FUNCTIONAL SPECIFICATION

CIVIL
LAST LINE OF DEFENCE (LLOD) FACILITY

Document No. : E-031607

Project Name : BTIP- Onshore Facilities / Offshore Pipelines

Contract No. : E-09335

Client : Shell Petroleum Development Company of Nigeria Limited

EPIC CONTRACTOR

Rev Date Description Prepared by Reviewed by Approved by

0 Original Issue

1 Revision 1
Issued for CDV
2 30 June 2002 C. K. Han C. Y. Chung K. B. Choi
and Ownership

1, Cheonha-Dong, Dong-Ku, Ulsan, Korea, 682-792, http//:www.hhi.co.kr

Tel: 82-52-230-5461/2, Fax: 82-52-230-3549, E-mail: j740hhi@hhi.co.kr
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REVISION HISTORY

EPIC CONTRACTOR SPDC

Prepared Reviewed Approved Validity Reviewed Approved

Rev Date Date
by by by Period by by

C. Y.
2 30/06/02 C. K. Han K. B. Choi 5 years
Chung
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TABLE OF CONTENTS

1.0 INTRODUCTION.................................................................................................................................... 4

2.0 SCOPE OF WORK................................................................................................................................. 4

3.0 GENERAL REQUIREMENTS................................................................................................................ 4

4.0 TECHNICAL SPECIFICATION.............................................................................................................. 5

4.1 GENERAL....................................................................................................................................... 5
4.2 DEFINITIONS................................................................................................................................... 5
4.3 DESIGN REQUIREMENTS................................................................................................................. 6
4.4 FACILITY DESCRIPTION................................................................................................................... 6
4.5 SPARE PARTS AND SPECIAL TOOLS................................................................................................. 7
4.6 PAINTING....................................................................................................................................... 8
4.7 QUALITY SYSTEM........................................................................................................................... 8
4.8 MATERIAL....................................................................................................................................... 8
4.8.1 Concrete............................................................................................................................. 8
4.8.2 Render and Mortar............................................................................................................. 8
4.8.3 Steelwork............................................................................................................................ 8
4.8.4 Connectors......................................................................................................................... 9
4.8.5 Procurement....................................................................................................................... 9
4.9 INSPECTION AND TESTING............................................................................................................... 9

5.0 REFERENCES....................................................................................................................................... 9

6.0 ENVIRONMENTAL DATA................................................................................................................... 13

1.
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2. 1.0 INTRODUCTION

Boonny Terminal requires an upgrade of facilities, process and systems. The existing holding
bassin situated on the west side of the terminal shall be demolished for extensive modifications
to be aable to act as a LLOD facility, and shall be re-built such that existing operations shall not
be interrrupted during the construction. A new holding basin shall be installed on the south side
of the terminal to be used as LLOD#2.

3. 2.0 SCOPE OF WORK

The scope of work of this specification covers the design, supply of material, fabrication, testing,
painting of LLOD internals and all necessary documentation.

4. 3.0 GENERAL REQUIREMENTS

Two holding basins are required as Last Line of Defence (LLOD) facilities to provide primary treatment
for contaminated storm water and fire fighting water from the bounded areas of the Open Hazardous
Drain Network within the terminal. LLOD facilities, which shall be located at the south side of the
terminal, will consist of the following parts:
 Foundation and structure.
 Common oily water inlet compartment.
 Two individual separation chambers.
 Common retention baffle.
 Common weir.
 Common water outlet compartment.
 Common skimmed oil pit.
 Two separation channels inlet sluice gates.
The contaminated effluent in the LLOD facility shall be fully emptied before the first flush and
pumped to the produced water header for secondary treatment.

The facility shall have an inlet section and oil separating chambers with adequate sizes and
internal members to provide an environment in which free oil can settle coincidentally with the
separation of the oil in the influent.

The separating chambers shall consist of an open rectangular basin with sufficient capacity to
handle AOC run-offs from potentially contaminated Fire-Fighting Water, and shall be able to
retain accidental spillages of up to 100 m3.

The LLOD facility shall have two compartments to facilitate uninterrupted terminal operations
when one compartment is shut down during maintenance and repair operations.

The combined capacity of the first flush and peak overflow chambers shall satisfy the retention
capacity required for potentially contaminated FFW effluents resulting from a fire duration of 6
hours.

Design for the facility shall incorporate the principle of gravity flow for all discharges flowing into
the LLOD.

Drain return pumps with a sparing philosophy of 2 X 100% shall be provided for the pumping of
contaminated effluents from the LLOD to secondary treatment.

