IGID 2013

NGA

IGID 2013

State of Israel

Ministry of Energy and Water Natural Gas Authority

Industrial Gas Installation Directive

(IGID)

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

State of Israel Ministry of Energy and Water

Natural Gas Authority

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Revision History:

Revision # Date Reason for change

0 1.2.09 Initial draft 1 2.3.09 Review with comments 2 22.3.09 Review with comments 3 6.4.09 submitted to NGA 4 19.11.09 submitted to NGA 5 08.08.10 Add'l comments in section 1.4, 6 & 7- 31792 6 10.09.13 General Update



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Table of Contents

PREFACE ....................................................................................................................... 4

SECTION 1.0 GENERAL ..................................................................................................... 7

SECTION 2.0 RELEVANT STATUTORY PLANS .............................................................. 9

SECTION 3.0 DESIGN OF THE SYSTEM ........................................................................ 11

SECTION 4.0 PROCUREMENT ....................................................................................... 19

SECTION 5.0 CONSTRUCTION ....................................................................................... 24

SECTION 6.0 REQUEST FOR GASSING UP .................................................................. 34

SECTION 7.0 OPERATIONS AND EMERGENCY.......................................................... 37

SECTION 8.0 HEALTH SAFETY AND ENVIRONMENT PLAN ..................................... 39

SECTION 9.0 QA/QC SYSTEM QUALITY ASSURANCE AND CONTROL PLAN ....... 45

SECTION 10.0 INSPECTION AND MAINTENANCE PROGRAM .................................... 46



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PREFACE

The NGA require all gas systems to be safe and operated within tolerable levels of

individual and societal risk and maintain the integrity of gas systems throughout the

operational life of these systems.

All gas system Owners/Operators 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/Operator bears the sole responsibility for the safe design, construction,

operation and maintenance of the system and shall implement the required

procedures, means and methods assuring that the system integrity is maintained

throughout its design life.

Approval issued by the State of Israel to the Owner 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 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, the Owner shall indemnify the

State, and/or on its representatives, accordingly. The Owner 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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Abbreviation/Definition List ABD - As Built Documentation

AGI - Above ground installation

ALARP - As Low As Reasonably Possible

CA/CB - Certifying Authority/Certifying Body

CAR - Corrective action report. Issued to close out a specific NCR.

Contractor - The body performing works. Deemed as the 1st party in this document

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

NCR - Nonconformance report detailing a non-conformity to the design requirement or a procedure.

NDT - Non Destructive Testing

NGA - Natural Gas Authority- Israel

OPM - Operating Manual

Owner - May be the owner and/or operator and is deemed as the 2nd party in in this document

P&ID - Process and instrumentation diagram

PE - Polyethylene

PFD - Process flow diagram

(W)PQR - (welding) Procedure qualification record



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QA/QC - Quality Assurance / Quality Control

QP - Quality Plan

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

- TABA’s, VATAL's, Building Permits etc.

TPI - Third Party Inspection Body. Deemed as the 3rd party supervision body in this directive

WPS - Welding procedure specification



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SECTION 1.0 GENERAL

1.1 This document shall be known as the Industrial Gas Installation Directive,

hereinafter entitled the IGID. The scope of this document takes into

consideration the upstream boundary limits from the NG provider up to the

first isolating valve in the appliance skid (Boiler, Gas Turbine, Kiln or other

facility). Therefore, it is considered that this valve is the downstream boundary

limit and therefore shall not be included in the design package.

1.2 The IGID shall be supplementary to the relevant statutory plans (TABA’s,

VATAL's, Building Permits etc.), the Natural Gas Law, Safety Decree and

other relevant regulations, and shall be read in conjunction with them.

1.3 The relevant statutory plans shall be in place and sanctioned independent of

the IGID. The IGID provides more detailed specification of some of the

requested information necessary to obtain NGA approval for the design,

fabrication, installation and operation of Industrial Gas Installation system.

1.4 The standards relevant for the IGID are the EN 15001 (series) or the ASME

B31.3 (Latest Editions). Hazardous Area Classification shall be carried out as

per the requirements of the IGEM/SR/25 or the EN 60079-10. Buried sections

of PE pipe shall be designed and tested as per the requirements set by the SI

5664 Part 3.

1.5 In case of conflict, the relevant statutory plans and the Natural Gas Law

and/or Safety Decree shall govern over the IGID.

1.6 The general objective of the IGID is to present instructions and guidelines

required by the Natural Gas Authority (NGA) to the supplier, Owner or

Operator (herein, owner) of an Industrial Gas Installation system, with the

intention of assisting the applicant obtaining required, necessary permits.



