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KUWAIT OIL COMPANY (K.S.C.

STANDARDS PUBLICATION

KOC STANDARD
FOR
METERING PUMP PACKAGES
DOC. NO. KOC-ME-006 PART 1

STANDARDS TEAM

DOC. NO. KOC-ME-006 PART 1

KUWAIT OIL COMPANY (K.S.C.)

STANDARDS PUBLICATION

KOC STANDARD

FOR
METERING PUMP PACKAGES
DOC. NO. KOC-ME-006 PART 1

STANDARDS TEAM

I~DOC.NO. KOC-ME-006 PART 1

Page 2 of 37

REV.l

KOC STANDARD
FOR
METERING PUMP PACKAGES
DOC. NO. KOC-ME-006 PART 1
(FORMERLY 015-GH-1001)

ISSUING AUTHORITY:

STANDARDS TEAM

28'"ay

Rev.

Issued As KOC
Standard

2003

Date

Task Force
(TF-MEIOS)
I

Description

Prepared by

\\

Snr. Engr. Stds.

Ag. Team Leader Standards

Tel. 61095

Tel. 61896

Page 3 of 37

DOC. NO. KOC-ME-006 PART 1

REV.1

TABLE OF CONTENTS

Page No.
FOREWORD
SCOPE
APPLICATION
TERMINOLOGY
3.1
Definitions
3.2
Abbreviations
REFERENCE STANDARDS, CODES AND SPECIFICATIONS
4.1
Conflicts
4.2
List of Standards and Codes
4.3
Project Specifications
4.4
Order of Precedence
ENVIRONMENTAL CONDITIONS
HEALTH, SAFETY AND ENVIRONMENT
MATERIALS
TECHNICAL REQUIREMENTS AND SYSTEM DESCRIPTION
8.1
General
8.2
Pumps, Drivers and Auxiliaries
GUARANTY & WARRANTY
9.1
Guaranty
9.2
Warranty
INSPECTION AND TESTING
10.1 Material lnspection and Certification
10.2 Shop lnspection
10.3 Quality Plan
QUALITY ASSURANCE
MARKING
DOCUMENTATION
SPARE PARTS AND MAINTENANCE DATA

DOC. NO. KOC-ME-006 PART 1

15.0

APPENDICES

APPENDIX 1: DATA SHEETS FOR METERING PUMP


APPENDIX 2: DATA SHEET FOR NOISE
APPENDIX 3: VENDOR DRAWINGS AND DATA REQUIREMENTS
FOR METERING PUMP PACKAGES
APPENDIX 4: SCOPE OF INSPECTION AND TESTS FOR METERING
PUMP PACKAGES
APPENDIX 5: MATERIAL SELECTION GUIDE FOR METERING
PUMP PACKAGES
APPENDIX 6: TANK DATA SHEET
ACKNOWLEDGEMENT

IOC. NO. KOC-ME-006 PART 1

FOREWORD
This document "KOC Standard for Metering Pump Packages" is intended to provide the
minimum requirements for metering pump packages purchased for installation at KOC
facilities in Kuwait. This document is based on API Standard 675 Positive Displacement
Pumps - Controlled Volume.
Other documents in this series include the following:

.
.

KOC-ME-006 Part 2:
KOC-ME-006 Part 3:

KOC Standard for Reciprocating Pumps


(based on API Standard 674)
KOC Standard for Rotary Pumps
(based on API Standard 676)

This Standard has been approved by the Standards Team, in consultation with the
Standards Technical Committee (STC), for use throughout the corporate engineering and
operational teams of Kuwait Oil Company.
This Standard sets out to achieve the following objectives:

.
.
.

To specify the minimum standard requirements, for Metering Pump Packages,


applicable for all new construction and to help ensure a consistent and cost-effective
approach in the selection of equipment, in line with API 675.
To utilize operational experience to avoid the repetition of past problems, and to
consolidate worthwhile and beneficial design, operating and cost saving features.
To cover the necessary aspects of design, fabrication, inspection and testing in order
to minimize the need for clarifications and resolution of disputes.
To provide standard data sheets which:

.
.
.

incorporate all essential features of API Standard 675,


are consistent with the text of this Standard,
provide a checklist to ensure that major specification items are considered.

Feedback, comments or suggestions, derived from the application of this Standard at any
stage of design, purchase, manufacture, installation, operation, and maintenance are
encouraged, and should be directed to:
The Team Leader Standards
(Chairman, Standards Technical Committee)
Industrial Services Group, KOC
P. 0 . Box 9758, Ahmadi 61008
State of Kuwait

IOC. NO. KOC-ME-006 PART 1

Page 6 of 37

REV.l

Task Force Responsible for This Standard


The Standards Technical Committee (STC) has entrusted the preparation of this Standard to
the Task Force No. (TF-MEI05) consisting of the following members:
Name

1 Team
I

1 Designation I Tel. No.


I

DOC. NO. KOC-ME-006 PART 1

SCOPE
This Standard specifies the minimum technical requirements for "Metering
Pump Packages" to be installed at KOC Facilities in Kuwait.
This Standard covers the basic requirements for design, selection of
materials and equipment, assembly, inspection, testing, and packing for
shipment of metering pump packages.
Project specific requirements will be further specified in KOC data sheets,
project specifications, or purchase documents.
APPLICATION
All materials and equipment used for metering pumps shall be new and of
high quality conforming to the requirements of this Standard and the
reference standards, codes, recommended practices and specifications.
Exceptions or deviations from this Standard will only be considered by KOC
when they are submitted in writing and are supported by evidence of merit or
justification.
Compliance with this Standard does not of itself confer immunity from legal or
statutory obligations.
TERMINOLOGY
Definitions
For the purpose of this Standard, the following definitions apply:
Contractor
The person, persons, firm or company contracted by KOC to undertake the
execution of the Work defined by the Contract.
KOC Controlling Team
Any KOC Team authorized to initiate a request for procurement of materials
and equipment for KOC.
Packager
The person or firm that manufactures, andlor assembles, the equipment,
products, and materials covered by this Standard. The Packager shall take
overall responsibility for the complete Metering Pump Package.
Purchaser
Either KOC or a KOC Contractor

