGA.
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Ministry of National Infrastructure, Energy and Water Natural Gas Authority
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2.13. The purpose of the CNGD is to create conditions for the safe and efficient
development and use of CNG systems in accordance with Israeli
governmental law and policy.
2.14. Before the Owner/Licensee can install and subsequently operate a CNG
system, the Owner/Licensee shall apply for a permit, and such permit shall be
granted prior to commencement of any installation related activity. The CNGD
provides guidelines and instructions for the Owner/Licensee to follow in his
application procedure for an installation and an operating permit.
2.15. Exemptions to the CNGD may be granted by the NGA only upon written
request by the Owner/Licensee and subject to agreed restrictions and
conditions. Such agreed exemption shall carry NGA signature. Exemptions to
the CNGD shall be considered on a case-by-case basis and a given
exemption can be withdrawn if:
2.14.1 If the data furnished by the Owner/Licensee in order to obtain an
exemption appears to be incorrect or incomplete to the extent that
the exemption would not have been granted if the actual data had
been known at the time the decision was made.
2.14.2 The circumstances on the basis of which the exemption was
granted have changed to the extent that the exemption would not
have been granted if the altered circumstances had existed at the
time the decision was made.
2.14.3 The exemption cannot be maintained in case a safety hazard
develops out of it.
2.14.4 It appears that one or more conditions, under which the exemption
was granted, have not been complied with.
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State of Israel
Ministry of National Infrastructure, Energy and Water Natural Gas Authority
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SECTION 3.0 RELEVANT STATUTORY PLANS
3.1 The design, procurement, construction and operation of the system shall fully
comply with the relevant statutory plans, instructions and law, as applicable.
3.2 The Owner/Licensee shall verify if more than one statutory permit is
applicable to the segment.
3.3 The designer shall provide a statement in the design package (as described
below) that the design conforms to the relevant statutory plans. Should this
not be the case, the designer shall list the non-conformities.
3.4 The Owner/Licensee shall prepare a risk assessment in accordance with the
instructions of the Ministry of Environmental Protection in order to obtain the
appropriate approvals from the planning committees.
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Ministry of National Infrastructure, Energy and Water Natural Gas Authority
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SECTION 4.0 DESIGN OF THE SYSTEM The Owner/Licensee shall submit, as part of the requirements of this Directive, a
Project Organogram. The Organogram shall identify the specific independent
organizations delivering the Certifying Body, Notified Body and Lead Designer
services, inclusive of a detailed explanation of each of their roles and responsibilities.
In addition, the Organogram shall identify the name of the lead designer against the
requirement for a single point of contact between the NGA or its representative.
4.1. Schedule
4.1.1 As an essential part of the preparation of the design, the Owner/Licensee
shall prepare a detailed schedule providing data on all aspects of the
planned project development including but not limited to design,
procurement, manufacturing, fabrication, installation, testing and
commissioning aspects. This data shall include:
i. Description of all key activities in logical sequence
ii. Early and late start of these activities
iii. Early and late completion of these activities
iv. Interfaces with third parties
v. Milestones
vi. Target dates for getting permits
vii. Contingencies and mitigation measures in case of conflicts
4.1.2 This schedule shall take into account the review process of the NGA, as
described below. This schedule shall be submitted to the NGA periodically
during the life of the project.
4.1.3 This planning stage shall be accompanied by a revision track record that
provides information, background of schedule changes and mitigation
measures in case schedule changes might create conflicts.
4.2. Detailed Design
4.2.1 The Design shall make reference to the relevant statutory plans and
shall provide more detailed information complementary to the
requested information therein.
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Ministry of National Infrastructure, Energy and Water Natural Gas Authority
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4.2.2 The design shall provide a complete and comprehensive summary of
all design related data and criteria applicable to the proposed
Installation system such as:
i. Reference to the precedence design code, guidelines,
technical specifications and all addenda to these.
ii. Relevant engineering decisions, their rationality, choice of
design related parameters and any other variables having
impact on the design.
iii. Software used for design and analyses.
iv. Decisive design factors, environmental, corrosion and
protection philosophy, specific operating criteria, required
lifetime for the pipeline, etc.
4.2.3 Code deviations will not be accepted by NGA.
4.2.4 This design should include a description and drawing that shows the
boundary limits of this project. These boundary limits should note the
upstream provider as well as the downstream Owner/Licensee (as
applicable).
4.2.5 The scope of the NGA review takes into consideration the following
boundary limits:
i. Compression Stations and NGV filling stations which are fed
from a piped supply: the upstream boundary limit is the isolating
valve downstream of the supplier meter and the downstream
boundary limit is the connection to the CNG Trailers or the NGV.
ii. NGV Filling stations which are fed by a CNG Trailers: the
upstream boundary limit is the connection to the CNG Trailers
unloading the CNG and the downstream boundary limit is the
connection to the NGV.
iii. CNG Trailers.
iv. Decompression station: the upstream boundary limit is the
connection to the CNG Trailers unloading the CNG and the
downstream boundary limit isolating valve downstream of the
Decompression station meter.
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Ministry of National Infrastructure, Energy and Water Natural Gas Authority
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4.2.6 General Design Requirements:
i. The design shall be undertaken by a competent design
organization with proven experience in the design of at least
two CNG installations similar to those designed. The
Owner/Licensee shall provide details of the designers track
record. The Owner/Licensee shall also include their own
operational and maintenance philosophies and details of any
incidents which may have occurred on existing installations
owned by them within any detailed design package
submitted for NGA Approval.
ii. A comprehensive site specific Quantitative Risk Assessment
(QRA) shall be carried out for Compression, Decompression
and daughter-NGV Filling Stations by a competent
organization which had successfully undertaken at least two
risk assessments for such CNG installations in order to
identify, mitigate and record all potential risks. This
assessment shall be based on site data and surveys and not
on assumptions. Please note that NGV filling stations which
are fed via a pipeline do not require the QRA mentioned
above.
iii. All components, pipe spools, instruments, electrical
apparatus, drying equipment, odorization system,
compressors, coolers, valves, pressure vessels etc. shall be
designed and selected in conformance with the applicable
design parameters and code requirements, and shall be
approved by the Notified Body.
iv. The overall global design of the installation shall be fully
assessed and certified as fit for purpose by the Certifying
Body.
v. All steel components shall be provided with 3.2 certificates in
accordance with the requirements of the EN 10204.
vi. The operational philosophy of the Decompression station
shall be 'fail-safe' e.g. two slam-shut valves per pressure
reduction stage.