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1.7 The IGID is applicable to the planning, designing, fabrication, constructing,

operating and maintaining of an Industrial Gas Installation system and does

not address local and regional permitting.

1.8 Owner shall be in full compliance with the IGID. When in full compliance with

the requirements of the IGID and all other specific requirements made by the

NGA, the NGA will submit written confirmation of compliance to the required

Regional Planning Committee.

1.9 Once written confirmation has been submitted by the NGA to the Regional

Planning Authorities, the owner may continue to apply for the required

building permits ( ).

1.10 Owner’s compliance with the IGID shall be verified with the NGA through the

ongoing process, as described below. Only upon completion of this process

will written approval be submitted, as described in section 1.8.

1.11 Owner shall bear all costs associated with Owner’s compliance with the IGID

and application for permits. The NGA shall not bear any commercial or other

responsibility related to Owner’s successful or unsuccessful compliance with

the IGID and application for permits.

1.12 The NGA shall be the custodian of the IGID. The Owner shall be obliged to

obtain the latest version of the IGID inclusive of all its supplements,

addendum, etc., from the NGA

1.13 The purpose of the IGID is to create conditions for the safe and efficient

development and use of an Industrial Gas Installation system in accordance

with Israeli governmental law and policy.

1.14 Before Owner can install and subsequently operate an Industrial Gas

Installation system, the Owner shall apply for a permit and such permit shall

be granted prior to commencement of any installation related activity. The



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IGID provides guidelines and instructions for Owner to follow in his application

procedure for an installation and operating permit.

1.15 Exemptions to the IGID may be granted by the NGA only upon written request

by Owner and subject to agreed restrictions and conditions. Such agreed

exemption shall carry NGA signature. Exemptions to the IGID shall be

considered on a case-by-case basis and a given exemption can be withdrawn

if:

1.15.1 The data furnished by Owner to obtain it appear 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.

1.15.2 The circumstances on the basis of which it 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.

1.15.3 It cannot be maintained in case a safety hazard develops out

of it.

1.15.4 It appears that one or more conditions, under which it was

granted, are not complied with.



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SECTION 2.0 RELEVANT STATUTORY PLANS

2.1 The design, procurement, construction and operations of the system shall

fully comply with the relevant statutory plans instructions (TABA’s, VATAL's,

Building Permits etc.), as applicable.

2.2 The owner shall verify if more than one statutory permit is applicable to the

segment.

2.3 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.

2.4 A detailed risk assessment shall be carried out on each Above Ground

Installation (AGI).



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SECTION 3.0 DESIGN OF THE SYSTEM

3.1 Schedule

3.1.1 As an essential part of the preparation of the design, the Owner 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:

Description of all key activities in logical sequence

Early and late start of these activities

Early and late completion of these activities

Scheduled or available float in all activities

Interfaces with third parties

Milestones

Target dates for getting permits

Contingencies and mitigation measures in case of conflicts

3.1.2 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.

3.1.3 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.

3.2 Detailed Design

3.2.1 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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3.2.2 The design shall provide a complete and comprehensive summary of

all design related data and criteria applicable to the proposed

Industrial Gas Installation system such as:

Reference to the design code stated in section 1.4,

guidelines, technical specifications and all addenda to

these.

Relevant engineering decisions, their rationality, choice of

design related parameters and any other variables having

impact on the design.

Software used for design and analyses.

Decisive design factors derived from the route survey,

environmental, corrosion and protection philosophy,

specific operating criteria, required lifetime for the pipeline,

etc.

3.2.3 Code deviations will not be accepted by NGA.

3.2.4 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 (as applicable).

3.2.5 The scope of the NGA review takes into consideration the upstream

boundary limits from the NG provider up to the first isolating valve in

the appliance skid (Boiler, Gas Turbine, Kiln or other facility).

Therefore, it is considered that this valve is the downstream boundary

limit and therefore shall not be included in the design package.

3.2.6 The design shall be carried out by a recognized, competent, design

firm to assure its robustness. If designed by a local design house, the

design shall be approved by a foreign design company with the

appropriate experience and track record in the design of similar

systems or an international expert with the appropriate qualifications

and competencies.



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3.2.7 To support the design, Owner shall conduct a detailed route survey of

the proposed system, on both sides of the theoretical centerline of the

pipeline corridor as well as around any above ground system facility,

(e.g. block valve station, PRMS, etc.) which shall provide the following

data along the route:

Land use limitations (as per the relevant statutory plans).

Surface topography.

Location of any infrastructure facilities, infrastructure lines,

(i.e. Overhead and Buried High Voltage Infrastructures,

below ground pipelines) buildings, above and underground

structures, etc.