IOC. NO. KOC-ME-006 PART 1

Vendor
Authorized manufacturer of pump from the KOC list of approved vendors.
Abbreviations
BHN
DP
GRP
HSE
ITP
KOC
MAWP
MRB
MSDS
NDE
NPSHA
NPSHR
O&M
OSHA
PIM
PQR
QNQC
SSPC
W PS

Brinnel Hardness Number


Design Pressure
Glass Reinforced Polyester
Health, Safety and Environment
Inspection and Test Plan
Kuwait Oil Company (K.S.C.)
Maximum Allowable Working Pressure
Manufacturer's Record Book
Material Safety Data Sheet
Non-Destructive Examination
Net Positive Suction Head Available
Net Positive Suction Head Required
Operating and Maintenance
Occupational Safety and Health Administration
Pre-inspection Meeting
Procedure Qualification Records
Quality AssuranceiQuality Control
The Society for Protective Coatings
Welding Procedures Specifications

REFERENCE STANDARDS, CODES AND SPECIFICATIONS


Conflicts
In the event of a conflict between this Standard, the standards and codes
referenced herein, or other purchase or contractual requirements, the subject
shall be brought to the attention of the KOC Controlling Team for resolution,
and review and/or amendment (by the Standards Team, if required) and
KOC's decision shall be final.
List of Standards and Codes
The latest edition of the following standards, codes and specifications shall
apply:
National 1 International Standards

ANSIIHI 9.1-9.5

Pumps - General Guidelines

API 12F

Specification for Shop-Welded Tanks for Storage of


Production Liquids

(/DOC.NO. KOC-ME-006 PART 1

Page 9 of 37

REV.l

API 675

Positive Displacement Pumps - Controlled Volume

API 678

Accelerometer-Based Vibration Monitoring Systems

ASME 815.1

Safety Standard for Mechanical Power Transmission


Apparatus

ASME B31.3

Process Piping

ASME Sec. Vlll

ASME Boiler and Pressure Vessel Code Rules for


Construction of Pressure Vessels

ASTM A488

Qualification of Procedures and Personnel for Welding of


Steel Castings

BS PD 5304

Safe Use of Machinery


Quality Management Systems - Fundamentals and Vocabulary
Quality Management Systems - Requirements
Quality Management Systems
Performance Improvements

Guidelines

for

Petroleum and Natural Gas Industries - Lubrication,


Shaft Sealing and Control - Oil Systems and Auxiliaries

4.2.2

NACE MR0175

Metals for Sulfide Stress Cracking and Stress Corrosion


Cracking Resistance in Sour Oilfield Environments

OSHA Standard

Sub Part 0 - Machinery and Machine Guarding Part


1910.219 - Mechanical Power - Transmission Apparatus

SSPC-SP6

Commercial Blast Cleaning

KOC Standards
KOC-C-007

KOC Standard for Structural Steel Work


Fabrication and Erection

Materials,

KOC Recommended Practice for Selection, Installation


and Maintenance of Electrical Equipment in Hazardous
Areas: General Requirements
KOC Recommended Practice for the Design, Selection
and Installation of Electric Cables, Cable Systems and
Wiring
KOC Standard for Low Voltage Induction Motors

Page 10 of 37

DOC. NO. KOC-ME-006 PART 1

4.3

KOC-E-020

KOC Recommended Practice for Electrical Installations


on Packaged Equipment

KOC-E-024

KOC Recommended Practice for Earthing and Bonding

KOC-G-004

KOC Standard for Packing, Marking and Documentation

KOC-G-007

KOC Standard for Basic Design Data

KOC-G-009

KOC Standard for Spare Parts and Maintenance Data

KOC-1-001

KOC Standard for Instrumentation and Control System


Design

KOC-1-010

KOC Standard for Control and Shutdown Valves

KOC-1-011

KOC Standard for Instrument Cables

KOC-P-001

KOC Standard for Painting and Coating of Metal


Surfaces - New Construction

Proiect Specifications
In addition to the KOC Standards and Recommended Practices referenced
above, the Controlling Team in KOC, shall designate other specifications as
required for the subjects listed below:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
I)

Nameplates
Plant Equipment Identification
lnstrumentation for Packaged Equipment
Variable Speed Drive Controller
PlantEquipment Noise Control
Pressure Vessels
Chemical Tanks
Piping Specifications
Welding Procedure Approval and Welding Quality Requirements
Utilization of Third Party lnspection Services
Non-Destructive Testing
lnspection and Testing of New Equipment in Manufacture

4.4

Order of Precedence

4.4.1

The supply of equipment, materials, services and documentation shall be in


accordance with the following State and local regulations, specific project and
purchase order requirements. Should any conflict exist among the listed
documents, the most stringent document shall govern.

4.4.2

In general the following order of precedence shall apply:


a)

Kuwait Governmental Rules and Regulations

IOC. NO. KOC-ME-006 PART 1

b)
c)
d)
e)
f)

Purchase order and supply specifications


Project data sheets and drawings
This KOC Standard (KOC-ME-006 Part 1)
International codes and standards
Packager's or Vendor's standards and specifications

ENVIRONMENTAL CONDITIONS
The environmental conditions in Kuwait are severe. Refer to "KOC Standard
for Basic Design Data" (KOC-G-007), which provides the general design
information regarding the environmental, site and utility supply conditions
prevailing throughout the KOC facilities.
The equipment shall, in all respects, be suitable for continuous operation in
the s~ecifiedenvironmental conditions.
HEALTH, SAFETY AND ENVIRONMENT
The Vendor, Packager and Contractor shall comply with the necessary Health,
Safety and Environment Management System (HSEMS) and KOC Fire &
Safety Regulations for the protection of KOC personnel, adjacent equipment,
property, and the environment during the installation, operation and
maintenance of equipment manufactured and assembled to this Standard.
All applicable safety requirements of Occupational Safety and Health
Administration (OSHA) Standard 1910.219 and British Standard PD 5304
shall be considered in the design, manufacture, and assembly of equipment
covered by this Standard.
MATERIALS
Steel casting repairs, if any, shall be per ASTM A488. Cast iron castings shall
not be repair-welded, peened, burnt-in or impregnated.
Section number f2.13 Materials} under clause 8.2 of this Standard (from API
675) describes additional KOC requirements for materials of construction.
Purchase documents, project specifications and project data sheets will
describe further KOC project specific requirements for the selection of
materials, equipment and supplies covered by this Standard.
TECHNICAL REQUIREMENTS AND SYSTEM DESCRIPTION
General
8.1 .I

Data sheets for pump performance and noise are included as Appendix 1 and
2 of this Standard.