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Ministry of National Infrastructure, Energy and Water Natural Gas Authority
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vii. All installations which physically connect to the CNG trailers
shall be equipped with an earth control system which would
allow for positive verification of a static ground connection
prior to the connection to the trailer and would stop the
filling/unloading operation if a fault is detected.
viii. The station shall be commissioned, operated and maintained
by a competent organization, experienced in the
commissioning, operations, maintenance and emergency
response of such CNG installations. The station
manufacturer shall accompany the Owner/Licensee and
provide on-going support during, at least, the first year of
operation and as per the CNG license.
ix. The design of Compression stations and NGV filling stations
which are supplied via pipe shall be coordinated with the
upstream supplier to avoid any disruption to the upstream
network. As per NGA, the station flow rate shall not exceed
30% of the total capacity of the consumers within the same
industrial area, including all future connections.
x. Compression, Decompression and NGV filling stations shall
be equipped with an inlet valve station with remotely
operated valves (Fail to Close).
a) CNG Trailers:
i. The CNG Trailers shall meet the requirements of the Israeli
Ministry of Transport and Israeli Law and approved
accordingly.
ii. The CNG license Owner shall receive an approval from the
Israeli Ministry of Transport regarding the routes to the
specific factories or NGV filling stations he wishes to truck
CNG to.
iii. Remotely operated pneumatic valves (Fail Close) shall be
installed in the CNG Trailers priority panel and operated by
the control system of the Compression, Decompression or
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NGV filling station if a mother-daughter method is used.
Manual Isolating valves shall be of a Ball Valve type and
designed to the appropriate differential pressure, design
conditions and cyclic duty.
iv. At least two TIT's and one PIT shall be installed inside two
separate CNG cylinders in the CNG Trailers. These shall
transmit the process data to the main station PLC
(compression, decompression and NGV filling station) and
would enable the closure of the remotely operated valves in
the event that the design limitations are reached.
b) NGV Filling Stations:
i. Temperature compensation filling shall be used with the
appropriate instrumentation and TIT's installed.
ii. Filling nozzles in public access stations shall automatically
vent the trapped gas between the receptacle and the
dispenser.
iii. The design shall consider the 'worst case scenario' in terms
of the expected temperatures in the NGV CNG cylinders,
whereby Type 4 cylinders are used, and detail how the risks
associated with this scenario were mitigated.
iv. NGV Filling Stations shall be equipped with the appropriate
signage to be erected in the entrance to the station indicating
the allowed number of vehicles and/or buses and trucks.
v. NGV Filling Stations which will serve buses/trucks and
private vehicles shall be equipped with the appropriate
dispensers, nozzles and meters for the specific application.
vi. NGV Filling Stations supplied by the distribution company
shall receive natural gas at an inlet pressure of at least 4
barg and up to 16 barg. The upstream distribution pipe flow
velocities shall not exceed 10 m/s.
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4.2.7 The detailed design shall include the following items that firmly
establish the system parameters, installation and operating criteria
and limitations:
a) List of design personnel names, roles and initials.
b) Basis of Design Document which include the following, but
not limited to:
i. Project specific introduction.
ii. Overall design philosophy and statements of code
compliance.
iii. A list of the codes applied and the precedence code.
iv. Design pressure and operating pressure ranges. The MIP
shall be lower than the design pressure.
v. Design and operational temperatures. Design
temperatures shall be at least -10 to +50 degrees C for
buried CS pipework and -10 to +65 degrees C for above
ground pipework. Wider design temperature ranges can
be applied, providing they encompass the ranges stated
above, and that all materials, fittings and equipment are
suitable for the design temperature ranges selected.
vi. The design shall address mitigation measures against the
effects of vibrations, mechanical and thermal fatigue etc.
vii. Pipe diameters, Material grade (composition, choice of
material etc.).
viii. The Pipe and Valve Specifications used.
ix. The design shall detail the mitigation measures and
protection systems against exceeding the design pressure
and temperature values of the designed system and of the
downstream consumer/vehicle/CNG Trailers.
x. Safety measures taken to mitigate third party interference
with the CNG trailer and the provision of a transportation
plan for the site.
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c) Wall thickness calculations. 1 mm corrosion allowance is
required by NGA.
d) Design drawings, Isometrics and an aerial photo ('Tatza')
with the pipe route, valve station, consumers etc.
superimposed.
e) Hazardous area classification report and drawings covering
the station scope and the scope downstream of it.
Hazardous Area Classification shall be carried out as per the
requirements of the EN 60079-10.
f) Ventilation assessment of enclosed spaces.
g) HAZOP and SIL Assessments.
h) Corrosion protection measures (Corrosion coating, CP,
impressed current). Isolation Joints and/or Isolating Flange
Kits shall be installed above ground. Isolation Joints shall be
installed in the Horizontal position only.
i) Geotechnical report.
j) Fire and Gas assessment and mapping.
k) Earthquake design.
l) Pipe support calculations.
m) Thermal calculations regarding the required heat input or
output.
n) Pressure regulator calculations, where applicable, and
equipment sizing.
o) Electrical basis of design and drawings.
p) P&ID and PFD indicating the battery limits. All tie-in
interfaces between the upstream provider (INGL or the
Distribution Company) shall be above ground and flanged.
q) Control and Instrumentation basis of design and drawings.
r) Stress analysis using commercially proven software, such as
Autopipe or Caesar II, which considers the influences of the
upstream and downstream pipeline stresses on the AGI
stress analyses.