3.2.8 The data obtained from this survey shall be evaluated and utilized in

the decision making regarding optimization of the proposed pipeline

route and or gas network within the plant and be taken into

consideration for the pipeline design, particularly taking into account

possible hazards to the NG system due to the surrounding areas.

Above ground installations such as an inlet valve station or a PRS etc.

shall be fitted with a sunshade.

3.2.9 The detailed design shall include the following items that firmly

establish the system parameters, installation and operating criteria and

limitations:

List of initials.

Basis of Design Document which include the following, but

not limited to:

Project specific introduction.

Overall design philosophy and statements of code

compliance.

A list of the codes applied and the precedence code.



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Design pressure and operating pressure ranges. The

MIP shall be lower than the design pressure.

Design and operational temperatures. Design

temperatures shall be -10 to +50 degrees C for buried

carbon steel pipe and -10 to +65 degrees C for above

ground pipework. PE pipe design temperatures shall be

chosen as dependent on the allowable MOP and the

provisions of SI 71555.

Pipe diameters, Material grade (composition, choice of

material etc.), flows and velocities.

The Pipe and Valve Specifications used.

Protection system against over pressurization.

P&ID and PFD indicating the battery limits.

All tie-in interfaces between the upstream provider

(INGL or the Distribution Companies) shall be above

ground and flanged.

Isolation Joints and/or Isolating Flange Kits shall be

installed above ground. Isolation Joints shall be installed

in the Horizontal position only.

Wall thickness calculations. 1 mm corrosion allowance is

required by NGA.

Design drawings, Isometrics and an aerial photo (Tatza) with

the pipe route, valve station, consumers etc. superimposed.

Hazardous area classification report and drawings for the

NGA scope and for the scope downstream of it.

Ventilation assessment of enclosed spaces.

HAZOP.

HAZID.

SIL Assessment, if applicable.

Corrosion protection measures. (Corrosion coating, CP,

impressed current).

Pipe depth of cover shall be at least 1.2 meters.



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PE to CS interfaces details and drawings. The transition

fittings shall be installed at or closed to the buried pipe level

and the buried CS section cathodically protected with

upstream and downstream Insulation Joints.

Geotechnical report.

Risk assessment which considers the upstream supplier's

skid (if applicable) with an A2 or larger drawing detailing the

calculated distances superimposed on the plant layout and

fence.

Fire and Gas assessment and mapping.

Earthquake design.

Pipe support calculations.

Specific HDD Design, if applicable.

Protection measures (burial, backfill, concrete coating,

saddles, vehicle crash protection etc.)

Installation criteria and limitations i.e. allowable stress level

and stress control during all phases of the pipeline

installation activities.

Electrical basis of design and drawings.

Control and Instrumentation basis of design and drawings.

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.

The submitted stress analysis files for design review shall

include the following:

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.



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Load case table (Sustained, Expansion, Occasional,

Operational, Hydrostatic and Fatigue).

Electronic copies of the output files.

Restraint summary report inclusive of the forces and

moments at each support type.

Code compliance summary report.

Stress isometrics generated by the software.

Pressure Test Plan which shall include the following:

A table containing the various test sections

(numbered and color coded), design and test

pressures, test medium and test duration.

PE pipe sections shall be tested using the guidance

given in Appendix T of SI 5664 Part 3.

General Arrangement Drawing or Pipe Isometrics

indicating the highlighted test sections in color and

cross referenced with the table detailed above.

Only one golden weld is permitted.

3.2.10 The detailed design package shall be signed and approved by the

designer, the international design firm or an international expert and

the owner.

3.2.11 The designer shall provide a statement that approves that the design

meets the requirements of the design code as found in section 1.4 as

well as the relevant statutory plans.

3.2.12 The Owner shall provide a statement approving the above as well and

stating his readiness to own and / or operate this line in a safe

manner.



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3.3 Provision of the Package

3.3.1 The owner 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.

3.4 The NGA Review Process

3.4.1 The NGA shall review the design for content and shall be allowed to

reject the design out of hand, should the package quality not meet the

required high standards.

In the event that the package is rejected as such, the owner 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 assure that the package is robust. This revised

package shall also be approved by the experienced and independent

international design firm.

3.4.2 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 for

response.

3.4.3 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.

3.4.4 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.



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3.4.5 Upon conclusion of the review, a final revised design package shall be

provided, as per the method described above.

3.4.6 The final design package shall be signed and approved by the

designer, owner and the international design firm.

3.4.7 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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SECTION 4.0 PROCUREMENT 4.1 Manufacturing of the System

4.1.1 Based on the approved design package, the owner shall begin to

carry out the procurement process.

4.1.2 The Owner shall obtain all materials from reputable suppliers with

proven track records.

4.1.3 Owner shall establish acceptance criteria associated with suppliers

and demonstrate that these are met through conducting a pre-

qualification process.