One holding basin shall be situated, for each of the two API-discharge outlets of the open -
haazardous drainage network located near the property fences at the west and south sides of
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the terminal.

The recovery of floating oil separated from water in the LLOD shall be carried out by means of
two adjustable slotted pipe oil skimmers. There shall be one per separating chamber.

The bottom of the facility shall be sloped to facilitate sediment or sludge removal.

There shall be one common skimmed oil collection pipe discharging to the skimmed oil
collection pit.

Support steelwork shall be provided for sump pumps and associated level and alarm
instrumentation located above skimmed oil collection pit.

There shall be handrailings, walkways and gratings for the LLOD facility for the operator safety
and access to the skimmers, pumps and filters.

All depressed locations shall be fitted with proper ventilation.

Lighting shall be provided to give adequate illumination for the LLOD facility, to facilitate night
shift operation and security monitoring.

The adjacent surrounding of the facility shall be paved to provide maintenance access for gully
sucker and vacuum truck. The paved area shall be lined with surface drainage.

A signboard with unit number and capacity should be installed at the approach of the facility.

The oil collection sump shall have a level instrument with high level alarm.

There shall be periodic measurements, control and registration of the effluent discharge quality
and quantities. This is required to provide a check on the water /effluent treatment facility’s
performance with the applicable standards.

Records shall be maintained of all cleaning and other related activities (Spill control), to
establish upgrading, cleaning, and maintenance schedules.

5. 4.0 TECHNICAL SPECIFICATION

4.1 GENERAL

Unless noted otherwise, the facility shall be designed, fabricated and constructed in accordance
with the attached drawings, codes and standards listed under section 5 of this specification
including environmental data for the Bonny Terminal.

4.2 DEFINITIONS

The following definitions shall apply throughout the specifications:

Owner: Shell Petroleum Development Company of Nigeria Limited (SPDC)

Purchaser: BTIP Management or its approved agent (Contractor) who is the party
placing the purchasing order for the equipment and services.

Vendor: The party supplying the equipment and services.

Sub Vendor: Any party providing service or equipment to the vendor.

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4.3 DESIGN REQUIREMENTS

The Holding Basin shall be designed in accordance with DEP 34.14.20.31-Gen and shall meet
the requirements of this specification and as amended or supplemented by SPDC standard
construction specification.

The environment in which the LLOD facility will be installed is as follows:

Maximum temperature, ambient 40 oC
Minimum temperature, ambient 18 oC
Deesign temperature, maximum 35 oC
Deesign temperature, minimum 18 oC
Design relative humidity 100 %
Bassic wind speed 35.6 m/s
Maximum hourly rainfall 100 mm
Atmosphere: Corrosive, humid and salt laden
The vendor shall ensure that the LLOD is installed in compliance with all applicable Nigerian
National, State or Local laws, codes and regulations.
Seismic forces need not be considered in the design analysis.
The minimum corrosion allowance shall be 3.0 mm.
Nozzle, bolt -holes shall straddle the natural centre lines, a minimum of 50 mm shall be
available as clearance from back of flange to shell.

4.4 FACILITY DESCRIPTION

The new LLOD facility shall be a reinforced concrete structure with overall dimensions of 80.00
m long X 8.00 m wide X 2.00 m depth. The facility shall have a minimum depth-to-width ratio of
0.3 and shall be provided with an installation plot space of approximately 100.00 m length X
20.00 m width.

The facility shall be located near the new Primary Tank Farm Fence at the south side of the
Terminal subject the minimum safety distances noted as follows:
 Distance to the edge of main road: 15 m
 Distance to a fixed source of ignition: 15 m
The location and orientation of the new LLOD should be designed with consideration of the
prevailing winds.

The LLOD shall have reinforced concrete foundation and superstructure walls using sulphate
resistant Portland cement complying to BS 4027. The LLOD foundation could be either spread
footings or piles, depending on the local Soil Bearing capacity and settlement characteristics in
the area of the facility. In either case grade beams will be required. The floor will be a slab-on-
grade complete with a dry shake non-metallic hardener resistant to oils. The thickness of slab
and sub-grade shall be designed for a maximum load during full capacity operation. Special
attention should be made to the pouring sequence and control joint locations to ensure a crack-
free slab. The Inlet and Sludge compartments shall be sloped to hold sediments/sludge and
facilitate their removal.

The LLOD facility shall have a common oily-compartment approach channel consisting of a
rectangular Basin fitted with two sluice gates. This compartment shall be of reinforced concrete.
The floor shall be sloped to allow for sand trap and sedimentation.