8.1.2

The Packager shall assume total unit responsibility for the complete metering
pump package.

DOC. NO. KOC-ME-006 PART 1

8.1.3

Each Metering Pump package shall be designed, manufactured, and


assembled as a complete unit, which shall include, but not be limited to the
following:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
I)
m)
n)

o)
8.2

Controlled volume pump.


Pump driver.
Gearbox, as necessary.
Coupling and coupling guard.
Chemical tank(s).
Interconnecting auxiliary piping, including valves fittings and wiring within
the confines of the base-plate.
Pipe work manifolds for multiple pump heads.
External relief valve for each pump head.
Pulsation dampeners, as necessary, including charging kits.
Calibration pots and instrumentation.
Locally mounted control panel with startistop push buttons.
Local instrumentation including pressure, vibration and temperature
monitoring signals, for transmission to the main control room.
Junction boxes, cable trays and supports.
Prefabricated structural steel base-plate to support the pump, drive
arrangement, chemical tank(s), pipe work and locally mounted
instrumentation.
Ladders and platforms as required for access.

Pumps, Drivers and Auxiliaries


Listed below are additional KOC requirements with additions, deletions,
modifications and substitutions to the current edition of API Standard 675
and its appendices (hereafter referred to as API 675). Section, paragraph,
and item numbers shown below, in {bold italic font style} inside
brackets, correspond to those of API 675, second edition, October 1994.
New clauses are introduced following the numerical order in each section
of API 675.
Unless specified otherwise in data sheets, project specifications or purchase
documents, API 675 with the modified specification items listed below shall
apply:

{1.2 - Substitute}

As an alternative, the Vendors and Packagers are encouraged to quote


their standard equipment that meets API 675, the performance requirements
specified on project data sheets, purchase order, and this Standard, but shall
list all exceptions with proper justifications such as equipment reliability
enhancements, cost savings and improvements in equipment delivery.
However, for comparison, Vendors or Packagers shall submit a base bid that
satisfies all the requirements of this Standard, data sheets, project
specifications and purchase documents.

IOC. NO. KOC-ME-006 PART 1

Page 13 of 37

{l.6 - Add}
The units of measurement used shall be in accordance with KOC Standard
for Basic Design Data (KOC-G-007).

{Z.1.3- Substitute}
Normal and rated operating points shall be in accordance with data sheets,
project specifications or purchase documents.

{Z.1.4- Add}
Where necessary to meet the specified noise level for the metering pump
package, suitable noise-attenuating devices shall be provided or noise control
measures taken in accordance with designated Project Specifications
PlantiEquipment Noise Control.

{Z.1.7- Add}
Motors, electrical components, and electrical installations shall be suitable for
the hazardous area classification specified in the Data Sheet. All electrical
equipment and components for hazardous areas shall be certified for the type
of protection appropriate to the zone specified and shall be in accordance with
the applicable sections of "KOC Recommended Practice for Selection,
Installation and Maintenance of Electrical Equipment in Hazardous Areas"
(KOC-E-004). The motors shall be in accordance with "KOC Standard for Low
Voltage Induction Motors" (KOC-E-010).

{2.1.12- Substitute}
Data sheets, project specifications or purchase documents will specify as to
whether the installation is indoor or outdoor and heated or not heated. The
equipment shall be suitable for continuous operation at a desert location under
high ambient temperatures and humidity. The atmosphere at the facility is
generally dusty and corrosive and may contain traces of hydrogen sulphide.
For weather and environmental conditions refer to "KOC Standard for Basic
Design Data" (KOC-G-007).

{2.1.20- Substitute}
Data sheets, project specifications or purchase documents will specify if liquid
ends need to be supplied with jacketed housings for heating or cooling of the
fluid being pumped.

While selecting the pump speed, due consideration shall be given to the
viscosity of the pumped fluid.

12.1.22 - New}

The pump NPSHR shall be a minimum 1.5 m less than NPSHA.


12.1.23 - New}

Pump stroke return mechanism shall be positive. Spring return mechanisms


are not acceptable.
12.2.1 - Add}

The maximum allowable working pressure (MAWP) of the pump shall be 1.2
times the rated discharge pressure defined in section 1.4.21 of API 675.
12.3.1 - Substitute}

Inlet and outlet connections shall be flanged and shall be suitable for the
maximum working pressure as defined in section 1.4.11 of API 675. Machined
and studded connections shall not be used unless specifically approved by
KOC in advance. Unless otherwise specified, pump suction and discharge
flanges shall have equal ratings in order to permit hydrostatic testing of the
whole pump at the same pressure.
12.3.9 - New}

The design shall provide sufficient free area through the suction valves so that
liquid velocities (obtained by dividing design capacity by free area) shall not
exceed either
a)

1.07 mls (for conditions when the pumping temperature is 175C or


below, and maximum viscosity 57 cSt or below, with more than 1.5 m
excess NPSH available, or

b)

0.7 mis (for conditions when the pumping temperature is above 175C
or maximum viscosity is above 57 cSt, or less than 1.5 m excess NPSH
is available).

The pump internal check valves shall be of the double-ball type and shall be
furnished on both the suction and discharge of the pump-head. The valve
material shall be suitable for the intended service. Pump check valves and
seats shall have a minimum Brinell hardness of 150 for carbon or low-alloy
steel, and 225 for 13 Cr steel. The difference in hardness between valves and
seats shall be 50 BHN.
12.5.2 - Add}

Double diaphragm pumps shall be used for corrosive or toxic services.