4.1.4 This process of approval by the owner shall be fully documented for

the possible audit by NGA.

4.1.5 Procured pipes shall be hydrostatically pressure tested at the mill.

4.1.6 Procured valves shall be API 6D compliant. Ball valves shall be of a

solid ball type.

4.2 Lawful code

Line pipe and pipeline appurtenances shall be specified in compliance with

lawful codes and NGA approved specification. Before commencement of any

manufacturing, fabricating or procurement, the NGA and Owner 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.

4.3 Certificates

4.3.1 PE

Each pipe and fitting shall have relevant documentation proving

manufacturing, inspection and test certificate to the applicable code

which shall be presented to the NGA or its appointed representative

for final acceptance.



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4.3.2 Steel

Each completed pipe or part (e.g. hot bend, T, valve) shall have its

own unique manufacturing, inspection and test certificate which shall

be presented to the NGA or its appointed representative for final

acceptance. The independent third party shall accept the definitive

material certificate by signing off the original documents. The

certificates of components fabricated/manufactured from other

certified parent components shall be provided with the certificate of the

parent component.

4.4 Traceability

4.4.1 PE

Each PE pipe and fitting shall have a fully traceable history of its

manufacturing process and acceptance testing.

4.4.2 Steel

Each pipe or part shall have a fully traceable history inclusive of its

base plate certificate and all steps of its manufacturing process and

acceptance testing.

4.5 Material Specification

4.5.1 P.E.

Material specification for P.E. pipes and fittings shall be in accordance

with the applicable codes.

4.5.2 Steel

The Material Specification shall provide details for the manufacturing

method, limitations, acceptance and rejection criteria, inspection



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method and the material traceability method, of the following related

elements (as applicable):

Bare Line pipe

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.

Chemical composition shall be 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.

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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4.5.3 Material Manufacturing Third Party Inspection

4.5.3.1 PE

Third party inspection is necessary at the establishment of the

contract between the pipe and fitting manufacturers and the

owner. This requirement may be reduced if the NGA is satisfied

that the manufacturer fully complies with the relevant codes

and specifications.

Owner shall provide the NGA with the inspection and testing

program and procedures proposed to verify that the chemical

and mechanical properties are met, frequency of testing not

limited to destructive and non-destructive testing method,

testing equipment, verification, acceptance and reject criteria,

etc.

The manufacturing process of pipe and fittings shall be

evaluated through a pre-agreed test and inspection plan, which

shall be conducted by qualified inspectors and submitted to the

NGA. The inspectors shall be employed by an independent

certifying body that is accepted by the NGA.

The NGA reserves the right to review the material

manufacturing specification, test and inspection plan, QA/QC

plan, etc. and to request changes and/or amendments, before

procurement of pipe and fittings is being initiated.

During any phase of the manufacturing process, Owner shall

provide the NGA ample warning (minimum 2 weeks) for the

NGA to witness agreed hold points.

4.5.3.2 Steel

Owner shall provide the NGA with the inspection and testing program

and procedures proposed to verify that the chemical and mechanical

properties are met, frequency of testing not limited to destructive and



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non-destructive testing method, testing equipment, verification,

acceptance and reject criteria, etc.

The manufacturing process shall be monitored through a pre-

agreed test and inspection plan, which shall be conducted by

qualified inspectors. The inspectors shall be employed by an

independent Certifying Body such as Lloyds, DNV, Bureau

Veritas, TUV etc. or any party to be acceptable to the NGA.

For already made, off the shelf materials, Owner shall supply

evidence of authenticity of base material, manufacturing

specification with reference to lawful codes, test and inspection

and acceptance certification, signed by independent Certifying

Body such as Lloyds, DNV, TUV or any party to be acceptable

to the NGA.

The NGA reserves the right to review the material

manufacturing specification, test and inspection plan, QA/QC

plan, etc. and to request for changes and/or amendments,

before pipe manufacturing and procurement of appurtenances

is being initiated.

During any phase of the manufacturing process, Owner shall

provide the NGA ample warning (minimum 2 weeks) for the

NGA to witness agreed hold points.



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SECTION 5.0 CONSTRUCTION 5.1 Construction of the system

Upon completion of the above items, the owner may commence with the

construction document's submittal. NGA will review and provide comments to

the issues stated above. Owner shall provide response to these comments in

a timely manner. No construction activity should 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 will provide the

following information:

5.1.1 Quality Management System procedure

The Owner 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.

5.1.2 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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5.1.3 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.

5.1.4 Organigram

Organigram shall include the role of each person on the project

inclusive of the contractor's personnel as well as the supervisory

staff's.

5.1.5 Schedule of project

As an essential part of the preparation of the design, the Owner 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.

