Kuwait National Petroleum Company (K.S.C.
)
New Refinery Project
Project Variation to Shell DEP 34.19.20.31 Reinforced Concrete Structures
Amendment History
Revision Date Reason for Revision
0 21.Jan.14 Issued for Use
P4049N-0000-DD00-VAR-0002_0
34.11.00.11-P4049NRP-00-PV_O Page 2 of 16
Kuwait National Petroleum Company (K.S.C.)
New Refinery Project
Project Variation to Shell DEP 34.11.00.11 Site Preparation and Earthworks
Introduction
This project variation (PV) is based on Shell Design and Engineering Practice (DEP)
34.11.00.11-Gen. April 2003, Site preparation and earthworks including tank foundations and tank
farms which is part of Shell Global Solutions International DEP, Version 32.
34.11.00.11-Gen. is adopted for the Kuwait National Petroleum Company (KNPC) New Refinery
Project (NRP) and is subject to project -specific amendments, as outlined herein, that may include
additions, deletions, exceptions, and revisions to the relevant DEP. This PV shall be referred, as a
requirement, wherever DEP 34.11.00.11-Gen. is referenced.
In general, the requirements stated in this PV take precedence over and supersede those in the Shell
DEPs. Any discrepancy between this PV and other NRP documents shall be brought to the attention
of the Principal for review and direction.
Section and clause numbers shown below correspond to the same numbers in
DEP 34.11.00.11-Gen.
Amendment Conventions
Amendments are changes to the Shell DEP that apply to all applications on the NRP where the DEP
is used. Types of amendments include additions, deletions, exceptions, and revisions, and may
include the complete replacement of a section of a DEP. Amendments are listed by the applicable
DEP section or item number and are collected together in this PV.
Each amendment type and symbol included in this PV is defined below.
Term or Symbol Description
Addition An amendment that adds text at the end of a designated portion of the DEP.
Deletion An amendment that indicates a portion of the DEP that should be deleted.
Exception An amendment that replaces a designated portion of the DEP.
Revision An amendment that revises a limited amount of existing text in the DEP.
Example 1:
(Revision) The value “3.5 ft.” shall now read as “3.25 ft.”
Example 2:
(Revision) The term “MAWP” shall now read as “design pressure (DP)”.
A line that indicates the beginning and end of an amendment section.
P4049N-0000-DD00-VAR-0002_0
34.11.00.11-P4049NRP-00-PV_O Page 3 of 16
Kuwait National Petroleum Company (K.S.C.)
New Refinery Project
Project Variation to Shell DEP 34.11.00.11 Site Preparation and Earthworks
1.1 SCOPE
After Last Paragraph: (Addition)
Add the following new paragraph:
The requirements included in this DEP and Project Variation for site preparation and earthworks
shall be considered as minimum requirements, which are based on the geotechnical
report of the preliminary site investigation performed for the project. The Contractor shall notify the
Company of any significant variations between the Company supplied geotechnical report and the
requirements specified
2.0, 3.0 & 4.0 EARTHWORKS
Sections 2, 3 and 4: (Exception)
Delete the entire sections and replace with the following:
PIP CVS02100, Site Preparation, Excavation and Backfill Specification, dated April 2007, is adopted
for project use with the modifications noted in Table 1 shown on page 11.
5. BUNDED AREAS AND FOUNDATIONS FOR TANKS
5.1.1 General
Last Paragraph: (Revision)
A finishing layer that shall be appropriate for the location shall cover the bunded area. In all cases,
erosion control on both sides of the bund shall be accommodated in the design to prevent
deterioration in the bund resulting from anticipated heavy rainfalls, or during a leakage of the tank.
5.1.2 Functions and requirements
3rd paragraph: (Deletion)
Layout sketches for various tank farm configurations are shown in (Appendix 7). The European
Model Code of Safe Practice, Part II may also be used for determining layouts and safety distances
for marketing and distribution facilities.