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The submitted stress analysis files for design review shall
include the following:
i. Input echo file with the geometry and restraints applied,
materials, process data used e.g. T1, P1, soil stiffness
values (taken from the soil report) etc.
ii. Load case table (Sustained, Expansion, Occasional,
Operational, Hydrostatic and Fatigue).
iii. Electronic copies of the output files.
iv. Restraint summary report inclusive of the forces and
moments at each support type.
v. Code compliance summary report.
vi. Stress isometrics generated by the software.
s) Pressure Test Plan which shall include the following:
i. A table containing the various test sections (numbered
and color coded), design and test pressures, test medium
and test duration.
ii. General Arrangement Drawing or Pipe Isometrics
indicating the highlighted test sections in color and cross
referenced with the table detailed above.
iii. Only one golden weld is permitted.
4.2.8 The completed detailed design package(s) shall be signed and
approved by the Lead Designer, the Certifying Body, and the
Owner/Licensee prior to submission to the NGA for review.
4.2.9 The Lead Designer shall provide a statement that approves that the
design meets the requirements of the design code as well as the
relevant statutory plans.
4.2.10 The Owner/Licensee shall also provide a statement approving the
above and stating his readiness to own and / or operate the system(s)
in a safe manner.
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4.2.11 All matters related to Cyber-Attacks and security shall be dealt with
the Ministry of National Infrastructure, Energy and Water's Security
Officer.
4.2.12 The design shall comply with the requirements of the Home Front
Command.
4.2.13 The issues related to Fire Detection and Extinguishing shall be
approved by the Fire Brigade.
4.2.14 All matters related to the Israeli Police as per the CNG Safety Order
shall be approved.
4.3. Provision of the Package
4.3.1 The Owner/Licensee shall provide the NGA with three color copies of
the design packages, during regular office hours, as well as three CDs
that include all documents found in the hard copies.
4.3.2 Office hours for submitting design packages and other material are
strictly 08:30 - 15:00 on weekdays. Design packages will NOT be
accepted outside of these hours.
4.4. The NGA Review Process
4.4.1 The NGA shall review the design for content and shall be allowed to
reject the design out of hand, should the package contents / quality
not meet the required high standards.
In the event that the package is rejected as such, the Owner/Licensee
shall have the right to reissue the package upon revision as described
above. This reissuance shall include a specific table of changes made
to the package that will clearly identify all the changes made and thus
will assure that the revised package is robust. This revised package
shall also be approved by the experienced international design
organization performing the required Lead Designer role and the
Certifying Body.
4.4.2 Upon initial acceptance of the design package, the NGA shall carry
out a design review and issue an approval or design comments.
These design comments will be provided in a tabular format, to the
Owner/Licensee for response.
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4.4.3 Responses to these comments shall be provided to NGA within the
table format to assure tracking of the comments. Revised
documentation shall be provided in the format as described above.
The tracking of this design review stage shall be carried out strictly
through the table and therefore, it is advised that a highly detailed
response be provided within the table along with a specific mention of
the location of the document within the revised package.
4.4.4 Upon conclusion of the review, a final revised design package shall be
provided, as per the method described above.
4.4.5 The final design package shall be signed and approved by the
designer, Owner/Licensee and the international design organization.
4.4.6 The NGA shall provide the design approval for this package upon
completion of this review as well as other requirements of the NGA
described elsewhere.
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Ministry of National Infrastructure, Energy and Water Natural Gas Authority
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SECTION 5.0 PROCUREMENT
5.1. Manufacturing of the System
5.1.1 Based on the approved design package, and only once the NGA
approval was granted, the Owner/Licensee shall begin to carry out the
procurement process.
5.1.2 The Owner/Licensee shall obtain all materials from reputable
suppliers with proven track records.
5.1.3 Owner/Licensee shall establish acceptance criteria associated with
suppliers and demonstrate that these are met through conducting a
pre-qualification process.
5.1.4 This process of approval by the Owner/Licensee shall be fully
documented for the possible audit by the NGA.
5.1.5 Procured pipes shall be hydrostatically pressure tested at the mill.
5.1.6 Procured valves shall be API 6D or ISO 14313 compliant. Ball valves
shall be of a solid ball type.
5.1.7 The use of unlisted components is not permitted in ASME B31.3
systems.
5.1.8 The Owner/Licensee shall provide NGA with a notification of 60 days
prior to the performance of the Factory Acceptance Testing (FAT).
5.2. Lawful code
Line pipe and pipeline appurtenances shall be specified in compliance with
lawful codes and the NGA approved specification. Before commencement of
any manufacturing, fabricating or procurement, the NGA and Owner/Licensee
shall have agreement on the material specification, the manufacturing
process and the QA/QC plan in place to assure compliance of the materials
with the specification and codes in place.
5.3. Certificates
Each completed pipe or equipment part (e.g. bend, tee, valve, etc.) shall have
its own unique manufacturing inspection certificates, countersigned by the
NB, which shall be presented to the NGA or its appointed representative for
final acceptance. The NB shall accept the definitive material certificate by
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signing off the original manufacturers documents. The certificates of
components fabricated/manufactured from other certified parent components
shall be provided with the certificate of the parent component.
5.4. Traceability
Each pipe, fitting or part shall have a fully traceable history inclusive of its
base certificate and all steps of its manufacturing process and acceptance
testing.
5.5. Material Specification
The Material Specification shall provide details for the manufacturing method,
limitations, acceptance and rejection criteria, inspection method and the
material traceability method, of the following related elements (as applicable
and not limited to):
Bare pipe certificate
Line pipe corrosion coating
Line pipe weight coating and/or protection coating
Anodes
Line pipe bends
Flanges, Tees, valves and any other appurtenances
Corrosion coating for Flanges, Tees, valves and any other
appurtenances
As a minimum, the following data shall be verified:
Chemical composition of base materials in compliance with chosen
material grade.