The transition channel shall comprise an open rectangular basin made of reinforced concrete.
The chamber shall be of two parallel bays in order to facilitate its cleaning and repair when
required. The walls shall allow for equal flow distribution. The separating chamber shall have
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overall dimensions of 8.0 m width X 80.0 m length x 2.0 m depth.

A common weir, which will be reinforced concrete of a rectangular cross-section, shall be

installed. Lateral contraction must be completely eliminated. The chamber in which it is installed
shall therefore have an overall height of 1.20 m and a length, which shall be exactly equal to the
width of the separating chamber.

Flight scrapers should be installed to gently move the sludge to the sludge collection pit and oil
to the oil-skimming device.

A sediment layer of 0.30 m on the bottom of the entire oil trap shall be provided.

Necessary precautions shall be taken to ensure that the approach velocities to the weir are
uniformly distributed and that the flow is two-dimensional and does not exceed a velocity of
0.015 m/s.

A common retention baffle shall be provided. This internal facility shall be of reinforced concrete
and installed at a distance of 0.50 m behind the oil skimmer. The underside of the baffle will be
a minimum of 0.60 m below the water level in the transition chamber. The flow rate of oily-water
beneath the baffle shall not exceed a velocity of 0.15 m/s.

Rotating trough skimmers with hand wheel operation should be installed. The skimmer should
allow the first flush and peak flow compartments to recover floating oil separated from the water.

The trough should always be kept in an upright position when unattended. These skimmers
should not be operated during rain conditions.

Skimmed oil shall be recovered in a reinforced concrete oil sump for reprocessing. The sump
shall have an overall depth of 2.0 m.

Two vertical centrifugal cantilever type pumps shall be provided for the oil sump. The pumps
shall have a rated capacity of 30 m 3/hr each. The level control and installed spare shall be set
for automatic start and stop. The installed spare shall have a HH level control and thea LL level
control. Both pumps shall be protected by a low level alarm and switch. Support steelwork shall
be provided for the sump pumps and the associated level/alarm instrumentation shall be located
above the skimmed oil collection pit.

The LLOD facility shall be designed to treat contaminated water to an effluent quality of not
more than 60ppm. Drain return pumps shall be provided to inject the treated effluent to
produced water treatment header for secondary treatment.

4.5 SPARE PARTS AND SPECIAL TOOLS

The vendor shall recommend and provide spare parts needed for start-up and commissioning.
In addition, the vendor shall furnish a separate itemised list of recommended spares for two (2)
years of operation.

Recommended spare parts should take into account dated factors of equipment reliability, effect
of equipment downtime upon production or safety, cost of spares and availability of equipment
service facilities.

A list of special tools required for commissioning and maintenance of equipment together with
the prices shall be furnished along with the vendor’s proposal.

All spare parts should be wrapped and packaged so that they are preserved as new in original
packaging under normal conditions of storage.
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Spare parts shall be properly tagged and coded. Start-up and commissioning spares shall be
packaged and identified separately from the operation /maintenance spares.

4.6 PAINTING

All surfaces shall be painted in accordance with SPDC standard construction specifications.

4.7 QUALITY SYSTEM

A quality manual, procedures and quality plans shall be submitted for review and approval prior
to first production. Such documents shall include requirements for sub-vendors. Vendor shall
maintain an effective system for quality assurance and quality control, planned and developed in
conjunction with all manufacturing, storage and application functions necessary to meet the
requirements of this specification.

The requirements shall be met by the establishment and implementation of procedures and a
Quality Plan, which shall ensure that acceptable service is presented.

The Quality Plan shall ensure that quality requirements are determined prior to commencement
of the works and subsequently satisfied throughout all phases of application.

The Vendor quality systems and quality control procedures shall conform to or be equivalent to
the requirements of ISO 9000/9001/9002.

4.8 MATERIAL

4.8.1 Concrete

The material mixing, placing and curing of concrete work, reinforcement and formwork shall be
in accordance with the British Standard BS 8110 Structural Use of Concrete and SPDC DEP
34.19.20.31-Gen. The concrete strength will be as required by design but no less than 30 MPa
at 28 days.

4.8.2 Render and Mortar

All sands, cement, lime, water, and admixtures used in the making of renders and mortars shall
be in accordance with BS 1200. The sands shall comply with the quality and grading
requirements of sands for renderings and mortars specified in BS 1199 and 1200.

4.8.3 Steelwork

Steel shall conform to BS 4360 or ASTM as noted with the following grade or equivalent
International standardss.

