SP-1208_Sep 2005 PIPELINE_CONSTRUCTION_SPECIFICATION_(PCS-01)_SP-1208

Petroleum Development Oman L.L.C.

UNRESTRICTED September 2005

Document ID: SP-1208 Filing key: xxxx

Pipeline Construction Specification

Keywords: This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any part of this document may be disclosed to others or reproduced, stored in a retrieval system, or transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise) without prior written consent of the owner.


Version 2.0

Authorised For Issue

Signed : Maqbool Al Zadjali, UIP CFDH Pipelines

The following is a brief summary of the 4 most recent revisions to this document. Details of all revisions prior to these are held on file by the issuing department.

Version No.

SP-1208

Date

Author

Scope / Remarks

Version 2.0

September 2005

Jan Belt, UIP/5

Specification reviewed updated. Requirements for GRE pipeline construction included.

Version 1.0

April 2001

R J Harris, OIP/31

Text of Specification PCS-01 adapted and re-formatted. References updated and text edited. No significant technical changes made.

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TABLE OF CONTENTS 1.1 Purpose............................................................................................................................1 1.2 Changes to the Specification............................................................................................1 1.3 Conflicting Requirements.................................................................................................1 1.4 Exceptions........................................................................................................................1 1.5 Health, Safety and Environment (HSE)............................................................................2 1.6 Quality Assurance............................................................................................................3 1.7 Materials Handling and Control........................................................................................6 1.8 R.O.W. and Trenching....................................................................................................11 1.9 Stringing and Bending....................................................................................................18 1.10 Welding and NDT.........................................................................................................20 1.11 Anti-Corrosion Field Joint Coating................................................................................21 1.12 Lowering-In, Backfilling and Reinstatement .................................................................29 1.13 Road and Wadi Crossings............................................................................................34 1.14 Concrete Coating for Wadi Crossings..........................................................................37 1.15 Permanent Markers and Barriers.................................................................................44 1.16 Station Works...............................................................................................................46 1.17 Cathodic Protection......................................................................................................49 1.18 Quality and Treatment of Hydrotesting Water..............................................................51 1.19 Hydrostatic Testing.......................................................................................................51 1.20 Precommissioning Of Pipelines....................................................................................52 1.21 Work on Live Pipe Systems.........................................................................................53 1.22 As-Built Records and Hand-Over Documentation........................................................53 1.23 Effective Period............................................................................................................55 1.24 Review and Improvement.............................................................................................55 Appendix A Glossary of Definitions, Terms and Abbreviations...........................................56 Appendix B Reference Documents.....................................................................................57 Appendix C: Facilities For Company Personnel..................................................................61 Appendix D: List of Handover and As-built Documentation.................................................64 Appendix E List of Typical Drawings for Pipeline Construction...........................................69 Appendix F CONSTRUCTION REQUIREMENTS FOR GRE PIPELINES.........................95 User Comment Form.........................................................................................................105

1.1 Purpose............................................................................................................................1 1.2 Changes to the Specification............................................................................................1 1.3 Conflicting Requirements.................................................................................................1 1.4 Exceptions........................................................................................................................1 1.5 Health, Safety and Environment (HSE)............................................................................2

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1.5.1 Scope 2 1.5.2 General...................................................................................................................................2 1.5.3 HSE Advisor............................................................................................................................2 1.5.4 Specific Pipeline Activities.......................................................................................................3

1.6 Quality Assurance............................................................................................................3 1.6.1 Scope 3 1.6.2 General...................................................................................................................................3 1.6.3 Quality Assurance Team........................................................................................................3

1.6.3.1 Personnel....................................................................................................................4 1.6.3.2 Organisation...............................................................................................................5 1.6.4 Company Inspection...............................................................................................................5

1.7 Materials Handling and Control........................................................................................6 1.7.1 Scope 6 1.7.2 General...................................................................................................................................6

1.7.2.1 Handling, including but not necessarily limited to receipt, checking, lifting, loading, transport, unloading, stacking, and storage of materials shall be carried out by the Contractor in such a manner as to avoid any damage and loss of materials. Method and means of transport and handling (including documentation) shall be subject to approval by the Company..........................................................................................6 1.7.2.2 Contractor’s material control and storage procedure shall be submitted to the Company within two weeks of the start of mobilisation on site, for approval.............6 1.7.2.3 Contractor shall give the Company at least 2 Company working days notice in writing on each occasion when he intends to start transporting Company supplied materials. A lapse greater than 2 working days shall require re-notification. Pipe can be removed from Company’s yard 7 days per week during daylight hours, unless otherwise specified by the Company. Contractor shall provide the Company with a written confirmation of receipt of all materials (identified by type and quantity) and a written reconciliation of all materials (identified by type and quality) transported by them from Company’s storage yard on a weekly basis..............................................6 1.7.2.4 Contractor is required to supply lifting equipment for lifting materials at all locations. Lifting equipment and operations shall be in accordance with SP-1239....................6 1.7.2.5 Contractor shall appoint a dedicated site-based materials Controller whose sole function shall be to control and report on the receipt, issue, and stock status of the Contractor and Company supplied materials.............................................................6 1.7.2.6 Contractor shall not be held responsible for manufacturing defects in Company supplied materials, but shall be held responsible for any delays to the Work caused by Contractors failure to report defects discovered during inspection by the Contractor within 24 hours of such inspection...........................................................6 1.7.2.7 Contractor’s procedures for material receipt and return of surplus materials shall conform to Company’s materials procurement/administration procedures................6 1.7.3 Pipe Inspection.......................................................................................................................6

1.7.3.1 The Contractor shall visually inspect at the Company storage yards, all pipes internally and externally for damages, surface defects and defective bevels. The Contractor shall satisfy himself at this stage of the suitability of each pipe for welding and shall accept all responsibility thereafter for all damages however caused.......................................................................................................................6 1.7.3.2 Prior to haulage of pipe from Company’s storage yard, Company and Contractor shall carry out a joint survey of pipe coating damage and bevel damages. On the basis of this survey, Company will pay the Contractor a lump sum for repair of all bevel and coating damage, based on the submitted unit rates in the Schedule of

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Rates, in accordance with this specification. For bevel damages between 1 and 3 mm deep, the repair shall be by grinding. For bevel damage depth greater than 3 mm, the repair shall be by re-bevelling......................................................................6 1.7.4 Pipe Handling..........................................................................................................................8

1.7.4.1 Pipe shall not be allowed to drop or strike objects which may damage the pipe and/or coating but shall be lifted, moved and lowered from one position to another by suitable equipment. When lifting pipe, non-abrasive wide nylon pipe slings or special lifting hooks equipped with a non-metallic bevel protectors curved to fit the curvature of the inside of the pipe shall be used. Temporary attachments for handling or lifting shall not be welded to any pipe. A spreader bar shall be used for all bulk pipe lifting/handling (excluding welding operations).......................................8 1.7.4.2 Trucks used to transport coated or bare pipes shall be free of any materials that might damage or contribute to movement of the pipe during transport. Pipes shall be protected against truck beds and side metallic posts by means of non-metallic soft materials. Pipes shall be loaded and stacked on trucks in such a manner that flexing and shifting of the pipe during transport is avoided. After loading, suitable non-metallic slings shall be used to tie the pipes securely to the truck. During transport the tension of these slings shall be regularly checked. Pipe ends shall be protected from contact with other metallic materials. Contractor shall ensure that no bevel protectors are lost during transport. Pipes shall only be transported on trucks (lifting equipment shall not be used to transport pipe)...............................................8 1.7.4.3 Trucks used for loading of pipes will be checked by the Company prior to lifting the pipes to ensure that the trucks and loading/load securing arrangements comply with the requirements of PDO’s Transport Manual TOM/04/001, SP-2000 ‘Road Transport’ and government regulations.....................................................................8 1.7.5 Pipe Stacking..........................................................................................................................8

1.7.5.1 Ground surfaces to be used for stacking of pipe shall be reasonably flat. Stacked pipes shall be raised above ground surfaces and prevented from movement by berms of screened sand covered by polyethylene sheeting or by using timber covered with non-metallic soft materials. When stacked, the bottom layer of pipes shall be wedged or clipped. Pipes of different diameter, wall thickness, grade or manufacturer shall be stacked separately. Each stack shall be properly marked to the satisfaction of the Company................................................................................8 1.7.5.2 Epoxy-coated pipes shall be stacked during transport and storage using rubber or other suitable separator strips....................................................................................8 1.7.5.3 Pipes shall not be stacked higher than 3.5 metres. Pipes shall be stacked in such a way that no water is retained inside the pipe during storage.....................................8 1.7.6 Linepipe Specifications...........................................................................................................8

1.7.6.1 Line-pipe shall be manufactured in accordance to DEP 31.40.20.35 and DEP 31.40.20.37 for non critical and critical services respectively. These specify amendments/supplements to ISO 3183 Specification...............................................8 1.7.6.2 Minimum average pipe length shall be 11.50m as per above DEP. The minimum and maximum length of pipe shall be between 9m and 13.7m long.................................8 1.7.6.3 Linepipes if required, shall be provided with a factory-applied polyethylene / polypropylene coating or a factory applied fusion bonded epoxy powder coating. Each polyethylene / polypropylene coated pipe shall be left bare for a distance of 150 ± 20 mm from each end. Each fusion-bonded epoxy powder coated pipe shall be left bare for a distance of 80 ± 15mm. Where concrete coating of linepipe is envisaged, the concrete coating cut back shall be increased by 100mm over and above the cut back left in the mill coated pipe...........................................................8 1.7.7 Inspection of Materials other than Pipe................................................................................10

1.7.7.1 Upon receipt of any materials, the Contractor shall ensure that they conform to the required specification and are suitable for their intended application. Any damage/defects shall be reported to the Company within 24 hours of receipt of

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these materials and prior to transportation to the Contractor’s own storage yard. Visual inspection shall be adequate for this purpose...............................................10 1.7.7.2 In the case of materials delivered in their original sealed crates, Contractor shall only open the crates to examine the materials upon arrival at his own storage yard, except in the case of damaged crates which shall be noted and the contents examined when Contractor takes receipt at Company’s storage yard.....................10 1.7.7.3 If no report is issued for damaged materials 24 hours after receipt (or in the case of 2.3.7.2 above, 24 hours after arrival of materials at the Contractors storage yard), then the materials shall be considered free from damage and the Contractor shall be considered liable for any damage reported or found at a later date....................10 1.7.8 Handling of Materials other than Pipe..................................................................................10

1.7.8.1 Materials other than pipe materials such as, but not limited to, valves, fittings, scraper traps etc., shall be lifted by suitable equipment provided by the Contractor at Company’s storage yard and at all other locations. When lifting lugs are provided on materials, suitable lifting hooks shall be used for lifting the materials. It is prohibited to use delicate parts such as hand wheels, nozzles, etc. for lifting of the materials..................................................................................................................10 1.7.8.2 Materials other than pipe materials will be issued to the Contractor whenever possible in their original sealed shipping cases/crates. Blinded openings of materials shall be kept closed until installation. The blinds shall be replaced by the Contractor in case of damage during transport or storage........................................................10 1.7.8.3 During transport, materials shall be secured by suitable non-metallic non-abrasive slings........................................................................................................................10 1.7.8.4 For materials which shall be stored cool and/or dry as required by the manufacturer or the Specifications, Contractor shall provide suitable storage, transport and handling facilities in accordance with the requirements of the manufacturer and/or the Specifications.....................................................................................................10 1.7.8.5 Contractor shall provide a separate fenced storage area for Company supplied materials. Stored materials shall be protected from ground surfaces by using timber covered with non-metallic soft materials. Ground surfaces in storage areas shall be clean and flat. It is prohibited to store and transport fragile materials in more than one layer..................................................................................................................10 1.7.8.6 Distribution and supply of materials from Contractor’s storage yard to the worksites shall be limited to quantities required for approximately one day’s production. Timing of the issue of materials shall be as per the Company approved work schedule.....10 1.7.9 Reconciliation........................................................................................................................10

1.7.9.1 At the end of the project, Contractor shall give reconciliation for all Company supplied materials issued, detailing materials installed, materials wasted and scrapped, and surplus materials. Contractor shall compile a list of the surplus materials, indicating quantity, description and MESC / SAP number when available. .................................................................................................................................11 1.7.9.2 On approval of the surplus list by the Company, Contractor shall return all surplus materials to Company’s storage yard......................................................................11 1.8 R.O.W. and Trenching....................................................................................................11 1.8.1 Pipeline Right-of-Way and Working Strip.............................................................................11

1.8.1.1 Scope........................................................................................................................11 1.8.1.2 Survey......................................................................................................................11 1.8.1.3 ROW Width ..............................................................................................................11 1.8.1.4 Planning/Approvals...................................................................................................11 1.8.2 Staking, Clearing and Grading..............................................................................................12

1.8.2.1 Scope........................................................................................................................12

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1.8.2.2 Definitions.................................................................................................................12 1.8.2.3 Staking......................................................................................................................12 1.8.2.4 Below and Aboveground Services............................................................................13 1.8.2.5 Clearing the Working Strip........................................................................................14 1.8.2.6 Explosives (not used for blasting as part of the construction work)..........................14 1.8.2.7 Grading the Working Strip........................................................................................15 1.8.3 Trenching..............................................................................................................................15

1.8.3.1 Scope........................................................................................................................15 1.8.3.2 Excavation................................................................................................................15 1.8.3.3 Blasting.....................................................................................................................17 1.8.3.4 Definition of Rock......................................................................................................18 1.8.3.5 Sloping Trenches......................................................................................................18 1.8.3.6 Trench Width............................................................................................................18 1.9 Stringing and Bending....................................................................................................18 1.9.1 Scope 18 1.9.2 Stringing................................................................................................................................19

1.9.2.1 No pipe shall be strung before the trench is excavated to full depth and accepted by the Company to meet the requirements of this Specification. Pipe shall not be placed directly on the ground but on wooden skids with proper protective padding. The skids and protective padding material shall be subject to Company (CSR) approval. Dragging, skidding or dropping of the pipe is not permitted. Wooden wedges shall be used to prevent movement of each strung pipe............................19 1.9.2.2 Where possible the skid elevations shall be planned such that minor differences between grade profile and bottom of trench profile (e.g. at locations where an increased trench depth is required) can be accommodated without requiring an additional tie-in. The distance between the trench edge and the pipe string shall be planned such that safe working space is provided...................................................19 1.9.2.3 Contractor shall be responsible for proper stringing and locating of the pipe by size, wall thickness, specification and manufacturer. Company may supply line pipe from different manufacturers. Contractor shall string all line pipe of one manufacturer before commencing the stringing of line pipe supplied by the second manufacturer. Pipes of different manufacturers shall not be mixed per line section without prior approval of the Company.........................................................................................19 1.9.2.4 Contractor shall string the pipe in such a manner so as to cause no interference with public roads, footpaths, tracks, etc. Suitable gaps shall be left at intervals as necessary to permit the passage of live stock and/or equipment across the Right-ofWay and as directed by the Company.....................................................................19 1.9.2.5 Contractor shall layout and measure the pipes such that, the number of pieces cutoff with less than one metre length is kept to a minimum........................................19 1.9.2.6 The length of pipe string shall be planned with due consideration of thermal expansion and other expected or accidental movement of the pipe string. Special attention shall be paid to strings with one or more bends, in view of the inherent increased risk of failure of skids due to movements of the pipe. Length of individual pipe strings shall be subject to Company approval and shall generally not exceed 1 km............................................................................................................................19 1.9.2.7 Pipe shall be strung with the use of a spreader bar and two guide lines. (See Section 2.3 for requirements for slings and hooks)...............................................................19 1.9.3 Pipe Bending.........................................................................................................................19

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1.9.3.1 Contractor shall make all necessary bends required for proper construction of the pipeline, following a trigonometric survey to establish the number and degree of bends required, to ensure that the installed pipe shall conform to the contours of the pre-padded trench....................................................................................................19 1.9.3.2 Contractor shall, before the start of the Work, submit and demonstrate to the Company a bending procedure, which shall conform to the recommendations of the manufacturer of the bending machine. This procedure shall be subject to Company’s approval. The procedure shall include amongst others, step length, degrees per pull and method and accuracy of measurement during pulling of the bend.........................................................................................................................19 1.9.3.3 Elastic bends with radius of curvature less than 500 x D, D being the pipeline diameter are not allowed unless approved by the Company...................................19 1.9.3.4 The radius of cold bends shall be not less than: ......................................................20 1.9.3.5 The cold bends shall be made by a smooth stretch bending machine. Bends with ripples with a depth exceeding 0.5 mm, wrinkles and kinks are not acceptable. Contractor shall provide a procedure for measuring ripples which shall be approved by the Company.......................................................................................................20 1.9.3.6 The pads, dies and rolls of the bending equipment shall have soft surfaces to avoid damage to the pipe coating. Where applicable, fully retaining bending shoes shall be used. Roller type bending machines are preferred. Bends in pipe of diameter 8" or greater shall be made by using an internal (hydraulic or pneumatic) mandrel.....20 1.9.3.7 All bends shall be tested in the presence of the Company with a gauging plate of 97.5% of the nominal internal diameter of the pipe prior to installation....................20 1.9.3.8 The procedure for bending shall be such that the extremities of each joint remain straight over a minimum distance of 2 m or twice the pipe diameter, whichever is greater. Contractor shall lay out and measure the pipe for bending such that the length of off-cuts is kept to a minimum....................................................................20 1.10 Welding and NDT.........................................................................................................20 1.10.1 Scope 20 1.10.2 Off-Plot Pipelines................................................................................................................20 1.10.3 On-Plot Pipework................................................................................................................21

1.11 Anti-Corrosion Field Joint Coating................................................................................21 1.11.1 Scope 21 1.11.2 Materials..............................................................................................................................21

1.11.2.1 Only materials supplied by Company approved manufacturers shall be used in the Work........................................................................................................................21 1.11.2.2 Contractor shall as a minimum follow manufacturer’s recommendations regarding material storage, application methods, equipment, spares and tools. Contractor shall submit for Company approval and demonstrate to the Company, the proposed work methods for coating application and coating repair, two weeks prior to application................................................................................................................21 1.11.2.3 The materials, at time of application by the Contractor, shall not be older than the shelf life stated by the manufacturers......................................................................21 1.11.2.4 The coating materials shall be properly packed and clearly marked with:..............21 1.11.2.5 Coating materials shall be kept dry and stored as long as possible in the manufacturer’s original packaging, not exposed to direct sunlight, and in accordance with manufacturer’s instructions...............................................................................22 1.11.2.6 The list of Company approved wrap-around shrink sleeves is given in the Approved Vendors, Manufacturers and Equipments (AVME) list of the company...................22 1.11.3 Surface Preparation............................................................................................................22

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1.11.3.1 Prior to coating, the field joint area shall be blast cleaned. Surface preparation, including blast cleaning, shall be carried out in accordance with SP-1246 and this specification.............................................................................................................22 1.11.3.2 The blast surface visual appearance shall conform to ISO 8501 grade Sa 2 1/2. Any field joint not coated within 4 hours of grit blasting shall be reblasted prior to the application of the coating.........................................................................................22 1.11.3.3 The surface profile attained by the grit blasting shall conform to ISO 8503-2 and shall be 40-75 microns peak to trough or as specified by field joint coating manufacturer............................................................................................................22 1.11.3.4 The surface cleanliness shall conform to ISO 8502-1 to 4 and shall be such that the chloride contamination is less than 20 mg/m2...................................................22 1.11.3.5 Coating of the field joint shall not take place until the weld has been nondestructively tested and approved by the Company................................................22 1.11.4 Shrink Sleeve Application...................................................................................................22

1.11.4.1 Contractor shall propose the application procedure for Company approval. The application procedure shall be in accordance with manufacturer’s instructions and the minimum requirements specified below, whichever are the most stringent, and shall be demonstrated to the Company prior to field application by means of a procedure qualification test joint...............................................................................22 1.11.4.2 The joint shall be heated to a temperature required by the procedure. Induction heaters, ring burners or propane torches of a suitable type may be used for pipe diameters smaller than 16". Induction heaters shall be used for pipe diameters of 16" and larger where the pre-heat temperature exceeds 100° C. In all other cases burners or torches may be used. Torches may be used for tie-in welds at Company’s discretion. To check that the required preheat temperatures have been achieved, a digital contact thermometer shall be used............................................22 1.11.4.3 The sleeve shall be wrapped entirely around the joint. The closure patch shall be positioned off to one side of the pipe. There shall be a minimum overlap of 50 mm onto the factory applied coating...............................................................................22 1.11.4.4 The procedure for shrinking the sleeve shall ensure that all entrapped air is forced out at either end using gloved hands and hand rollers. Special attention must be given to the closure patch and overlapping areas....................................................23 1.11.4.5 The installed sleeve shall be left undisturbed for 4 hours or until the adhesive has been solidified, whichever is the longer...................................................................23 1.11.4.6 The sleeves shall be visually inspected for the following points:............................23 1.11.5 F.B.E. Application...............................................................................................................23

1.11.5.1 The mill applied epoxy coating of the linepipe shall be applied in accordance with DEP 31.40.30.32. The epoxy material for the field joints shall be compatible with the linepipe coating and shall conform to the material requirements of DEP 31.40.30.32. .................................................................................................................................23 1.11.5.2 Contractor shall propose the application procedure for Company approval. The application procedure shall be in accordance with manufacturer’s instructions and the minimum requirements specified below, whichever are the most stringent, and shall be demonstrated to the Company prior to field application by means of a procedure qualification test joint. Contractor shall also submit test data to demonstrate that the applied coating satisfies the requirements DEP 31.40.30.32, with respect to:.........................................................................................................23 1.11.5.3 The resin powder shall be stored in waterproof containers which are insulated and cooled by refrigeration or air conditioning to a temperature not exceeding 27°C. Temperature recorders shall be used to monitor the storage temperature inside each container. During the daily powder coating operations, the powder in the fluid bed can be kept at ambient temperatures up to 85°C, but must be returned to the normal storage temperature below 27°C at the end of the day. For any powder that has temporarily experienced temperatures in excess of 27°C, gel time tests as per

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manufacturer’s recommendation must be carried out on each box of powder before use...........................................................................................................................23 1.11.5.4 The area of the pipe to be coated shall be preheated by induction heating coil to a maximum temperature of approximately 250°C. The actual temperature range shall be in accordance with the powder manufacturer’s recommendations. If the ambient temperature falls, it may be necessary to increase the preheating temperature slightly to provide adequate curing energy. Powder application shall start as soon as the metal temperature is within the qualified temperature range, such that the metal temperature does not drop below the specified lower temperature limit during coating application. Metal temperatures shall be checked by means of digital contact thermometers..............................................................................................23 1.11.5.5 For pipeline sizes equal to or greater than 12", Contractor shall use automatic coating machines, capable of applying the powder at a uniform rate over the entire width of the area to be coated. For smaller pipeline sizes, Company may accept powder application by a hand held device used by a skilled operator, using a technique which achieves an even coating thickness. There shall be a minimum overlap of 50 mm onto the factory coating...............................................................25 1.11.5.6 The applied coating shall have a minimum dry film thickness of 400 ± 75 micron. Dirt or deleterious materials shall not contaminate the powder coated area during the application and curing stages. In the event of contamination, the coating shall be rejected, stripped and recoated to the original procedure. The cured coating shall be free of blisters, pinholes, scratches or any other irregularities and shall be of uniform gloss and thickness..................................................................................................25 1.11.5.7 All operators shall wear Company approved safety equipment to prevent inhalation of powder dust and contact with eyes. Smoking shall not be allowed in the vicinity of the coating operation...............................................................................................25 1.11.5.8 The powder container, hoses, etc. on the application unit shall be cleaned after each day’s work.......................................................................................................25 1.11.6 Coating Repairs..................................................................................................................25

1.11.6.1 Coating repairs shall be executed on all coating damage and imperfections detected visually or by holiday testing......................................................................25 1.11.6.2 The coating repair procedure and the required materials for this, including the installation of repair sleeves when applicable, shall be in accordance with a procedure submitted by the Contractor and approved by the Company..................25 1.11.6.3 The repair procedure for mill applied polyethylene / polypropylene coatings shall be selected based on the criterion of magnitude of the damaged area, i.e.:................25 1.11.6.4 The repair procedure for both mill and field applied fusion bonded epoxy powder coatings shall be selected based on the criterion of magnitude of the damaged area, i.e.:...........................................................................................................................26 1.11.7 Testing, Inspection and Acceptance...................................................................................26