P4049N-0000-DD00-VAR-0002_0
34.11.00.11-P4049NRP-00-PV_O Page 4 of 16
Kuwait National Petroleum Company (K.S.C.)
New Refinery Project
Project Variation to Shell DEP 34.11.00.11 Site Preparation and Earthworks
5.2 IMPOUNDING BASIN
Section 5.2: (Deletion)
Delete the entire section.
5.3.1 Design of bunds
Paragraph 1: (Revision)
Bunds should be designed and constructed as a liquid-tight or essentially impermeable earthen or
clay structure with a slope not steeper than 1:1. For details, see Standard Drawing P4001NRP-00-
19-1-C005-015. In some instances, reinforced concrete or steel retaining walls may be more
economic or practical especially where embedded cut-off walls are required to prevent seepage.
Paragraph 3: (Revision)
The crest elevation of the earthen bund wall shall have a minimum width of 1.00 m. The height of the
bund wall above the bund floor shall be determined from the summation of the following heights
5.3.2 Bund Materials
Section 5.3.2: (Exception)
Replace the entire section with the following:
Bunds shall be constructed by fill placement using on-site materials or imported material,
meeting the requirements of this project variation, and covered with a mix of sand, bitumen and
cement.
5.3.3 Construction of Bunds
Section 5.3.3: (Exception)
Replace the entire section with the following:
Bund walls shall be constructed in accordance with the details shown on drawing P4001NRP-00-19-
1-C005-015. Bund wall material placement and compaction shall be in accordance with section 4.3.7
(PIP) and other applicable sections of this specification.
P4049N-0000-DD00-VAR-0002_0
34.11.00.11-P4049NRP-00-PV_O Page 5 of 16
Kuwait National Petroleum Company (K.S.C.)
New Refinery Project
Project Variation to Shell DEP 34.11.00.11 Site Preparation and Earthworks
5.3.4 Bund Coverings (Erosion Protection)
Section 5.3.4: (Exception)
Replace the entire section as follows:
The covering comprising a mix of sand, bitumen and cement shall be well compacted and given a
smooth finish. The durability of these covers shall be proven through a trial mix and application.
Cracks shall be repaired by removing the cover back to sound material and filling the cracks with
molten bitumen. Larger rejected areas shall be trimmed back to original base and repaired with a
minimum of a 75 mm thick layer of the sand, bitumen and cement mix. The minimum thickness of the
bund covering shall be 75mm. Refer to Appendix 4 for additional information.
5.4 SURFACE FINISHES OF BUNDED AREAS
Paragraph 1: (Revision),
Surface finishes in bunded areas shall have a minimum gradient of 1:200 towards the perimeter
drainage. Drainage systems shall be designed and constructed in accordance with DEP 34.14.20.31-
Gen.
Paragraph 2: (Exception)
The permeability of the surface finishes of bunded areas depends on the product stored in the tanks,
on local circumstances and on legal requirements that may in some instances require a completely
impermeable surface in accordance with Company’s document KNPC DEP 34.11.00.21-KNPC.
5.5 TANK FOUNDATIONS
Section 5.5: (Exception)
Delete the entire section and replace with the following:
5.5.1 General
The tank foundation shall be concrete ring wall type. However, for smaller diameter tanks, a concrete
pad is acceptable. The minimum width of the concrete ring wall shall be 300 mm. The design shall
consider the short and long term settlements of the foundations. The tank foundation base
material/sub-grade shall be per the recommendations of the geotechnical report developed for
the project.
5.5.2 Cathodic protection
All tanks on ring wall foundations shall be installed with cathodic protection per DEP 30.10.73.33.
The surface under the tank (inside the ring wall) shall be clean sand with low chloride and low
P4049N-0000-DD00-VAR-0002_0
34.11.00.11-P4049NRP-00-PV_O Page 6 of 16
Kuwait National Petroleum Company (K.S.C.)