12.5.5 - Add}

Double diaphragms shall be fitted with diaphragm failure indication. The


method of failure detection shall be by a proven method and fully defined in the
equipment proposal. The indication shall be local or remote as specified on the
equipment data sheets, project specifications or purchase documents.
12.6.3 - New}

Plungers shall have a minimum hardness of 550 BHN in the packing area
12.6.4 - New}

Liquid-end stuffing boxes shall be sized for a minimum of six rings of packing
plus a lantern ring.
12.8 - Add}

When a gearbox is required for a motor-driven pump, it shall be supplied and


selected by the Approved manufacturer of the pump.
12.12.1 - Add}

Pumps shall have micrometer volume adjustment from looh thru 100%
capacity and shall be capable of flow adjustment whilst running or stationary.
12.12.2 - Add}

Where automatic or remote capacity control is specified on the equipment data


sheets, project specifications or purchase documents, appropriate actuators
shall be provided to suit the incoming control signal.
12.13.1.6- Substitute}

Data sheets, project specifications or purchase documents will specify when


motive and process fluids contain any corrosive agents. Appendix 5 of this
Standard shall be used as a guide in selecting materials of construction.
Traces of hydrogen sulphide may be present in the atmosphere. Copper or
copper bearing alloys shall not be used.
12.13.1.9- Modify}

NACE MI30175 shall be used in place of MR-01-90


12.13.2.3.2- Add}

The repair of leaks and defects in pressure castings shall only be performed
with the express approval of KOC and when approved, shall be in accordance
with ASTM A488.

DOC. NO. KOC-ME-006 PART 1


(2.13.4.5.7 - Substitute}

All welded pressure-containing parts shall be 100h radiographed, and


inspected by magnetic particle or liquid penetrant methods. All pump
attachment welds shall receive 100% magnetic particle inspection (MPI)
or dye penetrant inspection (DPI) before post-weld heat treatment
(PWHT) and 100% DPI after PWHT. If the defect cannot be detected
using Radiography Technique, then Ultrasonic Scanning Technique shall
be used.
12.13.4.5.4 - Substitute}

Proposed connection designs and a general arrangement shall be submitted to


KOC for review and approval before fabrication. The drawing shall show weld
designs, size, materials, and pre-weld and post-weld heat treatments. WPS &
PQR records shall be included in the submittal.
12.14.3 - Add}

SI units shall be used for the machine's nameplate. The nameplate shall also
indicate the capacity in gallons per hour (gph) and the rated pressure in psig.
12.14.4 - New}

In addition to appearing on the nameplate, the pump serial number shall be


plainly stamped on the pump casing.
12.14.5 - New}

In addition to the API standard information, the year of manufacture shall be


shown.
13.1.1 - Add}

Unless specified otherwise in data sheets, project specifications or purchase


documents, electric motor drivers shall be furnished.

Refer to sections 2.1.4, 2.1.7 and 2.1.12 and modifications required by this
Standard.

The scope of this Standard also extends to air-driven pumps if such a drive is
specified in the equipment data sheets, project specifications or purchase
documents.

13.2.1 - Add}

Motor to gearbox couplings, which are fully enclosed within the gearbox, shall
be of the Approved manufacturer's standard design.
13.2.2 - Add}

Where external couplings are required, these shall be of the flexible membrane,
removable spacer type and of non-sparking materials.
(3.2.3 - Add}

Coupling guards shall be in accordance with BS PD 5304. Coupling guards


shall be sufficiently rigid to withstand damage when a force exerted by a 100-kg
mass is applied to the guard. All guards shall be removable and made of nonsparking materials.

Note: Neither aluminium nor aluminium alloys are considered to be acceptable


non-sparking materials.
13.3.4 - Add}

Epoxy grout and primer shall be utilised unless specified othenuise.


plates shall have facilities to assist grouting.

Base-

13.3.11 - New}

Where applicable, base-plates shall extend under the chemical tank(s) pump(s)
and driver(s) and be fitted with a drip tray and appropriate drain connection.
Grating shall be utilized and the piping shall be installed under grating to
minimize tripping hazards.
13.3.12 - New}

Two earthing points shall be provided on the base-plate, located diagonally


opposite each other, in accordance with KOC's standard drawing.
13.4.1.4 - New}

The Packager's scope of supply for instrumentation and controls shall be as


indicated on the data sheets, project specifications or purchase documents. All
instrumentation and controls shall comply with the requirements of KOC
Standards and Project Specifications.
13.4.2.1 - Add}

The source of control signal, its sensitivity and range, and the equipment to be
furnished by the Packager will be specified by the data sheets, project
specifications, or purchase documents.

DOC. NO. KOC-ME-006 PART 1

Page 18 of 37

REV.1

13.4.3.1 - Add}

When specified, a free-standing local control panel shall be supplied. The


location and description of the panel and the instruments to be mounted on
the panel will be specified in project specifications, data sheets or purchase
documents.
13.4.4.3 - Add}

Oil-filled pressure gauges shall be furnished in locations subject to


vibration.

Metering pumps shall be supplied with external relief valves for each
pump-head. A single relief valve shall be located upstream of any block
valve or filter in the injection piping and shall discharge through a sightglass back to the chemical tank. The relief valve setting shall be lower or
equal to the MAWP of the pump and the design pressure of the injection
piping.
Metering pump internal relief valves shall have their set point higher than the
external relief valve. The internal relief valve shall only be used to protect the
drive system and not the process side of the pump.
13.4.4.6 - Substitute}

The Vendor's or Packager's proposal shall state whether a backpressure


valve is required. When a backpressure valve is required, either internal
or external, it shall be provided by the Packager. Internal backpressure
valves shall be of materials consistent with API 675 section 2.2, external
backpressure valves shall comply with the relevant KOC Piping
Specification.
13.4.5.1 - Add}

Electrical power supply characteristics for the motor, heaters, and


instrumentation will be specified in data sheets, project specifications, or
purchase documents.
13.4.5.6 - Add}

Special treatment for tropical location shall be provided.


(3.5.1.1 - Substitute]

Piping design and joint fabrication, examination and inspection shall be in


accordance with ASME 831.3 and project specifications.
The design
pressure of the injection piping shall be 1.2 times the rated discharge
pressure defined in section 1.4.21 of API 675.