1.11.7.1 The testing and inspection for acceptance of the coating system shall be carried out and recorded by the Contractor as instructed and witnessed by Company’s representative. The frequency of testing as specified herein may be altered by the Company at Company’s sole discretion...................................................................26 1.11.7.2 The cleanliness of the blast cleaned surfaces for every field joint shall be inspected and shall be in accordance with ISO 8501 grade Sa 2 1/2. After the surface has been blast cleaned and dusted off, a strip of transparent cellotape shall be applied to the surface, and subsequently removed and examined for particle contamination. This shall be done on the first joint cleaned each day, plus two more times during the day and when a new batch of grit is used. If in the opinion of the Company the test has failed, Contractor shall undertake to perform additional cleaning to the specified standard....................................................................................................26 1.11.7.3 The profile of the blast cleaned surfaces shall be tested by means of Testex Replica Tape (type X-course), produced at least twice a day and additionally the

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first few joints and at each change or replenishment of grit. Before applying the coating, the surface shall be free of rust or residual grit. The surface profile shall be evaluated from the replicas in accordance with manufacturer’s instructions, using a recently calibrated micrometer. As an alternative to the above, the Company may allow the surface profile to be tested on site by a suitable profile gauge in accordance with SP-1246........................................................................................26 1.11.7.4 Additionally, general checks at random shall be carried out such as monitoring of particle size of copper slag, grit/shot used for blast cleaning, cleanliness of materials used for blast cleaning and coating, and temperature control of the pipe surface.. .26 1.11.7.5 Contractor shall supply all equipment required for inspection and testing including dry film thickness gauges and holiday detectors. All equipment shall be approved by the Company prior to use.........................................................................................26 1.11.7.6 Shrink Sleeves Testing...........................................................................................27 1.11.7.7 Fusion Bonded Epoxy Testing................................................................................27 1.11.7.8 Holiday detection of 100% of the surface area of all coated pipeline shall be carried out immediately prior to lowering in the ditch. The holiday detection equipment which shall be Company approved shall be set at 2000 Volts DC for Fusion Bonded epoxy and 22000 Volts DC for PE coated pipes based on 5V per micron of coating thickness. However, the voltage setting for holiday detection may be lowered slightly at Company’s discretion if coating gets damaged. The electrode shall be a conductive rubber or a spiral metal ring. Brush type electrodes shall not be used. The voltage applied by the holiday detection equipment shall be measured by means of a voltage read out. Alternatively a means of calibration of the applied voltage of holiday detection equipment shall be provided to enable daily calibration of each piece of equipment. All holidays, imperfections and damaged areas shall be identified with a waterproof marker at sufficient distance from the defect to allow surface preparation and patching to take place without detriment to the adhesion of the coating...............................................................................................................28 1.11.7.9 Company will carry out a ‘Pearson Survey’ to check the integrity of the buried coating. If coating defects are found on any portion of the coating, Contractor shall excavate, repair and backfill at Contractor’s expense..............................................28 1.12 Lowering-In, Backfilling and Reinstatement .................................................................29 1.12.1 Scope 29 1.12.2 Pre-Padding........................................................................................................................29

1.12.2.1 All trenches shall be padded before lowering in of pipe string. No padding shall be placed until the Company has inspected and approved the trench bottom..............29 1.12.2.2 To ensure that fine and clean padding material is used, the Contractor shall use mobile screening plants that enable a continuous direct application of padding from the plant to the trench. The type of screening plant is to be approved by Company prior to mobilisation to site (minimum sieve size shall be 5 x 5 mm). Mobile screening plants are defined as screening plants which move along the trench whilst they are in operation. Only in those areas where mobile screening plants cannot be used due to access problems, pre-screened material may be used after approval of the source by the Company. Pre-screened material shall be stored in areas which have been cleared of rocks and stones and protected with plastic sheets to prevent contamination with unacceptable padding materials................................................29 1.12.2.3 The installed padding material shall be free of sharp rocks, stones, metal parts, roots, clods, etc. and without sharp edges which could damage the pipeline. Base materials from which pre and post padding material will be produced shall consist mainly of sandy material. More than 75% by weight of the screened material should have grain size between 0.06 and 3.0 mm and no more than 25% by weight shall have a grain size between 3.0 and 5.0 mm. To ensure compliance with the above requirements, the Contractor shall produce a grading curve with typical screened material from the proposed source of sand or a representative section of the working strip. If the base material is not sourced from the working strip, sources of

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padding material shall first be approved by the Company. Suitable base material from the working strip may not always be available or acceptable, in which case it shall be Contractor’s responsibility to obtain suitable padding material from a source approved by the local government authorities. Near residential areas and roads, padding material shall be dust free (e.g. 'coarse sand' with a minimum grain size of 0.6 mm) in order to avoid inconvenience or danger to the public.............................29 1.12.2.4 The bottom of the trench shall be padded with sand throughout its length, whether in normal ground or rock, so as to provide a minimum compacted padding thickness of 150 mm below the invert of the pipe. Contractor shall keep the pre-padding operation within 1 km of the lowering-in operation...................................................29 1.12.3 Lowering-in and Post-Padding............................................................................................29

1.12.3.1 Welded pipe strings shall be lowered-in within 96 hours of completion of joint coating.....................................................................................................................29 1.12.3.2 Immediately before commencing the lowering-in operation, the coating shall be checked for holiday and if necessary, repaired to the satisfaction of the Company, as specified in Section 2.7.6....................................................................................29 1.12.3.3 Wide non-abrasive slings or belts shall be used in all lowering-in operations and care shall be taken when removing the slings from around the coated pipe after it has been lowered into the trench. Any damage caused to the pipe and coating during lowering operations shall be repaired before backfill commences................29 1.12.3.4 The trench shall be maintained in a dry condition during lowering-in and backfill operations................................................................................................................31 1.12.3.5 Contractor shall take measures to restrain the pipe in the trench by means of ‘plugging’, i.e. placing sand on top and around the pipe at regular intervals (one 2m ‘plug’ on every welded joint) or Company approved equivalent method. Contractor shall plan the work such that the lowering in and ‘plugging’ operations take place during the hottest part of the day. Company may, at its sole discretion, waive the requirement for ‘plugging’ and allow the post-padding operation to be executed as one continuous operation, dependant on completion time and ambient temperature considerations..........................................................................................................31 1.12.3.6 Sand padding shall be placed around and above the pipe, so as to fill the trench to a depth of 300 mm above the crown of the pipe, with the sand padding shaped to its natural angle of repose and with a minimum of 150 mm at any point around the pipe. No pipe shall be left overnight in the trench without sand padding around and above the pipe.........................................................................................................31 1.12.3.7 Where the trench has been excavated through or along drive-ways, walk ways, roads, etc. and at live stock passage ways and other locations indicated on the drawings, the sand padding shall be thoroughly compacted by watering and Company approved hand tools, to achieve a compacted sand fill around the pipe and up to 300 mm above the crown of the pipe.......................................................31 1.12.4 Tie-ins.................................................................................................................................31 1.12.5 Backfilling............................................................................................................................31

1.12.5.1 The trench shall not be backfilled until the Company has approved the sand padding around and above the pipe and has approved starting the backfilling operation. Backfilling shall be performed as soon as possible after padding has been approved.........................................................................................................31 1.12.5.2 In areas containing buried cables, backfilling shall not be performed until all tiles have been replaced and protected and/or all cables have been supported to Company’s satisfaction. The backfill around all underground services shall be thoroughly compacted by hand................................................................................31 1.12.5.3 The material used for initial backfill shall be from the screening plant or other loose material not greater than 100 mm in diameter, all subject to Company approval. The fill material shall be placed in such a manner as to avoid disturbing the sand padding and excessive penetration (more than 150 mm) of rocks into the sand

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layer. Contractor shall demonstrate that his proposed method of backfilling achieves this requirement. The initial backfill shall be placed in the trench to a level slightly above surrounding ground.......................................................................................31 1.12.5.4 After the initial backfill, the remaining excavated material shall be neatly crowned over the trench (the windrow), except in wadi areas. Where rock is excessively large, in Company’s opinion, shall be removed from site and not used as windrow material. On either side of road crossings, the windrow shall be tapered from full height to ground level to improve the visibility of drivers on the ROW.....................31 1.12.5.5 Trenches crossing ditches shall be backfilled with the material excavated from the trench at the location. If the excavated material, in Company’s opinion is not suitable for backfilling, Contractor shall provide and use suitable material from another source. Ditches with lined or otherwise improved surfaces shall be resurfaced in a manner satisfactory to and approved by the Company and the Authorities. Backfill in or on banks of ditches, wadis shall be compacted as necessary to prevent soil erosion or other damage which might be caused by the construction of the pipeline......................................................................................32 1.12.5.6 Where the trench has been excavated through or along drive-ways, walks, roads, etc., and at live stock passage ways and other locations indicated on the drawings, the initial backfill shall be thoroughly compacted by mechanically tamping the material into place. The surface of such areas shall be stabilised and/or restored to its original condition to the satisfaction of the Company and the Authorities...........32 1.12.5.7 ‘Sloping trenches’ (see Section 2.4.3.5) shall be backfilled as shown on Standard Drawing TYP 3 0015 001.........................................................................................32 1.12.6 Stabilising Sand Areas........................................................................................................32 1.12.7 Livestock Passageways......................................................................................................32 1.12.8 Reinstatement.....................................................................................................................32

1.12.8.1 Contractor shall clean-up the Working Strip and all working areas used by the Contractor regularly during the course of the work, and shall restore the lands traversed, to the satisfaction of the Company. Areas of soft sand in the continuous 6 m wide vehicle access strip shall be removed and replaced by approved infill material so as to leave the vehicle access strip in a safe condition for driving. The vehicle access strip shall be deviated at road crossings in order to give a visual indication to drivers of the presence of the road......................................................32 1.12.8.2 The excess soil in the working strip shall be levelled in a manner satisfactory to the Company. All loose rock exposed by the construction operations which is scattered over the working strip or adjacent property shall be removed and placed over the windrow. However, rocks larger than 750mm in diameter shall not be placed directly on the backfill material, but may be placed next to the windrow..............................32 1.12.8.3 All creeks, water courses, wells, syphons, drains, streams, wadis, ditches and irrigation channels shall be reinstated by the Contractor to their former condition and their banks shall, if deemed necessary by the Company, be pitched with stone and/or faced with special protection to prevent washing out or erosion...................34 1.12.8.4 All enclosures, walls, gates, etc. shall be restored by the Contractor to at least as good a condition as they were prior to the commencement of the Contractor’s operations to approval of the Company...................................................................34 1.12.8.5 All private roads, bridges and other private structures used by the Contractor for access or haulage shall be restored by the Contractor to a condition equal to or better than that which existed prior to the commencement of the Contractor’s operations................................................................................................................34 1.12.8.6 Construction roads, used at escarpments, may be required by the Company to be left as they are.........................................................................................................34 1.12.8.7 Construction markers shall not be removed, unless requested by the Company.. .34 1.12.8.8 All rubbish/debris left over after removal of camp facilities shall be removed to designated scrap dumps. The sites shall be levelled and cleared in accordance with

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the Regulations for Pipeline Contractor Camps in the Interior and to Company’s satisfaction...............................................................................................................34 1.13 Road and Wadi Crossings............................................................................................34 1.13.1 Scope 34 1.13.2 Road Crossings..................................................................................................................34

1.13.2.1 The carbon steel pipeline shall cross all roads and highways, without the installation of casings. All road crossings shall be made by the open cut method. Trench less methods such as horizontal drilling, pipe jacking may be considered for major road crossing to avoid disruption of traffic.....................................................34 1.13.2.2 The construction of road crossings shall meet the requirements of API RP 1102 latest issue and shall be installed as shown on the drawings. The crossings shall be installed to meet at all times the requirements and conditions set forth by the Authorities having jurisdiction...................................................................................34 1.13.2.3 Contractor shall install an off-set diversion road, when specifically permitted or required to do so by the Company and/or responsible Authorities and provide adequate maintenance to ensure safe passage of vehicles. The diversion shall not cross the pipeline where it has already been installed.............................................34 1.13.2.4 Contractor shall at all times and at every unfinished road crossing provide adequate and proper traffic aids, such as warning signs, and other safeguards to the satisfaction of the Company and the Authorities to ensure safety of the public. All warning signs shall be in both Arabic and English language...............................34 1.13.2.5 Contractor shall comply with the following minimum requirements of the Directorate General of Roads for major road crossings:............................................................34 1.13.3 Wadi-Crossings...................................................................................................................35

1.13.3.1 ‘Wadi’ shall mean dry river bed which could be temporarily filled with water following rain. The wadis will be identified on the Alignment Sheets as ‘Flood plains’, ‘Wadi type ‘A’’, ‘Wadi type ‘B’’, or ‘Wadi type ‘C’’. Pipe installed in ‘Flood plains’ does not require casing protection, but shall be stabilised at 3 meter intervals by means of bags of dry cement/sand mix placed on top of the pipeline. The Contractor shall demonstrate by calculations that the weight of the cement bags and soil overburden (excluding the windrow and post padding) is sufficient to counteract the buoyancy force of the pipeline in empty condition. Wadis may be classified based on judgement and careful evaluation of the crossing location with due consideration to wadi’s width, bed slope, past discharge history and erosion potential at the crossing location. The wadi types are described below...................35 1.13.3.2 Wadi crossings shall be installed to meet at all times the requirements and conditions issued by the Authorities having jurisdiction in the area.........................35 1.13.3.3 All concrete coated pipes shall be electrically tested on site prior to installation in order to demonstrate that there is no contact between the reinforcing steel and the pipe steel. The concrete shall be applied in accordance with Section 2.10, following. .................................................................................................................................35 1.13.3.4 At locations where concrete protection has been applied, the trench shall be backfilled with coarse gravel and rock with a minimum dimension of 50 mm up to a level 500 mm below grade level...............................................................................35 1.13.3.5 For type `C` wadi-crossing, gabions consisting of packages of boulders with dimensions between 100 and 200 mm contained in galvanised, coated steel wire mesh, shall be placed on top, up to grade level over the full width of the trench. The type of wire mesh shall be approved by the Company prior to use.........................36 1.13.3.6 Normally the windrow shall not be installed over the pipeline through the wadi section. However for wide wadi crossings, greater than 100m, the windrow shall be installed intermittently in order to mark the location of the pipeline (Windrow lengths shall be approximately 25m at 75m intervals)..........................................................37 1.14 Concrete Coating for Wadi Crossings..........................................................................37

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1.14.1 Scope 37 1.14.2 General...............................................................................................................................37

1.14.2.1 Contractor shall be responsible for the supply and installation of all concrete coatings, including all associated handling and transport of linepipe etc. Contractor shall furnish all materials, equipment, labour, supervision, worksite and services incidental to and necessary for the application of concrete in accordance with this specification and all subject to Company approval..................................................37 1.14.2.2 The concrete shall have a minimum dry density of 2400 kg/m3 after 28 days. The minimum thickness shall depend on the pipe outside diameter as specified below:37 1.14.2.3 The mill identity of each pipe length shall be preserved and records kept during and after the coating process. A certified permanent record shall be supplied to the Company showing the serial number, average outside diameter, length and all weights.....................................................................................................................37 1.14.2.4 The concrete coating of line pipe shall be applied either in an approved coating plant or in the field, at Contractor’s option. Field application shall be by dry mix gunite technique or Company approved equivalent. The plant application procedure and the coating plant may involve methods other than guniting and shall be Company approved..................................................................................................37 1.14.3 Concrete Materials..............................................................................................................39

1.14.3.1 The cement shall be ordinary Portland cement conforming to BS EN197 or ASTM C150. Cement which is held in stock for longer than three months, or any cement which shows signs of deterioration, partial setting or other defects or which fails when tested, shall be rejected.................................................................................39 1.14.3.2 Aggregates shall be naturally occurring washed sand and shall be hard, dense, durable, clean, sharp and graded evenly from fine to coarse, as per the grading limits specified below, and be in compliance with BS 882. If in the opinion of the Company, the aggregate contains an undesirable proportion of chemicals, dust, clay, organic matter or other undesirable constituents, the consignment shall be rejected. The grading of aggregate when plotted against sieve size shall be within the limits tabulated below: .......................................................................................39 1.14.3.3 Water for use in concrete shall be clean and free from all substances which may be injurious to concrete or steel. It shall satisfy the requirements of BS 3148 and contain no staining or colouring...............................................................................39 1.14.3.4 Reinforcement of concrete coating shall be by one layer of electrically welded galvanised steel mesh fabric reinforcement to BS 4483. Maximum mesh dimensions shall be 38mm x 38mm x 2 mm wire diameter. The minimum overlap between two consecutive rolls of mesh shall be 50 mm except at field joints where no overlap is required. The reinforcement shall be placed at the centre of the concrete coating layer by using P.V.C. spacer blocks or a Company approved equivalent. The reinforcement shall be clean, free from scale, mud, grease, hardened rebound or anything likely to destroy adhesion or promote corrosion........................................39 1.14.4 Application...........................................................................................................................39

1.14.4.1 Prior to concrete coating, Contractor shall apply a protective layer or ‘barrier coat’ to epoxy coated pipe. The type of barrier coat to be used shall be a two component fibre reinforced cementetious coating such as FBE Brushcrete, Fosroc H.I.M, Epoxytar, Rezex water based epoxy coating ES2 or equivalent. Contractor shall demonstrate to the satisfaction of the Company that the proposed barrier coat prevents the occurrence of holidays in the epoxy coating due to the concrete application process, and promotes a good bond between the epoxy and concrete coating.....................................................................................................................39 1.14.4.2 Batching, proportioning and mixing of the materials shall be such that a concrete coating is provided with the minimum specified strength and density. No batch of cement and aggregate shall be used in the work if it has stood for more than half an hour after mixing. No rebound material shall be mixed into any batch.....................40

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1.14.4.3 Contractor shall pay attention to the moisture content of the sand used for guniting. If the sand is too wet, the hose will block and a mortar layer will build up inside the gun. If the sand is too dry the cement will not adhere to the sand grains on mixing and excessive separation will occur in the hose. In case the moisture content falls outside the critical range of 5 to 8%, Contractor shall make the sand suitably damp either by spraying the dry sand with water or mixing wet sand with specially supplied dry sand.....................................................................................................40 1.14.4.4 The mixing equipment shall be capable of providing a uniform mix. The dry mix used for guniting shall be screened to prevent inclusion of stone, flakes from the mixer drum, pieces of cement bag, etc. Mix temperature shall not exceed 32°C....40 1.14.4.5 Concrete shall not be placed until:..........................................................................40 1.14.4.6 Since the technique of guniting relies significantly on the skill of the nozzle man, he shall have at least 3 years experience in work of a similar nature. Other operators of the guniting crew shall have a minimum of one year’s experience. Written evidence of such experience shall be furnished to the Company. Contractor shall have a minimum of five years experience in guniting or alternatively shall subcontract the guniting work to a specialist Sub Contractor with similar minimum experience level. The guniting crew shall demonstrate their ability to consistently coat pipe to this specification by guniting at least three separate quarter length pipe samples prior to start of production....................................................................................................40 1.14.4.7 Before directing the guniting nozzle onto the pipe surface the nozzle man shall ensure that the proportioning of water and dry mix is correct. Further regulating of the water supply should be kept to a minimum to ensure uniform concrete quality. The nozzle shall be held in the optimum position for placement at all times i.e. 0.6 to 1.2 m from and at right angles to, the surface of the pipe........................................40 1.14.4.8 The outer surface of the concrete coating shall be smooth, without corrugations and concentric with the steel pipe. At both ends of each pipe, a distance of approx. 0.30 m from the end shall be completely left free of concrete to facilitate field joints. The concrete shall taper back from these points at a two-to-one slope until the required thickness of coating is reached..................................................................40 1.14.5 Curing42

1.14.5.1 The finished concrete coating shall be completely protected from wind, draught, rain, spray, etc. for a minimum period of 7 days by wrapping with suitable hessian or polyethylene sheeting. Also during this period the pipe shall not be exposed to direct sunlight and/or temperature below freezing point. After a period of 4 hours from placement and for the 7 days curing period, the concrete surface shall be kept wet...........................................................................................................................42 1.14.5.2 The concrete coated pipe shall not be lifted or transported from the curing area during the 7 day curing period. The Contractor shall take precautions to prevent detrimental movement of line pipe after concrete coating to minimise handling stresses whilst concrete is hardening and curing.....................................................42 1.14.5.3 For factory applied coating, any other curing methods apart from that mentioned in 2.10.5.1 may be adopted subject to approval of the Company................................42 1.14.6 Inspection and Testing........................................................................................................42

1.14.6.1 Every length of coated pipe shall be inspected visually and by spiral ring holiday detector and repaired, in accordance with Section 2.7, Anti-Corrosion Coatings, prior to concrete application.....................................................................................42 1.14.6.2 The concrete shall be visually inspected immediately after the application and after approximately 3 days. If concrete is faulty, Contractor shall remove cores from the suspected pipe. If the compressive strength tests of the cores fail to meet the specified strengths, Contractor shall remove the defective coatings by Company approved method, inspect and where necessary repair the corrosion coating or reapply the concrete coating. Contractor may optt not to wait for the test results and immediately initiate the stripping and subsequent coating repair work....................42

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1.14.6.3 Test panels, made from mild steel, shall be made every day, one at the start of work, and one during the day as instructed by the Company. These test panels shall be positioned alongside the work and in a position similar to the work (horizontal, vertical or overhead) and gunited. On a regular basis, to be decided by the Company, cores shall be taken from each test panel after it has cured in a similar manner as the coated pipe...........................................................................42 1.14.6.4 Core samples shall be obtained using a diamond core cutter set to ensure that the cut is perpendicular to the surface and fitted with a positive depth of cut limit to ensure that the core barrel shall not penetrate closer than 6 mm to the corrosion coat of the line pipe, where applicable.....................................................................42 1.14.6.5 The thickness of applied concrete coating shall be measured on every joint at three or more points to check compliance with the minimum requirements as per Section 2.10.2.2. The three points shall be spaced at approximately equal intervals with distance between the end points at least eighty (80) percent of the coated length. Concrete coatings not in accordance with the dimensional requirements shall be repaired or stripped and recoated at the discretion of the Company.......................43 1.14.6.6 Factory applied coated pipes shall be weighed and weight of each coated pipe shall have a tolerance of +10% on any one joint and a tolerance of –4% on the total length as calculated from the specified density and thickness. Weighing devices used to determine the weights of the coated joints shall be certified in writing to provide an accuracy of one half on one percent (0.5%)...........................................43 1.14.6.7 Effective electrical separation between reinforcing steel and pipe shall be determined for each pipe joint by electrical tests.....................................................43 1.14.7 Concrete Coating Repairs..................................................................................................43

1.14.7.1 Concrete coating that is found to be defective at the time of coating shall be immediately stripped from the pipe and the pipe recoated. All other defects shall only be repaired once the concrete has hardened...................................................43 1.14.7.2 Defective concrete coating areas affected by spalling due to compression or shearing caused by impact against other objects which have caused a loss of not more than twenty five percent (25%) of the total thickness of the coating shall be repaired. An area of less than 0.1 m2 per joint where the concrete remaining on the joint is sound shall be accepted without repairs. Should the area affected be more than 0.1 m2 and less than 0.33 m2 per joint, the concrete remaining in place over that area shall be undercut so as to provide a key lock for the same basic material as the coating. Should the damaged area be more than 0.33 m2 per joint, the coating shall be removed around the entire periphery of the line pipe throughout the entire damaged area and repaired...........................................................................43 1.14.7.3 Concrete cracks that are in excess of 1.5 mm in width and extend over 180° circumferentially around the pipe, or where cracks are over 330 mm in length longitudinally along the pipe irrespective of width, shall be repaired. Repairs shall be made by chiselling the crack out to width of not less than 25 mm throughout the length of the crack. The crack shall be repaired with materials similar to that from which the coating is made and in a manner similar to that outlined above..............43 1.14.7.4 Core sample holes shall be repaired with materials similar to that from which the coating is made and in a manner similar to that outlined above. The repairs shall be kept moist and allowed to remain undisturbed for a period of not less than 36 hours. Further curing shall be in accordance with the Specification...................................44 1.15 Permanent Markers and Barriers.................................................................................44 1.15.1 Scope 44 1.15.2 General...............................................................................................................................44 1.15.3 Chainage Markers...............................................................................................................44 1.15.4 Block Valve Station Markers...............................................................................................44 1.15.5 Road Crossing Markers......................................................................................................44 1.15.6 Wadi Crossing Markers......................................................................................................44