New Refinery Project
Project Variation to Shell DEP 34.11.00.11 Site Preparation and Earthworks
sulphate content to ensure regular current distribution. (Refer to 30.10.73.10, Sec 15.2.2, also DEP
Standard Drawing PV 12.003-P4049NRP-00-PV).
5.5.3 Hydrostatic testing of tanks
Hydrostatic testing of the tanks shall be in accordance with DEP 34.51.01.31-Gen, and the
corresponding Project Variation.
5.6 TANK FOUNDATIONS WITH LEAK & DETECTION OF LEAK MANAGEMENT
SYSTEM
5.6.1 General
Paragraph 3: (Revision)
The leak control system shall not be used where products will solidify due to cooling after passing
through a leak, i.e. liquid sulphur, bitumen, wax etc. For details of leak control systems, see Standard
Drawing 12.003. P4049NRP-00-PV.
Paragraph 4: (Deletion)
An HDPE liner shall be used in storage tanks containing hydrocarbons and/or very toxic
substances that can contaminate the tank foundation and its subsoil and groundwater. HDPE may
not be resistant against all chemicals, particularly acids. The durability of HDPE shall be assessed
for the product to be stored in the bunded area.
5.6.2 Installation and testing
Paragraph 1: (Revision)
The HDPE liner (or equivalent) as shown on Standard Drawing 12.003-P4049NRP-00-PV comprises
lap welded sheets with the overlap placed in the down slope direction towards the centre drain sump.
The placement of HDPE sheets and the welding and testing of joints, etc., shall be carried out in line
with the Manufacturer’s instructions and procedures. In locations where there are large differences in
temperature between day and night, the HDPE lining should be installed in the early morning and
covered with sand to avoid excessive rippling of the sheet due to increase in temperature during the
day.
Paragraph 3: (Revision)
The primary function of the liner is to direct any product leakage that occurs through the tank bottom
to the drain sump. From the drain sump, the leaked product will flow along the drainpipe to the
inspection sump. To allow this flow of leaked product, the levels and gradients of each component of
the leakage detection system shall comply with Standard Drawing 12.003-P4049NRP-00-PV, Table
1. The design installation levels for each component of the leak detection system shall take into
account the maximum allowable settlement of the tank bottom and tank edge, as well as the
maximum allowable tilt. The design shall ensure that, given these allowable maximum movements,
the leaked product shall flow through the entire system and into the inspection sump under gravity.
P4049N-0000-DD00-VAR-0002_0
34.11.00.11-P4049NRP-00-PV_O Page 7 of 16
Kuwait National Petroleum Company (K.S.C.)
New Refinery Project
Project Variation to Shell DEP 34.11.00.11 Site Preparation and Earthworks
5.7 SPECIAL TANK FOUNDATIONS
Section 5.7: (Deletion)
Delete the entire section
6.0 TANK MAINTENANCE
Section 6.0: (Deletion)
Delete the entire section
8.0 REFERENCES
NOTES: (Revsion):
Revise Notes as follows:
NOTES: 1. Unless specifically designated by date, the latest edition of each
publication in effect on the date of pre-tender meeting shall be used,
together with any amendments, supplements, or revisions thereto.
2. For referenced standards that may be withdrawn/superseded (as
indicated by the organization of the particular standard), the document
replacing the superseded document shall be used.
SHELL STANDARDS
Shell Standards: (Exception)
Index to DEP publications and standard specifications DEP 00.00.05.05-Gen.
Index to standard drawings DEP 00.00.06.06-Gen.
Amended per
Circular 60/08
Definition of temperature, pressure and toxicity levels DEP 01.00.01.30-Gen.
Minimum requirements for structural design and DEP 34.00.01.30-Gen.
engineering
Site investigations DEP 34.11.00.10-Gen.
Geotechnical and foundation engineering DEP 34.11.00.12-Gen.
Roads, paving, surfacing, slope protection and fencing DEP 34.13.20.31-Gen.
Drainage and primary treatment facilities DEP 34.14.20.31-Gen.
Standard vertical tanks – selection, design and fabrication DEP 34.51.01.31-Gen.