Mechanical properties of base materials based testing as per the
relevant code.
Destructive tests may include: tensile testing (longitudinal and
traverse), fracture toughness, hardness (Charpy V, CTOD),
lamination detection, bending, etc.
Mechanical properties of all welds inclusive HAZ.
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Mechanical properties after bending, forging, heat treatment, forming
of base materials.
Corrosion sensitivity of end product. Accelerated corrosion testing of
weld, HAZ and base material sample.
Dimensions.
Measurements of wall thickness, pipe straightness, pipe body ovality,
pipe end ovality.
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SECTION 6.0 CONSTRUCTION
6.1. Construction of the system
Upon completion of the above items, the Owner/Licensee may commence
with the construction document's submittal. NGA will review and provide
comments to the issues stated above. Owner/Licensee shall provide
response to these comments in a timely manner. No construction activity
shall take place prior to resolving all comments to the satisfaction of NGA.
The construction procedures review process may be timely and should be
taken into account when developing the schedule. 60 days prior to
construction the Owner/Licensee will provide the following information:
6.1.1 Quality Management System procedure
The Owner/Licensee shall be responsible to supply the NGA with a
detailed Quality Management System Plan. This plan shall be
assessed by the NGA on its safety aspects through a formal and
systematic review of the installation plan with the objective of hazard
identification and execution concerns. The plan shall provide full
details of the pipeline installation aspects with emphasis on
management of personnel safety and pipeline integrity control during
all phases of the installation. Procedures shall be developed for all
specific installation aspects such as the pipe laying, pipe burial,
pressure testing etc. The procedures shall noticeably address how
human safety and pipeline integrity are managed through all steps of
the installation, how this is monitored and judged.
6.1.2 Spread Supervision Procedures
Spread Supervision procedures shall include a description of the
project that is to be carried out as well as the roles and responsibilities
of each supervisory entity in the project.
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6.1.3 Inspection and Test Plan
Inspection and Test Plan shall include specific construction actions
and the inspection and supervision coverage that is required by each
entity on the project, inclusive of the contractor and supervisory
bodies. A definition of each method of coverage should be included to
assure that the definitions are fully understood by all parties.
6.1.4 Organogram
Organogram shall include the role of each person on the project
inclusive of the contractor's personnel as well as the supervisory
staff's.
6.1.5 Schedule of project
As an essential part of the preparation of the design, the
Owner/Licensee shall prepare a detailed schedule providing data on
all aspects of the planned pipeline development including but not
limited to design, procurement, manufacturing, fabrication, installation,
testing and commissioning aspects.
6.1.6 Risk Assessment for construction
Risk Assessments shall include any risks that may arise during the
construction phase. This may include but is not limited to; personnel
risk, equipment risk, material risk, and environmental risk.
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6.1.7 Construction Procedures
Construction procedures shall include a detailed process for each and
every construction action that is expected to take place on the project.
These may include, but not limited to, the following procedures:
Welding and Inspection QA plan.
Welding consumables handling procedure.
Mechanical connections assembly procedure.
Painting procedure.
Coating procedure.
Holiday Detection procedure.
Pipe and Fitting Alignment procedure.
Excavation and Trenching procedure.
Lowering Procedure.
Backfilling procedure.
Stringing procedure.
Pipe and Fitting Site Storage.
Receiving, Transporting and Piling of Pipes and Fittings
procedure.
Factory Acceptance Test procedure.
Site Acceptance procedure.
Pipe and Fitting Identification and Traceability procedure.
Change Control procedure.
Document control procedure.
Pressure test procedure.
Drying and cleaning procedure.
6.1.8 WPS, PQR, welder qualifications and NDT Examination for the project
Owner/Licensee shall develop, test and implement approved welding
and NDT procedures for all of the welding of the pipeline in obedience
of the lawful codes and the requirements of the design code, stated in
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section 2.5, augmented with the additional requirements to be detailed
in a project specific specification.
The 3rd supervision body shall verify compliance with the codes for all
phases of the weld procedure development inclusive its mechanical
and chemical testing. The NGA or its representative shall have the
right to witness the welding qualification process.
The WPSs shall not be written by the 3rd supervision body used in the
specific project.
Welder's qualifications and PQRs shall be performed to the specific
WPSs issued for the project. Personnel performing the installation
activities related to mechanical connections shall be appropriately
trained and certified.
Owner/Licensee shall apply a strict material traceability record of all
base material, weld consumables and test coupons identification and
verification procedures. Similarly Owner/Licensee shall apply strict
recording of the applied welding parameters including the WPS used
and the welder number. The approved welding procedure shall have
been signed by the 3rd supervision body and supplied to the NGA for
review.
Each welder or welding machine operator shall be qualified in
accordance with design code requirements prior to the start of
production welding by making a test weld using the qualified welding
procedure whereas Owner/Licensee shall assure that only qualified
welders and welding operators are employed during the welding of the
Installation.
Production welding shall not commence until the qualified welding
procedures, qualified welders and qualified inspection personnel lists
have been reviewed and supplied to the NGA and satisfy the
inspection requirements of the 3rd supervision body.
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All CS pipeline and station welds (100%) shall be non-destructively
examined. (NDT) Weld quality shall be in accordance with design
code requirements.
NDT shall be carried out to written procedures, which shall be
submitted to the NGA or its representative prior to the commencement
of the work and shall be reviewed and accepted by 3rd party
supervision body.
Owner/Licensee shall submit detailed procedure and technique sheets
for NDT examination signed off by the 3rd party supervision body for
approval by NGA prior to the start of production.
6.1.9 Electrical and Instrumentation Procedures shall describe the method
of construction of these systems.
6.1.10 All compression fitting assemblies shall be strength tested.
6.1.11 The Cathodic protection procedures shall describe the methods of
installation of the CP system to assure that the system is protected
both temporarily and permanently as per the requirements of the
approved design.