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1.15.7 Pipeline Crossing Markers..................................................................................................45 1.15.8 Cable Crossing Markers.....................................................................................................45 1.15.9 Markers at Horizontal Bends..............................................................................................45 1.15.10 Cathodic Protection Markers............................................................................................45 1.15.11 Pearson Survey Hole Marker...........................................................................................45 1.15.12 R.O.W. `STOP` Signs.......................................................................................................45 1.15.13 Corrosion Monitoring Pit Marker.......................................................................................45 1.15.14 Access Barriers.................................................................................................................45

1.15.14.1 When specified on the drawings, access barriers shall be constructed in accordance with Standard Drawing GEN-2-1633-01...............................................45 1.15.14.2 Breaks in the barriers shall be provided at each road/track/livestock crossing and at least once every two kilometres to coincide with livestock crossings. At these crossings, removable barriers shall be installed to prevent normal access from the crossing to the Right-of-Way, but allowing inspection vehicles to pass when required. Final configuration shall be approved by the Company Site Representative.........................................................................................................45 1.15.14.3 Painting of access barriers shall be in black and yellow bands of 0.3 m length. Paintings shall be carried out in accordance with Section 2.12, Station Works.......45 1.16 Station Works...............................................................................................................46 1.16.1 Scope 46 1.16.2 Earthworks..........................................................................................................................46 1.16.3 Civil and Mechanical Works................................................................................................47

1.16.3.1 General...................................................................................................................47 1.16.3.2 Concrete/ Block work..............................................................................................47 1.16.3.3 Structural Steel.......................................................................................................47 1.16.3.4 Process Pipework...................................................................................................47 1.16.4 Painting...............................................................................................................................48 1.16.5 Instrumentation...................................................................................................................48 1.16.6 Electrical Works..................................................................................................................49 1.16.7 Fencing...............................................................................................................................49

1.17 Cathodic Protection......................................................................................................49 1.17.1 Impresssed Current Cathodic Protection ..........................................................................49

1.17.1.2 The cathodic protection design shall be in accordance with SP-1128 Specification for Cathodic Protection Design’. Details of various design aspects are indicated in the standard drawings specified in SP-1136 ‘Specification for Cathodic Protection Standard Drawings’..................................................................................................49 1.17.1.3 When a complete new C.P test points connects to an existing system, then the Contractor shall employ a qualified C.P supervisor who shall have the prior approval of the Company. When solar panels are required, Contractor shall sub-contract the supply/installation to a Company approved supplier/contractor...............................49 1.17.1.4 Contractor shall give the Company 5 days notice prior to installation of special C.P items i.e. solar stations, T/R units and ground bed anode systems, in order to mobilise a Company CP Inspector...........................................................................49 1.17.2 Materials..............................................................................................................................50 1.17.3 Installation...........................................................................................................................50

1.17.3.1 Installation of the C.P. System shall be carried out concurrently with the main pipeline laying work..................................................................................................50

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1.17.3.2 At approximately 2 km intervals, as shown on the drawings, a C.P. Standard Test Post shall be installed (Ref. STD-7-3001). Welding of the attachments to the pipeline, including procedure and welder qualification shall be in accordance with Section 2.6, Welding and NDT.................................................................................50 1.17.3.3 Cable connections to the pipeline (Ref. STD-7-2001) shall also be required, as shown on the Drawings, at the following locations:..................................................50 1.17.3.4 All C.P. testing facilities shall be installed in accordance with SP-1129.................50 1.17.3.5 Where Foreign Service Bonding Facilities are required on foreign services, for cross bonding, the connection pad may be attached by welding a pad on the foreign services (Ref. STD-7-3005).....................................................................................50 1.17.3.6 Current Measuring Stations shall be installed on the pipeline every 10 km, unless shown otherwise on the drawings (Ref. STD-7-3004).............................................50 1.17.3.7 A Grounding Facility shall be installed at power line crossings and where the pipeline runs parallel to, and within 50m of a power line (Ref. STD-7-3006)...........50 1.17.3.8 Drain Point Facilities shall be installed as shown on the Drawings (Ref. STD-73003)........................................................................................................................51 1.17.3.9 Insulating joints/flanges shall be installed in accordance with Drawings (Ref. STD7-3007)....................................................................................................................51 1.17.3.10 All C.P. cables shall be installed in accordance with SP-1129. Cable to pipeline connections shall be made prior to hydrostatic testing. Cable markers shall be installed in accordance with drawing STD-7-7001...................................................51 1.17.3.11 Ground beds, when required and shown on the Drawings, shall be installed in accordance with SP-1129(Ref. STD-7-6001, STD-7-6002, STD-7-6003, and STD-76004)........................................................................................................................51 1.17.4 Temporary Cathodic Protection..........................................................................................51 1.17.5 Pearson Survey..................................................................................................................51

1.17.5.1 Company will carry out a ‘Pearson Survey’, after installation of the pipeline, to check the integrity of the buried pipeline coating. In order to achieve good earthing for this survey, Contractor shall install Pearson Survey Earthing Points adjacent to each 2 km C.P. Standard Test Post. If coating defects are found on any portion of the coating, Contractor shall excavate, repair and backfill at Contractor’s expense. .................................................................................................................................51 1.17.5.2 These earthing points shall be constructed during the main pipelay work, in accordance with drawing GEN-2-1633-01...............................................................51 1.17.6 Commissioning....................................................................................................................51

1.18 Quality and Treatment of Hydrotesting Water..............................................................51 1.19 Hydrostatic Testing.......................................................................................................51 1.20 Precommissioning Of Pipelines....................................................................................52 1.20.1 Scope 52 1.20.2 General...............................................................................................................................52

1.20.2.1 Contractor shall make detailed proposals, for Company approval, for the precommissioning work including but not limited to detailed procedures, programme and schedule for Work. Contractor’s proposals shall include complete information regarding the following aspects:...............................................................................52 1.21 Work on Live Pipe Systems.........................................................................................53 1.21.1 Scope 53 1.21.2 General...............................................................................................................................53

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1.21.2.1 The work permit system shall apply to all work on live pipe systems. Contractor shall do all that is necessary to obtain work permits and to execute the Work in adherence to the work permit..................................................................................53 1.21.2.2 Specialised tools and equipment as required for the performance of work on live pipe systems shall only be acquired form the Company approved vendors. A vendor’s representative shall be present at all times during the use of such tools and equipment.........................................................................................................53 1.21.2.3 Hot tapping on live pipe systems shall be carried out in accordance with DEP 31.38.60.10. Welding on pressurised pipes shall be carried out in accordance with SP-1167...................................................................................................................53 1.22 As-Built Records and Hand-Over Documentation........................................................53 1.22.1 Scope 53 1.22.2 Storage Format...................................................................................................................53 1.22.3 Storage Location.................................................................................................................54 1.22.4 Pipeline As-Built Documentation........................................................................................54 1.22.5 Documents..........................................................................................................................54 1.22.6 Test, Calibration and Inspection Reports...........................................................................54 1.22.7 Material Certificates............................................................................................................54 1.22.8 As-built Drawings and Pipeline Data Sheets......................................................................55

1.23 Effective Period............................................................................................................55 1.24 Review and Improvement.............................................................................................55 Appendix A Glossary of Definitions, Terms and Abbreviations...........................................56 i. Terms and Definitions.................................................................................................................56 ii. Abbreviations..............................................................................................................................56

Appendix B Reference Documents.....................................................................................57 Appendix C: Facilities For Company Personnel..................................................................61 Appendix D: List of Handover and As-built Documentation.................................................64 Appendix E List of Typical Drawings for Pipeline Construction...........................................69 Appendix F CONSTRUCTION REQUIREMENTS FOR GRE PIPELINES.........................95 User Comment Form.........................................................................................................105

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1 1.1

Introduction Purpose

This document shall be used as the base specification for construction of all new carbon steel pipelines required in PDO operations. Hydrostatic testing and Pre-commissioning of new pipelines are covered separately in SP-1212 and DEP 31.40.50.30 respectively. Appendix – F of this specification specifies requirements for construction of GRE pipelines. This revision updates the earlier Pipeline Construction Specification (SP-1208) Version 1.0 April 2001. With the inclusion of requirements for GRE pipeline construction in this revision, the existing SP-1247 (Dec.2002) stands withdrawn.

1.2

Changes to the Specification

This specification shall not be changed without approval from the Custodian (UIP, CFDH Pipelines), who owns this specification. If you think any part of this specification is not correct, write your comments on a copy of the User Comments Form. The form is included as the last page of this specification. Send the copy with your comments and personal details to Document Control Section (DCS).

1.3

Conflicting Requirements

In case of conflicting requirements between documents relating to an inquiry or order, the following priority of documents shall apply: -

Contractual Scope of Work, Purchase Orders and Variations thereto.

-

Project Specification and Requisition Sheets.

-

This document and PDO/Group standards referred to in this document.

-

International Standards and Specifications referred to in this document.

1.4

Exceptions

The user shall obtain written approval prior to construction from the appropriate Technical Authority within PDO for any deviation from or exception to the requirements of this Standard. The appropriate technical authorities are set out in GU-272. Any work completed with unauthorised modifications may be rejected by the Company. Any subsequent re-work shall be in accordance with this specification and shall be to the Contractor’s expense.

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2 1.5

Specification Requirements

Health, Safety and Environment (HSE) 1.5.1

Scope

This Section of the Specification covers the minimum HSE requirements required during installation work. 1.5.2

General

The Contractor shall comply in all respects with all HSE Specifications listed in C-6 and C-9 documents of the Contract, paying particular attention to: The requirements for construction and lifting equipment in SP-1143, SP-1239, SP-1251 and PR-1508; the specification for Aqueous Effluents SP-1006; The Transport Operations manual TOM/04/001 as well as SP-2000 “Road Transport” and GU-140. As part of Contractor’s mobilisation, Contractor shall submit and obtain Company’s approval for the HSE Plans and Procedures for the Work, prior to any Work commencing. 1.5.3

HSE Advisor

Contractor shall appoint one or more HSE Advisors, to be approved by the Company, reporting directly to the Contractor’s Project Manager. The HSE Advisor shall be fully conversant with the Work and shall have previous experience and qualifications as specified in the HSE Regulations. Details of qualifications and experience of the HSE Advisor(s) proposed by the Contractor shall be submitted to the Company for approval before mobilisation of the HSE Advisor(s). The work of the HSE Advisor(s) is to ensure that all Contractor’s work and conditions are in accordance with the Company’s HSE Regulations. The Contractor’s HSE Advisor(s) shall make daily reports about all accidents, unsafe acts, unsafe situations etc. noticed by himself or brought to his attention. The daily report shall be transmitted to Contractor’s Project Manager on each morning following the reported day. A copy shall be handed to the Company’s Site Engineer. The daily report is in addition to those required by the Safety Regulations. Contractor’s Project Manager shall advise the Company’s Site Engineer in writing within 24 hrs of the report being issued, what action has been taken to prevent re-occurrence of any incidents reported. The HSE Advisor(s) shall carry out his work from the moment the Contractor starts mobilisation and until the date of completion. Contractor shall provide a dedicated vehicle with VHF radio, for the sole use of the HSE Advisor(s), for communications with Contractor’s Construction camp/head office.

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1.5.4

Specific Pipeline Activities

Contractor shall specifically instruct all personnel of the dangers relating to the internal inspection of pipelines. Only under special circumstances shall anyone be allowed to enter a pipeline, and only after a specific procedure has been agreed and approved by the Company. During construction of pipelines, the working strip shall be marked with road traffic signs and specific warning signs relating to the construction activities. This applies particularly to road crossings. Generic pipeline construction hazards are identified in the Company’s Pipeline Construction HSE Case. The Contractor shall make use of the information contained in the Pipeline Construction HSE Case to identify and control HSE risks specific to the Work. Any additional hazards identified through the HEMP process shall be advised to the Company for incorporation in future issues of the Pipeline Construction HSE Case.

1.6

Quality Assurance 1.6.1

Scope

This Section of the Specification and SP-1171 “Specification for Quality Assurance of Design, Construction and Engineering Works” covers the minimum requirements of Quality Assurance required for the Work. 1.6.2

General

Before starting the Work, Contractor shall submit his proposed quality assurance procedures and organisation to the Company for Company’s approval. Contractor’s proposed plan shall include the internal procedures to report non conformances, how corrective action requests are to be generated and how it will be demonstrated that such actions have been carried out and are effective. 1.6.3

Quality Assurance Team

It is the duty of the Quality Assurance Team to ensure that the Work is carried out in accordance with this Specification and other Contract Specifications. The Contractor shall have a full time Quality Assurance Team and all necessary equipment at the Work Site. The Team shall have no other work or responsibilities apart from Quality Assurance. The Quality Assurance Team should as a minimum consist of: One Contractor’s Quality Assurance Engineer responsible for procedure preparation and implementation, drawing and document control and supervision. Required number of Contractor’s Inspectors (depending on contract size and geographical spread of the work sites) to cover welding/jointing, NDT, joint coating/painting, sand padding, lowering, backfilling, tie-ins, hydro testing and pre commissioning activities.

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Quality Inspector’s duties include but not limited to the following activities: -

incoming materials inspection and acceptance

-

materials certification

-

traceability of materials

-

check pot life of adhesives (GRE pipelines)

-

welding / jointing procedures as the case may be

-

field welding / jointing

-

NDT procedures (CS pipelines)

-

identification numbering systems

-

shrink sleeve application (CS pipelines)

-

trench depth

-

sand padding

-

lowering in

-

post padding / plugging

-

backfilling

-

painting/coating (CS pipework)

-

as-built drawings

-

reports and general documentation

-

document control

1.6.3.1

Personnel

The Head of Quality Assurance shall have a detailed knowledge of welding and NDT and other activities of pipeline construction. He shall have experience in quality assurance matters and be suitably qualified. All Contractor’s inspectors shall be fully conversant with and experienced in the aspects of the Work for which they will be employed. They shall have previously worked on similar projects in similar capacities. All Contractor inspectors shall be suitably qualified and a copy of all qualification certificates relevant to the inspection function for which they are proposed by the Contractor and shall be submitted for Company approval before mobilisation of the Inspectors. All Contractor’s inspectors shall have a dedicated vehicle. Following Company’s approval and the arrival of the Inspectors on site, Company has the right to request all Inspectors to an examination to ensure their suitability for the work they are required to do, and reject any Inspector who is found unsuitable, at the Company’s sole discretion.

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1.6.3.2

Organisation

The Head of Quality Assurance shall report directly to the Contractor’s Project Manager. His duties shall be to liaise with the Company, organise the Contractor’s Inspectors so that they carry out their duties in an efficient manner, and prepare all necessary reports. The Head of Quality Assurance shall not carry out inspection work himself other than in supervision of the Contractor’s Inspectors. Contractor’s NDT supervisors and shrink sleeves manufacturers representative shall report directly to the Head of Quality Assurance on quality assurance matters. The Quality Assurance organisation shall be similar to that shown in Figure 1. 1.6.4

Company Inspection

Company will employ a team of Inspectors throughout the contract period, to monitor all work activities including safety aspects. These Company Inspectors are hereafter referred to as the Inspectors. The Inspectors will have authority to stop the work in the case of unsafe situations and non-compliance with the HSE Specifications, as well as documented non compliance with agreed installation or quality procedures which could impact on the future safety of the pipeline during hydro testing or in service. Interpretation of weld radiographs shall be performed by Contractor’s Specialist sub Contractor and the Inspectors independently, in accordance with the NDT flowchart included in the Procedures. Non-compliance certificates and other forms are also to be included in the Procedures. The inspectors will report non-compliances with this specification and other contract standards to the CSR, who will advise the Contractor formally of any required corrective action.

Figure 1 Quality Assurance Organisation

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1.7

Materials Handling and Control 1.7.1

Scope

This Section of the Specification covers the minimum requirements for handling, storage and administration of all materials, either Company or Contractor supplied, to be incorporated in the Work. 1.7.2

General

1.7.2.1

Handling, including but not necessarily limited to receipt, checking, lifting, loading, transport, unloading, stacking, and storage of materials shall be carried out by the Contractor in such a manner as to avoid any damage and loss of materials. Method and means of transport and handling (including documentation) shall be subject to approval by the Company.

1.7.2.2

Contractor’s material control and storage procedure shall be submitted to the Company within two weeks of the start of mobilisation on site, for approval.

1.7.2.3

Contractor shall give the Company at least 2 Company working days notice in writing on each occasion when he intends to start transporting Company supplied materials. A lapse greater than 2 working days shall require renotification. Pipe can be removed from Company’s yard 7 days per week during daylight hours, unless otherwise specified by the Company. Contractor shall provide the Company with a written confirmation of receipt of all materials (identified by type and quantity) and a written reconciliation of all materials (identified by type and quality) transported by them from Company’s storage yard on a weekly basis.

1.7.2.4

Contractor is required to supply lifting equipment for lifting materials at all locations. Lifting equipment and operations shall be in accordance with SP1239.

1.7.2.5

Contractor shall appoint a dedicated site-based materials Controller whose sole function shall be to control and report on the receipt, issue, and stock status of the Contractor and Company supplied materials.

1.7.2.6

Contractor shall not be held responsible for manufacturing defects in Company supplied materials, but shall be held responsible for any delays to the Work caused by Contractors failure to report defects discovered during inspection by the Contractor within 24 hours of such inspection.

1.7.2.7

Contractor’s procedures for material receipt and return of surplus materials shall conform to Company’s materials procurement/administration procedures.

1.7.3

Pipe Inspection

1.7.3.1

The Contractor shall visually inspect at the Company storage yards, all pipes internally and externally for damages, surface defects and defective bevels. The Contractor shall satisfy himself at this stage of the suitability of each pipe for welding and shall accept all responsibility thereafter for all damages however caused.

1.7.3.2

Prior to haulage of pipe from Company’s storage yard, Company and Contractor shall carry out a joint survey of pipe coating damage and bevel damages. On the basis of this survey, Company will pay the Contractor a lump sum for repair of all bevel and coating damage, based on the submitted unit

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rates in the Schedule of Rates, in accordance with this specification. For bevel damages between 1 and 3 mm deep, the repair shall be by grinding. For bevel damage depth greater than 3 mm, the repair shall be by re-bevelling.

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1.7.4

Pipe Handling

1.7.4.1

Pipe shall not be allowed to drop or strike objects which may damage the pipe and/or coating but shall be lifted, moved and lowered from one position to another by suitable equipment. When lifting pipe, non-abrasive wide nylon pipe slings or special lifting hooks equipped with a non-metallic bevel protectors curved to fit the curvature of the inside of the pipe shall be used. Temporary attachments for handling or lifting shall not be welded to any pipe. A spreader bar shall be used for all bulk pipe lifting/handling (excluding welding operations).

1.7.4.2

Trucks used to transport coated or bare pipes shall be free of any materials that might damage or contribute to movement of the pipe during transport. Pipes shall be protected against truck beds and side metallic posts by means of non-metallic soft materials. Pipes shall be loaded and stacked on trucks in such a manner that flexing and shifting of the pipe during transport is avoided. After loading, suitable non-metallic slings shall be used to tie the pipes securely to the truck. During transport the tension of these slings shall be regularly checked. Pipe ends shall be protected from contact with other metallic materials. Contractor shall ensure that no bevel protectors are lost during transport. Pipes shall only be transported on trucks (lifting equipment shall not be used to transport pipe).

1.7.4.3

Trucks used for loading of pipes will be checked by the Company prior to lifting the pipes to ensure that the trucks and loading/load securing arrangements comply with the requirements of PDO’s Transport Manual TOM/04/001, SP2000 ‘Road Transport’ and government regulations.

1.7.5

Pipe Stacking

1.7.5.1

Ground surfaces to be used for stacking of pipe shall be reasonably flat. Stacked pipes shall be raised above ground surfaces and prevented from movement by berms of screened sand covered by polyethylene sheeting or by using timber covered with non-metallic soft materials. When stacked, the bottom layer of pipes shall be wedged or clipped. Pipes of different diameter, wall thickness, grade or manufacturer shall be stacked separately. Each stack shall be properly marked to the satisfaction of the Company.

1.7.5.2

Epoxy-coated pipes shall be stacked during transport and storage using rubber or other suitable separator strips.

1.7.5.3

Pipes shall not be stacked higher than 3.5 metres. Pipes shall be stacked in such a way that no water is retained inside the pipe during storage.

1.7.6

Linepipe Specifications

1.7.6.1

Line-pipe shall be manufactured in accordance to DEP 31.40.20.35 and DEP 31.40.20.37 for non critical and critical services respectively. These specify amendments/supplements to ISO 3183 Specification.

1.7.6.2

Minimum average pipe length shall be 11.50m as per above DEP. The minimum and maximum length of pipe shall be between 9m and 13.7m long.

1.7.6.3

Linepipes if required, shall be provided with a factory-applied polyethylene / polypropylene coating or a factory applied fusion bonded epoxy powder coating. Each polyethylene / polypropylene coated pipe shall be left bare for a distance of 150 ± 20 mm from each end. Each fusion-bonded epoxy powder coated pipe shall be left bare for a distance of 80 ± 15mm. Where concrete

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coating of linepipe is envisaged, the concrete coating cut back shall be increased by 100mm over and above the cut back left in the mill coated pipe.

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1.7.7

Inspection of Materials other than Pipe

1.7.7.1

Upon receipt of any materials, the Contractor shall ensure that they conform to the required specification and are suitable for their intended application. Any damage/defects shall be reported to the Company within 24 hours of receipt of these materials and prior to transportation to the Contractor’s own storage yard. Visual inspection shall be adequate for this purpose.

1.7.7.2

In the case of materials delivered in their original sealed crates, Contractor shall only open the crates to examine the materials upon arrival at his own storage yard, except in the case of damaged crates which shall be noted and the contents examined when Contractor takes receipt at Company’s storage yard.

1.7.7.3

If no report is issued for damaged materials 24 hours after receipt (or in the case of 2.3.7.2 above, 24 hours after arrival of materials at the Contractors storage yard), then the materials shall be considered free from damage and the Contractor shall be considered liable for any damage reported or found at a later date.

1.7.8 1.7.8.1

Handling of Materials other than Pipe Materials other than pipe materials such as, but not limited to, valves, fittings, scraper traps etc., shall be lifted by suitable equipment provided by the Contractor at Company’s storage yard and at all other locations. When lifting lugs are provided on materials, suitable lifting hooks shall be used for lifting the materials. It is prohibited to use delicate parts such as hand wheels, nozzles, etc. for lifting of the materials.

Temporary attachments for handling or lifting shall not be welded to any materials. Fittings shall only be handled by suitable non-abrasive slings. 1.7.8.2

Materials other than pipe materials will be issued to the Contractor whenever possible in their original sealed shipping cases/crates. Blinded openings of materials shall be kept closed until installation. The blinds shall be replaced by the Contractor in case of damage during transport or storage.

1.7.8.3

During transport, materials shall be secured by suitable non-metallic nonabrasive slings.

1.7.8.4

For materials which shall be stored cool and/or dry as required by the manufacturer or the Specifications, Contractor shall provide suitable storage, transport and handling facilities in accordance with the requirements of the manufacturer and/or the Specifications.

1.7.8.5

Contractor shall provide a separate fenced storage area for Company supplied materials. Stored materials shall be protected from ground surfaces by using timber covered with non-metallic soft materials. Ground surfaces in storage areas shall be clean and flat. It is prohibited to store and transport fragile materials in more than one layer.

1.7.8.6

Distribution and supply of materials from Contractor’s storage yard to the worksites shall be limited to quantities required for approximately one day’s production. Timing of the issue of materials shall be as per the Company approved work schedule.