IOC. NO. KOC-ME-006 PART 1

Page 19 of 37

REV.1

13.5.1.3 - Add}
The minimum amount of pipe-work to be supplied between the chemical tank
and each pump suction shall comprise the following:
a)
b)
c)
d)
e)
f)

An isolation valve on the supply tank outlet.


A calibration pot connected to the supply pipe-work via an isolation valve.
A pump suction block valve.
A Y-Type strainer (75 micron nominal filtration) fitted with a drain valve.
A Pulsation dampener (if required, refer to section 3.6 of API 675).
All other pipe-work as indicated by the Project Specification P&ID.

The minimum amount of pipe-work to be supplied between each pump


discharge and the package terminal point shall comprise the following:
a) A relief valve connection with the relief valve piped back to the chemical
tank, a sight-glass shall be installed in this piping.
b) A pulsation dampener (if required, refer to section 3.6 of API 675).
c) A pressure gauge connection including an isolation valve.
d) A maintenancelsampling connection (comprised of valves and piping) for
flushing the outlet stream, piped down to the base-plate drip tray.
e) A check valve.
f) A discharge block valve.
g) All other pipe-work as indicated by the Project Specification P&ID.
13.5.1.6 - Substitute}
Fabrication of pipe by bending is not allowed. Piping shall be fabricated by
welding. Threaded connections shall be held to a minimum. Pipe bushings
shall not be used.
13.5.1.14 - New}
All chemical tanks shall be in accordance with the tank data sheet. The
chemical tank(s) shall be elevated to provide adequate NPSH. The Packager
shall ensure that the suction pipe-work is as short and direct as possible so as
to minimize acceleration head losses. The tanks shall have a cone or dished
bottom and a flat, hinged top cover. The tank material shall be selected using
Appendix 5 of this Standard as a guide.
13.5.3.7 - Add}
The Packager shall furnish on-skid process piping and critical pump control
instrumentation. Piping shall be terminated with a flanged connection at skidedge, unless specified otherwise.
13.5.3.3 - Substitute}
The Packager shall review all piping, appurtenances, and vessels immediately
upstream and downstream of the equipment and supports for vibration.

IOC. NO. KOC-ME-006 PART 1

REV.l

13.6.1 - Substitute}

The Packager shall furnish pulsation suppression devices to be located


at pump suction and discharge piping as required. Sizing calculations
for the dampener selection shall be submitted for KOC Approval.
Pulsation in the liquid flow entering and leaving the pump shall not
exceed +or- 1.5% of the operating pressure in the suction or discharge
manifolds respectively.
13.6.3 - New}

Charging kits shall be provided with the pulsation dampeners


13.6.4 - New}

Unless specified otherwise, pulsation-suppression devices shall be designed


and fabricated in accordance with ASME Section VIII, Division 1 (with any
cyclic analysis in accordance with ASME Section VIII, Division 2).
14.1.1 -Add} 14.2.3.3 - Add} 14.2.3.4 - Add}

At the time of request for tender, the extent of KOC's participation in


inspection and testing shall be indicated utilizing Appendix - 4 of this
Standard. The successful bidder shall prepare its quality plan (QP) and
inspection & test plan (ITP) for KOC's approval. KOC will then indicate the
intended scope of participation in the inspection & testing process. The final
confirmation of the KOC scope of participation in inspection & testing as
indicated in the ITP shall be confirmed during the Pre-Inspection Meeting
(PIM) to be held with the successful bidder.
14.2.1. 1 - Substitute}

The Vendor andlor Packager shall keep material certificates, such as mill test
reports and the final assembly maintenance and running clearances for at
least 20 years for examination or reproduction by KOC or their representative
upon request.
The Vendor and/or Packager shall provide material certificates complying with
the contract requirements for all pressure-containing piping and load-bearing
parts. The material certificates shall be submitted to KOC for review and
approval.
14.2.2.7 - Substitute}

The criteria in sections 4.2.2.2 through 4.2.2.5 of API 675 shall apply for
radiographic, ultrasonic, magnetic particle, or liquid penetrant inspection of
welds and materials.

14.3.1.3 - Substitute}
During the PIM the Packager and KOC will review and finalize the mark - up
of the ITP, confirm the requirements for witnessing (W), surveillance (S),
monitoring (M), and reviewing (R) in the plan and confirm the inspection
notification requirements. The approved quality plan shall be strictly adhered to
throughout the entire fabrication, assembly, inspection, and testing period.
14.3.2.1 - Add}
All hydrostatic pressure tests shall be carried out prior to the application of any
paint or primer.
14.3.2.4 - Add}
The quality of the test water shall be certified by the Packager
14.3.3.2 - Add}
All pump packages shall be subjected to a witnessed 4-hour mechanical run
test at rated operating conditions. Only the drivers included with the package
shall be utilised for the test.
14.3.3.4 - Substitute}
Flow repeatability and linearity test shall be run using 100, 75, 50, 25 and 10
percent of rated capacity points in descending and ascending order. The flow
variations shall not exceed plus or minus 3 percent of the value at rated
capacity. Each pump shall undergo flow repeatability and linearity test at rated
speed using the dedicated site driver.
14.3.3.6 - New}
A factory witnessed NPSH test is required to confirm the requirements of
section 2.1.22 for each pump. The Approved Manufacturer of the pump shall
define the onset of cavitation in the test procedure.
14.4.1 - Substitute}
Equipment shall be suitably prepared for export in accordance with "KOC
Standard for Packing, Marking and Documentation'' (KOC-G-004).
14.4.3.1 - Substitute}
All equipment shall be painted in accordance with "KOC Standard for Painting
and Coating of Metal Surface - New Construction" (KOC-P-001).
15.2.5 - Substitute}
The Vendor andlor Packager shall furnish procedures for any special tests.