6.1.12 Specific Construction and Supervision Requirements:
a) The Owner/Licensee shall employ piping contractors certified to ISO
3834-2.
b) The Owner/Licensee shall employ the services of a supervision body
to operate on his behalf (2nd party supervision) to supervise all
aspects of construction i.e. mechanical works, welding, civil work,
control and instrumentation CP etc. and to issue reports accordingly.
Personnel performing these supervision activities shall be
appropriately certified, experienced and competent to perform their
respective tasks e.g. AWS, API etc. certification for carbon steel
mechanical and welding supervision.
c) The Owner/Licensee shall employ the services of a 3rd party
supervision body to oversee specific key items in the project, as per
the ITP, and to issue a final inspection certificate and report. The
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inspectors performing these inspection activities shall be directly
employed and approved by the 3rd party supervision body to perform
their specific tasks in their respective disciplines. The 3rd supervision
body body, or inspectors on their behalf, shall not be hired by the
Owner/Licensee as a consultant in the project.
d) Supervision activities shall be carried out by the contractor, 2nd party
and 3rd party supervision bodies, as per the approved ITP.
e) Supervision bodies shall be certified to ISO 17020.
f) The NDT contractor shall be employed by the Owner/Licensee.
g) Re-repairs of welds are not allowed.
6.2. NGA Supervision
The NGA will visit the project over the course of the project and review issues
such as mechanical works, welding works, NDT, CP and Electrical, Control
and Instrumentation.
6.3.1 Contact between the 3rd supervision body and the NGA should be
open and independent. The reports of the 3rd supervision body shall
be provided to NGA for information, as needed.
6.3.2 The Owner/Licensee shall provide the supreme supervision reports
written and Approved by the Lead Designer organization.
6.3.3 Owner/Licensee shall routinely update the NGA with regards to the
project schedule and the foreseen upcoming construction activities.
6.3.4 In the event of a significant design change, the Owner/Licensee shall
provide a design change with the revised drawings/documentation to
the NGA for review and subsequent approval.
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6.3. Notification to the NGA
The Owner/Licensee will provide NGA with notification of the following
activities at least 72 hours in advance. NGA will have the option to attend
these actions as appropriate.
6.3.1 Welding of sample for WPS approval.
6.3.2 Destructive tests at a certified lab.
6.3.3 Approval of welder's to the WPS.
6.3.4 Commencement of mechanical construction activities.
6.3.5 Completion of 30% of the project.
6.3.6 Completion of 75% of the project.
6.3.7 Pressure testing (strength, tightness).
6.3.8 Function testing and SAT.
The Owner/Licensee shall notify NGA if the repair rate of welds exceeds 5%
during any stage of construction.
6.4. Testing and Commissioning
6.4.1 Owner/Licensee shall conduct and successfully complete both
strength and tightness pressure testing before taking the system into
service. Pressure testing shall only be initiated after all construction
activities inclusive any remedial work, have been successfully
completed and the specific piping systems, as a whole, shall no
longer be subjected to any abnormal loading or displacements, other
than those expected for normal operating.
6.4.2 Pressure testing of the complete system shall be carried out in
compliance with the requirements of the precedence code and the
approved pressure testing procedure.
6.4.3 Tightness testing is normally executed in continuation with the
strength test whereby the tightness test pressure is lower than the
strength pressure. A pneumatic tightness test is permitted after the
successful performance of a hydrostatic pressure test.
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6.4.4 Owner/Licensee shall develop and present to the NGA a detailed
pressure test procedure based on the designer's pressure test
procedure submitted during the design stage. The NGA reserves the
right to review the pressure test procedure and to request any
changes and/or amendments, before pipe pressure testing begins.
6.4.5 The agreed Pressure Test Procedure shall be accepted by the 3rd
supervision body and the Lead Designer and shall contain as a
minimum the following key criteria:
Testing criteria to meet inclusive settings, allowable margins.
Test rejection criteria.
Remedial action(s) in case that the test fails.
6.4.6 Following the completion of the hydrotest, the Owner/Licensee shall
provide the NGA with an acceptance of hydrotest certificate as well as
back up documentation that includes:
Pre-hydrotest checklist.
Pressure test report.
Filling reports.
Equalizing reports.
Table of pressures.
Graphs of pressure and temperature values.
6.4.7 This certificate shall be approved and signed by the contractor, the
supervision team on behalf of the Owner/Licensee and the 3rd
supervision body.
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6.5. As built Documentation Provision
The Owner/Licensee shall supply the NGA with one hard copy and two
electronic copies of the As Built Documentation (ABD). The ABD shall
encompass as-manufactured, as-built and as-installed data of the completed
pipeline system and all its parts. This includes but is not limited to:
6.5.1 All line pipe-manufacturing records, approved and signed by a
recognised and by the NGA accepted Notified Body and procured
from pre-qualified known manufacturers.
6.5.2 Inspection and acceptance certificates of all associated materials
such as flanges, elbows, anodes, valves, etc., signed by a
recognised and by the NGA accepted Notified Body and procured
from pre-qualified known manufacturers.
6.5.3 WPSs, PQRs and WPQRs.
6.5.4 All welding and NDT records of welds. All RT films shall include
the letter 'B' for Backscattered Radiation control.
6.5.5 Pipe log book and a daily welding log book.
6.5.6 All inspection and test reports of the field joint coating.
6.5.7 All other construction reports pertinent to the system.
6.5.8 As laid co-ordinates of the pipeline and stations on the original
design layout.
6.5.9 As buried data of the buried pipeline and station sections with
confirmed depth of cover.
6.5.10 Civil engineering as made documentation.
6.5.11 Cathodic protection as made documentation.
6.5.12 Electrical and instrumentation and loop diagram as made
documentation.