1.7.9

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Reconciliation

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1.8

1.7.9.1

At the end of the project, Contractor shall give reconciliation for all Company supplied materials issued, detailing materials installed, materials wasted and scrapped, and surplus materials. Contractor shall compile a list of the surplus materials, indicating quantity, description and MESC / SAP number when available.

1.7.9.2

On approval of the surplus list by the Company, Contractor shall return all surplus materials to Company’s storage yard.

R.O.W. and Trenching 1.8.1 1.8.1.1

Pipeline Right-of-Way and Working Strip Scope

This Section of the Specification covers the minimum requirements for the Pipeline Right-of-Way (ROW) and the Working Strip. 1.8.1.2

Survey

The Company shall survey the route for the pipeline and prepare route maps from which the centreline of the pipeline shall be staked out. The actual centreline of the pipeline can in some instances deviate from the line staked e.g. at station approaches. This should be taken into account where the word `centreline` is used in the remainder of this Section. 1.8.1.3

ROW Width

The Right-of-Way for the pipeline is a corridor of 50 metres overall width and comprises: The “Restricted Area”, a strip of land 25 meters wide on either side of the pipeline measured from the centre line of the pipeline. Where two or more pipelines are laid in parallel in the same corridor, the Right Of Way corridor shall be enlarged by the space between the pipelines. The space between two pipelines shall not be less than 2 meters from the existing or new pipeline. Contractor may make use of a Working Strip, having a width of 31 metres (including a continuous 6 metre wide vehicle access strip) from one edge of the Restricted Area. Variations, if any, in this width caused by local conditions will be indicated on the drawings or instructed to Contractor by the Company. 1.8.1.4

Planning/Approvals

Contractor shall, before starting any clearing operations, familiarise himself with any requirements by the Authorities for work along the pipeline route or in connection with the use of other lands or roads for construction purposes. Contractor shall notify the Company 7 days in advance before start of work at road, pipeline, cable, stream, river and wadi crossings and crossings of other existing structures, if any. Contractor shall not commence work on such crossings before having obtained approval from the Authorities and landowners concerned. The crossings shall be installed to meet all requirements and conditions of the permits, issued by the Authorities concerned.

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In the absence of any specific requirements by the Authorities, Contractor shall comply with the Company’s instructions. Where the pipeline is laid close to any existing buried or above ground pipeline, flowline and utility cables, the Contractor shall propose methods to safeguard the existing line (e.g. a demarcation fence). No work is allowed in such an area without Company approval. Work near live pipelines shall comply with the requirements of ERD 38-11, ‘Guidelines for Excavating and Working around Live Pipelines’ and paragraph 2.4.3.2–f) of this specification. 1.8.2

Staking, Clearing and Grading

1.8.2.1

Scope

This Section of the Specification covers the minimum requirements for staking, clearing and grading along the pipeline route as required for the Work. Company will have obtained ‘approval in principle’ for laying the pipelines along the routes. Contractor however will have to obtain permission from the concerned Authorities to execute the work. 1.8.2.2

Definitions a)

‘Clearing’ shall mean but is not necessarily limited to the cutting and disposal of trees, farm crops, bushes and undergrowth.

b)

‘Grading’ shall mean but is not necessarily limited to removal and disposal of rock, sand dunes, tree stumps and roots.

c)

‘Point of Intersection’ shall mean a point in which the centreline of the straight sections of the pipeline route changes direction in the horizontal plane. In general such a point will be outside the actual pipeline centreline because of the bending radius to be applied.

1.8.2.3

Staking a)

b)

The centreline of the pipeline shall be staked by the Contractor with markers inter visible by binoculars or theolodite. i)

Markers are located at the centreline of the pipeline where straight. Reference markers are established at the Points of Intersection, perpendicular to the previous pipeline direction, at 25 metre steps from the pipeline centreline.

ii)

The markers are angle-iron profiles or wooden posts with sequential numbers, starting with no. 1 at start point of the pipeline. Reference markers are marked with the letter ‘A’ or ‘B’. All markers extend approximately 500 mm above grade. The ‘A’ and ‘B’ markers are located at the same side of the centreline marker, ‘A’ being closest to the pipeline centreline.

Prior to the clearing operations Contractor shall stake: i)

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Markers in the centreline of the pipeline at distances of maximum 100 metres for straight line sections and maximum 10 metres for horizontal bends, but in any case not less than one at the centre of every bend.

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ii)

c)

Contractor shall be responsible for the maintenance and replacement of the construction reference markers until the permanent pipeline markers are placed.

d)

The Contractor shall verify that the radius of curvature of the pipeline trench in any plane is greater than the minimum allowable bending radius specified. Any deviation from the routing as staked by the Company and/or indicated on the route maps shall be approved by the Company prior to the clearing operations.

1.8.2.4

SP-1208

Two construction markers shall be installed at every existing marker location or at least every 500 metres except where these have already been provided at Points of Intersection. Construction markers and existing markers are to be in one line, perpendicular to the pipeline route. The distance from construction marker to pipeline centreline shall be 25 metres wherever possible. Construction markers shall be painted red with numbers painted in white. These shall be identical to existing marker numbers with letters A (left-side) and B(right-side) added, (looking in direction of construction). All construction markers shall be angle iron profiles (min. 60 x 60 mm). Each marker shall be erected sturdily enough to perform its purpose during the construction of the Work.

Below and Aboveground Services a)

Existing cables, pipelines, tunnels, falaj, etc. if indicated on the drawings are for information only. Company does not guarantee that the information shown on the Drawings is either complete or correct. Contractor is entirely responsible for detecting and locating all underground obstacles whether shown on the drawings or not, using metal detectors, cable/pipe detectors and other suitable equipment for detecting buried non-metallic infrastructure like GRE pipelines, FO cables etc.

b)

Contractor shall take utmost care to mark all exposed obstacles to avoid any possible damage throughout the performance of the Work and restore them to their previous state if damage occurs.

c)

Trenching or other excavation near any underground services shall be by hand only (refer to ERD 38-11 for detail requirements).

d)

Contractor is entirely responsible for protecting all foreign services throughout the Work. Contractor shall propose methods of temporary and, if necessary, permanent support and backfilling for all foreign services encountered, to the Company and the relevant Authority for their approval.

e)

Contractor shall furnish all angle iron and other support material required at crossings of underground obstacles. Contractor shall furnish and install all tiles and tile supports to replace existing damaged ones encountered in the course of the Work. Telephone, telegraph or electric power cables or foreign piping encountered in the pipeline trench shall be supported prior to sand padding and backfilling by a Company approved method.

f)

Contractor shall contact the local Electricity Authority to determine the minimum safe clearances allowed underneath overhead power lines at each point where these cross the Working Strip or access roads. Contractor shall then erect goal posts at the agreed height on each side of any overhead lines which cross the Working Strip or any access roads to it which will be used by the Contractor.

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g)

Contractor shall liaise closely with relevant Authorities and give adequate notice to them of trench excavation, and subsequently backfilling, in the vicinity of all underground services to allow such Authorities to inspect and witness such excavation and backfilling should they required to do so.

h)

Contractor shall repair without delay any ‘falaj’ (gravity water transport system) damaged during the performance of the Work and restore it to the same state as before the damage occurred.

i)

Line and cable marking posts, tiles, etc. shall be replaced by the Contractor in the correct position.

j)

Where it is necessary for the Contractor to construct a temporary ROW crossing over an existing service, Contractor shall hand-dig to expose the service and verify cover. Contractor shall submit proposals for Company approval of all ROW crossings. Surface flow line crossings shall be made by ramping over in accordance with the Standard Drawing TYP 3 0005001 in Appendix E.

k)

Crossings of major pipelines may require special precautions against damage by equipments and vehicles. As a minimum, the cover to the existing pipeline shall be 1.5m, achieved if necessary by temporary ramping or installation of slabs. Stresses imposed on the pipeline shall be evaluated in accordance with API 1102 standard. The windrow and any marker posts shall be reinstated after construction.

1.8.2.5

1.8.2.6

Clearing the Working Strip a)

The Working Strip shall be cleared over its entire width, unless restricted by the terrain or other features shown on the drawings. Contractor shall carry out all operations within the limits of the Working Strip and shall not operate within 25 meters from existing pipe lines without Company approval.

b)

Holes remaining, after stumps have been grubbed, shall be filled with suitable fill material and compacted.

c)

Contractor shall protect all shrines and monuments, including border stones. If it is necessary to remove a number of these items for safekeeping, the Contractor shall contact the responsible persons concerned and conform to their requirements.

d)

Where blasting is considered necessary, the Contractor is to comply with the Sections of the General and Special Conditions and this Specification (ref. 2.4.3.3 Blasting). Explosives (not used for blasting as part of the construction work)

In the event, the Contractor finds explosives in or along the Working Strip the Contractor shall notify the Company and the appropriate Authority without delay. Contractor shall be responsible for making all necessary arrangements to have the explosives removed by a specialist approved by the controlling Authorities.

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1.8.2.7

Grading the Working Strip a)

Contractor shall grade off high points and fill low points to allow the pipe to be bent and laid within the limits set forth herein with due regard to the minimum radius of bends allowed and shall drill, blast, and excavate rock or other material which cannot be graded off with ordinary grading equipment in order to provide an adequate working space along the pipeline route. Contractor shall in general be required to grade the whole of the Working Strip, but a narrower width may be allowed by the Company, depending on ground conditions.

b)

Contractor shall perform all necessary grading at road or wadi crossings and at any other location, required to permit the passage of construction equipment. Contractor shall bridge over or ford through ditches, wadis and small streams so as not to interfere with or cause pollution of the water flow and to avoid damage to stream banks. Contractor shall be responsible for moving all personnel, equipment and materials across or around all crossings, which may require the construction of temporary bridges. No ditches, wadis or drains shall be filled, bridged or otherwise obstructed without written approval of the Company and/or the Authorities having effective control over such watercourses.

c)

In rough or steep terrain, Contractor may wish to grade access roads into the Working strip to facilitate moving in materials, personnel and construction equipment. Where such roads are required by the Contractor he shall obtain the necessary permission in writing from the Authorities concerned and shall furnish the Company with a copy of such permission, prior to commencing any work on roads. Contractor shall be responsible for and make good, all damage caused by the construction and use of such roads.

d)

Contractor shall only obtain access to the Working Strip from existing road where such roads cross the Working Strip, or via access roads constructed by the Contractor between existing roads and the Working Strip at all other locations. Such access roads shall be agreed with the Company prior to commencement of Right-of-Way preparation, and shall be sign posted. Existing pipeline ROW shall not be used for access to the Working Strip.

1.8.3

Trenching

1.8.3.1

Scope a)

This Section of the Specification covers the minimum requirements for trenching as required for the work.

b)

A banks man shall attend the operation of each unit of excavation equipment to prevent personnel entering the field of work of such equipment.

1.8.3.2

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Excavation a)

Contractor shall excavate the pipeline trench on the staked centreline of the pipeline.

b)

Contractor shall keep trenching operations ahead of bending and stringing operations, but at a maximum distance of 15000 metres ahead of backfilling operations.

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c)

The trench shall be excavated so as to provide a minimum depth of cover as specified in the table below, unless specified otherwise in the Contract scope of work or drawings. MINIMUM COVER (M) LOCATION CLASS (as defined in ASME B 31.8)

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IN NORMAL GROUND

IN ROCK, REQUIRING BLASTING OR ROCK CUTTING

Location Class 1

0.80

0.60

Location Class 2

0.90

0.60

Location Class 3 and 4

0.90

0.80

Roads, Wadi, and live stock passageways

1.50

1.50

i)

Minimum depth of cover shall be measured from the top of the pipe to the top of the undisturbed surface of the soil or top of graded Working Strip which ever is smallest. Fill material in Working Strip shall not be considered to add to the depth of cover. However, surface of fill material placed to fill low points to accommodate pipe bending limitations may be used to determine depth of cover subject to approval by the Company of detailed location-specific design drawings including soil stabilisation measures such as rip-rap or gabions.

ii)

The minimum depth of cover at crossing of wadis, drainage ditches, tarmac and graded roads, tracks and live stock crossings, whether or not indicated on the route maps, shall be measured from the bottom of wadis, ditches or from the top of roads and tracks as the case may be. This depth shall be extended 5m outside the edge of the road, track, wadi, ditch, etc. measured perpendicular to its axis.

d)

Contractor shall excavate and grade the trench sufficiently deep and wide to provide space for 150 mm of padding material after compaction all around the pipe and for the continuous length of the pipeline.

e)

The trench bottom and sides shall be kept free of all brush, skids, pipe protectors, rocks, large clods, sticks, projecting rocks and other hard objects at all times. Any such items encountered shall be removed prior to pre-padding operations so that the pipe is not damaged, punctured or abraded.

f)

Where the pipeline crossed other pipelines, sewers, water lines, cables, conduits or other underground structures of any kind, Contractor shall excavate and grade the trench to a depth in such a manner that the top of the pipeline will be at a minimum of 500 mm below the bottom of the underground structure crossed, subject to compliance with the minimum specified bending radius of the pipe. If clearance of more than 500 mm is required by the Authorities having jurisdiction, Contractor shall provide such increased clearance. The construction over or under all existing structures such as roads, water lines, telephone lines, and other pipelines shall be the responsibility of Contractor. In the event that the pipeline crosses over existing structures, the same clearance as described above shall be maintained and depth of cover as per paragraph (c) above. For crossings of buried live pipelines, the requirements of ERD38-11 shall apply.

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g)

In locations where the trench is cut across roads, tracks, paths, walkways, etc. Contractor shall provide temporary bridges or diversion road of adequate strength and properly constructed to allow the passage of normal traffic with a minimum of inconvenience and interruption. Whenever it is permissible to open cut a road, Contractor shall remove and restore the surface in accordance with the requirements of the Authorities having jurisdiction thereof or as directed by the Company. Wherever possible, Contractor shall arrange to complete the trenching, laying and backfilling of such crossings and to remove the temporary bridging before the end of the regular work day in order to minimise hazard to night traffic. Proper warning signals shall be placed and maintained while such crossings are open. If the crossings are open at night, Contractor shall provide and use warning lights or lanterns, all as required and approved by the Authorities having jurisdiction and/or the Company.

h)

Contractor shall provide and use sheet piles, struts, walling, jacks, pumps etc., as required to maintain the trench in good condition until the pipe is laid in place and backfilled.

i)

Contractor shall do hand work in the trench as is necessary to free the bottom of the trench of loose rock and stones, and all other irregularities so as to leave the trench bottom in a clean and suitable condition to receive the pipe.

j)

If Contractor elects to carry out a rip survey, then the results of this survey shall be made available to Company. The extent of rock encountered during trenching shall be recorded on the as-built Alignment Sheets by the Contractor, whether or not a rip survey is carried out.

1.8.3.3

Blasting

All activities including but not limited to storage, transportation of explosives and blasting shall be carried out in accordance with the N.F.P.A. No. 495, BS 5607 and the instructions of the Authorities and/or the requirements in this section, whichever are the most stringent. Blasting shall be performed only by a specialist blasting contractor approved and registered with the Company. A blasting procedure shall be submitted to the Company for review and approval. The procedure shall detail the restrictions and special requirements for controlled blasting to be applied when operating in the proximity of existing pipelines and structures, as defined in clause b), following. a)

A qualified blasting inspector may be appointed by the Company. If an inspector is appointed, he will be present at all blasting operations to monitor compliance with the approved blasting procedures.

b)

Areas to be blasted are categorised as follows: i)

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1.8.3.4

ii)

Where blasting is to be carried out between 50 and 20 metres from any existing pipeline or structure (either above or below ground), the Contractor shall submit a procedure for controlled blasting, which shall also detail safety precautions to safeguard existing pipelines or structures (e.g. break holes, slit trenches, etc.). No trial blasting shall be performed until the procedures are approved by the Company.

iii)

No blasting is allowed within 20 metres of any existing pipeline or structure (either above or below ground).

c)

Blasting shall be carried out prior to stringing the pipes.

d)

Ground vibrations due to blasting within 50 m of existing structures shall be continuously monitored with certified instruments to be provided by the Contractor and approved by the Company. Peak particle velocities near existing structures (e.g. pipelines running parallel) shall be kept to a minimum and must be approved by the Company as part of the Contractors proposed blasting procedure. In no case shall the peak particle velocity exceed 10 mm/sec.

e)

Blasting shall not be permitted in any location where possible danger exists to the general public, property, existing utilities or other structures. In such locations other methods of extracting rock shall be proposed by the Contractor for approval by the Company. Definition of Rock

For depth of cover purposes, rock in trench is defined as the rocky part of the specified trench which cannot be removed by ditching machines, rock plough, back hoe or ripper, to be decided after two passes of a D9 Caterpiller tractor (or one pass of a tandem D9) or equal, equipped with proper ripping equipment. 1.8.3.5

Sloping Trenches

Trenches having a longitudinal slope of more than 10% shall be provided with structures or retaining barrier(s) as specified on the drawing TYP 3 0015 001 provided in Appendix E of this specification. No retaining barriers are required in areas of sand dunes. 1.8.3.6

Trench Width

In the case of a single pipeline to be laid in the trench, the trench width shall normally be outside diameter of the pipe plus 300 mm (i.e. 150 mm on each side of the pipe) unless otherwise approved by the Company (refer drawing TYP 3 0002 001). In the case of more than one pipeline to be laid in common trench, the trench width shall normally be the sum of the diameters of the pipes plus 300 mm (i.e. 150 mm on each side of the pipe) plus 500 mm clearance between the outside edges of adjacent pipes unless otherwise approved by the Company.

1.9

Stringing and Bending 1.9.1

Scope

This Section of the Specification covers the minimum requirements for stringing the line pipe along the trench side and for cold bending of metallic pipe as required for the work.

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1.9.2

Stringing

1.9.2.1

No pipe shall be strung before the trench is excavated to full depth and accepted by the Company to meet the requirements of this Specification. Pipe shall not be placed directly on the ground but on wooden skids with proper protective padding. The skids and protective padding material shall be subject to Company (CSR) approval. Dragging, skidding or dropping of the pipe is not permitted. Wooden wedges shall be used to prevent movement of each strung pipe.

1.9.2.2

Where possible the skid elevations shall be planned such that minor differences between grade profile and bottom of trench profile (e.g. at locations where an increased trench depth is required) can be accommodated without requiring an additional tie-in. The distance between the trench edge and the pipe string shall be planned such that safe working space is provided.

1.9.2.3

Contractor shall be responsible for proper stringing and locating of the pipe by size, wall thickness, specification and manufacturer. Company may supply line pipe from different manufacturers. Contractor shall string all line pipe of one manufacturer before commencing the stringing of line pipe supplied by the second manufacturer. Pipes of different manufacturers shall not be mixed per line section without prior approval of the Company.

1.9.2.4

Contractor shall string the pipe in such a manner so as to cause no interference with public roads, footpaths, tracks, etc. Suitable gaps shall be left at intervals as necessary to permit the passage of live stock and/or equipment across the Right-of-Way and as directed by the Company.

1.9.2.5

Contractor shall layout and measure the pipes such that, the number of pieces cut-off with less than one metre length is kept to a minimum.

1.9.2.6

The length of pipe string shall be planned with due consideration of thermal expansion and other expected or accidental movement of the pipe string. Special attention shall be paid to strings with one or more bends, in view of the inherent increased risk of failure of skids due to movements of the pipe. Length of individual pipe strings shall be subject to Company approval and shall generally not exceed 1 km.

1.9.2.7

Pipe shall be strung with the use of a spreader bar and two guide lines. (See Section 2.3 for requirements for slings and hooks).

1.9.3

Pipe Bending

1.9.3.1

Contractor shall make all necessary bends required for proper construction of the pipeline, following a trigonometric survey to establish the number and degree of bends required, to ensure that the installed pipe shall conform to the contours of the pre-padded trench.

1.9.3.2

Contractor shall, before the start of the Work, submit and demonstrate to the Company a bending procedure, which shall conform to the recommendations of the manufacturer of the bending machine. This procedure shall be subject to Company’s approval. The procedure shall include amongst others, step length, degrees per pull and method and accuracy of measurement during pulling of the bend.

1.9.3.3

Elastic bends with radius of curvature less than 500 x D, D being the pipeline diameter are not allowed unless approved by the Company.

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1.9.3.4

The radius of cold bends shall be not less than: -

25 D for pipe OD of less than 200mm

-

30 D for pipe OD of 200mm to 400mm

-

40 D for pipe OD of over 400mm

The radius of hot bends shall not be less than: -

Pipeline DN100 and below: 10D

-

Pipeline DN150 to DN 250: 5D

-

Pipeline DN 300 and above: 3D

1.9.3.5

The cold bends shall be made by a smooth stretch bending machine. Bends with ripples with a depth exceeding 0.5 mm, wrinkles and kinks are not acceptable. Contractor shall provide a procedure for measuring ripples which shall be approved by the Company.

1.9.3.6

The pads, dies and rolls of the bending equipment shall have soft surfaces to avoid damage to the pipe coating. Where applicable, fully retaining bending shoes shall be used. Roller type bending machines are preferred. Bends in pipe of diameter 8" or greater shall be made by using an internal (hydraulic or pneumatic) mandrel.

1.9.3.7

All bends shall be tested in the presence of the Company with a gauging plate of 97.5% of the nominal internal diameter of the pipe prior to installation.

The longitudinal weld of the cold bend shall be located approximately within 10° from the pipe’s neutral axis. The position of the longitudinal weld for successive pipe joints shall be chosen such that the longitudinal welds are staggered and always occur in the top half of the pipe (as specified in the welding specification). 1.9.3.8

1.10

The procedure for bending shall be such that the extremities of each joint remain straight over a minimum distance of 2 m or twice the pipe diameter, whichever is greater. Contractor shall lay out and measure the pipe for bending such that the length of off-cuts is kept to a minimum.

Welding and NDT 1.10.1

Scope

This Section of the Specification covers the minimum requirements for the fabrication, welding, and non-destructive testing of ‘on-plot’ piping and ‘off-plot’ pipelines for oil and gas service, as required for the Work. 1.10.2

Off-Plot Pipelines

‘Off-Plot’ Pipelines are defined as all pipelines and pipe work covered by Codes ASME B31.4 or ASME B31.8 as specified in the drawings. This includes all pipeline work, block valve stations and most parts of the pig trap stations. The minimum requirements for welding are contained in Specification SP-1177 (for Class 1 Pipelines), SP-1174 (for Class 2 & 3 Pipelines) and SP-1097 (for Duplex Stainless Steel Pipelines).

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1.10.3

On-Plot Pipework

‘On-Plot’ Pipework is defined as all pipework and pipe runs covered by the code ASME B31.3 as specified in the drawings. The minimum requirements are contained in Specification SP-1173.

1.11

Anti-Corrosion Field Joint Coating 1.11.1

Scope

This Section of the Specification covers the minimum requirements for the external field coating of pipeline weld joints and repair of damaged coating. Painting of station pipework, valves, fittings etc. is specified in Section 2.12, Station Works. Line-pipe is supplied with mill applied anti-corrosion coating unless specifically stated to the contrary in the contract Scope of Work. The type of field joint coating that can be applied shall be compatible with and have good adhesion to the mill applied coating: -

For Fusion Bonded Epoxy (FBE) coated line pipe, the field joint coating shall be by FBE field joint coating.

-

For Polyethylene (PE) / Polypropylene (PP) coated line pipe, the field joint coating shall be by heat shrink sleeves.

Contractor shall supply all equipment including spares and skilled manpower required for pipe cleaning, application of coating, coating repair in the field, and inspection and testing of the same in accordance with this Specification. 1.11.2

Materials

1.11.2.1

Only materials supplied by Company approved manufacturers shall be used in the Work.

1.11.2.2

Contractor shall as a minimum follow manufacturer’s recommendations regarding material storage, application methods, equipment, spares and tools. Contractor shall submit for Company approval and demonstrate to the Company, the proposed work methods for coating application and coating repair, two weeks prior to application.

1.11.2.3

The materials, at time of application by the Contractor, shall not be older than the shelf life stated by the manufacturers.

1.11.2.4

The coating materials shall be properly packed and clearly marked with:

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-

The manufacturer’s name

-

Material qualification and identification

-

Batch number

-

Date of manufacture

-

Test certificates and test data

-

Storage temperatures

-

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1.11.2.5

Coating materials shall be kept dry and stored as long as possible in the manufacturer’s original packaging, not exposed to direct sunlight, and in accordance with manufacturer’s instructions.