DOC. NO. KOC-ME-006 PART 1

15.3.7 - Substitute}
The Vendor, Packager or Contractor shall furnish technical data manuals to
KOC within 30 days of completion of shop testing. Data sheets and purchase
documents will specify the number of manuals required.
GUARANTY & WARRANTY
Guaranty
All equipment and component parts, shall be guaranteed by the Packager,
against defective materials, design and workmanship.
Warranty
The Packager shall provide a Warranty for all equipment and component
parts in accordance with the purchase order or contract documents.
INSPECTION AND TESTING
Material Inspection and Certification
Materials of construction and quality of workmanship shall be inspected and
certified in accordance with applicable parts of the standards and codes
referenced in the data sheets and this Standard.
Material test certificates shall be submitted to KOC for review and approval
before start of fabrication. Refer to data sheets and Appendix 4 of this
Standard for additional details.
Testing of materials shall be carried out by the manufacturer or by a
recognized testing organization.
When 100% radiography is specified, back gouged surfaces and completed
welds on nozzle and flange attachment welds shall be checked by magnetic
particle or dye-penetrant examination.
After finish machining, all surfaces of forgings, regardless of thickness, shall
be magnetic particle inspected per the requirements of ASME Section VIII,
Division 2, Article 9-1 of Appendix 9.
All surfaces where temporary attachment welds have been removed shall
receive a magnetic particle inspection after grinding.
All non-destructive examination acceptance tests shall be carried out after
completion of post weld heat treatment.
Radiographic examination shall be performed after post weld heat treatment
(PWHT). The manufacturer may perform radiography testing on his own
before PWHT to determine the defect and repair it before carrying out PWHT.

DOC. NO. KOC-ME-006 PART 1

Prior to the final inspection, all slag, loose scale, dirt, grit, weld splatter, paint,
oil, test medium and other foreign matter shall be removed from inside and
outside of the equipment.
Shop Inspection
The Packager shall be responsible for all required Q N Q C and inspection
work to satisfv the requirements of this Standard. KOC mav additionallv
employ the services of inspectors, as deemed appropriate; to- witness the
required inspection and testing of materials and equipment covered by this
Standard.
All inspection shall be made at the Packager's facilities prior to shipment and
shall be conducted in a manner as not to interfere unnecessarily with
fabrication and assembly operations. KOC will decide if KOC inspector is
required to be present when work is in progress.
Quality Plan
The equipment Packager shall prepare and submit a detailed quality plan fol
KOC approval. The quality plan shall consist of the following:
a)

lnspection and Test Plan (ITP)


The ITP shall list the sequence of all inspection and testing activities.
The plan shall include fabrication, assembly, inspection, testing, and
packing for shipment in a chronological order, showing the frequency
of control, the acceptance limits, the governing code and whether a
document or report is produced for each activity.

b)

Pre-inspection Meeting (PIM)


During the PIM the Packager and KOC will review and finalize the
mark-up of the ITP, confirm the requirements for witnessing (W),
surveillance (S), monitoring (M), and reviewing (R) in the plan and
confirm the inspection notification requirements. The approved quality
plan shall be strictly adhered to throughout the entire fabrication,
assembly, inspection, and testing period.

QUALITY ASSURANCE
The Packager shall operate quality systems to ensure that the requirements
of this Standard are achieved. The quality systems shall be preferably based
on I S 0 9000 series of Standards and the Packager shall demonstrate
compliance by providing a copy of the accredited Certificate and a copy of
their quality manual. Verification of a Packager's quality system is normally
part of the pre-qualification procedure and is, therefore, not detailed in this
Standard.

IOC. NO. KOC-ME-006 PART 1

MARKING
Packing, marking, and shipping documentation shall comply with KOC
Standard for "Packing, Marking and Documentation" (KOC-G-004).
DOCUMENTATION
All correspondence, instructions, data sheets, drawings, calculation or any
other written information shall be in English language. In case of dual
languages, one language shall be English.
All dimensions, units of measurement, physical constants etc. shall be in SI
units, unless otherwise specified. (Pipe sizes to be generally mentioned in
inches).
In addition to hard copies, all final documents such as specifications, data
sheets, drawings and Manufacturer's Record Book (MRB) shall be provided in
approved electronic software formats (Latest versions of Microsoft Word, Excel,
and Auto-Cad). Calculations shall be submitted in widely used software forms
agreed upon by KOC.
The Packager shall submit to KOC for review and approval the Manufacturer's
Record Book (MRB) with all test certificates, documents, drawings and
completed data sheets in accordance with Appendix 3 of this Standard.
SPARE PARTS AND MAINTENANCE DATA
The Packager shall comply with the requirements of "KOC Standard for
Spare Parts and Maintenance Data" (KOC-G-009).
The Vendor, Packager or Contractor shall provide a material safety data
sheet (MSDS) for rust preventatives and other chemicals contained in the
Metering Pumps. One copy of each MSDS shall be shipped with the
equipment.
The Vendor, Packager or Contractor shall provide KOC with Operating and
Maintenance (O&M) manuals upon completion of work. O&M manuals shall
contain installation, operating, and maintenance instructions. Operating
instructions shall be in sufficient depth to allow KOC and Construction
Contractor to train their personnel in the safe installation, operation and
maintenance of the equipment being supplied.
APPENDICES
Appendix 1
The data sheets included as Appendix 1 are to be utilized in place of the data
sheets from Appendix A of API 675.

DOC. NO. KOC-ME-006 PART 1

Page 25 of 37

REV.1

Appendix 2
The data sheet for noise included as Appendix 2 shall be completed to satisfy the
requirements of section 5.2.3.b of API 675.

Appendix 3
Appendix 3 shall be used in place of API 675 Appendix D to indicate the Vendor
Drawing and Data Requirements.

Appendix 4
At the time of request for tender, the extent of KOC's participation in inspection
and testing shall be indicated utilizing Appendix - 4 of this Standard. The
successful bidder shall prepare its quality plan (QP) and inspection & test plan
(ITP) for KOC's approval. KOC will then indicate the intended scope of
participation in the inspection & testing process. The final confirmation of the
KOC scope of participation in inspection & testing as indicated in the ITP shall
be confirmed during the Pre-Inspection Meeting (PIM) to be held with the
successful bidder.

Appendix 5
Appendix 5 shall be used to assist in the selection of metering pump package
materials. The materials listed in Appendix 5 shall be the minimum specification
acceptable. The Vendor or Packager should indicate to KOC if a more suitable
material is available.

Appendix 6
Appendix 6 presents a Tank Data Sheet for the chemical storage tank.