Section Grade
1. Hot rolled sshapes 275 MPaBS 4360 Grade 43 with min. yield strength of
275 MPa or
Built up shapes with a min. yield strength of 275 MPaJIS G3106 SM400B
Welded girders with a min. yield strength of 275 MPa
Welded wide flanges with a min. yield strength of 275 MPa
Plates and bars with a min. yield strength of 275 Mpa
Base plates with a min. yield strength of 275 MPa
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2. Hollow sections BS 4360 Grade 50C with min. yield strength of 355 MPa
or JIS G3106 SM520B
Pipe hand railing ASTM A53 SCH80 seamless Grade B or equivalent British
standard
Grating shall be in accordance with BS 4592 or approved equal with serrated 32 X 4.8 bearing
bars.

4.8.4 Connectors
A. High strength bolts, nuts & washers BS 3692

B Machine bolts, nuts & washers BS 4190

C. Electrodes BS 639

4.8.5 Procurement

The vendor shall be responsible for the supply, selection and quality of all material inclusive of
all consumables, welding testing, protecting devices, machinery, tools, and all other necessary
materials and services whether or not they are identified in this specification.

Materials procured and used for fabrication of the LLOD facility/internals shall be new, of first
quality and shall meet the requirement of referenced codes and specifications.

4.9 INSPECTION AND TESTING

The purchaser or his authorised representative or inspection agency shall have access to
inspect the equipment at any stage during fabrication.

During inspection, material certificates, shop test data, certificates for bought-out components
and other relevant information shall be furnished so as to ascertain that specifications and
quality are complied with.

The LLOD internals shall be subject to vendors standard testing. Tests may at Purchaser’s
option, be carried out in presence of the Purchaser, his authorised representative or certifying
agency.

6. 5.0 REFERENCES

The order of precedence of requirements shall be as follows, unless directed otherwise, in

writing by SPDC.

1) Nigerian National Standards.

2) SPDC Construction Specifications.

3) ENGL Specifications.

4) Shell DEP Manuals.

5) International Standards.

SPDC Standard Construction Specifications

S-3 Clearing, grading and surface stripping.

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S-4 Earthwork at Construction sites.

S-11 Fencing.

S-12 Concrete and Cement Finish Work.

S-13 Building Construction.

S-14 Structural Steel.

S-15 Sewage, Sewage Treatment and Drainage.

S-21 Welding.

S-22 Painting.

ENGL Specifications
ENGL /27 /22 Rev.2 General Specification for the Design and Installation
/02, of Steel-Cased Piping.

ENGL /29 /20 Rev. 2 General Specification for the Design of Structural
/01, Steelwork Design and Fabrication of Supply
Packages.

ENGL /21 /20 Rev. 2 General Specification for Export Packaging and
/02, Crating.
Shell DEP Manuals
DEP 30.10.60.18 - Gen Welding of Metals.

DEP 31.38.01.29 - Gen. Pipe Supports.

DEP 31.76.10.10 - Gen. Heating, Ventilation and Air Conditioning for Plant
Buildings.

DEP 31.76.10.11 - Gen Installation, Testing and Balancing and

Commissioning of HVAC Systems.

DEP 32.30.20.11 - Gen Fire, Gas and Smoke Detection Systems.

DEP 34.00.01.30 - Gen Minimum Requirements for Structural Designs and

Engineering.

DEP 34.11.00.11 - Gen Site Preparation and Earthworks.

DEP 34.11.00.12 - Gen Geotechnical and Foundation Engineering.

DEP 34.13.20.31 - Gen Road, Paving Surfacing Slope Protection and

Fencing.

DEP 34.17.00.32 - Gen Minimum Requirements for Design and Engineering

of Buildings.

DEP 34.18.51.10 - Gen Minimum Requirements for the Construction and

Maintenance of Tank Foundations, Bundwalls and
Drainage Systems for Small Storage Installations.
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DEP 34.19.20.11 - Gen Fire Hazards and Fire Proofing /Cold Splash
Protection of Steel Structures.

DEP 34.19.20.31 - Gen Reinforced Concrete Foundations and Structures.

DEP 34.28.00.31 - Gen Steel Structures.

DEP 33.64.10.10 - Gen General Electrical Engineering.

British Standard Institution
BS 4 Part 1-Structural Steel Sections.

BS 12 Specification for Portland Cement.

BS 499 Part 1-Welding Terms and Symbols.

BS 639 Specification for Carbon and Carbon Manganese Steel Electrodes

for Metal-arc Welding.

BS 729 Specification for Hot Dip Galvanised Coatings on Iron and Steel
Articles.

BS 812 Testing Aggregates.

BS 882 Specification for Aggregates from Natural Sources for Concrete.