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SECTION 7.0 REQUEST FOR GASSING UP
7.1 Request Requirements
Upon completion of the construction and pressure testing stages, the
Owner/Licensee shall submit a formal request for gassing up to NGA. This
request will include the following items:
7.1.1 A formal letter addressed to the NGA requesting an operations permit.
This letter should clearly define the system which is under request.
7.1.2 Construction Completion certificate (as noted in section 7.2) signed by
the contractor, the supervising company, the 3rd supervision body, the
Owner/Licensee and other relevant supervision. This certificate should
base its approval of completion to the design code stated in section
2.5.
7.1.3 Final mechanical completion certificate stating clearly parts of the
system completed. This certificate shall be related to a relevant
specification. This document shall be signed by all relevant parties.
7.1.4 The Owner/Licensee shall provide the letter he receives from the
downstream consumer (or upstream provider) stating the readiness to
receive/accept gas at the relevant pressures, quantities, flows, etc., as
applicable.
7.1.5 Approval letters from the Lead Designer of the installation.
7.1.6 Check list for cold commissioning including general diagrams and
P&IDs.
7.1.7 Operation, Maintenance and Emergency procedures are approved by
NGA and other relevant parties and in place. (as described below)
7.1.8 Pressure test results and approvals inclusive of mechanical
completion checklist that was issued prior to the pressure test
commencing.
7.1.9 A copy of the building permits.
7.1.10 List and approved copies of all NCR/CAR reports.
7.1.11 The final inspection report issued by the 3rd party supervision body.
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7.1.12 Approval of the risk assessor that his recommendations were
implemented and the approval of the risk assessment by the Ministry
of Environmental Protection.
7.1.13 Approval of the CNG road trailers routes to the factory or NGV Filling
Station, as applicable.
7.1.14 The Certificate of conformity to all applicable EU directives and the
PED by the Notified Body.
7.1.15 All items required by the Israeli CNG Safety Decree and the CNG
License.
7.2 Construction Completion Certificate
Upon completion of all work and documentation, the following construction
completion certificate, by each contractor covering his scope of work, will be provided
to NGA:
# Statement Requires Signature of:
1 All materials have been fabricated and
constructed according the relevant designer
documents.
Owner/Licensee, 2nd party
supervision, 3rd party
supervision , contractor
2 All materials were purchased by
Owner/Licensee or on his behalf and
supplied in accordance with the design and
standards.
Owner/Licensee, 3rd party
supervision
3 All welds have been checked, approved and
accepted in accordance with the standards
and design.
Owner/Licensee, 2nd party
supervision, 3rd party
supervision , contractor
4 All works have been constructed in
accordance with the approved design.
Owner/Licensee, Designer, 2nd
party supervision, 3rd party
supervision , contractor
5 Holiday detection was performed in
accordance to the standard.
Owner/Licensee, 2nd party
supervision, 3rd party
supervision , contractor
6 All pressure testing, dewatering and drying Owner/Licensee, 2nd party
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of the system piping within the CNG
facilities and systems has been performed
in accordance with the approved procedures
and the results have been completed and
accepted in accordance with the standards.
supervision, 3rd party
supervision , contractor
7 The Golden weld was performed and
accepted by all.
Owner/Licensee, 2nd party
supervision, 3rd party
supervision , contractor
8 All NCRs and CARs have been successfully
closed out.
Owner/Licensee, 2nd party
supervision, 3rd party
supervision , contractor
9 Permanent Cathodic Protection has been
put in place as per the design and relevant
standards and accepted by all.
Owner/Licensee, 2nd party
supervision, contractor
10 All electrical works have been constructed
as per design and relevant specifications
and are ready for startup of the facility.
Owner/Licensee, 2nd party
supervision, contractor
11 The SCADA/Control system has been
constructed as per design and relevant
specifications and is ready for operation
upon startup of the facility.
Owner/Licensee, 2nd party
supervision, contractor
12 The firefighting system has been
constructed as per design specifications,
successfully hydrotested and is ready for
startup of the facility.
Owner/Licensee, 2nd party
supervision, contractor
13 All safety and security measures are in
place and are ready for startup of the
facility.
Owner/Licensee
14 Cold commissioning has taken place
successfully and accepted by all.
Owner/Licensee, 2nd party
supervision, 3rd party
supervision , contractor
15 The system is ready for gassing up as per
the design and relevant specifications.
Owner/Licensee, Designer, 2nd
party supervision, 3rd party
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supervision , contractor
16 Operations, Maintenance and Emergency
Procedures are complete and approved, all
operators personnel have been trained, all
parties are aware and knowledgeable of the
emergency procedures.
Owner/Licensee
17 All issues and recommendations raised in
the risk assessment (carried out during the
design phase) have been successfully
addressed.
Owner/Licensee, Risk Assessor
18 All issues and recommendations raised in
the geotechnical assessment and structural
assessment (carried out during the design
phase) have been successfully addressed.
Owner/Licensee/operator,
Geotechnical and/or structural
engineer
Any request for concession from the above language shall be raised, in writing, to the
NGA.
7.3 NGA Review
The NGA shall review the documentation provided for the above items and
will provide comments and request clarification as necessary.
Owner/Licensee shall allow for sufficient time for NGA review of these items.
7.4 Provision of Gassing Up Permit
Upon fulfillment of the requirements of this chapter, the NGA shall provide a
gassing up permit to the Owner/Licensee for the initial startup phase.
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SECTION 8.0 OPERATIONS AND EMERGENCY
8.1 Procedure Details
The Owner/Licensee shall prepare signed and approved copy of the detailed
emergency, maintenance and operations procedures that will be reviewed by
the NGA.
8.1.1 The emergency procedure will take into account the natural gas
facilities in the premises as well as mutual influences possible from
other, nearby gas works and/or other infrastructure in the area. This
plan shall provide all possible emergencies related to the operation of
an Industrial Gas Installation system.
The Owner/Licensee shall identify and classify emergencies and their
consequences regarding HSE.