)OC. NO. KOC-ME-006 PART 1

Page 26 of 37

REV.1

APPENDIX-1: DATA SHEETS FOR METERING PUMP - Sheet 1 of 2


SI UNITS

APPLICABLE TO: 0

PROPOSALS

0 PURCHASE

0 AS BUILT

NOTE: 0 INDICATES INFORMATION TO BE COMPLETED BY PURCHASER

1 BY MANUFACTURER

0 GENERAT.
--..-.--

NO. OF MOTOR DRIVEN:

OTHER DRIVER TYPE:

- ....
.- ..... ..
...
-.
:' PERFORMANCE

'. . NWMBER

OF FEEDS:
N D S FI REQUIRED, m

RATED CAPACITY, m3/hr:

LIQUID END
0 DIAPHRAGM

0 JACKET REQUIRED
0 PLUNGER

10 SITE AND UTILITY DATA


I LOCATION 0 INDOOR 0 OUTDOOR
0 HEATED
0 UNHEATED
0 UNDER ROOF

52

ISSUED FOR QUOTATION


REV

BY

CHECKED

APPROVED

DATE

REVISION

DOC. NO. KOC-ME-006 PART 1


APPENDIX-1: DATA SHEETS FOR METERING PUMP - Sheet 2 of 2
SI UNITS

EQUIPMENT NUMBER:

VENDOR

FURNISHED

PULSATION

SUPPRESSION

0 NO
EXTERNAL

0 VENDOR FURNISHED RELIEF VALVE: 0 YES

VENDOR FWRNISHED CONTROL PANEL:

.. .. .. .. .. .............

0 F W I S H PROCEDURES FOR OPTIONAL TESTS


TESTS
REQ'D.
WITN.

HYDROSTATIC
STEADY
ACCmACY
REPEATABILITY
LINEARITY

OBSERV.

PROVIDE TECHNICAL DATA MANUAL:

DOC. NO. KOC-ME-006 PART 1

Page 28 of 37

APPENDIX-2: DATA SHEET FOR NOISE

QUIPMENT No.

Center
Frequency

Designated 1,ocation

KOC
Specifications

Vendor Guarantee

j P L = Sound Pressure 1.e~eI~ne&urcd tit I mctcr from the source.


'ilckilfer 5h;lll \late thc m c t h ~ i duscd to sccure the specifled v;llues.

REV.1

DOC. NO. KOC-ME-006 PART 1


APPENDIX 3: VENDOR DRAWINGS AND DATA REQUIREMENTS
FOR METERING PUMP PACKAGES
{Substitute for Appendix D of API 675)

ualono

U I I ~

DOC.NO. KOC-ME-006 PART 1

R1 : Due from vendor ;


R2 : Received from vendor ;
R3 : Returned to vendor ;
F1 : Due from vendor;
F2 : Received from vendor ;
Number of weeks prior to shipment ;
S:
F : ~ . . . . Number of weeks after firm order ;
D:Number of weeks after receipt of approved drawings.

Proposal drawings and data do not have to be certified or as-built. Typical data shall be clearly
identified.
b Purchaser will indicate in this column the time frame for submission of materials (documents) using
the above nomenclature (S, F, D).
c Bidder shall complete these two columns to reflect his actual distribution schedule and include this
form with his proposal.
I.

2.

Send all drawings and data to : Kuwait Oil Company (KOC).


All drawings and data must show project, appropriation, purchase order, and item numbers in
add~tionto the plant location and untt In addition to the copies specified above, one set of the
drawings/instructions necessary for the field installation must be forwarded with the shipment.

IOC. NO. KOC-ME-006 PART 1

Page 31 of 37

DESCRIPTION
1. Certified dimensional outline drawing and list of connections, including the following:
a. Size, rating, and location of all customer connections.
b. Approximate overall handling weights.
c. Overall dimensions.
d. Shaft centreline height.
e. Dimensions of base-plates (if furnished), complete with diameter, number, and locations of
bolt holes and thickness of the metal through which the bolts must pass; centers of gravity;
and details for foundation design.
2

Cross-sectional drawing and bill of materials, including journal-bearing clearances and tolerances

3. Auxiliary system schematics and bills of materials, including the following:


a. Control, alarm, and trip settings (pressures and recommended temperatures)
b. Utility requirements, including electricity, water, and air.
c. Pipe and valve sizes.
d. Instrumentation, safety devices, and control schemes.
4.

Electrical and instrumentation schematics and bills of materials for all systems. The schematics shall
show all alarm and shutdown l~mits(set points).

5.

Electrcal and instrumentation arrangement drawing and lists of connections.

6.

Hazardous Area Certificates for Electrical Equipment & Motors

7. Tabulation of utility requirements (may be on as-built purchaser data sheets)

8.

Curve showing output - power shaft speed versus torque

9. Allowable flange loadings for all customer connections, including anticipated thermal movements
referenced to a defined point.
10. Welding procedures for fabrication and repair (see section 2.13.2.3.1 12.13.4.1 12.13.4.3 12.13.4.5.4
13.5.1.12and4.2.2.1 ofAPI675).
11. Certified hydrostatic test logs,
12. Performance test logs
13. Non-destructive test procedures as itemized on the purchase order data sheets or the Vendor
Drawing and Data Requirement Form.
14. Certified mill test reports as agreed upon in the pre-commtment or pre-inspection meetings
15. As-built data sheets,
16. As-built dimensions (including nomnal dimensions with design tolerances) and data for the following
listed parts:
a. Shaft or sleeve diameters at each journal bearing
b. Each journal bearing inside diameter.
c. Thrust-bearing concentricity (axial run out).

DOC. NO. KOC-ME-006 PART 1


17. Installation manual describing the following (see section 5.3.6.2 of API 675):
a. Storage procedures
b. Foundation plan.
c. Grouting details.
d. Setting equipment, rigging procedures, component weights, and lifting diagrams.
e. Piping recommendations, including allowable flange loads.
f . Composite outline drawings for the driverldriven-equipment train, including anchor-bolt
locations.
g. Dismantling clearances.
18. Operating and maintenance manuals describing the following:
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
1.
m.
n.
o.
p.