5.1.6 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.

5.1.7 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 include, but not limited to, the following procedures:

Welding and Inspection QA plan.



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Welding consumables handling procedure.

Polyethylene Butt welding and Electrofusion Visual Inspection

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.

Site Acceptance procedure.

Pipe and Fitting Identification and Traceability procedure.

Change Control procedure.

Document control procedure.

Pressure test procedure.

Drying and cleaning procedure.

5.1.8 WPS, PQR, welder qualifications and NDT Examination for the project

Owner 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

section 1.4, augmented with the additional requirements to be detailed

in a project specific specification.

An independent Certifying Body shall verify compliance with the codes

for all phases of the weld procedure development inclusive its



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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 party supervision body used

in the specific project.

Welder's qualifications and PQRs shall be performed to the specific

WPSs issued for the project.

Owner shall apply a strict material traceability record of all base

material, weld consumables and test coupons identification and

verification procedures. Similarly Owner 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 independent Certifying 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 shall assure that only qualified welders and

welding operators are employed during the welding of the Industrial

Gas 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 independent third party.

All pipeline and station welds (100%) shall be non-destructively

examined. (NDT) Weld quality shall be in accordance with design

code requirements.



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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 independent third

party certifying body.

Owner shall submit detailed procedure and technique sheets for NDT

examination signed off by independent Certifying Body for approval by

NGA prior to the start of production.

5.1.9 Electrical and Instrumentation Procedures shall describe the

method of construction of these systems.

5.1.10 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.

5.1.11 Specific Construction and Supervision Requirements

5.1.11.1 The Owner shall employ piping contactors certified to ISO 3834.

5.1.11.2 Supervision activities shall be carried out by the contactor, 2nd

party and 3rd party, as per the approved ITP.

5.1.11.3 The Owner 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 certified,

experienced and competent to perform their respective tasks e.g.

AWS, API etc. certification for carbon steel mechanical and welding

supervision.

5.1.11.4 The Owner shall employ the services of a third 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 inspectors

performing these inspection activities shall be directly employed and



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approved by the 3rd party supervision body to perform their specific

tasks in their respective disciplines. The third party supervision body,

or inspectors on their behalf, shall not be hired by the owner as a

consultant in the project.

5.1.11.5 Supervision bodies shall be certified to ISO 17020.

5.1.11.6 Third party supervision is also applicable to PE segments of pipe.

5.1.11.7 The NDT contractor shall be employed by the Owner.

5.1.11.8 Re-repairs of carbon steel welds are not allowed.

5.1.11.9 At least one production weld shall be carried out during the course

of construction (two if PE and CS are used). Additional welds shall

be cut out for testing as per best practice and the results of the

testing of the first production weld/s cut out.

5.2 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.

5.2.1 Contact between the third party agency and the NGA should be open

and independent. The reports of the third party agency shall be

provided to NGA for information, as needed.

5.2.2 The owner shall provide the supreme supervision reports written by

the designer.

5.2.3 Owner shall routinely update the NGA with regards to the project

schedule and the foreseen upcoming construction activities.

5.2.4 In the event of a significant design change, the owner shall provide a

design change with the revised drawings/documentation to the NGA

for review and subsequent approval.



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5.3 Notification to the NGA

The Owner 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.

5.3.1 Welding of sample for WPS approval.

5.3.2 Destructive tests at a certified lab.

5.3.3 Approval of welder's to the WPS.

5.3.4 Commencement of mechanical construction activities.

5.3.5 Completion of 30% of the project.

5.3.6 Completion of 75% of the project.

5.3.7 Pressure testing (strength, tightness).

5.3.8 Function testing and SAT.

The Owner shall notify NGA if the repair rate of welds exceeds 5% during any

stage of construction.



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5.4 Testing and Commissioning

5.4.1 Owner shall conduct and successfully complete a pressure test

before taking the system into service. The testing shall only be

initiated after all construction activities inclusive any remedial work,

have been successfully completed and the body, as a whole, shall no

longer be subjected to any loading, displacements, other than those

for normal operating. The testing program shall be comprised of three

steps:

Conclusive confirmation that the system has been installed

without any form of buckling, dents or damage.

Pressure testing of the complete system shall be carried

out to meet with the precedence code requirements and

the approved procedure. The guidance given in IGEM/UP/1

shall be used for the choice of the test medium and the

appropriate safety distances.

Pressure testing of PE pipework shall adhere to the

requirements set in IGEM/UP/1.

Tightness testing is normally executed in continuation with

the strength test whereby the leak test pressure is lower

than the strength pressure. A pneumatic tightness test is

permitted after the successful performance of a hydrostatic

pressure test, as per the provisions of IGEM/UP/1.