1.11.2.6

The list of Company approved wrap-around shrink sleeves is given in the Approved Vendors, Manufacturers and Equipments (AVME) list of the company.

1.11.3 1.11.3.1

Surface Preparation Prior to coating, the field joint area shall be blast cleaned. Surface preparation, including blast cleaning, shall be carried out in accordance with SP-1246 and this specification.

Any weld spatter or sharp edges of the mill coating shall be removed by filing or light grinding prior to blast cleaning. If the mill coating is disbonded along the edges, or if there is an evidence of corrosion under the coating, the coating shall be cut-back until sound coating has been obtained. Polyethylene coating shall be chamfered by torch and knife and F.B.E. coating shall be feathered over a distance of 10-15 mm during grit blasting. Abrasives for blast cleaning shall be certified in accordance with the relevant parts of ISO 11124 or ISO 11126. Certificates shall be maintained by the Contractor. The blasting nozzle shall be fitted with a dead man’s handle so that the equipment will not operate unless the handle is held. 1.11.3.2

The blast surface visual appearance shall conform to ISO 8501 grade Sa 2 1/2. Any field joint not coated within 4 hours of grit blasting shall be reblasted prior to the application of the coating.

1.11.3.3

The surface profile attained by the grit blasting shall conform to ISO 8503-2 and shall be 40-75 microns peak to trough or as specified by field joint coating manufacturer.

1.11.3.4

The surface cleanliness shall conform to ISO 8502-1 to 4 and shall be such 2 that the chloride contamination is less than 20 mg/m .

1.11.3.5

Coating of the field joint shall not take place until the weld has been nondestructively tested and approved by the Company.

1.11.4

Shrink Sleeve Application

1.11.4.1

Contractor shall propose the application procedure for Company approval. The application procedure shall be in accordance with manufacturer’s instructions and the minimum requirements specified below, whichever are the most stringent, and shall be demonstrated to the Company prior to field application by means of a procedure qualification test joint.

1.11.4.2

The joint shall be heated to a temperature required by the procedure. Induction heaters, ring burners or propane torches of a suitable type may be used for pipe diameters smaller than 16". Induction heaters shall be used for pipe diameters of 16" and larger where the pre-heat temperature exceeds 100° C. In all other cases burners or torches may be used. Torches may be used for tie-in welds at Company’s discretion. To check that the required preheat temperatures have been achieved, a digital contact thermometer shall be used.

1.11.4.3

The sleeve shall be wrapped entirely around the joint. The closure patch shall be positioned off to one side of the pipe. There shall be a minimum overlap of 50 mm onto the factory applied coating.

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1.11.4.4

The procedure for shrinking the sleeve shall ensure that all entrapped air is forced out at either end using gloved hands and hand rollers. Special attention must be given to the closure patch and overlapping areas.

1.11.4.5

The installed sleeve shall be left undisturbed for 4 hours or until the adhesive has been solidified, whichever is the longer.

1.11.4.6

The sleeves shall be visually inspected for the following points: a) Adhesive extruded from the ends of the sleeve indicates proper application. The ends of the sleeve shall be firmly bonded to the surface of the coated pipe. b) There shall be no sign of punctures or pinholes. The external appearance of the sleeves shall be smooth and without dimples.

1.11.5

F.B.E. Application

1.11.5.1

The mill applied epoxy coating of the linepipe shall be applied in accordance with DEP 31.40.30.32. The epoxy material for the field joints shall be compatible with the linepipe coating and shall conform to the material requirements of DEP 31.40.30.32.

1.11.5.2

Contractor shall propose the application procedure for Company approval. The application procedure shall be in accordance with manufacturer’s instructions and the minimum requirements specified below, whichever are the most stringent, and shall be demonstrated to the Company prior to field application by means of a procedure qualification test joint. Contractor shall also submit test data to demonstrate that the applied coating satisfies the requirements DEP 31.40.30.32, with respect to: -

impact resistance

-

hardness

-

hot water resistance

-

cathodic disbondment

In the event that the Contractor cannot demonstrate that the coating satisfies these requirements, in Company’s opinion, then the Contractor shall perform field tests followed by full laboratory testing of the coating in accordance with DEP 31.40.30.32. A Manufacturer’s representative shall be present on site full time during field applied epoxy coating work. 1.11.5.3

The resin powder shall be stored in waterproof containers which are insulated and cooled by refrigeration or air conditioning to a temperature not exceeding 27°C. Temperature recorders shall be used to monitor the storage temperature inside each container. During the daily powder coating operations, the powder in the fluid bed can be kept at ambient temperatures up to 85°C, but must be returned to the normal storage temperature below 27°C at the end of the day. For any powder that has temporarily experienced temperatures in excess of 27°C, gel time tests as per manufacturer’s recommendation must be carried out on each box of powder before use.

1.11.5.4

The area of the pipe to be coated shall be preheated by induction heating coil to a maximum temperature of approximately 250°C. The actual temperature range shall be in accordance with the powder manufacturer’s recommendations. If the ambient temperature falls, it may be necessary to increase the preheating temperature slightly to provide adequate curing energy. Powder application shall start as soon as the metal temperature is

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within the qualified temperature range, such that the metal temperature does not drop below the specified lower temperature limit during coating application. Metal temperatures shall be checked by means of digital contact thermometers.

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1.11.5.5

For pipeline sizes equal to or greater than 12", Contractor shall use automatic coating machines, capable of applying the powder at a uniform rate over the entire width of the area to be coated. For smaller pipeline sizes, Company may accept powder application by a hand held device used by a skilled operator, using a technique which achieves an even coating thickness. There shall be a minimum overlap of 50 mm onto the factory coating.

1.11.5.6

The applied coating shall have a minimum dry film thickness of 400 ± 75 micron. Dirt or deleterious materials shall not contaminate the powder coated area during the application and curing stages. In the event of contamination, the coating shall be rejected, stripped and recoated to the original procedure. The cured coating shall be free of blisters, pinholes, scratches or any other irregularities and shall be of uniform gloss and thickness.

1.11.5.7

All operators shall wear Company approved safety equipment to prevent inhalation of powder dust and contact with eyes. Smoking shall not be allowed in the vicinity of the coating operation.

1.11.5.8

The powder container, hoses, etc. on the application unit shall be cleaned after each day’s work.

1.11.6

Coating Repairs

1.11.6.1

Coating repairs shall be executed on all coating damage and imperfections detected visually or by holiday testing.

1.11.6.2

The coating repair procedure and the required materials for this, including the installation of repair sleeves when applicable, shall be in accordance with a procedure submitted by the Contractor and approved by the Company.

1.11.6.3

The repair procedure for mill applied polyethylene / polypropylene coatings shall be selected based on the criterion of magnitude of the damaged area, i.e.: a)

for pinholes and damages with a diameter or width of 10 mm maximum, a thermoplastic repair stick shall be used.

b)

for damages from 10 mm width to 100 mm diameter, a patch of thermoplastic heat shrink materials shall be used.

c)

for damages with a greater diameter than 100 mm, a thermoplastic wraparound shrink sleeve shall be used.

d)

minor flaws of polyethylene / polypropylene coating may be smoothed down using a torch and a hot iron.

Polyethylene / polypropylene coating repair materials shall as a minimum be in accordance with DEP 31.40.30.31.

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1.11.6.4

1.11.7

The repair procedure for both mill and field applied fusion bonded epoxy powder coatings shall be selected based on the criterion of magnitude of the damaged area, i.e.: a)

Holidays or minor coatings damages upto 100 mm in diameter or width, and scratches over 100 mm in length shall be repaired by a two pack liquid epoxy, compatible with the original FBE coating, and manufactured by a Company approved manufacturer. A rapid curing two pack is preferred to enable repairs prior to lowering the pipe in the trench. All contamination shall be removed from the surface by cleaning with solvent or water detergent and using a combination of wire brushes and scrapers. The surface shall then be abraded using coarse emery paper or a flexible grinding disc, ensuring that the coating surrounding the defect is also abraded but not removed. The mixing instructions supplied with the two pack epoxy by the manufacturer must be strictly adhered to. Application is carried out using a clean palette knife or filling knife, to a nominal thickness of 500 microns dry film thickness.

b)

Damages, other than scratches, with a diameter or width greater than 100 mm, are above the maximum limit for liquid epoxy repair shall be repaired by using FBE coating method for field joints, to the original specification. The damaged coating shall be removed around the entire circumference by grit blasting. Testing, Inspection and Acceptance

1.11.7.1

The testing and inspection for acceptance of the coating system shall be carried out and recorded by the Contractor as instructed and witnessed by Company’s representative. The frequency of testing as specified herein may be altered by the Company at Company’s sole discretion.

1.11.7.2

The cleanliness of the blast cleaned surfaces for every field joint shall be inspected and shall be in accordance with ISO 8501 grade Sa 2 1/2. After the surface has been blast cleaned and dusted off, a strip of transparent cellotape shall be applied to the surface, and subsequently removed and examined for particle contamination. This shall be done on the first joint cleaned each day, plus two more times during the day and when a new batch of grit is used. If in the opinion of the Company the test has failed, Contractor shall undertake to perform additional cleaning to the specified standard.

1.11.7.3

The profile of the blast cleaned surfaces shall be tested by means of Testex Replica Tape (type X-course), produced at least twice a day and additionally the first few joints and at each change or replenishment of grit. Before applying the coating, the surface shall be free of rust or residual grit. The surface profile shall be evaluated from the replicas in accordance with manufacturer’s instructions, using a recently calibrated micrometer. As an alternative to the above, the Company may allow the surface profile to be tested on site by a suitable profile gauge in accordance with SP-1246.

1.11.7.4

Additionally, general checks at random shall be carried out such as monitoring of particle size of copper slag, grit/shot used for blast cleaning, cleanliness of materials used for blast cleaning and coating, and temperature control of the pipe surface.

1.11.7.5

Contractor shall supply all equipment required for inspection and testing including dry film thickness gauges and holiday detectors. All equipment shall be approved by the Company prior to use.

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1.11.7.6

Shrink Sleeves Testing a)

All shrink sleeves shall be visually inspected in accordance with Section 2.7.4 above.

b)

Destructive testing on shrink sleeves shall be executed as follows: Sleeves for testing will be chosen by the Company.

-

From each test sleeve one or more strips of 2.5 cm wide and 20 cm long shall be cut perpendicular to the pipe axis and slowly peeled off, using an approved peel strength gauge.

-

The temperature of sleeve and pipe during such a peel test shall be as per manufacturer’s recommendation, i.e. the time of day of the testing shall be taken into account.

-

The required peel strength for the above strip shall be in accordance with the manufacturer’s temperature/strength correlation data. Repair shall be carried out as per Section 2. 7.6.

c)

Following the peel test, the Company may request the Contractor to remove the entire sleeve to check the overall degree of adhesion and absence of bare metal voids achieved. After removal of the shrink sleeve, the bulk of the adhesive layer which remains on the pipe surface shall be essentially free from voids, although a certain amount of voids may be allowed at the discretion of the Company, upto a maximum of 6 mm x 6 mm. Voids exposing bare metal shall not be acceptable and shall be reason to fail the shrink sleeve application. In the event that the test fails, it shall be repeated on the two sleeves adjacent to the tested sleeve. Tests shall continue until the sleeves which are inspected are acceptable.

d)

Company shall have the right to test one out of every hundred shrink sleeves applied or one sleeve out of every days production if less than one hundred sleeves are applied in any day.

1.11.7.7

Fusion Bonded Epoxy Testing a)

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-

Every day at least one representative epoxy coated field joint shall be subjected to an adhesion test. With a Stanley knife, two cuts shall be made through the coating to the substrate to form a vee with an intersection at about 30 degrees. Starting at the point of the vee, Contractor shall attempt to force the coating from the substrate with the Stanley knife. Peel off exposing bare metal constitutes a failure. This test shall be carried out on the same day that the coating is applied. In the event of failure, the joint on either side shall also be tested. The test area of the passed joints shall be repaired with the liquid epoxy system as per 2.7.6. Failed joints and other joints rejected on the basis of the test results shall be stripped and recoated to the original specification.

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b)

Every day at least one representative epoxy coated field joint shall be subjected to a cure test. This is done by rubbing a smooth coated area, free from overspray and surface powder contamination, with a suitable solvent and judge the amount of colouration as compared with a previously carried out test on a laboratory prepared and cured panel. No softening of the coating shall be noticeable by comparing the rubbed area with the adjacent non rubbed area of the joint. This can be checked by pushing a finger nail in the rubbed area and the adjacent untreated area and judge the difference between the two impressions. The solvent shall be either MEK (Methyl Ethyl Ketone), MIBK (Methyl Iso Butyl Ketone), or others (ref SP-1246) as per powder manufacturer’s recommendation and the outcome of the laboratory test. Contractor shall provide a fully cured laboratory prepared sample. During the test, the coated substrate must be cooled down to ambient temperature. The test shall be carried out on the same day that the coating is applied. In the event of failure, the joints on either side shall also be subjected to a cure test. Failed joints and other joints rejected, on the basis of the test results shall be stripped and recoated to the original specification.

c)

The gel time of fusion bonded epoxy powders shall be tested daily, by spreading a sample of approximately 0.5 gram un-ground or powdered epoxy resin onto a hot plate (at controlled and stable temperature) and measuring the time lapse between the start of melting and the formation of a gelled product, all in accordance to Company approved procedure. At a temperature of 204°C, the epoxy powder shall exhibit a gel time within the range of 25 to 50 seconds.

d)

The dry film thickness of epoxy coatings shall be measured at each joint or application by means of a Company approved type of coating thickness gauge, which shall be calibrated at regular intervals (at least daily).

1.11.7.8

Holiday detection of 100% of the surface area of all coated pipeline shall be carried out immediately prior to lowering in the ditch. The holiday detection equipment which shall be Company approved shall be set at 2000 Volts DC for Fusion Bonded epoxy and 22000 Volts DC for PE coated pipes based on 5V per micron of coating thickness. However, the voltage setting for holiday detection may be lowered slightly at Company’s discretion if coating gets damaged. The electrode shall be a conductive rubber or a spiral metal ring. Brush type electrodes shall not be used. The voltage applied by the holiday detection equipment shall be measured by means of a voltage read out. Alternatively a means of calibration of the applied voltage of holiday detection equipment shall be provided to enable daily calibration of each piece of equipment. All holidays, imperfections and damaged areas shall be identified with a waterproof marker at sufficient distance from the defect to allow surface preparation and patching to take place without detriment to the adhesion of the coating.

1.11.7.9

Company will carry out a ‘Pearson Survey’ to check the integrity of the buried coating. If coating defects are found on any portion of the coating, Contractor shall excavate, repair and backfill at Contractor’s expense.

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1.12

Lowering-In, Backfilling and Reinstatement 1.12.1

Scope

This Section of the Specification covers the minimum requirements for pre and post padding, lowering the pipe and backfilling, compacting and stabilising the trench as required for the work. 1.12.2

Pre-Padding

1.12.2.1

All trenches shall be padded before lowering in of pipe string. No padding shall be placed until the Company has inspected and approved the trench bottom.

1.12.2.2

To ensure that fine and clean padding material is used, the Contractor shall use mobile screening plants that enable a continuous direct application of padding from the plant to the trench. The type of screening plant is to be approved by Company prior to mobilisation to site (minimum sieve size shall be 5 x 5 mm). Mobile screening plants are defined as screening plants which move along the trench whilst they are in operation. Only in those areas where mobile screening plants cannot be used due to access problems, pre-screened material may be used after approval of the source by the Company. Prescreened material shall be stored in areas which have been cleared of rocks and stones and protected with plastic sheets to prevent contamination with unacceptable padding materials.

1.12.2.3

The installed padding material shall be free of sharp rocks, stones, metal parts, roots, clods, etc. and without sharp edges which could damage the pipeline. Base materials from which pre and post padding material will be produced shall consist mainly of sandy material. More than 75% by weight of the screened material should have grain size between 0.06 and 3.0 mm and no more than 25% by weight shall have a grain size between 3.0 and 5.0 mm. To ensure compliance with the above requirements, the Contractor shall produce a grading curve with typical screened material from the proposed source of sand or a representative section of the working strip. If the base material is not sourced from the working strip, sources of padding material shall first be approved by the Company. Suitable base material from the working strip may not always be available or acceptable, in which case it shall be Contractor’s responsibility to obtain suitable padding material from a source approved by the local government authorities. Near residential areas and roads, padding material shall be dust free (e.g. 'coarse sand' with a minimum grain size of 0.6 mm) in order to avoid inconvenience or danger to the public.

1.12.2.4

The bottom of the trench shall be padded with sand throughout its length, whether in normal ground or rock, so as to provide a minimum compacted padding thickness of 150 mm below the invert of the pipe. Contractor shall keep the pre-padding operation within 1 km of the lowering-in operation.

1.12.3

Lowering-in and Post-Padding

1.12.3.1

Welded pipe strings shall be lowered-in within 96 hours of completion of joint coating.

1.12.3.2

Immediately before commencing the lowering-in operation, the coating shall be checked for holiday and if necessary, repaired to the satisfaction of the Company, as specified in Section 2.7.6.

1.12.3.3

Wide non-abrasive slings or belts shall be used in all lowering-in operations and care shall be taken when removing the slings from around the coated pipe

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after it has been lowered into the trench. Any damage caused to the pipe and coating during lowering operations shall be repaired before backfill commences.

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1.12.3.4

The trench shall be maintained in a dry condition during lowering-in and backfill operations.

1.12.3.5

Contractor shall take measures to restrain the pipe in the trench by means of ‘plugging’, i.e. placing sand on top and around the pipe at regular intervals (one 2m ‘plug’ on every welded joint) or Company approved equivalent method. Contractor shall plan the work such that the lowering in and ‘plugging’ operations take place during the hottest part of the day. Company may, at its sole discretion, waive the requirement for ‘plugging’ and allow the post-padding operation to be executed as one continuous operation, dependant on completion time and ambient temperature considerations.

1.12.3.6

Sand padding shall be placed around and above the pipe, so as to fill the trench to a depth of 300 mm above the crown of the pipe, with the sand padding shaped to its natural angle of repose and with a minimum of 150 mm at any point around the pipe. No pipe shall be left overnight in the trench without sand padding around and above the pipe.

1.12.3.7

Where the trench has been excavated through or along drive-ways, walk ways, roads, etc. and at live stock passage ways and other locations indicated on the drawings, the sand padding shall be thoroughly compacted by watering and Company approved hand tools, to achieve a compacted sand fill around the pipe and up to 300 mm above the crown of the pipe.

1.12.4

Tie-ins

Unless otherwise agreed by the Company, tie-ins shall take place in the trench. For tieins outside the trench, holding and lowering operations shall be undertaken in such a manner as to minimise stresses in the pipe and therefore avoid movement of the pipe from the skids, for safety reasons. Due consideration shall be given to ambient temperature changes throughout the day and the resultant pipe length changes/stresses. 1.12.5

Backfilling

1.12.5.1

The trench shall not be backfilled until the Company has approved the sand padding around and above the pipe and has approved starting the backfilling operation. Backfilling shall be performed as soon as possible after padding has been approved.

1.12.5.2

In areas containing buried cables, backfilling shall not be performed until all tiles have been replaced and protected and/or all cables have been supported to Company’s satisfaction. The backfill around all underground services shall be thoroughly compacted by hand.

1.12.5.3

The material used for initial backfill shall be from the screening plant or other loose material not greater than 100 mm in diameter, all subject to Company approval. The fill material shall be placed in such a manner as to avoid disturbing the sand padding and excessive penetration (more than 150 mm) of rocks into the sand layer. Contractor shall demonstrate that his proposed method of backfilling achieves this requirement. The initial backfill shall be placed in the trench to a level slightly above surrounding ground.

1.12.5.4

After the initial backfill, the remaining excavated material shall be neatly crowned over the trench (the windrow), except in wadi areas. Where rock is excessively large, in Company’s opinion, shall be removed from site and not used as windrow material. On either side of road crossings, the windrow shall be tapered from full height to ground level to improve the visibility of drivers on the ROW.

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1.12.5.5

Trenches crossing ditches shall be backfilled with the material excavated from the trench at the location. If the excavated material, in Company’s opinion is not suitable for backfilling, Contractor shall provide and use suitable material from another source. Ditches with lined or otherwise improved surfaces shall be resurfaced in a manner satisfactory to and approved by the Company and the Authorities. Backfill in or on banks of ditches, wadis shall be compacted as necessary to prevent soil erosion or other damage which might be caused by the construction of the pipeline.

1.12.5.6

Where the trench has been excavated through or along drive-ways, walks, roads, etc., and at live stock passage ways and other locations indicated on the drawings, the initial backfill shall be thoroughly compacted by mechanically tamping the material into place. The surface of such areas shall be stabilised and/or restored to its original condition to the satisfaction of the Company and the Authorities.

Where wadis or roads are graded, trenched or otherwise disturbed, the Contractor shall restore the property to its original contour and condition even to the extent of hauling in and placing new fill materials, gravel and stabilising materials or compounds, or by using special compaction methods, as necessary to obtain the approval of the Company and the Authorities. 1.12.5.7 1.12.6

‘Sloping trenches’ (see Section 2.4.3.5) shall be backfilled as shown on Standard Drawing TYP 3 0015 001. Stabilising Sand Areas

To ensure the retention of sand cover in active sand areas (i.e. where the windrow consists of sand only), the backfill shall be stabilised, preferably with a 150 mm layer of marl or other stable material. The width of stabilisation shall be 3 metres on each side of the pipeline (plus 0.6 metres for every 3 metres of dune height if the line passes through a sand dune). 1.12.7

Livestock Passageways

Unless otherwise indicated on the drawings, livestock passageways shall be installed at intervals of approximately 2 km and may be combined with graded road and track crossings. The livestock passageways shall be constructed with a minimum of 1.5 m cover over the total pipeline length of 6.5m. The width of the live stock passage shall be 2.5 m. Compaction of the livestock passageways shall be such that the passing of light vehicles will not have any detrimental effect on the passageway. Access barriers shall be installed on the ends of the crossing to indicate the safe crossing width of the livestock passageway for light vehicles. 1.12.8

Reinstatement

1.12.8.1

Contractor shall clean-up the Working Strip and all working areas used by the Contractor regularly during the course of the work, and shall restore the lands traversed, to the satisfaction of the Company. Areas of soft sand in the continuous 6 m wide vehicle access strip shall be removed and replaced by approved infill material so as to leave the vehicle access strip in a safe condition for driving. The vehicle access strip shall be deviated at road crossings in order to give a visual indication to drivers of the presence of the road.

1.12.8.2

The excess soil in the working strip shall be levelled in a manner satisfactory to the Company. All loose rock exposed by the construction operations which is scattered over the working strip or adjacent property shall be removed and placed over the windrow. However, rocks larger than 750mm in diameter shall

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not be placed directly on the backfill material, but may be placed next to the windrow.

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1.13

1.12.8.3

All creeks, water courses, wells, syphons, drains, streams, wadis, ditches and irrigation channels shall be reinstated by the Contractor to their former condition and their banks shall, if deemed necessary by the Company, be pitched with stone and/or faced with special protection to prevent washing out or erosion.

1.12.8.4

All enclosures, walls, gates, etc. shall be restored by the Contractor to at least as good a condition as they were prior to the commencement of the Contractor’s operations to approval of the Company.

1.12.8.5

All private roads, bridges and other private structures used by the Contractor for access or haulage shall be restored by the Contractor to a condition equal to or better than that which existed prior to the commencement of the Contractor’s operations.

1.12.8.6

Construction roads, used at escarpments, may be required by the Company to be left as they are.

1.12.8.7

Construction markers shall not be removed, unless requested by the Company.

1.12.8.8

All rubbish/debris left over after removal of camp facilities shall be removed to designated scrap dumps. The sites shall be levelled and cleared in accordance with the Regulations for Pipeline Contractor Camps in the Interior and to Company’s satisfaction.

Road and Wadi Crossings 1.13.1

Scope

This Section of the Specification covers the minimum requirements for road and wadi crossings as required for the work. 1.13.2

Road Crossings

1.13.2.1

The carbon steel pipeline shall cross all roads and highways, without the installation of casings. All road crossings shall be made by the open cut method. Trench less methods such as horizontal drilling, pipe jacking may be considered for major road crossing to avoid disruption of traffic.