8.1.2 For all cases the Owner/Licensee shall analyze the short term and
long term effects of such emergency and the response to the
occurrence.
8.1.3 For each type of emergency, the Owner/Licensee shall have a pre-
established response and effect mitigation plan with the objective of
avoiding, or at least, limiting the negative effect regarding HSE. To
accomplish this, the Owner/Licensee must demonstrate to the NGA
that an effect mitigation / limitation philosophy is in place, that
personnel rescue and evacuation procedures is in place, that
associated spare/repair materials are in stock, that specialist contracts
are in place, and that repair and clean-up procedures are developed,
etc.
8.1.4 The emergency procedure will also include a valve by valve opening
and closing status to assure proper closure in the event of an
emergency.
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8.1.5 The Owner/Licensee shall prepare a copy of the operations
procedures that will include venting, gassing up, start up, restart,
commissioning and decommissioning procedures (air to N2 to NG and
NG to N2 to air), and maintenance and will include specific valve
maneuvering and all other actions to be carried out to assure safe
practices on site. Valve maneuvering tables shall be prepared that
clearly note the status of each and every valve during the operation in
order to assure safe practices. These tables will provide for the
signature of the operator for each and every maneuvering action of
valves.
8.1.6 The operations manual shall provide more detailed and specific
information applicable to the CNG systems and complementary to the
requested information therein.
8.1.7 The operations manual shall address the following topics:
Steady flow operating conditions of the piping system(s)
Planned shut-down of the system
Unplanned shut-down of the system
Planned re-start-up of the system
Emergency shut-down and blow-down
Corrosion management
Inspection and maintenance
8.1.8 For the above operations, the Owner/Licensee shall develop detailed
procedures, inclusive of step-by-step description of necessary actions,
plans, drawings, signs, manpower requirements, organization, names
and contacts.
8.1.9 As per NGA, of the CNG license Owner/Licensee shall operate a 24/7
main control room. The Compression and NGV Filling Stations shall
be manned at all times.
8.1.10 The License Owner shall develop the appropriate operations
procedure which will ensure that the gas quality in NGV filling stations
meets with the requirements of SI 6119.
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8.2 System Final Approval
Upon successful completion of the hot commissioning of the system, the
Owner/Licensee shall provide a completion of hot commissioning and transfer
to normal operations certificate to the NGA. The NGA shall consider the
provision of the final operation approval based on the information provided.
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SECTION 9.0 HEALTH SAFETY AND ENVIRONMENT PLAN
9.1 General safety
Health, Safety and care of the Environment are of prime importance to the
NGA. The Owner/Licensee shall be committed to maintain a safe, healthy and
injury free workplace for its employees and any person working on behalf of
the Owner/Licensee. Furthermore, the Owner/Licensee shall be committed to
avoid damage to the environment.
9.2 Adherence to Procedures
Adherence to agreed procedures, work-plan, operating philosophy, etc., of all
personnel is fundamental to ensuring safe and efficient working conditions. It
should be stressed that the responsibility for Health, Safety and care for the
Environment is the responsibility of the Owner/Licensee and shall be an
integral part of and is inseparable from all daily operations.
9.3 HSE Objectives
9.3.1 Owner/Licensees HSE objective shall be to:
9.3.2 Provide effective safety systems and plans for managing HSE in all his
operations to ensure those risks are assessed and reduced to level:
As Low As Reasonably Possible (ALARP).
9.3.3 Properly inspect and maintain all equipment and tools.
9.3.4 Promote safety awareness, near miss reporting and a healthy,
responsible attitude amongst all personnel.
9.3.5 Ensure effective emergency response arrangements, backed-up with
trained and exercised personnel.
9.3.6 Establish and maintain clear written standards and procedures to
control the risk to HSE and ensure that these are adhered to.
9.3.7 Ensure that all personnel involved, either staff or subcontractors, are
competent and able to perform their tasks safely.
9.3.8 Ensure prompt investigation of incidents and that adequate corrective
actions are taken.
9.3.9 Promote joint consultation and lateral learning for all personnel
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9.3.10 Provide sufficient resources for HSE advisory and audit services to
assist management to meet set HSE policy objectives.
9.3.11 Co-operate with statutory and professional bodies to promote
workable, practical standards and improve codes of practice and
legislation in relation to HSE matters.
9.4 Training and Maintenance
9.4.1 The NGA requires that all work under supervision of the
Owner/Licensee shall be carried out with due observance of all legal
requirements to achieve the required statutory standards for Health,
Safety and Environment.
9.4.2 Owner/Licensee shall ensure that for all parties, personnel,
contractors, working on behalf of Owner/Licensee, are fully familiar
with and will adhere to statutory health, safety and environmental
standards and regulations. The HSE-Plan shall include for regular
audits, inspections, HAZIDs and HAZOPs. The NGA reserves the right
to witness audits, inspections, HAZOPs, HAZIDs and if considered
required, the NGA request for changes and/or amendments of the
plans prior to implementation.
9.4.3 The Owner/Licensee shall ensure that the training and certification
requirements for Safety Advisors, Fillers, Drivers etc. contained within
the ADR are satisfied.
9.4.4 The Owner/Licensee shall provide appropriate general NG safety
related training and specific CNG certification to all relevant personnel.
9.5 Safety Management System
9.5.1 Owner/Licensee shall develop and implement a safety management
system (SMS).
9.5.2 The SMS is a systematic approach to safety and health aspects in the
execution of onshore pipeline installation operations.
9.5.3 The approach must be laid down in a formal description in which it
must be demonstrated that the work is organized in such a way that it
can be executed safely.
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9.5.4 The SMS relates to all phases and combination of phases involved in
installation operations.
9.5.5 The SMS must in general contain objectives relating to safety and
health:
The way it is intended to accomplish these objectives.
The standards applicable to accomplish these objectives.
The way in which observance of these standards will be
monitored.