5.4.2 Owner 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. NGA reserves the right to review the test

specification and to request for changes and/or amendments, before

pipe testing begins.



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5.4.3 The agreed Test Specification shall be accepted by the independent

third party certifying body and designer and shall contain as a

minimum the following key criteria:

Testing criteria to meet inclusive settings, allowable margins.

Test rejection criteria.

Remedial action in case that the test fails.

5.4.4 Following the completion of the hydrotest, the owner 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.

Gauging reports.

Table of pressures.

Graphs of pressure and temperature values.

5.4.5 This certificate shall be approved and signed by the contractor, the

supervision team on behalf of the owner and the third party agency.

5.5 As built Documentation Provision

The Owner shall supply the NGA with two hard copies 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:

5.5.1 All line pipe-manufacturing records, approved and signed by a

recognised and by the NGA accepted independent Certifying Body

and procured from pre-qualified known manufacturers.



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5.5.2 Inspection and acceptance certificates of all associated materials

such as flanges, elbows, anodes, valves, etc., signed by a

recognised and by the NGA accepted independent Certifying Body

and procured from pre-qualified known manufacturers.

5.5.3 WPSs, PQRs and WPQRs.

5.5.4 All welding and NDT records of welds. All RT films shall include

the letter 'B' for Backscattered Radiation control.

5.5.5 Pipe log book and a daily welding log book.

5.5.6 All inspection and test reports of the field joint coating.

5.5.7 All other construction reports pertinent to the system.

5.5.8 As laid co-ordinates of the pipeline and stations on the original

design layout.

5.5.9 As buried data of the buried pipeline and station sections with

confirmed depth of cover.

5.5.10 Civil engineering as made documentation.

5.5.11 Cathodic protection as made documentation.

5.5.12 Electrical and instrumentation and loop diagram as made

documentation.



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SECTION 6.0 REQUEST FOR GASSING UP

6.1 Request Requirements

Upon completion of the construction and testing stage, the owner shall issue

a formal request for gassing up to NGA. This request will include the following

items:

6.1.1 A formal letter addressed to the NGA requesting an operations

permit. This letter should clearly define the system which is under

request.

6.1.2 Construction Completion certificate (as noted in section 6.2) signed

by the contractor, the supervising company, the third party agency,

the owner and other relevant supervision. This certificate should

base its approval of completion to the design code stated in section

1.4.

6.1.3 Final mechanical completion certificate/checklist stating clearly parts

of the system completed and parts yet to be completed. This

certificate shall be related to a relevant specification. This document

shall be signed by all relevant parties.

6.1.4 The owner shall provide the letter he receives from the downstream

consumer (or upstream providing) stating the readiness to

receive/accept gas at the relevant pressures, quantities, flows, etc.

6.1.5 Statements from the Plant Manager, designer, risk assessor,

contractor and equipment supplier stating that the downstream kit

(out of the scope of the NGA) has been designed, constructed and

will be operated to a recognized, international standard.

6.1.6 Approval letters from the designer of the segment.

6.1.7 Signed statements as per Appendix 1.

6.1.8 Check list for cold commissioning including general diagrams and

P&IDs.

6.1.9 Operation, Maintenance and Emergency procedures are approved

by NGA and other relevant parties and in place. (as described below)



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6.1.10 Pressure test results and approvals inclusive of mechanical

completion checklist that was issued prior to the pressure test

commencing.

6.1.11 A copy of the building permits ( 2 ).

6.1.12 List and approved copies of all NCR/CAR/ deviation reports.

6.1.13 As Made Documentation.

6.1.14 The final inspection report issued by the 3rd party supervision body.

6.2 Construction Completion Certificate

Upon completion of all work and documentation, the following construction

completion certificate will be provided to NGA:

# Statement Requires Signature of:

1 All materials have been fabricated and constructed

according the relevant designer documents.

Owner, 2nd party

supervision, 3rd party

supervision , contractor

2 All materials were purchased by Owner or on his

behalf and supplied in accordance with the design

and standards.

Owner, 3rd party

supervision

3 All welds have been checked, approved and

accepted in accordance with the standards and

design.

Owner, 2nd party



4 All works have been constructed in accordance with

the approved design.

Owner, Designer, 2nd

party supervision, 3rd

party supervision ,

contractor

5 Holiday detection was performed in accordance to

the standard.

Owner, 2nd party





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6 All pressure tests, dewatering and drying of the

pipeline and stations have been performed in

accordance with approved procedures and the

results have been completed and accepted in

accordance with the standards.

Owner, 2nd party



7 The Golden weld was performed and accepted by

all.

Owner, 2nd party



8 All NCRs and CARs have been successfully closed

out.