1.13.2.2

The construction of road crossings shall meet the requirements of API RP 1102 latest issue and shall be installed as shown on the drawings. The crossings shall be installed to meet at all times the requirements and conditions set forth by the Authorities having jurisdiction.

1.13.2.3

Contractor shall install an off-set diversion road, when specifically permitted or required to do so by the Company and/or responsible Authorities and provide adequate maintenance to ensure safe passage of vehicles. The diversion shall not cross the pipeline where it has already been installed.

1.13.2.4

Contractor shall at all times and at every unfinished road crossing provide adequate and proper traffic aids, such as warning signs, and other safeguards to the satisfaction of the Company and the Authorities to ensure safety of the public. All warning signs shall be in both Arabic and English language.

1.13.2.5

Contractor shall comply with the following minimum requirements of the Directorate General of Roads for major road crossings:

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a) Contractor shall submit details of all proposed diversions, methods of crossings, reinstatement and standards of construction to the Directorate General of Roads for approval before commencing work on site. b) Reinstatement of roads must be to the same standard as existing roads. Diversion roads must be constructed with compacted non-plastic materials, which must not degenerate into dust during use. c) Approvals must be obtained from all Utility Authorities and the Ministry of Land Affairs and Municipalities prior to seeking permission from the Directorate General of Roads. d) Final approval of any proposed road works must be obtained from the Royal Oman Police. e) Contractor shall be required to give to the Directorate General of Roads, a Bank Guarantee. This requirement applies to each individual crossing point. 1.13.3

Wadi-Crossings

1.13.3.1

‘Wadi’ shall mean dry river bed which could be temporarily filled with water following rain. The wadis will be identified on the Alignment Sheets as ‘Flood plains’, ‘Wadi type ‘A’’, ‘Wadi type ‘B’’, or ‘Wadi type ‘C’’. Pipe installed in ‘Flood plains’ does not require casing protection, but shall be stabilised at 3 meter intervals by means of bags of dry cement/sand mix placed on top of the pipeline. The Contractor shall demonstrate by calculations that the weight of the cement bags and soil overburden (excluding the windrow and post padding) is sufficient to counteract the buoyancy force of the pipeline in empty condition. Wadis may be classified based on judgement and careful evaluation of the crossing location with due consideration to wadi’s width, bed slope, past discharge history and erosion potential at the crossing location. The wadi types are described below. a)

Type ‘A’ wadis are those where low velocity flow is expected after heavy rains. At these wadi crossings, line pipe without concrete protection shall be installed (TYP 3 0008 001) with a minimum cover of 1500 mm.

b)

Type ‘B” wadis are those where erosion due to high velocity flow is expected after heavy rains At these wadi crossings, line pipe with continuous concrete protection shall be installed (TYP 3 0009 001) with a minimum cover of 1500 mm.

c)

Type ‘C” wadis are those where heavy erosion due to high velocity flow is expected after heavy rains combined with the existence of large stones and boulders. At these wadi crossings, line pipe with continuous concrete protection shall be installed (TYP 3 0010 001) with a minimum cover of 1500 mm. Additionally, the pipeline trench shall be protected with gabions placed at the surface.

1.13.3.2

Wadi crossings shall be installed to meet at all times the requirements and conditions issued by the Authorities having jurisdiction in the area.

1.13.3.3

All concrete coated pipes shall be electrically tested on site prior to installation in order to demonstrate that there is no contact between the reinforcing steel and the pipe steel. The concrete shall be applied in accordance with Section 2.10, following.

1.13.3.4

At locations where concrete protection has been applied, the trench shall be backfilled with coarse gravel and rock with a minimum dimension of 50 mm up to a level 500 mm below grade level.

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1.13.3.5

SP-1208

For type `C` wadi-crossing, gabions consisting of packages of boulders with dimensions between 100 and 200 mm contained in galvanised, coated steel wire mesh, shall be placed on top, up to grade level over the full width of the trench. The type of wire mesh shall be approved by the Company prior to use.

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1.13.3.6

1.14

Normally the windrow shall not be installed over the pipeline through the wadi section. However for wide wadi crossings, greater than 100m, the windrow shall be installed intermittently in order to mark the location of the pipeline (Windrow lengths shall be approximately 25m at 75m intervals).

Concrete Coating for Wadi Crossings 1.14.1

Scope

This Section of the Specification covers the minimum requirements for concrete coating of the pipeline at Wadi crossings type B and C as required for the work. 1.14.2

General

1.14.2.1

Contractor shall be responsible for the supply and installation of all concrete coatings, including all associated handling and transport of linepipe etc. Contractor shall furnish all materials, equipment, labour, supervision, worksite and services incidental to and necessary for the application of concrete in accordance with this specification and all subject to Company approval.

1.14.2.2

The concrete shall have a minimum dry density of 2400 kg/m3 after 28 days. The minimum thickness shall depend on the pipe outside diameter as specified below: Up to 6.625"

:

40 mm

6.625" to 12.75"

:

50 mm

over 12.75"

:

60 mm

The concrete shall be Grade 30 to BS 8110 with a characteristic crushing strength of 21 N/mm2 at 7 days and 30 N/mm2 at 28 days. 1.14.2.3

The mill identity of each pipe length shall be preserved and records kept during and after the coating process. A certified permanent record shall be supplied to the Company showing the serial number, average outside diameter, length and all weights.

1.14.2.4

The concrete coating of line pipe shall be applied either in an approved coating plant or in the field, at Contractor’s option. Field application shall be by dry mix gunite technique or Company approved equivalent. The plant application procedure and the coating plant may involve methods other than guniting and shall be Company approved.

Reference is made to Company Specification SP-1282 for concrete production. The Contractor shall prepare, and submit to the Company for approval, a minimum of 1 month before commencement of the work, a detailed coating procedure specification containing, but not limited to, the following.

SP-1208

-

Contractor-supplied materials: specifications, type, supplier, methods of control, etc.;

-

concrete coating procedures covering the concrete mix, placement of steel reinforcement, concrete application, curing, repair procedures, coating equipment and facilities and identifying the ranges of parameters to be used;

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-

SP-1208

inspection and testing (including procedures and pro-forma)

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1.14.3

Concrete Materials

1.14.3.1

The cement shall be ordinary Portland cement conforming to BS EN197 or ASTM C150. Cement which is held in stock for longer than three months, or any cement which shows signs of deterioration, partial setting or other defects or which fails when tested, shall be rejected.

1.14.3.2

Aggregates shall be naturally occurring washed sand and shall be hard, dense, durable, clean, sharp and graded evenly from fine to coarse, as per the grading limits specified below, and be in compliance with BS 882. If in the opinion of the Company, the aggregate contains an undesirable proportion of chemicals, dust, clay, organic matter or other undesirable constituents, the consignment shall be rejected. The grading of aggregate when plotted against sieve size shall be within the limits tabulated below: BS 410 Sieve Size

Percent by Weight

passing a 3/8 inch

100

passing a no. 4

95 - 100

passing a no. 8

65 - 90

passing a no. 16

45 - 75

passing a no. 30

30 - 50

passing a no. 50

10 - 22

passing a no. 100

2-8

Stockpiles of aggregates shall be covered by tarpaulins. 1.14.3.3

Water for use in concrete shall be clean and free from all substances which may be injurious to concrete or steel. It shall satisfy the requirements of BS 3148 and contain no staining or colouring.

1.14.3.4

Reinforcement of concrete coating shall be by one layer of electrically welded galvanised steel mesh fabric reinforcement to BS 4483. Maximum mesh dimensions shall be 38mm x 38mm x 2 mm wire diameter. The minimum overlap between two consecutive rolls of mesh shall be 50 mm except at field joints where no overlap is required. The reinforcement shall be placed at the centre of the concrete coating layer by using P.V.C. spacer blocks or a Company approved equivalent. The reinforcement shall be clean, free from scale, mud, grease, hardened rebound or anything likely to destroy adhesion or promote corrosion.

1.14.4 1.14.4.1

SP-1208

Application Prior to concrete coating, Contractor shall apply a protective layer or ‘barrier coat’ to epoxy coated pipe. The type of barrier coat to be used shall be a two component fibre reinforced cementetious coating such as FBE Brushcrete, Fosroc H.I.M, Epoxytar, Rezex water based epoxy coating ES2 or equivalent. Contractor shall demonstrate to the satisfaction of the Company that the proposed barrier coat prevents the occurrence of holidays in the epoxy coating due to the concrete application process, and promotes a good bond between the epoxy and concrete coating.

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To this end one or more sections of a test joint shall each be coated with a proposed barrier coat, in accordance with manufacturer’s recommendations. The number of applications, film thickness and curing time shall be representative for the application in the production process. The test joint shall be concrete coated, whereupon the concrete is immediately washed off and each test section subjected to a holiday test and an adhesion test both in accordance with Section 2. 7. 1.14.4.2

Batching, proportioning and mixing of the materials shall be such that a concrete coating is provided with the minimum specified strength and density. No batch of cement and aggregate shall be used in the work if it has stood for more than half an hour after mixing. No rebound material shall be mixed into any batch.

1.14.4.3

Contractor shall pay attention to the moisture content of the sand used for guniting. If the sand is too wet, the hose will block and a mortar layer will build up inside the gun. If the sand is too dry the cement will not adhere to the sand grains on mixing and excessive separation will occur in the hose. In case the moisture content falls outside the critical range of 5 to 8%, Contractor shall make the sand suitably damp either by spraying the dry sand with water or mixing wet sand with specially supplied dry sand.

1.14.4.4

The mixing equipment shall be capable of providing a uniform mix. The dry mix used for guniting shall be screened to prevent inclusion of stone, flakes from the mixer drum, pieces of cement bag, etc. Mix temperature shall not exceed 32°C.

1.14.4.5

Concrete shall not be placed until: a)

The line pipe corrosion coating has been holiday detected and approved by the Company.

b)

The barrier coat (if required) has been applied and cured.

c)

Reinforcement has been adequately secured in the correct position with use of spacer blocks, to prevent displacement during concrete application.

d)

Shading has been installed to prevent the line pipe temperature exceeding 35°C.

1.14.4.6

Since the technique of guniting relies significantly on the skill of the nozzle man, he shall have at least 3 years experience in work of a similar nature. Other operators of the guniting crew shall have a minimum of one year’s experience. Written evidence of such experience shall be furnished to the Company. Contractor shall have a minimum of five years experience in guniting or alternatively shall subcontract the guniting work to a specialist Sub Contractor with similar minimum experience level. The guniting crew shall demonstrate their ability to consistently coat pipe to this specification by guniting at least three separate quarter length pipe samples prior to start of production.

1.14.4.7

Before directing the guniting nozzle onto the pipe surface the nozzle man shall ensure that the proportioning of water and dry mix is correct. Further regulating of the water supply should be kept to a minimum to ensure uniform concrete quality. The nozzle shall be held in the optimum position for placement at all times i.e. 0.6 to 1.2 m from and at right angles to, the surface of the pipe.

1.14.4.8

The outer surface of the concrete coating shall be smooth, without corrugations and concentric with the steel pipe. At both ends of each pipe, a distance of approx. 0.30 m from the end shall be completely left free of

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concrete to facilitate field joints. The concrete shall taper back from these points at a two-to-one slope until the required thickness of coating is reached.

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1.14.5

Curing

1.14.5.1

The finished concrete coating shall be completely protected from wind, draught, rain, spray, etc. for a minimum period of 7 days by wrapping with suitable hessian or polyethylene sheeting. Also during this period the pipe shall not be exposed to direct sunlight and/or temperature below freezing point. After a period of 4 hours from placement and for the 7 days curing period, the concrete surface shall be kept wet.

1.14.5.2

The concrete coated pipe shall not be lifted or transported from the curing area during the 7 day curing period. The Contractor shall take precautions to prevent detrimental movement of line pipe after concrete coating to minimise handling stresses whilst concrete is hardening and curing.

1.14.5.3

For factory applied coating, any other curing methods apart from that mentioned in 2.10.5.1 may be adopted subject to approval of the Company.

1.14.6

Inspection and Testing

1.14.6.1

Every length of coated pipe shall be inspected visually and by spiral ring holiday detector and repaired, in accordance with Section 2.7, Anti-Corrosion Coatings, prior to concrete application.

1.14.6.2

The concrete shall be visually inspected immediately after the application and after approximately 3 days. If concrete is faulty, Contractor shall remove cores from the suspected pipe. If the compressive strength tests of the cores fail to meet the specified strengths, Contractor shall remove the defective coatings by Company approved method, inspect and where necessary repair the corrosion coating or reapply the concrete coating. Contractor may optt not to wait for the test results and immediately initiate the stripping and subsequent coating repair work.

1.14.6.3

Test panels, made from mild steel, shall be made every day, one at the start of work, and one during the day as instructed by the Company. These test panels shall be positioned alongside the work and in a position similar to the work (horizontal, vertical or overhead) and gunited. On a regular basis, to be decided by the Company, cores shall be taken from each test panel after it has cured in a similar manner as the coated pipe.

1.14.6.4

Core samples shall be obtained using a diamond core cutter set to ensure that the cut is perpendicular to the surface and fitted with a positive depth of cut limit to ensure that the core barrel shall not penetrate closer than 6 mm to the corrosion coat of the line pipe, where applicable.

The minimum diameter of the core shall be at least three times the nominal maximum aggregate size. The length to diameter ratio of the core when trimmed for testing shall not be less than one-to-one. Sampling, storing, testing and calculation shall be in accordance with the provisions of BS 1881. Cores shall be cut four days after concreting and stored in a curing tank until tested. Samples shall be tested as specified in BS 1881. The compressive strength of each specimen shall be calculated using the computed cross-sectional area based on the average diameter of the specimen. For acceptance, each core shall have the minimum density and compressive strength as specified in Section 2.10.2.2.

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Company may accept any other method of testing that Contractor can demonstrate to give a consistently reliable measure of strength attained by the concrete coating. Cube tests will be accepted for crushing strength instead of core samples, but the required compressive strengths will be 20% greater than specified for core tests. The Contractor shall arrange for an independent agency acceptable to the Company to test these cubes. 1.14.6.5

The thickness of applied concrete coating shall be measured on every joint at three or more points to check compliance with the minimum requirements as per Section 2.10.2.2. The three points shall be spaced at approximately equal intervals with distance between the end points at least eighty (80) percent of the coated length. Concrete coatings not in accordance with the dimensional requirements shall be repaired or stripped and recoated at the discretion of the Company.

1.14.6.6

Factory applied coated pipes shall be weighed and weight of each coated pipe shall have a tolerance of +10% on any one joint and a tolerance of –4% on the total length as calculated from the specified density and thickness. Weighing devices used to determine the weights of the coated joints shall be certified in writing to provide an accuracy of one half on one percent (0.5%).

1.14.6.7

Effective electrical separation between reinforcing steel and pipe shall be determined for each pipe joint by electrical tests.

1.14.7

Concrete Coating Repairs

1.14.7.1

Concrete coating that is found to be defective at the time of coating shall be immediately stripped from the pipe and the pipe recoated. All other defects shall only be repaired once the concrete has hardened.

1.14.7.2

Defective concrete coating areas affected by spalling due to compression or shearing caused by impact against other objects which have caused a loss of not more than twenty five percent (25%) of the total thickness of the coating shall be repaired. An area of less than 0.1 m 2 per joint where the concrete remaining on the joint is sound shall be accepted without repairs. Should the area affected be more than 0.1 m2 and less than 0.33 m2 per joint, the concrete remaining in place over that area shall be undercut so as to provide a key lock for the same basic material as the coating. Should the damaged area be more than 0.33 m2 per joint, the coating shall be removed around the entire periphery of the line pipe throughout the entire damaged area and repaired.

Repairs shall be made by satisfactorily restoring the reinforcing, removing all cracked or broken concrete at the point of coating damage, wetting the fresh surface of the broken coating (unless the coating is still too ‘green’ to require it), and troweling a stiff mixture of cement, water and aggregate, of the same materials and proportions as the coating, into and through the reinforcing. This mixture shall be built up until the surface is level with the coating around the repair. The pipe shall then be allowed to moist cure for a minimum of four days. The resulting coating shall be equal in weight, density, uniformity, strength and characteristics to the originally applied coating. 1.14.7.3

SP-1208

Concrete cracks that are in excess of 1.5 mm in width and extend over 180° circumferentially around the pipe, or where cracks are over 330 mm in length longitudinally along the pipe irrespective of width, shall be repaired. Repairs shall be made by chiselling the crack out to width of not less than 25 mm throughout the length of the crack. The crack shall be repaired with materials similar to that from which the coating is made and in a manner similar to that outlined above.

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1.14.7.4

1.15

Core sample holes shall be repaired with materials similar to that from which the coating is made and in a manner similar to that outlined above. The repairs shall be kept moist and allowed to remain undisturbed for a period of not less than 36 hours. Further curing shall be in accordance with the Specification.

Permanent Markers and Barriers 1.15.1

Scope

This Section of the Specification covers the minimum requirement for the supply and installation of permanent pipeline markers and access barriers, as required for the Work. 1.15.2

General

The Contractor shall supply and install permanent pipeline markers along the pipeline route as close as possible to the windrow. Construction details of all types of markers are shown on the drawings. Each marker consists of a post sealed with a cap end, mounted with two marker plates as per the drawings. Marker plate no. 1 shows general information about the pipeline involved, whereas marker plate no.2 shows relevant information for each location. The different types of pipeline markers are listed below. As-built chainage shall be indicated on the marker plates with an accuracy of one meter. (The start point of the pipeline, KP 0, shall be the pipeline isolation valve in the scraper trap station). Colour coding of the background of the pipeline markers shall be as follows: Crude :

red

Gas

blue

:

Water :

green

The marker plates shall be parallel with the pipeline i.e. they shall face the R.O.W. access road. Separate markers are required on parallel lines. 1.15.3

Chainage Markers

Chainage markers shall be installed along the pipeline at each one (1) kilometre chainage station. A chainage marker is not required if the distance between its location and any other type of pipeline marker, as mentioned hereafter in this section is less than 200 metres. 1.15.4

Block Valve Station Markers

Block valve station markers shall be installed along the pipeline at each block valve station. A schematic diagram of the block valve station pipe work layout shall be installed on the block valve station fencing. 1.15.5

Road Crossing Markers

Road crossing markers shall be installed at both sides of each paved or graded road crossing. Location shall be 5metres from the borders of the road. 1.15.6

Wadi Crossing Markers

Wadi crossing markers shall be installed at both sides of each wadi crossing.

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1.15.7

Pipeline Crossing Markers

Pipeline crossing markers shall be installed at each crossing with an existing underground or above ground pipeline. (This does not apply to flowlines). 1.15.8

Cable Crossing Markers

Cable crossing markers shall be installed at each crossing with an existing underground cable. 1.15.9

Markers at Horizontal Bends

Markers shall be installed at the tangent points of each horizontal bend, with an indication of the actual bend angle of the pipeline at that location. 1.15.10

Cathodic Protection Markers

At all C.P. test stations, bonding stations and negative connection stations, a pipeline marker shall be installed. Locations shall preferably be combined with chainage markers. At pig trap stations, the insulating joint test station post/marker shall be installed outside the station fence but no further than 25 m from the insulating joint. 1.15.11

Pearson Survey Hole Marker

A marker shall be installed adjacent to each Pearson Survey earthing hole. Ref. GEN-21632-01. 1.15.12

R.O.W. `STOP` Signs

At each road crossing, permanent `STOP` signs shall be installed on the R.O.W. access strip, at both sides of the road for the attention of drivers of maintenance vehicles on the R.O.W. 1.15.13

Corrosion Monitoring Pit Marker

A marker shall be installed adjacent to each of the corrosion monitoring pit, in the case where the pit is not located inside a station. The marker shall be inside the pit with fencing. 1.15.14

Access Barriers

1.15.14.1

When specified on the drawings, access barriers shall be constructed in accordance with Standard Drawing GEN-2-1633-01.

1.15.14.2

Breaks in the barriers shall be provided at each road/track/livestock crossing and at least once every two kilometres to coincide with livestock crossings. At these crossings, removable barriers shall be installed to prevent normal access from the crossing to the Right-of-Way, but allowing inspection vehicles to pass when required. Final configuration shall be approved by the Company Site Representative.

1.15.14.3

Painting of access barriers shall be in black and yellow bands of 0.3 m length. Paintings shall be carried out in accordance with Section 2.12, Station Works.

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1.16

Station Works 1.16.1

Scope

This Section of the Specification covers the minimum requirements for all above and below ground station works, including pig trap and block valve stations. The sections below make reference to relevant PDO Specifications and detail any additional requirements. The following works are included in this Section: -

Earthworks

-

Civil and Mechanical Work

-

Painting

-

Instrumentation

-

Electrical Works

-

Fencing

Requirements for the following related activities are included in other sections of this document or other Specification. -

Materials

-

Cathodic Protection

-

Supply of hydrotest water

-

Hydrotesting

-

Work on `live` systems

-

Use of explosives

-

Access barriers

Contractor shall supply all materials and equipment unless stated otherwise in the Schedules. 1.16.2

SP-1208

Earthworks a)

Pig trap station plots will be prepared, by others, to final elevations unless specifically stated otherwise in the Scope of Work/Drawings.

b)

All earthworks, specifically those relating to supports, drain pits and corrosion monitoring pits, shall be in accordance with SP1279-C.

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1.16.3

Civil and Mechanical Works

1.16.3.1

General a)

All station works shall be fabricated and installed in accordance with the Drawings and this Specification, including standard Civil and Mechanical drawings from ERD 10-11 and ERD 38-04, respectively.

b)

Precautions shall be made to prevent entry of sand or debris etc. into pipework and fittings during construction.

c)

Contractor shall maintain the elevations shown on the drawings and carry out any pipework adjustment necessary to achieve this.

d)

Valves with flow arrows shall be installed in the normal flow direction of the product.

1.16.3.2

Concrete/ Block work a)

All concrete works shall be in accordance with SP1279-D. Reference is also made to SP-1282.

b)

The block work of corrosion monitoring pits shall be in accordance with SP-1279-E.

c)

Anchor bolts, pipe sleeves, anchor rails, insert and sliding plates shall be built in as formwork proceeds. They shall be positioned accurately and be firmly fixed such that no movement shall occur during the concrete pour. If provision is to be made to allow for slight adjustment in position of anchor (holding-down) bolts, this shall be clearly indicated on the detail foundation drawings with the method(s) to be applied. Anchor bolts, etc. shall be properly protected against damage and corrosion. Threaded parts shall be greased and securely protected from damage before pouring of concrete. Anchor bolts shall be as shown on the drawings. All embedded parts shall be free from oil, loose scale, rust, paint, grease or other harmful matter.

1.16.3.3

Structural Steel

All structural steelworks shall be in accordance with SP1279-G. 1.16.3.4

Process Pipework a)

Fabrication and welding of process pipework and fittings shall be in accordance with SP-1173 Specification for Welding of On-Plot Pipework. The on-plot Specification states that all welding shall be by the uphill technique. In certain circumstances, downhill welding may be considered for filling and capping runs, any proposals for which shall be reviewed on a case by case basis by the Company welding TA-2 and endorsed by the CFDH Welding.

SP-1208

c)

Corrosion probe fittings shall be welded and drilled prior to hydrostatic testing. Flame cutting of holes is not permitted.

d)

The bases and valves of pig indicators shall be installed prior to hydrostatic testing and the complete assembly fitted after test.

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e)

If temporary vents are required by Contractor for hydrostatic testing, in stations or on the pipeline, these shall be provided with prior approval of the Company. The size of such vents shall be 1 inch. All welds shall be subject to MPI and the final cap to nipple weld shall be radiographed. Thereafter the cap, nipple and weldolet shall be painted as specified in Section 12.4 below. The proposed location for temporary vents shall be U.T. checked for laminations and to confirm adequate wall thickness. A MPI check shall also be made to confirm the absence of surface breaking defects, prior to welding or cutting.

f)

In the event that anchors are required, these shall be installed at the locations shown in the drawings. The anchor flange with a pipe joint welded at both ends shall be completely installed prior to start of civil work. The anchor flange to be embedded in the concrete shall be coated in accordance with Section 2.12.4 below. Pipe coating shall be tested with the holiday detector prior to embedding in concrete. The concrete work shall be backfilled and left to cure a minimum of three weeks before further joints are allowed to be welded to the anchor flange assembly.