9.5.6 The description of the SMS should satisfy the principles of quality
management as formulated in the ISO-9000 series and should
contain, as a minimum, the following elements:
Safety policy and control.
Establishment of safety management evaluation criteria.
Design, safety margins, review, applicable codes.
Operations, HAZOPs, compliance with statutory regulations
and industry standards, environmental limitations,
Personnel required training standards, required courses, and
job selection criteria.
Supervision, required experience, job analysis, risk
identification, incident and near miss reporting, accident
and incident investigation
Emergency planning and drills
9.6 Items to be addressed in HSE Procedures
9.6.1 Disposal of chemicals used for the commissioning and conservation of
pipelines such as dye, corrosion inhibitors, oxygen scavengers,
biocides, etc.
9.6.2 Any limitations to exposure to the environment of chemicals i.e. zinc
anodes.
9.6.3 For each project installation a HSE plan shall be developed. This plan
needs to address all measures taken to support safe and healthy
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working conditions for all personnel involved and all measures taken to
avoid pollution of the environment. The HSE shall include safety
training of personnel, health and safety measures related to personnel
transport to and from the offshore installation sites, health and safety
training and standards applied for hazardous.
9.6.4 The HSE plan shall provide details of and schedule for safety audits.
9.7 Environmental Responsibility
An Environmental Management Plan shall be prepared by the
Owner/Licensee. The EMP shall address the effects of materials, anodes, and
coating on its environment. With respect to cleaning and testing of the
pipeline/AGI's using inhibited water, the used chemicals shall be of a
biodegradable nature. The EMP will specify all areas of possible impacts due
to the construction of the pipeline and all proposed mitigation measures.
9.8 Incident reporting
9.8.1 Any incident occurring during the course of the manufacturing,
construction, installation and commissioning phase shall be reported
immediately to NGA and by written statement within 48 hours of the
incident. Such Incident Report shall provide a full description of the
course of such an incident and the measures to mitigate reoccurrence
of a similar type of incident. The Owner/Licensee shall maintain
statistics with respect to the incidents occurring. These statistics shall
be evaluated against threshold values, pre-agreed between the NGA
and the Owner/Licensee. In case unacceptable levels of incidents take
place, the NGA shall instruct the Owner/Licensee to re-assess his
SMS and might stop all work until such re-assessment has been
undertaken.
9.8.2 Similarly, the Owner/Licensee shall report near-misses, situations
that have not caused incidents but had the potential to do so. The
Owner/Licensee shall actively pursue near miss reporting amongst all
personnel involved in the work.
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9.9 Hazard Identification Study (HAZID)
9.9.1 The Owner/Licensee shall apply a structured manner in hazard
identification, by conducting frequent assessments of the work. These
HAZIDs shall be in the form of a meeting in which a multidisciplinary
brainstorming season shall be held about the work activities, the
circumstances on the work place, the human factor, etc. The end
result of a HAZID should lead to identification of potential hazards,
shortcomings and out of this, possible recommendation, improvements
could be accomplished.
9.9.2 The objective of a HAZID is to provide the NGA with assurance that:
The Owner/Licensees selected technology can be applied
with confidence so as to provide a safe and operable
Industrial Gas Installation system.
The manufacturing, fabrication and installation of the
system can and will be achieved without unacceptable
dilution of design intent.
That the Owner/Licensee is adequately prepared to
commission and operate the pipeline
That the system is achieving an acceptable level of safe
operation consistent with commercial intent.
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SECTION 10.0 QA/QC SYSTEM QUALITY ASSURANCE AND
CONTROL PLAN
10.1 The Owner/Licensee shall develop, implement, maintain and report using an
approved Quality System, which shall be in accordance with ISO 9000 series.
The Owner/Licensee shall present to the NGA his quality system as a
document hereinafter referred to as the Quality Plan (QP). The QP shall
address the measures taken to assure that all aspects of manufacturing,
procurement, installation and commissioning are executed to internationally
and/or domestically recognised standards and, as a minimum, to ISO 9000
series.
10.2 The QP shall include for hold points related to, witnessing, inspection and
acceptance hold points by the NGA. The NGA reserves the right to review the
QP and to request for changes and/or amendments, before the QP is
implemented.
10.3 Upon implementation of the QP, the Owner/Licensee shall timely invite the
NGA for witnessing the agreed hold points. It will be up to the NGAs
discretion to witness these hold points.
10.4 The 3rd supervision body shall further check the quality of the work and the
effectiveness of the Owner/Licensees quality system on spot check basis.
The Owner/Licensee shall carry out all remedial actions as a result of such
sampling.
10.5 Contractors, sub-contractors, suppliers, fabrication and installation
contractors, proposed by the Owner/Licensee for the pipeline work, shall be
reputable, pre-qualified entities. The Owner/Licensee shall, on request, supply
the NGA information regarding the proposed entities track record, reputation,
pre-qualification criteria and compliance with these, audit results. On request,
the Owner/Licensee shall supply the list of pre-qualified entities.
10.6 The QP plan shall further include for an inspection, test and audit plan.
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SECTION 11.0 INSPECTION AND MAINTENANCE PROGRAM
11.1 The Owner/Licensee shall develop and submit to the NGA a system
inspection and maintenance program for the lifetime of the complete system
including all sections based on the NGA Factories Operation and
Maintenance Directive (FOMED).
11.2 The internal inspection shall confirm the system(s) integrity. The integrity
could be jeopardized as the result of corrosion, pitting, and buckling
resulting from internal or external accidental loads.
11.3 The external inspection shall confirm that the external piping system(s) has
not suffered from accidental loads.
11.4 External inspection shall be conducted using approved methods of
inspection.
11.5 The NGA or its appointed representative shall be invited by the
Owner/Licensee to witness the inspection.
11.6 If the inspection results give reason for concern and the piping system(s)
integrity is considered an HSE concern, the NGA has the right and will
request the Owner/Licensee to shut-down the system and to make it safe
without delay.