Start-up.
Normal shutdown.
Emergency shutdown.
Lube-oil recommendations.
Routine operational procedures, including recommended inspection schedules and
procedures.
Instructions for disassembly and reassembly of journal bearings.
Performance data, including curve showing certified flow versus turndown setting.
As-built data sheets.
As-built dimensions or data, including assembly clearances.
Hydrostatic test logs.
Performance test logs.
Cert~fieddimensional outline drawing and list of connections.
Cross-sectional drawing and bill of materials.
Journal-bearing assembly drawings and bill of materials.
Electrical and instrumentation schematics and bill of materials.
Electrical and instrumentation assembly drawings and list of connections.

19. Spare parts list with stocking level recommendations, in accordance with section 5.3.5 of API 675.

20. Progress reports and delivery schedule, including vendor buy-outs and milestones
21. List of drawings, includ~nglatest revision numbers and dates
22. Shipping list, including all major components that will ship separately.
23. List of special tools furnished for maintenance (see 3.7).
24. Technical data manual, including the following:
a. As-built purchaser data sheets (item 14).
b. Cert~fiedperformance curves (item 7 ) .
c. Draw~ngsin accordance with 5.3.2.
d. As-built assembly clearances.
e. Spare parts list in accordance with 5.3.5.
f.
Utility data (item 6).
g. Reports (items 10, 11, 12, and 13).
25. Material Safety Data Sheets (OSHA Form 20).

Page 33 of 37

DOC. NO. KOC-ME-006 PART 1

REV.1

APPENDIX 4: SCOPE OF INSPECTION AND TESTS FOR METERING PUMP PACKAGES


Project No. :
~ s Order
e
No. :
Requisition No.
Inquiry No. :
Page No. : 1 of 1
Customer : Kuwait Oil Company
Location : Kuwait
Service :

I
--

Item No. :

1 Date :

Date :
Date :
By:
Revision :
Unit :
No. Required :

M
I
D
e
s
c
r
l
p
t
l
o
n
1

-23
24

. -.. . ... .

( Shipping documents and tags

Match-marked removed piping

KOC Scope of

. . . .- . .

1 (4.4.3.6)
1 (4.4.5)
I

Notes:
check against certfied dimensional outline drawing.
KOC Scope of Inspection is defined in the following categories:

A - approval
R - review
S -surveillance
W - witness
H - hold

DOC. NO. KOC-ME-006 PART 1

APPENDIX 5: MATERIAL SELECTION GUIDE FOR METERING PUMP PACKAGES


~Pum ed Fluid
~ -. .

Note:
1

Consult with chemical supplier.

p Matenal spec.
l

IOC. NO. KOC-ME-006 PART 1

Page 35 of 37

REV.1

APPENDIX 6: TANK DATA SHEET


PREPARED BY:

EQUIPMENT NUMBER:

DATE:
1

OPURCHASE
OAS BUILT
- APPLICABLE TO: OPROPOSALS
2
NOTE: 0 INDICATES TO BE COMPLETED BY PURCHASER
BY PUMP PACKAGERIMANUFACTURER
3
I + 0 BY MANUFACTURERIPURCHASER AS APPLICABLE
4
FOR: KUWAIT
5

OIL C O M P M (KOCI
TRNK SERVICE:

SITE: KTJWAlT
TANK CAPACITY:

25

TANK SHELL THICKNESS:

26

TANK COATINGS

ISSUED FOR QUOTATION


REV

BY

CHECKED

APPROVED

DATE

REVISION

ACKNOWLEDGEMENT
This Standard has been approved by the Standards Technical Committee (STC) consisting
of the following:
Mr. Mohd. Emam
Mr. S. Kumar
Dr. Mohd. Ilyas
Mr. Khalid S. AI-Ali
Mr. Henry S. Hill
Mrs. Amina Rajab
Mr. Khalaf Hamada
Mr. N. Ramanathan
Mr. Faris Mansouri
Mr. Modistaba Araghi
Mr. Anwar Al-Sayer
Mr. Abdul Aziz Akbar
Mr. Moataz Khalaf

Insp.&Corr. Team S&E


Standards Team
Standards Team
Gen. Proj. Team
Ops. Tech. Sevcs. Team S&E
Design Team
Design Team
Export Facilities Team
HSE Group
Insp.&Corr. Team N&W
Utilities Team
Proj. Mgmt. Team N
Information Systems Team

Deputy Chairman
SecretaryIMember
Member
Member
Member
Member
Member
Member
Member
Member
Member
Member
Member

The draft of the Standard has been circulated to the KOC User Teams for their review and
responses were received from the following:
ENGINEERING GROUP

AHMADI SERVICES GROUP

Team Leader Design


Team Leader Construction
Team Leader General Projects

Team Leader Projects Design


Team Leader Utilities

MAJOR PROJECTS GROUP

DIVIDED ZONE GROUP

Team Leader Export Facilities Project


Team Leader Major Project Support

Team Leader Proj. Engg. & Facilities

INDUSTRIAL SERVICES GROUP

OPERATIONS GROUP (SK)

Team Leader Insp. & Corr. (S&E)


Team Leader Fire

Team Leader Maintenance


Team Leader Opns. Tech. Svcs,
Team Leader Gas Operations

OPERATIONS GROUP (NK)

OPERATIONS GROUP (WK)

Team Leader Maintenance


Team Leader Opns. Tech. Svcs.

Team Leader Opns. Tech. Svcs,

OPERATIONS GROUP (EK)

EXPORT AND MARINE OPERATIONS

Team Leader Maintenance

Team Leader Export Services

DRILLING OPERATIONS GROUP


Team Leader Drilling Services

IOC. NO. KOC-ME-006 PART 1

Page 37 of 37

REV.1

This KOC Standard for "Metering Pump Packages'' (KOC-ME-006, Rev.1) has been
prepared by the Task Force (TF-MEI05) consisting of the following members:

I Name
Mr. John Hitchcock
Ms. Dalal Al-Whaib
Mr. Yousef Zaman
Mr. Met Welke
Mr. Santanu Banerjee

I Team
Standards Team
Design Team
Opns. Tech. Services
Inspection & Corrosion (N&W)
General Projects Team

I Designation I Tel. No.


TIF Leader
Member
Member
Member
Member

61 095
61107
22241
61 365
61 584