BS 1010 Specification for Draw Off Taps and Stop Valves for Water Service
(Screw Down Pattern).

BS 1014 Specification for Pigments for Portland Cement and Portland

Cement Products.

BS 1200
BS 1305 Specification for Batch Type Concrete Mixers.

BS 1881 Testing Concrete.

BS 3083 Specification for Hot-Dip Zinc coated and Hot-Dip Aluminium /Zinc
Coated Corrugated Steel Sheet for General Purposes.

BS3148 Methods of Test for Water for Making Concrete.

BS 3692 Specification for ISO Metric Precision Hexagon Bolts Screw and
Nuts.

BS 3693 Method for Testing the Mixing Performance of Concrete Mixers.

BS 4027 Specification for Sulphate Resistant Portland Cement.

BS 4190 Specification for ISO Metric Black Hexagon Bolts, Screws and
Nuts.

BS 4320 Specification for Metal Washers for General Engineering

Purposes.

BS 4360 Weldable Structural Steels.

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BS 4395 Specification for High Strength Friction Bolts and Associated Nuts
and Washers for Structural Engineering.

BS 4449 Specification for Carbon Steel Bars for the Reinforcement of

Concrete.

BS 4466 Specification for Scheduling, Dimensioning, Bending, and Cutting

of Steel reinforcement.

BS 4483 Specification for Steel Fabric for the Reinforcement of Concrete.

BS 4550 Method of Testing Concrete.

BS 4604 Specification for the use of High Strength Friction Bolts in

Structural Steelwork.

BS 4660 Specification for Unplasticised Polyvinyl Chloride (PVC - U) Pipes

and Plastic Fittings of Nominal Steel 110 and 160 for Below
Ground Gravity Drainage and Sewerage.

BS 4848 Specification for Hot Rolled Structural Steel Sections.

BS 4871 Part 1-Fusion Welding of Steel.

BS 4872 Part 1-Specification Testing for Approval Testing of Welders When

Welding Procedure Approval is not Required.

BS 4921 Specification for Standardised Coating on Iron or Steel.

BS 4933 Specification for ISO Metric Black Cup and Countersunk Head
Bolts and Screws with Hexagon Nuts.

BS 4952 Part 1-Specification for Open Bar Grating.

BS 5095 Concrete Admixtures.

BS 5135 Specification for the Welding of Carbon Manganese Steels.

BS 5395 Stairs, Ladders, and Walkways Quality Systems.

BS 5950 Structural use of Steelwork in Buildings.

BS 6150 Code of Practice for Painting of Buildings

BS 6180 Code of Practice for Protective Barriers In and About Buildings.

BS 6399 Part 1-Design Loading For Buildings.

BS 6512 Specification for Limit and Repair of Surface Discontinuities of Hot

Rolled Steel Plates and Wide Flats.

BS 7079 Part 0-Preparation of Steel Substrates Before Application of

Paints and Related Produces.

BS 7419 Specification for Holding Down Bolts.

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BS 8110 Structural Use of Concrete.

ASTM
ASTM A53.88a Standard Specification for Pipe, Steel, Black and Hot Dipped,
Zinc Coated, Welded and Seamless or British Equivalent.

ASTM A1-84 Crane Rails or British Equivalent.

API 421 Monographs on Refinery Environment Control Management

of Water Discharges.

AISC Specification of Steel Construction.

AWS D1.1 Structural Welding Code - Steel.

ACI 301 Specification for Structural Concrete for Buildings.

ANSI B16.5 Pipe Flanges and Flange Fittings.

ASTM American Society for Testing of Materials.

Other Specification

ISO 9000 /9001 /9002 Quality Systems.

7. 6.0 ENVIRONMENTAL DATA

Ambient Temperature
Mean minimum temperature 23 oC
Minimum temperature 18 oC
Meean maximum temperature 31 oC
Maximum temperature 40 oC
Deesign temperature, maximum 35 oC
Deesign temperature, minimum 18 oC
Rainfall

Heavy rainfall can be expected in the wet season during the months of April through October.
Aveerage annual rainfall 3800 mm
Mean maximum hourly rainfall 100 mm
Wind Speed

Basiic wind speed 35.6 m/s

Entomology and Vermin

As prevalent in the Niger Delta with thick forest and swamp habitat.

Fungi and Morbid Growths

As prevalent in the Niger Delta with thick forest and swamp habitat.

Lighting

Frequent in rainy season, up to 140 strikes per year.

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Altitude

Processing area of Bonny Terminal 5.0 metres above mean sea level.

Earthquake

None.