Owner, 2nd party



9 Permanent Cathodic Protection has been put in

place as per the design and relevant standards and

accepted by all.

Owner, 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, 2nd party


11 The SCADA/Control (as applicable) system has been

constructed as per design and relevant specifications

and is ready for operation upon startup of the facility.

Owner, 2nd party


12 The firefighting system has been constructed as per

design specifications, successfully hydrotested and

is ready for startup of the facility.

Owner, 2nd party


13 All safety and security measures are in place and are

ready for startup of the facility.

Owner

14 Cold commissioning has taken place successfully

and accepted by all.

Owner, 2nd party



15 The system is ready for gassing up as per the design

and relevant specifications.

Owner, Designer, 2nd

party supervision, 3rd

party supervision ,

contractor



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16 Operations, Maintenance and Emergency

Procedures are complete and approved, all

operators have been trained, all parties are aware

and knowledgeable of the emergency procedures.

Owner

17 All issues and recommendations raised in the risk

assessment (carried out during the design phase)

have been successfully addressed.

Owner, 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/operator,

Geotechnical and/or

structural engineer

Any request for concession from the above language shall be raised, in writing, to

NGA.

6.3 NGA Review

The NGA shall review the documentation provided for the above items and

will provide comments and request clarification as necessary. Owner shall

allow for sufficient time for NGA review of these items.

6.4 Provision of Gassing up permit

Upon fulfillment of the requirements of this chapter, NGA shall provide a

gassing up permit to the owner for the initial start up phase.



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SECTION 7.0 OPERATIONS AND EMERGENCY

7.1 Procedure Details

The owner shall prepare a copy of an emergency and operations procedure

that will be reviewed by NGA.

7.1.1 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.

7.1.2 Owner shall identify and classify emergencies and their consequences

on HSE.

7.1.3 For all cases Owner shall analyze the short term and long term effects

of such emergency and the response to the occurrence.

7.1.4 For each type of emergency, Owner shall have a pre-established

response and effect mitigation plan with the objective of avoiding or, at

least, limiting the negative effect on HSE. To accomplish this Owner

must demonstrate to the NGA that an effect mitigation / limitation

philosophy is in place, that a personnel rescue and evacuation

procedures is in place, that associated spare/repair materials are in

stock, that specialist contracts are in place, that repair and clean-up

procedures are developed, etc.

7.1.5 This emergency procedure will also include a valve by valve opening

and closing status to assure proper closure in the event of an

emergency.

7.1.6 The owner shall prepare a copy of the operations procedures that will

include venting, gassing up, start up, restart and operations, and



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commissioning and decommissioning procedures (air to N2 to NG and

NG to N2 to air) and will include specific valve maneuvering and

assurances of safe practices on site. Valve maneuvering tables shall

be prepared that clearly note the status of each and every valve

during the operation to assure safe practices. These tables will

provide for signature of at least two people for each and every

maneuvering action of valves.

7.1.7 The operations manual shall provide more detailed and specific

information applicable to the Industrial Gas Installation system,

complementary to the requested information therein.

7.1.8 The operations manual shall address the following topics:

Steady flow operating conditions of the pipeline

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

7.1.9 For the above operations, Owner shall develop detailed procedures,

inclusive of step-by-step description of necessary actions, plans,

drawings, signs, manpower requirements, organisation, names and

contacts.

7.2 System Final Approval

Upon successful completion of the commissioning of the system, and

completion of the necessary adjustments to the downstream systems the

owner shall provide a "completion of hot commissioning and transfer to

normal operations" certificate to the NGA as per Appendix 2.



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SECTION 8.0 HEALTH SAFETY AND ENVIRONMENT PLAN

8.1 General safety

Health, Safety and care of the Environment are of prime importance to the

NGA. Owner shall be committed to maintain a safe, healthy and injury free

workplace for its employees and any person working on behalf of the Owner.

Furthermore, Owner shall be committed to avoid damage to the environment.

8.2 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 and shall be an integral part of

and, is inseparable from all daily operations.

8.3 HSE Objectives

Owner’s HSE objective shall be to:

8.3.1 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).

8.3.2 Properly inspect and maintain all equipment and tools.

8.3.3 Promote safety awareness, near miss reporting and a healthy,

responsible attitude amongst all personnel.

8.3.4 Ensure effective emergency response arrangements, backed-up

with trained and exercised personnel.

8.3.5 Establish and maintain clear written standards and procedures to

control the risk to HSE and ensure these are adhered to



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8.3.6 Ensure that all personnel involved, either staff or subcontractors,

are competent and able to perform their tasks safely.

8.3.7 Ensure prompt investigation of incidents and those adequate

corrective actions are taken.