P4049N-0000-DD00-VAR-0002_0
34.11.00.11-P4049NRP-00-PV_O Page 8 of 16
Kuwait National Petroleum Company (K.S.C.)
New Refinery Project
Project Variation to Shell DEP 34.11.00.11 Site Preparation and Earthworks
Mounded horizontal cylindrical bulk storage vessels DEP 34.51.11.30-Gen.
for pressurised gases at ambient temperatures
Note: In this DEP, reference is made to other DEP specifications and standard drawings. For project use, these
referenced DEPs (specifications and drawings) shall be used in conjunction with its project variations, as applicable.
Cathodic Protection DEP 30.10.73.10-Gen.
Installation and Commissioning of Cathodic Protection DEP 30.10.73.33-Gen.
System
STANDARD DRAWINGS
Standard Drawings: (Exception)
Conceptual tank foundation and tank leak detection 12.003.P4049NRP-00-PV
and management system
OTHER STANDARDS / PUBLICATIONS
OTHER STANDARDS / PUBLICATIONS: (Deletion)
NRP PROJECT DOCUMENTS
NRP PROJECT DOCUMENTS: (Addition)
P4033NRP-0097-19R-11 Phase1- Geotechnical Study New Refinery Project
- EPC3 by Fugro Consultants, Inc. Houston,
Texas. Protection
P4033NRP-0097-19R-12 Phase1- Geotechnical Study New Refinery Project
– EPC1 by Fugro Consultants, Inc. Houston,
Texas. Protection
P4033NRP-0097-19R-13 Phase1- Geotechnical Study New Refinery Project
– EPC4 by Fugro Consultants, Inc. Houston,
Texas. Protection
P4033NRP-0097-19R-14 Phase1- Geotechnical Study New Refinery Project
– EPC2 by Fugro Consultants, Inc. Houston,
Texas. Protection
P4033NRP-0097-19R-15 Phase1- Geotechnical Study New Refinery Project
– EPC5 by Fugro Consultants, Inc. Houston,
Texas. Protection
P4033NRP-0097-19R-AG Phase1-Onshore Geotechnical Investigation- Factual
Report New Refinery Project - by ABJ Engineering &
Contracting Co.,/Gulf Inspection Intl. Co.,
P4001NRP-00-19-1-C005-015 Final Surfacing – Plan and Sections
APPENDIX
Delete all appendices except Appendix 4:
P4049N-0000-DD00-VAR-0002_0
34.11.00.11-P4049NRP-00-PV_O Page 9 of 16
Kuwait National Petroleum Company (K.S.C.)
New Refinery Project
Project Variation to Shell DEP 34.11.00.11 Site Preparation and Earthworks
TABLE 1
PIP CVS02100, Site Preparation, Excavation and Backfill Specification, dated April 2007, is
adopted for project use (to replace sections 2, 3, and 4 of DEP 34.11.00.11) with the following
modifications. The following requirements are defined as additions, deletions, and revisions to
PIP CVS02100.
PIP Section PIP Modification Description
1.0 Delete entire section
2.1 Delete entire section
2.2 Add the following:
DEP 33.64.10.10-GEN Electrical Engineering Guidelines
Note: In above specification list, reference is made to DEP
publications. For project use, these referenced DEPs shall be used in
conjunction with its project variations, as applicable.
2.3 Replace entire section with the following:
Safety and Environmental regulations of the local authorities with any
additional requirements of the Kuwait National Petroleum Company
shall apply.
3 Add:
Structural Fill: Fill or backfill placed beneath or immediately surrounding
footings, grade beams, or mats, or beneath slabs, buildings, roads,
paved areas, and parking areas.
General Fill: Fill or Backfill other than Structural Fill.
4.1.1.4 Revise items 5b, 5c, and 5e as shown below:
5b. Structural fill under roadways, area pavement and parking areas –
one test every 1600 square feet (150 square meters) of each lift.