1.16.4

Painting a)

All above and below ground steel surfaces (with the exception of polyethylene or epoxy coated pipework and items supplied in a manufacturer’s finish) shall be prepared and painted in accordance with this Specification.

b)

Valves and insulating joints shall be supplied with a single coat primer only, in accordance with SP-1246.

c)

Underground steelwork, pipework, fittings and valves, including those inside corrosion monitoring pits, shall be coated in accordance with SP1246.

d)

Above-ground steelwork, pipework, fitting and valves shall be painted in accordance with SP-1246. All items shall be colour white, except for the following: Actuators and insulating couplings

red

Covers of corrosion monitoring pits

black

Access barriers and Pearson hole markers Handrails

black/yellow black

(In special instances Camouflaged paint may be required). e) 1.16.5

Surface preparation and painting shall be in accordance with SP-1246. Instrumentation

Contractor shall carry out instrumentation works in accordance with SP-1088 and DEP 62.10.08.11 GEN.

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1.16.6

Electrical Works a)

This section refers to permanent electrical works as specified in the Drawings (normally earthing and bonding only), including standard drawings from SP-1105, Electrical Standard Drawings.

b)

All work shall be carried out in accordance with the following Specifications:

1.16.7

1.17

SP-1099

Electrical Installation Practice

SP-1104

Electrical Safety Rules

SP-1109

Specification for Earthing and Bonding

Fencing a)

The fencing required for the Work shall be of the medium security type, and be supplied and constructed in accordance with SP1279-P. The exact requirements for each location are shown in the drawings.

b)

If Contractor requires an opening in an existing fence for construction purposes, he shall obtain prior approval of the Company and restore the relevant part to its original condition upon instruction of the Company.

Cathodic Protection 1.17.1

Impresssed Current Cathodic Protection

1.17.1.1 1.17.1.2

The cathodic protection design shall be in accordance with SP-1128 Specification for Cathodic Protection Design’. Details of various design aspects are indicated in the standard drawings specified in SP-1136 ‘Specification for Cathodic Protection Standard Drawings’.

1.17.1.3

When a complete new C.P test points connects to an existing system, then the Contractor shall employ a qualified C.P supervisor who shall have the prior approval of the Company. When solar panels are required, Contractor shall sub-contract the supply/installation to a Company approved supplier/contractor.

1.17.1.4

Contractor shall give the Company 5 days notice prior to installation of special C.P items i.e. solar stations, T/R units and ground bed anode systems, in order to mobilise a Company CP Inspector.

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1.17.2

Materials

Contractor shall procure all materials required for the Work, unless stated otherwise in the Schedules. Specifications for materials shall be as shown on the drawings. The following Company Specifications are applicable: •

SP-1129 (Construction, Installation and Commissioning)

•

SP-1130 (Materials and Equipment)

•

SP-1136 (Standard Drawings)

•

PR-1234 (Safe Working Procedures)

1.17.3

Installation

1.17.3.1

Installation of the C.P. System shall be carried out concurrently with the main pipeline laying work.

1.17.3.2

At approximately 2 km intervals, as shown on the drawings, a C.P. Standard Test Post shall be installed (Ref. STD-7-3001). Welding of the attachments to the pipeline, including procedure and welder qualification shall be in accordance with Section 2.6, Welding and NDT.

1.17.3.3

Cable connections to the pipeline (Ref. STD-7-2001) shall also be required, as shown on the Drawings, at the following locations: -

pipeline crossings

-

current measuring stations

-

buried or overhead high voltage powerline

-

negative connections

-

earthing electrodes

-

permanent reference cells

-

insulating joints

Where the required connections at pipeline crossings, current measurement stations, etc. are within 200m of the planned location of a C.P. test station/pup piece point, the latter may be relocated to coincide with the connection, subject to prior Company approval. 1.17.3.4

All C.P. testing facilities shall be installed in accordance with SP-1129.

1.17.3.5

Where Foreign Service Bonding Facilities are required on foreign services, for cross bonding, the connection pad may be attached by welding a pad on the foreign services (Ref. STD-7-3005).

1.17.3.6

Current Measuring Stations shall be installed on the pipeline every 10 km, unless shown otherwise on the drawings (Ref. STD-7-3004).

1.17.3.7

A Grounding Facility shall be installed at power line crossings and where the pipeline runs parallel to, and within 50m of a power line (Ref. STD-7-3006).

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1.17.3.8

Drain Point Facilities shall be installed as shown on the Drawings (Ref. STD-73003).

1.17.3.9

Insulating joints/flanges shall be installed in accordance with Drawings (Ref. STD-7-3007).

1.17.3.10

All C.P. cables shall be installed in accordance with SP-1129. Cable to pipeline connections shall be made prior to hydrostatic testing. Cable markers shall be installed in accordance with drawing STD-7-7001.

1.17.3.11

Ground beds, when required and shown on the Drawings, shall be installed in accordance with SP-1129(Ref. STD-7-6001, STD-7-6002, STD-7-6003, and STD-7-6004).

1.17.4

Temporary Cathodic Protection

In the case that the pipeline is to be buried in a highly corrosive soil and when the installation of the permanent cathodic protection system cannot be finalized before the pipeline is buried (pipelines with long construction periods) a temporary cathodic protection system shall be installed. Such a system shall be designed in the same way as a permanent cathodic protection system with the exception that material quantities and quality shall be adequate to cover a lifetime equal to the time of the pipeline construction until the expected commissioning of the permanent cathodic protection system. Anode connections shall be constructed such that they can easily be connected / disconnected during and/or after commissioning of the permanent system. 1.17.5

Pearson Survey

1.17.5.1

Company will carry out a ‘Pearson Survey’, after installation of the pipeline, to check the integrity of the buried pipeline coating. In order to achieve good earthing for this survey, Contractor shall install Pearson Survey Earthing Points adjacent to each 2 km C.P. Standard Test Post. If coating defects are found on any portion of the coating, Contractor shall excavate, repair and backfill at Contractor’s expense.

1.17.5.2

These earthing points shall be constructed during the main pipelay work, in accordance with drawing GEN-2-1633-01.

1.17.6

Commissioning

Contractor is required to provide a PDO approved C.P. Contractor to commission the C.P. system after installation in accordance with documents SP-1129 and PR-1169. The Contractor should inform the name of sub-contractor they intend to use to execute the commissioning not less than 28 days prior to commencement of commissioning.

1.18

Quality and Treatment of Hydrotesting Water The minimum requirements for the quality and treatment of flushing and hydrostatic testing water as required for the Work is stipulated in SP-1212: Hydrostatic Testing of New Pipelines.

1.19

Hydrostatic Testing The minimum requirements for hydrostatic testing operations, i.e. cleaning, gauging, filling, hydrostatic testing and dewatering of pipeline and station works as required for the Work are covered under a separate specification SP-1212: Hydrostatic Testing of New Pipelines.

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1.20

Precommissioning Of Pipelines 1.20.1

Scope

The minimum requirements for precommissioning of oil and gas pipelines including but not limited to bulk dewatering, final dewatering, cleaning, drying and preservation of oil and gas pipelines as required for the Work are covered under a separate DEP 31.40.50.30. 1.20.2

General

The Contractor shall carry out the pre-commissioning activities of pipelines in accordance with the requirements of the Scope of Work, this specification and DEP 31.40.50.30. Pre-commissioning records shall be in accordance with chapters 6 and 8 of DEP 31.40.50.30. Hydrotest water shall be disposed of in accordance with SP-1006. Contractor shall supply all materials, consumables, equipment, spares, labour, supervision and other services incidental to and necessary for the successful performance of the pre-commissioning work in a manner satisfactory to the Company. 1.20.2.1

SP-1208

Contractor shall make detailed proposals, for Company approval, for the precommissioning work including but not limited to detailed procedures, programme and schedule for Work. Contractor’s proposals shall include complete information regarding the following aspects: -

precise definition of the sections to be precommisioned

-

the method or combination of methods to be employed

-

complete summary and lay out of the temporary pipework, equipment and facilities including spares for each section to be pre-commissioned.

-

the method(s) to be employed to preserve the dryness and cleanliness of the line.

-

any tie-in work to be carried out after pre-commissioning.

-

precommissioning of valves, branch off takes, etc.

-

tests to verify the success of the operation.

-

a summary of the amount of material and consumables and the number and qualifications of personnel, to be used for the precommissioning work.

-

test/calibration procedures for all main equipment and instrumentation.

-

calculations and any other evidence necessary to demonstrate that the work will be executed in accordance with the requirements of the Contract. The sizing of drying equipment and calculations of the time required for drying shall be based on a film thickness of residual water of not less than 0.1 mm. Lower values may be assumed if the Contractor can demonstrate, to the Company's satisfaction, their validity from previous experience.

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1.21

Work on Live Pipe Systems 1.21.1

Scope

This Section of the Specification covers the minimum requirement for work on live pipe systems as required for the Work. 1.21.2

1.22

General

1.21.2.1

The work permit system shall apply to all work on live pipe systems. Contractor shall do all that is necessary to obtain work permits and to execute the Work in adherence to the work permit.

1.21.2.2

Specialised tools and equipment as required for the performance of work on live pipe systems shall only be acquired form the Company approved vendors. A vendor’s representative shall be present at all times during the use of such tools and equipment.

1.21.2.3

Hot tapping on live pipe systems shall be carried out in accordance with DEP 31.38.60.10. Welding on pressurised pipes shall be carried out in accordance with SP-1167.

As-Built Records and Hand-Over Documentation 1.22.1

Scope

This Section of the Specification covers the minimum requirements for keeping and maintaining records, drawings and documents of all aspects of the pipeline project. These requirements supplement those contained in SP-1131, to which reference should be made for the definitions and general requirements. The scope includes new pipeline construction and modifications to existing lines and related facilities. The primary purpose is to provide a comprehensive list of Handover and As-Built documentation that should form the handover package at the completion of a pipeline project. The scope also covers responsibility for document preparation and custody, the minimum recommended retention period for each type of document and the appropriate form in which storage should take place. Where any conflict occurs with the requirements of SP-1131, this specification shall take precedence. The types of documents/drawings required for handover of a pipeline are detailed in subsequent sections. These requirements are developed as a comprehensive list of documentation specific to pipeline projects and listed in Appendix D of this specification. This Appendix also include, the recommended storage period before disposal, storage format and the storage location. 1.22.2

Storage Format

Retention of information as hard copy shall be minimised and wherever possible master copies of documentation shall be acquired and stored in a suitable electronic format. Route survey data shall be presented in accordance with XTO documents TS18v1-0: Pipeline Data Specification and TS19v1-0: Flowline Data Specification. All master documents should be classified, coded and compiled on to a minimum number of fully indexed compact discs or other media that may be specified by the Company. Controlled and separately stored back-up copies of key items shall be maintained.

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Documentation available only as hard copy shall be scanned for archiving. In the cases where the required storage life is short (say, less than 2 years), or the document is not suitable for scanning, exceptions to this requirement should be agreed by the responsible Project Engineer in consultation with the relevant CFDH or nominated discipline engineer. Hard copies of whichever master documents are required for day to day operation and maintenance, or for permanent reference to support future engineering activities during the operational life, may be made as required provided documents maintained ‘As-Built’ are formally issued as controlled copies. 1.22.3

Storage Location

Master copies of all textual documentation after handover shall be held by the pipeline owner (Asset Manager) in a properly managed archive. This shall include storage of pipeline radiographs for the prescribed retention period before disposal. Autocad drawings shall be stored and referenced in EDMS in accordance with Company practice. Controlled hard copies of documents required for pipeline operation and maintenance (Operating Manuals, Design Reference Manual, PEFS etc. as per Appendix D) should be provided to Operations as part of the handover package. Issue of further documents should be authorised and controlled by the Asset Manager. A detailed listing shall be filed within EDMS Business Records of the storage location of all master documents for each pipeline. This list, along with copies of all key drawings within EDMS and the basic pipeline design and operating data held in SAP, shall be linked to the relevant pipeline location in GIS to enable the data to be readily identified and/or retrieved. 1.22.4

Pipeline As-Built Documentation

Original pipeline drawings and other documents required to be maintained ‘As-Built’ (see Appendix D) shall be updated during the construction and commissioning phase in line with SP-1131, Section 4. Subsequent revisions of the master documents shall be authorised and all As-Built copies issued on a properly controlled basis in accordance with CP-102. 1.22.5

Documents

The required documents to be provided by the Contractor are: -

Test, Calibration and Inspection Reports

-

Material Certificates for Contractor Supplied materials

-

As-built Drawings and Pipeline Data Sheets

Unless otherwise stated, Contractor shall provide originals of documents plus two copies. 1.22.6

Test, Calibration and Inspection Reports

Contractor shall make available inspection, calibration and testing reports, (including welding procedures, NDT procedures, radiographs, ultrasonic test reports, hydrostatic testing and drying reports), as specified in applicable Sections of the Specification. 1.22.7

Material Certificates

Contractor shall make available Mill and Test Certificates, where applicable, for all materials supplied by Contractor and incorporated in the permanent facilities.

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1.22.8

As-built Drawings and Pipeline Data Sheets

Contractor shall return to the Company one copy of each drawing (provided by the Company) corrected with as-built information for those drawings in the Drawing List which are indicated to be revised as as-built. These as-built drawings shall be submitted for approval to the Company within 2 weeks of the Completion Date and shall be approved by the Company before Acceptance of Work. The as-built information shall include but not be limited to: -

Measured trench depth at each 12 meter intervals, with chainage

-

Measured top of pipe level at each installed joint location, with chainage

-

Cover and grade elevations at 12 meter intervals, with chainage

-

Type of rock/soil encountered in trench preparation, and depth at which it was encountered.

-

The location and degree of all points of intersection.

-

The locations of all temporary vents.

-

The chainage, elevation, size, type, shape of all roads, wadis, pipes, cables and other objects crossing and/or obstructing the pipeline.

-

The identification and the location of circumferential welds and pipe lengths with the manufacturer’s number, heat number, sequence number and length installed.

-

The position of all permanent markers.

-

Other relevant data including the chainage of block-valves, anchors, changes in pipe grade, wall thickness, diameter, cathodic protection appliances, instrumentation, etc.

Contractor shall provide a site-based experienced, full-time ‘As-Built’ surveyor, with valid driving licence and vehicle, throughout the duration of the Contract. He shall maintain the Pipeline Data Sheets (originals provided by the Company) and shall collect and maintain all data required for the ‘As-Built’ drawings. Refer to Pipeline Data Base requirements in Appendix D. ‘As-Built’ drawings shall be prepared during the progress of the Construction Work and Contractor shall provide a drawing office, personnel, and all necessary equipment and facilities, to the approval of the Company, for the purpose of producing as-built drawings. Preliminary ‘As-Built’ drawings shall be submitted to the Company for approval on a weekly basis within 2 weeks of the completion of backfilling of the trench on that part of the pipeline route contained on the drawing concerned.

1.23

Effective Period The requirements of this specification shall remain in force indefinitely unless superseded by an authorised revision.

1.24

Review and Improvement It is intended that the present version (2.0) of this specification will be reviewed and updated once in every three years. The review authority will be UIP (CFDH Pipelines).

SP-1208

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APPENDIX A

GLOSSARY OF DEFINITIONS, TERMS AND ABBREVIATIONS i. Terms and Definitions

Company

Petroleum Development Oman LLC. The Company may also include an agent or consultant authorised to act for, and on behalf of, the Company.

Contractor

The party which carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project, or operation or maintenance of a facility. The Company may undertake all or part of the duties of the Contractor.

Corporate Functional Discipline Head

The person within the Company responsible for the discipline to which the standard belongs.

Manufacturer/Supplier

The party which manufactures or supplies equipment and services to perform the duties specified by the Company.

User

The Company, Consultant or Contractor that uses this document.

shall

Indicates a requirement.

should

Indicates a recommendation.

may

Indicates a possible course of action.

ii. Abbreviations

SP-1208

BCD

Business Control Document

CFDH

Corporate Functional Discipline Head

CP

Cathodic Protection

CSR

Company Site Reprensative

EPC

Engineering, Procurement, Construction

FBE

Fusion Bonded Epoxy

GRE

Glass Reinforced Epoxy

GRP

Glass Reinforced Plastic

GRVE

Glass Reinforced Vinyl Ester

HDPE

High Density Polyethylene

HEMP

Hazard and Effects Management Process

MPI

Magnetic Particle Inspection

NDT

Non-Destructive Testing

PE

Polyethylene

PP

Polypropylene

ROW

Right of Way

RTP

Reinforced Thermoplastic

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APPENDIX B

REFERENCE DOCUMENTS

In this SP, reference is made to the following publications. Unless specifically designated by date, the latest edition of each publication shall be used, together with any amendments/supplements/revisions thereto. REFERENCE

REF #

PDO STANDARDS Code of Practice Corporate Document Management

CP-102

Health Safety and Environment Management System

CP-122

Specification

SP-1208

Civil and Building Standard Drawings

ERD 10-11

Mechanical Standard Drawings

ERD 38-04

Guidelines for excavation and working around live pipelines

ERD 38-11

Specification for Qualification, application and inspection of shrink sleeves for corrosion protection

ERD 48-04

Specification for Aqueous Effluents

SP-1006

Specification for Waste Management

SP-1009

Specification for Site Preparation, Abandonment and Restoration

SP-1012

Mounting of Plant Instruments

SP-1088

Specification for welding of Duplex Stainless Steel Pipelines

SP-1097

Electrical Installation Practice

SP-1099

Electrical Safety Rules

SP-1104

Electrical Standard Drawings

SP-1105

Specification for Earthing and Bonding

SP-1109

Specification for Cathodic Protection Design

SP-1128

Specification for Construction, Installation Commissioning of Cathodic Protection System

and

SP-1129

Specification Equipment

and

SP-1130

for

Cathodic

Protection

Materials

Specification for Handover and As-built Documentation

SP-1131

Specification for Cathodic Protection Standard Drawings

SP-1136

Specification for Earthmoving and Construction Equipment

SP-1143

Specification for welding of martensitic Stainless Steel Pipelines

SP-1147

Specification for welding on pressurised pipes

SP-1167

Specification for Quality Assurance of Design, Construction and Engineering works

SP-1171

Specification for welding of on-plot Pipework

SP-1173

Specification for welding of Class 2 Pipelines (Flowlines)

SP-1174

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REFERENCE

REF #

PDO STANDARDS Specification for Welding of Class 1 Pipelines

SP-1177

Specification for Application and selection of Standard Pipe Supports

SP-1187

Pipeline Operations and Maintenance

SP-1210

Onshore Pipeline Engineering

SP-1211

Hydrostatic Pressure Testing of New Pipelines

SP-1212

Specification for Lifting Equipment and Lifting Operations

SP-1239

Specification for painting and coating of oil and gas production facilities (Part 1 – 5)

SP-1246

Training requirements for lifting operations personnel

SP-1251

HSE Specification, Camps, Offices, Laboratories, Workshops and Industrial Safety Specification

SP-1256

HSE Specification, Safety, Training Observation Programme (STOP)

SP-1259

Specification for Civil and Building Construction

SP-1279

Specification for Reinforced Concrete – Production & Construction Guidelines

SP-1282

HSE Specification, Road Transport

SP-2000

Procedure Initial Start up Procedure

PR-1169

Safe working Procedures for Cathodic Protection Systems

PR-1234

Procedures for Lifting Operations

PR-1508

Procedure for Analysis of Pipeline Road Crossings

PR-1522

WinPCS Procedure

PR-1561

Guideline

SP-1208

C-09 HSE Requirements and Guidance for use

GU-140

Environmental Assessment Guideline

GU-195

Guideline for the Granting of Engineering Technical Authorities

GU-272

Guidelines for the protection of buried sections of surface laid Pipelines/Flowlines

GU-368

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REFERENCE

REF #

SHELL STANDARDS

SP-1208

Index to DEP publications

DEP 00.00.05.05-Gen.

Piping – General requirements

DEP 31.38.01.11-Gen

Piping classes – exploration and production

DEP 31.38.01.15-Gen.

Hot tapping on pipelines, piping and equipment

DEP 31.38.60.10-Gen

Design of pipeline pig trap systems

DEP 31.40.10.13-Gen.

Pipeline overpressure protection

DEP 31.40.10.14-Gen

Upheaval buckling of pipelines

DEP 31.40.10.16-Gen

GRP Pipelines and piping systems (amendments / supplements to ISO 14692)

DEP 31.40.10.19-Gen.

Line pipe induction bends (amendments / supplements to ISO 15590 – 1)

DEP 31.40.20.33-Gen

Linepipe for non-critical service (Amendments/supplements to ISO 3183-1)

DEP 31.40.20.35-Gen

Linepipe for critical (Amendments/supplements to ISO 3183-3)

service

DEP 31.40.20.37-Gen

Pipeline Fittings (amendments / supplements to MSS SP – 75)

DEP 31.40.21.30-Gen

Pig signallers: Intrusive type

DEP 31.40.21.33-Gen

Carbon and low alloy steel pipeline flanges for use in oil and gas operations (amendments / supplements to MSS SP – 44)

DEP 31.40.21.34-Gen

Concrete coating of linepipe

DEP 31.40.30.30-Gen.

External polyethylene and polypropylene coating for line pipe

DEP 31.40.30.31-Gen

External fusion-bonded epoxy powder coating for line pipe

DEP 31.40.30.32-Gen.

Thermoplastic lined pipelines Precommissioning of pipelines

DEP 31.40.30.34-Gen

Pipeline Repairs (supplements to ASME B31.4 / B31.8)

DEP 31.40.60.12-Gen

Inspection and Functional testing of instruments

DEP 62.10.08.11-Gen

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AMERICAN STANDARDS Process Piping

ASME B31.3

Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids

ASME B31.4

Gas Transmission and Distribution Piping Systems

ASME B31.8

Issued by: American Society of Mechanical Engineers Publications and Distribution Section 1220 L Street Northwest Washington DC 20005, USA

Specification for Linepipe

API Std 5L

Standard for welding pipelines and related facilities

API Std 1104

Recommended practice for liquid petroleum pipelines crossing railroads and API RP 1102 highways Issued by: American Petroleum Institute Publications and Distribution Section 1220 L Street Northwest Washington DC 20005, USA

Steel Pipeline Flanges

MSS SP-44

Specification for high test wrought butt welding fittings

MSS SP-75

Issued by: Manufacturers Standardization Society of the Valve and Fittings Industry, Inc.127 Park street, Northeast Vienna, VA 22180, USA

BRITISH STANDARDS Code of Practice for the Safe Use of Explosives in the Construction Industry

BS 5607

Issued by: British Standards Institution 389 Chiswick High Road London, W4 4AL, UK

INTERNATIONAL STANDARDS Preparation of Steel Substrates before Application of Paints and Related Products – Visual Assessment of Surface Cleanliness Preparation of Steel Substrates before Application of Paints and Related Products – Tests for the Assessment of Surface Cleanliness Preparation of Steel Substrates before Application of Paints and Related Products - Surface Roughness Characteristics of Blast-Cleaned Steel Substrates Preparation of Steel Substrates before Application of Paints and Related Products - Specification for Metallic Blast-Cleaning Abrasives Preparation of Steel Substrates before Application of Paints and Related Products - Specification for Non-Metallic Blast-Cleaning Abrasives Petroleum and Natural Gas Industries – Glass Reinforced Plastics (GRP) Piping Petroleum and Natural Gas Industries – Induction bends, fittings and flanges for pipeline transportation systems – Part 1: Induction Bends

ISO 8501-1 ISO 8502-1 to 4 ISO 8503-1 to 4 ISO 11124 ISO 11126 ISO 14692 ISO 15590-1

Issued by: International Organization for Standardization 1,Rue de Varembé CH-1211 Geneva 20, Switzerland

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APPENDIX C: FACILITIES FOR COMPANY PERSONNEL C.1

Scope This Section of the Specification covers the minimum requirements for facilities for Company personnel at Contractor’s Construction Camp and is supplementary to the Regulations for Pipeline Contractor Camps in the Interior.