8.3.8 Promote joint consultation and lateral learning for all personnel

8.3.9 Provide sufficient resources for HSE advisory and audit services

to assist management to meet set HSE policy objectives.

8.3.10 Co-operate with statutory and professional bodies to promote

workable, practical standards and improve codes of practice and

legislation in relation to HSE matters.

8.4 Training and Material Maintenance

8.4.1 The NGA requires that all work under supervision of the Owner shall

be carried out with due observance of all legal requirements to achieve

the required statutory standards for Health, Safety and Environment.

8.4.2 Owner shall ensure that for all parties, personnel, contractors, working

on behalf of Owner, 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.

8.5 Safety Management System

8.5.1 Owner shall develop and implement a safety management system

(SMS).



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8.5.2 The SMS is a systematic approach to safety and health aspects in the

execution of onshore pipeline installation operations.

8.5.3 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.

8.5.4 The SMS relates to all phases and combination of phases involved in

installation operations.

8.5.5 The SMS must in general contain objectives relating to safety and

heath:

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.

8.5.6 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

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8.6 Items to be addressed in HSE Procedures

8.6.1 Disposal of chemicals used for the commissioning and conservation

of pipelines such as dye, corrosion inhibitors, oxygen scavengers,

biocides, etc.

8.6.2 Any limitations to exposure to the environment of chemicals i.e. zinc

anodes.

8.6.3 For each project installation a HSE plan shall be developed. This plan

needs to address all measures taken to support safe and healthy

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.

8.6.4 The HSE plan shall provide details of and schedule for safety audits.

8.7 Environmental Responsibility

An Environmental Management Plan shall be prepared by the Owner. 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.

8.8 Incident reporting

8.8.1 Any incident occurring during the course of the manufacturing,

construction, installation and commissioning phase shall be reported,

by written statement, to the NGA within 48 hours of the incident. Such

Incident Report shall provide a full description of the course of such



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an incident and the measures to mitigate reoccurrence of a similar

type of incident. Owner shall maintain statistics with respect to the

incidents occurring. These statistics shall be evaluated against

threshold values, pre-agreed between the NGA and Owner. In case

unacceptable levels of incidents take place, the NGA shall instruct

Owner to re-assess his SMS and might stop all work until such re-

assessment has been undertaken.

8.8.2 Similarly Owner shall report ’near-misses’, situations that have not

caused incidents but had the potential to do so. Owner shall actively

pursue near miss reporting amongst all personnel involved in the

work.

8.9 Hazard Identification Study (HAZID)

8.9.1 Owner 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.

8.9.2 The objective of HAZID is to provide the NGA assurance that:

The Owner 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 is adequately prepared to commission and operate the pipeline

The system is achieving an acceptable level of safe operation consistent with commercial intend.



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SECTION 9.0 QA/QC SYSTEM QUALITY ASSURANCE AND

CONTROL PLAN

9.1 Owner shall develop, implement, maintain and report using an approved

Quality System, which shall be in accordance with ISO 9000 series.

Owner shall present 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.

9.2 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.

9.3 Upon implementation of the QP, Owner shall timely invite the NGA for

witnessing the agreed hold points. It will be up to the NGA’s discretion to

witness these hold points.

9.4 The independent third party shall further check the quality of the work and

the effectiveness of Owner’s quality system on spot check basis. Owner

shall carry out all remedial actions as a result of such sampling.

9.5 Contractors, sub-contractors, suppliers, fabrication and installation

contractors, proposed by Owner for the pipeline work, shall be reputable,

pre-qualified entities. Owner 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,

Owner shall supply the list of pre-qualified entities.

9.6 The QP plan shall further include for an inspection, test and audit plan.



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SECTION 10.0 INSPECTION AND MAINTENANCE PROGRAM

10.1 Owner shall develop and submit to the NGA a system inspection and

maintenance program for the lifetime of the complete system including all

sections. The inspection of the pipeline shall be internal and external.

10.2 The internal inspection shall confirm the internal pipe body integrity. The

pipeline internal integrity could be jeopardized as the result of corrosion,

pitting, and buckling resulting from internal or eternal accidental loads.

10.3 The external inspection shall confirm that the external pipeline body has

not suffered from accidental loads.

10.4 External inspection shall be conducted using approved methods of

inspection.

10.5 The NGA or its appointed representative shall be invited by Owner to

witness the inspection.

10.6 If the inspection results give reason for concern and the pipeline integrity

is considered to become a HSE concern, the NGA has the right and will

request Owner to shut-down the system and to make it safe without

delay.



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Appendix 1 – Statements Related to the Scope Downstream of the NGA Scope



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Appendix 2 – Statement Regarding the Successful Completion of Hot Commissioning

Date post:	21-Dec-2015
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