5c. Road base and sub-base – one test every 1600 square feet (150
square meters) of base or sub-base.
5e. General Fill – one test every 2700 square feet (250 square
meters) of each lift.
4.1.3.2 Replace item 1 with the following:
All procedures and work shall be in accordance with the local and
Kuwait National Petroleum Company regulations.
P4049N-0000-DD00-VAR-0002_0
34.11.00.11-P4049NRP-00-PV_O Page 10 of 16
Kuwait National Petroleum Company (K.S.C.)
New Refinery Project
Project Variation to Shell DEP 34.11.00.11 Site Preparation and Earthworks
TABLE 1
PIP CVS02100, Site Preparation, Excavation and Backfill Specification, dated April 2007, is
adopted for project use (to replace sections 2, 3, and 4 of DEP 34.11.00.11) with the following
modifications. The following requirements are defined as additions, deletions, and revisions to
PIP CVS02100.
PIP Section PIP Modification Description
4.1.4.1 Replace item 1 with the following:
The contractor shall comply with applicable local codes and with any
safety requirements of the Owner.
Revise part of the sentence as shown below:
4.2.1.3
Replace: “larger than 3 inches (75mm)”
With: “larger than 2 inches (50 mm)”
4.2.3.1 Add the following:
Fill material shall be imported clean to contract specifications, Excavated
dredged material shall not be used for this purpose unless it meets the
contract specifications for structural fill material including, but not
limited to low chloride and sulphate contents.
4.2.3.2 The bullet items a & b shall be replaced with the following:
Liquid limit: 25 maximum
Plasticity Index: 6 maximum
Gradation: 100% passing 50 mm Sieve,
0-12 % passing 0.075 mm (75
micron or No 200 Sieve).
P4049N-0000-DD00-VAR-0002_0
34.11.00.11-P4049NRP-00-PV_O Page 11 of 16
Kuwait National Petroleum Company (K.S.C.)
New Refinery Project
Project Variation to Shell DEP 34.11.00.11 Site Preparation and Earthworks
TABLE 1
PIP CVS02100, Site Preparation, Excavation and Backfill Specification, dated April 2007, is
adopted for project use (to replace sections 2, 3, and 4 of DEP 34.11.00.11) with the following
modifications. The following requirements are defined as additions, deletions, and revisions to
PIP CVS02100.
PIP Section PIP Modification Description
4.3.2.3 Replace the entire sentence with the following
4.3.2.3 Trenching
Trenching, bedding and backfill for underground pipes and
electrical shall confirm to the following:
4.3.2.3.1 Trench Excavation
All excavation and trenching shall be in accordance with the
local codes requirements/guidelines for:
• Shoring, bracing, and sloping wall construction.
• Marking and flagging requirements for the open
construction.
• Permitting and confined space requirements.
For concrete pipes, trench width shall be as narrow as possible
while still permitting proper access for bedding and assembly of
the pipe. If practical, maximum trench width from the bottom of
the trench to 300 mm(12 inches) above the pipe shall be 4/3 the
nominal diameter of the pipe plus 200 mm (8 inches).
For flexible (HDPE/FRP) pipes, refer to figure 2 for trench width
requirements.
TABLE 1
PIP CVS02100, Site Preparation, Excavation and Backfill Specification, dated April 2007, is
adopted for project use (to replace sections 2, 3, and 4 of DEP 34.11.00.11) with the following
modifications. The following requirements are defined as additions, deletions, and revisions to
PIP CVS02100.
PIP Section PIP Modification Description
P4049N-0000-DD00-VAR-0002_0
34.11.00.11-P4049NRP-00-PV_O Page 12 of 16
Kuwait National Petroleum Company (K.S.C.)
New Refinery Project
Project Variation to Shell DEP 34.11.00.11 Site Preparation and Earthworks
The bedding material shall be firm and graded to provide
4.3.2.3 (Continued)
uniform bearing of the pipe.
Adequate measures shall be taken to prevent erosion and cave-
in. Excavated or other material and equipment shall not be
stored within a distance equal to one and one half the depth of
the excavation.
4.3.2.3.2
Trench Bedding:
• Trench bedding material shall be as per Figure 1 for
concrete pipes.
• Trench bedding and embedment material for the HDPE and
FRP pipes shall be as per Figure 2, unless otherwise
directed by the pipe manufacturer. Bedding and embedment
shall be installed and compacted in maximum 150 mm
4.3.2.3.3 layers.
Trench Backfilling:
The trench general fill shall be back filled in 150 mm (6 inches)
lifts to the required elevation and shall be compacted to at least
90% of the maximum dry density as determined by ASTM
D1557. The material shall be as per PIP section 4.2.2
4.3.2.3.4 Trench Requirements for Electric Cables & Conduits:
For all the underground electric cable trenching requirements,
refer to DEP 33.64.10.10-Gen, Electrical Engineering
Guidelines, section 5.3.3 “Underground Cabling”, and the
corresponding Project Variation, as applicable.
Delete the 1st paragraph and replace the 2nd paragraph with the
4.3.2.5 following:
The constructor is solely responsible for designing and constructing
stable, temporary excavations and should shore, slope, or bench the
sides of the excavations as required to maintain stability of both the
excavation sides and bottom. Safety regulations of the
local authorities with any additional requirements of the Kuwait
National Petroleum Company shall apply.
P4049N-0000-DD00-VAR-0002_0
34.11.00.11-P4049NRP-00-PV_O Page 13 of 16
Kuwait National Petroleum Company (K.S.C.)
New Refinery Project
Project Variation to Shell DEP 34.11.00.11 Site Preparation and Earthworks
TABLE 1
PIP CVS02100, Site Preparation, Excavation and Backfill Specification, dated April 2007, is
adopted for project use (to replace sections 2, 3, and 4 of DEP 34.11.00.11) with the following
modifications. The following requirements are defined as additions, deletions, and revisions to
PIP CVS02100.
PIP Section PIP Modification Description
4.3.6.3 & 4.3.6.4 Replace entire section with the following:
The density of the top 150 mm (6 inches) in these areas shall not be
less than the following:
• For General Fill Areas: 90% of the maximum Modified Proctor
density as determined by ASTM D1557.
• For Structural Fill Areas: 95% of the maximum Modified Proctor
density as determined by ASTM D1557.
4.3.7.5 Replace bullet item 1 with following
Structural Fill material shall be placed in lifts not to exceed 150 mm
compacted layers.
Replace bullet item 2 with following
General Fill material (including the initial mass backfill to raise the site
elevation) shall be placed in lifts not to exceed 200 mm compacted
layers.
4.3.7.7 Bullet Item1 Replace bullet item 1 with following
Structural Fill shall be compacted to at least 95% of the maximum
Modified Proctor density, as determined by ASTM D1557.
4.3.7.7 Bullet Item2 Replace bullet item 2 with following
General Fill shall be compacted to at least 90% of the maximum
Modified Proctor density, as determined by ASTM D1557.
4.3.7.7 Bullet Item3 Revise the first sentence as shown below:
The moisture content of the material to be compacted shall be
within +/- 2% of the optimum moisture content as determined by
ASTM D1557.
P4049N-0000-DD00-VAR-0002_0
34.11.00.11-P4049NRP-00-PV_O Page 14 of 16
Kuwait National Petroleum Company (K.S.C.)
New Refinery Project
Project Variation to Shell DEP 34.11.00.11 Site Preparation and Earthworks
P4049N-0000-DD00-VAR-0002_0
34.11.00.11-P4049NRP-00-PV_O Page 15 of 16
Kuwait National Petroleum Company (K.S.C.)
New Refinery Project
Project Variation to Shell DEP 34.11.00.11 Site Preparation and Earthworks
P4049N-0000-DD00-VAR-0002_0
34.11.00.11-P4049NRP-00-PV_O Page 16 of 16