C.2

Accommodation

C.2.1

Where the Contractor is required in the Contract Scope of Work to provide his own camp, Contractor shall provide and maintain in its camp, good quality accommodation for the number of Company’s senior personnel stated in the Scope of Work. Company may choose to use this accommodation for personnel other than Company personnel.

C.2.2

Where the Contractor is required in the Contract Scope of Work to provide accommodation for the Company’s personnel, the minimum accommodation requirements for each of Company’s aforementioned senior personnel shall be: a)

Bed-sitting room of 14.0 square metres floor area. This shall be furnished with: one standard bed and mattress, of minimum width 1.2 metres one full length wardrobe. one writing desk with drawers and with a matching chair. one refrigerator. one 14” portable colour TV+ DVD Player one bedside rug, 1.5 metres long and 1 metre wide. one bedside table. one chest of drawers. two coffee tables, each 0.75 metres square. one bedside light. two easy chairs, adequate heating and air-conditioning, sewerage, electricity, general lighting, electrical power points, fly screens, ashtrays, glasses, cups and saucers. one waste paper basket. one electric kettle.

b)

Private toilet/shower of minimum 3.5 square metres floor area (minimum width 1.5 m) containing: one western type flush toilet one shower with shower curtain one wash basin hot and cold running water of potable quality one shaving cabinet with mirror towel rails

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c)

All necessary bed and bathroom linen.

C.2.3

Contractor shall replace all linen twice per week, clean all accommodation daily, and keep all accommodation in good repair.

C.2.4

All accommodation provided for the Company’s use shall be subject to Company’s approval.

C.3

Messing

C.3.1

Where the Contractor is required in the Contract Scope of Work to provide messing, Contractor shall provide and maintain complete and clean messing facilities for the Company personnel and shall provide adequate good quality meals with soft drinks at such meals. The menu should have at least one alternative main course.

C.3.2

Contractor shall provide an adequate laundry service for the personal clothing of the Company personnel.

C.3.3

Contractor shall keep the Company personnel refrigerators stocked with a selection of soft drinks.

C.4

Offices and Office Services

C.4.1

Contractor shall furnish, clean and maintain good quality office equipment and accommodation at each spread camp for 5 members of the Company’s personnel.

C.4.2

Unless otherwise agreed by the Company, office space for these persons shall have a minimum floor area of 45 square metres and shall be supplied with the following for sole use by the Company’s personnel: four desks, each with plain drawers and filling drawers four swivel chairs four plain chairs one drawing rack one drawing table one side board/bookcase shelves two filling cabinets adequate heating and air conditioning, general lighting, electricity, electrical power points, in trays, waste paper baskets, and ashtrays. one Pentium V PC with MS Office 2000 software including a CDRW drive one laser printer one facsimile machine type RICHO 3300 or similar one photocopier type XEROX 1035 or equivalent. five handheld radios office telephones internet / email facilities two digital camera one refrigerator

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C.4.3

The offices shall be interconnected. At each spread camp, the Contractor shall provide and maintain for Company’s sole use such materials and equipment (computer, stationary, etc.) as may be required for the Company’s clerical work at the camp.

C.4.4

As and when required, Contractor shall make available for Company’s use at the main spread camp site, a furnished conference room of minimum floor area 24 square metres and with seating for a minimum of 15 persons.

C.4.5

All offices and office services, provided for Company’s use shall be subject to Company’s approval.

C.4.6

Contractor shall provide an administration clerk who is proficient in English, typing and general office procedures, for Company use seven days per week throughout the duration of the Contract.

C.4.7

Contractor shall provide a suitable Digital camera with two 128 MB memory sticks and photo editing software for the exclusive use of the Company Site Representative.

C.5

Vehicles and Maintenance

C.5.1

Throughout the construction period Contractor shall fuel, service, maintain and repair the vehicles which Company uses on the Work Site, up to the number given in the Scope of Work.

C.5.2

Maintenance procedures shall be strictly in accordance with vehicle manufacturer’s local representative’s recommendations for the specific terrain and climatic conditions involved. A daily status check for all cars being used is required. Contractor shall maintain vehicles of the Company with due diligence and utmost care to ensure safety of the vehicles. Contractor shall keep a record of all checks and services for each Company vehicle.

C.5.3

Contractor shall provide an English speaking driver with the necessary experience to obtain a PDO driving licence for Company use seven days per week for the duration of the Contract.

C.5.4

Where Contractor is required in the Scope of Work to provide vehicles for the use of Company personnel, they shall at the start of the Contract be either new or have less than 10,000 Km mileage. The vehicles shall be 4 wheel Drive, preferably Mitsubishi Pajero V6 (LWB) or Company approved equivalent.

C.6

Recreational facilities

C.6.1

Contractor shall make available separate recreational facilities for the Company personnel, with a floor area of minimum 24 square metres, and furnished with easy chairs.

C.6.2

In each camp a 29” colour TV with DVD player shall be available for the sole use of Company personnel.

C.6.3

Magazines and daily newspapers shall be provided by the Contractor as per Company’s Site Representative’s requirements.

C.6.4

At each Contractor Camp, facilities shall be provided for outdoor sports (football, tennis, etc.), type to be agreed with Company Site Representative.

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General Reports

1.1

Drawing control register

DC

(See remarks)

N/A

N/A

Retained until drawings are as-built and stored in EDMS.

1.2

Pipeline inspection reports

CC

Service life

Electronic or Paper

Archive

Archived items to be referenced in EDMS.

1.3

Equipment reports

Vendor

Service life

Electronic or Paper

✓

Archive


1.4

Operating manual

DC

Service life

Electronic

✓

EDMS

Essential data for each line held in PACER, accessed via GIS

1.5

Design reference manual

DC

Service life

Electronic

✓

EDMS

Essential data for each line held in PACER, accessed via GIS

1.6

Soil investigation report

SC

2 years

Paper

Archive

Storage reference in EDMS.

1.7

Environmental data

SC

2 years

Paper

Archive


1.8

Studies - feasibility/conceptual/ front end

DC

Project completion (see remarks)

N/A

N/A

Conceptual data underlying chosen design options to be retained with DRM (1.5 above)

1.9

Technical audit/HAZOP reports

DC

(See remarks)

Electronic

EDMS

Retained until close out of HAZOP actions.

1.10

Close-out reports

PE

2 years

Electronic

EDMS

2.0

General Drawings

2.1

Plot plans

DC

Service life

Electronic/Paper

✓

EDMS

Drawing reference in GIS. Note, benchmark locations included in plot plans.

2.2

Hazardous area classification drawing

DC

Service life

Electronic/Paper

✓

EDMS

Drawing reference in GIS.

2.3

Process flow schemes

DC

Service life

Electronic/Paper

✓

EDMS


2.4

Utility flow schemes

DC

Service life

Electronic/Paper

✓

EDMS


2.5

Process and engineering flow scheme

DC

Service life

Electronic/Paper

✓

EDMS


2.6

Utility and engineering flow scheme

DC

Service life

Electronic/Paper

✓

EDMS


2.7

Material identification diagram

DC

Service life

Electronic/Paper

✓

EDMS


3.0

Civil Documents

3.1

Road and paving plan

DC

Service life

Electronic/Paper

✓

EDMS

3.2

Foundation location plan

DC

Service life

Electronic/Paper

✓

EDMS


3.3

Fencing and grading plan

DC

Service life

Electronic/Paper

✓

EDMS


3.4

Non-standard pipe supports, guides and anchors

DC

Service life

Electronic/Paper

EDMS


4.0

Mechanical Documents

SP-1208


Remarks Location

Originator *

Page 64

Keep As-Built

1.0

Document Category

Custodian **

Storage format

LIST OF HANDOVER AND AS-BUILT DOCUMENTATION Retention time

APPENDIX D:

Version 2.0 Retention time

Storage format

Keep As-Built

Location

4.1

Piping key plans

DC

Service life

Electronic/Paper

✓

EDMS


4.2

Piping plans

DC

Service life

Electronic/Paper

✓

EDMS


4.3

Equipment data sheets

Vendor

Service life

Electronic or Paper

Archive


4.4

Isometrics

DC

Project completion

N/A

N/A

4.5

Material take off

DC

Project completion

N/A

N/A

4.6

Material/equipment requisitions

DC/PE

See remarks

Electronic

EMA

Retain for longer of guarantee period or 2 years. Reference in EDMS

5.0

Pipeline Documents

5.1

Pipeline routing key plan

DC

Service life

Electronic

✓

EDMS


5.2

Route maps

XTO/2

Service life

Electronic or Paper

✓

GIS

Ref. TS18V1-0.doc & TS-19V1-0.doc

5.3

Alignment sheets

DC

Service life

Electronic/Paper

✓

EDMS


5.4

Station approach drawings

DC

Service life

Electronic/Paper

✓

EDMS


5.5

Tie-in schedule

DC

Project completion

N/A

✓

N/A

6.0

Electrical Documents

6.1

Single line diagram

DC

Service life

Electronic/Paper

✓

EDMS


6.2

Power cable layout layout drawing

DC

Service life

Electronic/Paper

✓

EDMS


6.3

Custodian **

Document Category

Originator *


Remarks

Earthing layout drawing

DC

Service life

Electronic/Paper

✓

EDMS


6.4

Lighting layout drawing

DC

Service life

Electronic/Paper

✓

EDMS


6.5

Cable schedule

DC

Service life

Electronic/Paper

✓

EDMS


6.6

Trench layout

DC

Service life

Electronic/Paper

✓

EDMS


6.7

Electrical material requisitions

DC/PE

See remarks

Electronic

EMA

As 4.6, above.

7.0

Instrument Documents

7.1

Instrument location plan

DC

Service life

Electronic/Paper

✓

EDMS


7.2

Instrument data sheets

DC

Service life

Electronic/Paper

✓

EDMS


7.3

List of alarm and trip settings

DC

Service life

Electronic/Paper

✓

EDMS


7.4

Shutdown matrices

DC

Service life

Electronic/Paper

✓

EDMS


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Version 2.0 Storage format

Keep As-Built

Location

Functional logic diagram

DC

Service life

Electronic/Paper

✓

EDMS


7.6

Loop diagrams

DC

Service life

Electronic/Paper

✓

EDMS


7.7

Alarm annunciator system

DC

Service life

Electronic/Paper

✓

EDMS


7.8

Control room layout

DC

Service life

Electronic/Paper

✓

EDMS


7.9

List of telemetry points

DC

Service life

Electronic/Paper

✓

EDMS


7.10

Control room instrument cable layout

DC

Service life

Electronic/Paper

✓

EDMS


7.11

Junction box layout

DC

Service life

Electronic/Paper

✓

EDMS


7.12

Instrument requisitions

DC/PE

See remarks

Electronic

✓

EMA

As 4.6, above

8.0

Cathodic Protection Documents

8.1

Ground bed layouts

DC

Service life

Electronic/Paper

✓

EDMS


8.2

Wiring diagrams/cable sizes

DC

Service life

Electronic/Paper

✓

EDMS


8.3

Cabling routing layout

DC

Service life

Electronic/Paper

✓

EDMS


8.4

Transformer rectifier plot layout

DC

Service life

Electronic/Paper

✓

EDMS


8.5

Layout of CP facilities

DC

Service life

Electronic/Paper

✓

EDMS


8.6

CP survey report

SC

Service life

Electronic or Paper

Archive


8.7

CP material specification report

SC

Service life

Electronic or Paper

Archive


8.8

CP installation specification

SC

Service life

Electronic or Paper

Archive


8.9

CP requisitions

DC

Service life

Electronic

EMA

As 4.6, above.

9.0

Pipeline Construction Documents

9.1

Welding and NDT procedures

CC

Service life

Electronic or Paper

Archive


9.2

Welding/NDT progress chart

CC

2 years

Paper

Archive


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Custodian **

7.5

Document Category

Originator *

Retention time



Remarks

Version 2.0

NDT reports/Test packs

CC

Service life

Electronic or Paper

Archive

Archived items to be referenced in EDMS. Relevant data to be entered in PACER.

9.4

Radiographs

CC

2 years

Film

Archive


9.5

Commissioning documentation

OTL

2 years

Paper

Archive


9.6

Hydrotest certificates

CC

Service life

Electronic or Paper

Archive


9.7

Insulating coupling test forms

CC

Service life

Electronic or Paper

Archive


9.8

Instrument calibration certificates

CC

2 years

Paper

Archive


9.9

Launcher and receiver inspection form

CC

Service life

Electronic or Paper

Archive


9.10

Punch list

PE

(See remarks)

N/A

N/A

Retained until actions cleared.

9.11

CP Installation inspection report

CC

Service life

Paper

Archive


9.12

Construction drawings

CC

(See remarks)

N/A

N/A

Retained until master drawings are updated.

9.13

Misc. site correspondence, records, MOM etc.

CC

Project completion

N/A

N/A

Selected documents of contractual significance may be archived for 2 years.

10.0

Vendor Documents

10.1

Vendor drawings for end closures, insulating couplings, barred tees

Vendor

Service life

Electronic or Paper

Archive


10.2

Material certification, reports and test data for linepipe and fittings.

Vendor/TPI

Service life

Electronic or Paper

Archive

Archived items to be referenced in EDMS. Surplus material documentation held by TSP.

10.3

Material certification, reports and test data for static and rotating equipment

Vendor/TPI

Service life

Electronic or Paper

Archive


10.4

Certification, reports and test data for surplus materials

Vendor/TPI

Until required

Electronic or Paper

Archive


10.5

Operating instruction manuals

Vendor

Service life

Electronic or Paper

Archive


10.6

Maintenance instruction manuals

Vendor

Service life

Electronic or Paper

Archive


10.7

SPIR forms

Vendor

Service life

Electronic or Paper

Archive


Abbreviations CC

SP-1208

Construction Contractor

Page 67


Remarks Location

Originator * valves,

Keep As-Built

Storage format

9.3

Document Category

Custodian **

Retention time


**

DC

Design Contractor

PE

Project Engineer (Company)

SC

Specialist Contractor

TPI

Third Party Inspector

The Project Engineer shall distribute the documents to the respective Custodians as per Company policy.

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Remarks Location

Keep As-Built

Retention time

Custodian **

Originator *

Document Category

Storage format

Version 2.0


Version 2.0


APPENDIX E

LIST OF TYPICAL DRAWINGS FOR PIPELINE CONSTRUCTION

Sr. No.

Sketch No.

Rev.

Drawing Title

1

TYP-3-0001-001

O

ROW and working strip details

2

TYP-3-0002-001

O

Trench Dimensions

3

TYP-3-0003-001

O

Cold field bending details

4

TYP-3-0004-001

O

Road crossing over existing above ground pipeline

5

TYP-3-0005-001

O

Road crossing over existing under ground pipeline

6

TYP-3-0006-001

O

Pipeline crossing tarmac road

7

TYP-3-0007-001

O

Live stock passageway crossing

8

TYP-3-0008-001

O

Pipeline crossing Wadi Type A

9

TYP-3-0009-001

O

Pipeline crossing Wadi Type B

10

TYP-3-0010-001

O

Pipeline crossing Wadi Type C

11

TYP-3-0011-001

O

Pipeline crossing existing above ground pipeline

12

TYP-3-0012-001

O

Pipeline crossing existing under ground pipeline

13

TYP-3-0013-001

O

Pipeline crossing existing under ground cables

14

TYP-3-0014-001

O

Pipeline in parallel transmission line

15

TYP-3-0015-001

O

Retaining Barriers in sloping trenches

16

TYP-3-0016-001

O

Pipeline Markers & signs

17

TYP-3-0017-001

O

GRE pipeline crossing road

and

crossing

high

voltage

The drawings are for information only.

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•

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NOTES:

A

A TYPICAL ROAD CROSSING OVER EXISTING UNDER GROUND PIPELINE

SECTION A-A

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APPENDIX F

CONSTRUCTION REQUIREMENTS FOR GRE PIPELINES

1.

Introduction

1.1

Background and Scope This Appendix specifies additional requirements for the construction of all new GRE pipeline systems in PDO operations. Construction of LLRTP and LLGRE pipelines shall be carried out as per requirements provided by the vendor and approved by the Company. The numbering system in this Appendix is designed to allow for easy reference back to the main text by using the same numbering system contained therein. Wherever applicable, only additional requirements and modifications pertaining to construction of GRE pipelines are given in this Appendix. Activities that are largely common to both material groups, e.g. HSE, clearing, trenching etc., are included in the main text of this specification. Whilst these general topics may be applied to the installation of any non-metallic linepipe material, including thermoplastic liners, specific requirements and guidelines in the current version of this Appendix are primarily concerned with GRE pipelines. Apart from PE linings, GRE is the only non-metallic pipe material which has been used by PDO for Class 1 pipelines in Hydrocarbon service. PE lining and RTP linepipe have been in regular use for Class 2 pipelines (mostly flowlines) for a number of years. Current PDO specifications DEP 31.40.30.34 / ERD 43-15 and ERD 43-16 apply for procurement and installation of these materials. GRE pipelines shall be installed in accordance with this specification and ISO 14692-4, taking due account of the limitations noted in the GRE linepipe purchase requisition and associated stress analysis executed by the GRE linepipe vendor.

2.

Specification Requirements

2.2

Quality Assurance

2.2.3

Quality Assurance Team

2.2.3.1 Personnel The Head of Quality Assurance shall have a detailed knowledge of installation and inspection of GRE pipelines. He shall have general experience in quality assurance matters and be suitably qualified. 2.2.3.2 Organisation Contractor’s supervisors and all manufacturer’s representatives of GRE pipe vendor, field service engineers working for the Contractor under EPC contracts shall report directly to the Head of Quality Assurance on quality assurance matters. (Under non-EPC contracts the pipe vendor representatives and, if applicable, other manufacturer’s representatives for other Company supplied materials, shall report to the Company CSR).

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2.3

Materials Handling and Control

2.3.2

General Contractor shall confirm to the Company at an early stage in the project that the testing methods of factory made GRE spools, piping and fittings are acceptable for installation. The Company shall review and approve the test results prior to start of construction.

2.3.3

Pipe Inspection

2.3.3.1 The Contractor shall visually inspect and dimensionally check each pipe and fitting. For Company supplied materials, the inspection shall be done before removal of the material from the Company’s storage yards. Whereafter the Contractor shall accept responsibility for all material losses and damage however caused. The inspection shall include a detailed check for damage or dimensional non-conformances of bells and spigots. Any shortages, dimensional non-conformance, missing end protectors or damage, including scratches, gouges, crushing, cracking etc. shall be reported to the Company within 24 hours of receipt. 2.3.4

Pipe Handling

2.3.4.1 Pipe shall not be allowed to drop or strike objects which may damage the pipe but shall be lifted, moved and lowered from one position to another by suitable equipment. Nonabrasive wide nylon or canvas pipe slings of minimum width 200mm shall be used for lifting pipe. Chains, cables or clamps shall not be used. 2.3.4.2 Trucks used to transport pipes shall be flat-bottomed and free of any projections or loose materials that might damage or contribute to movement of the pipe during transport. Pipes shall be protected against truck beds and side metallic protrusions by means of non-metallic soft materials. Pipes shall be loaded and stacked on trucks in such a manner that flexing and shifting of the pipe during transport is avoided. After loading, suitable non-metallic slings shall be used to tie the load securely to the truck. During transport the tension of these slings shall be regularly checked. The Contractor shall ensure that no pipe end protectors can be lost during transport. Pipes shall only be transported on trucks (sidebooms and other lifting equipment shall not be used to transport pipe on site for distances in excess of 50 meters). 2.3.5

Pipe Stacking

2.3.5.1 Ground surfaces to be used for stacking of pipe shall be reasonably flat. Pipe shall not be laid directly on the ground, concrete floors or on to rails. Pipes shall be laid on suitable supports, such as timber of 100mm x 50mm section. End protectors shall remain in place during storage and care shall be taken to ensure adjacent socket and spigot ends are kept out of contact. End protectors may be punctured with a 5mm drill to prevent them blowing off the pipes. 2.3.5.2 Pipes may be stacked to a height of 1.5m provided suitable supports are provided both at the sides of the stack and between layers. Typically, 100mm x 50mm timber (spacer stripping) may be used for both purposes. Supports between layers should be in vertical alignment, located no more than 3m apart and a minimum of 1m from the pipe ends. Where strapping down of stacks is necessary, nylon straps should be used, and for long storage periods a suitable cover should be fitted on each stack. Additionally, the Contractor shall comply with GRE pipe manufacturer’s recommendations for pipe stacking. In the case of a conflict or ambiguity, the Company will determine which requirements shall apply.

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2.3.5.3 Pipes of different diameter, wall thickness, pressure class, material grade or manufacturer shall be stacked separately. Each stack shall be properly marked to the satisfaction of Company.

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2.3.6

Handling and Control of Consumable Products

2.3.6.1 Adhesives, resins and additives shall be stored in accordance with the manufacturer’s written instructions in a cool air conditioned area, away from direct sunlight and excessive humidity. Adhesives shall be kept in refrigerated conditions if the storage period is in excess of one month, or as specified by the manufacturer, whichever is shorter. Contractor shall demonstrate compliance with site storage procedures for all consumables in accordance with detailed consumable handling procedures. A continuous record of temperatures of adhesive storage conditions shall be maintained. 2.3.6.2 For reasons of safety, hardeners, catalysts and accelerators shall be stored separately in accordance with manufacturer’s instructions. Solvents shall be similarly segregated as required by the relevant Material Safety Data Sheets. 2.3.6.3 No consumables shall be stored or used beyond its stated shelf life. 2.3.6.4 GRE fittings shall be stored inside or in their original crates out of direct sunlight.

2.4

R.O.W. and Trenching

2.4.3

Trenching

2.4.3.2 Excavation d) The Contractor shall excavate and grade the trench sufficiently deep and wide to provide a minimum of 500 mm working space on both sides of the pipe (where jointing is done in the trench) and space for 150 mm of padding material after compaction all around the pipe and for the continuous length of the pipeline. The trench profile after excavation shall be such that the radius of curvature in any plane is greater than the minimum allowable bending radius specified by the linepipe vendor. Local high and low points in the trench bottom shall be levelled off to provide a smooth continuous profile. The Contractor’s surveyor shall survey the trench and submit a formal report with photographs, survey data and a detailed profile drawing with invert levels at 12 m spacing, providing evidence that this requirement is achieved. i)

SP-1208

The Contractor shall do hand work in the trench as is necessary to free the bottom of the trench of loose rock, stones and all other irregularities so as to leave the trench bottom in a clean and suitable condition to receive the pipe. A fulltime dedicated crew shall be employed by the contractor to maintain the trench in a rockfree condition before and after pre-padding has been installed, at all times until the trench is completely backfilled.

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2.5

Pipe Stringing and Bending

2.5.3

Bends

2.5.3.1 Small changes in direction, in the vertical as well as the horizontal plane, may be achieved by elastic bending, provided the bend radius is greater than the specified minimum elastic bending radius specified by the pipe manufacturer for the supplied linepipe. Where this is not possible, e.g. due to right-of-way restrictions, fabricated elbows shall be used, as specified in the design drawings and approved by the linepipe manufacturer and the Company. Special attention is required at transitions between above ground and buried installation to avoid elastic bending. At locations where the pipeline comes above ground, the bottom of the trench shall be flat for a minimum distance of 25 m. In this section, elastic bends are not permitted. Any changes to the design layout of the pipeline, including moving of bend locations shall be subject to written approval of the Company and the linepipe manufacturer. This may require revised stress analyses to be executed for the pipeline. 2.5.3.2 To allow for large expansion at bends such as those caused by wide temperature fluctuations or hydrotest conditions, expansion cushions shall be installed as per design behind each bend and extending to approximately 5 m each side of the bend. However, it is required to accommodate the expansion of bends through proper design and stress analysis.

2.6

Jointing

2.6.1

This section of the specification covers requirements for the jointing of GRE pipelines. The requirements for qualification and production jointing of all types joints including laminated joints are specified in ISO 14692-4.

2.6.2

The Contractor shall prepare a Method Statement covering the jointing work to be carried out and a detailed procedure for each type and size of joint and fitting to be joined. These shall be in accordance with the Manufacturer’s instructions, Company specification and standards. Separate procedures shall be prepared for shop fabrication, site jointing work and repair work. All joint types shall be qualified and approved by the Company before its use in production joints.

2.6.3

In order to ensure piggability of the pipeline during hydrotest water filling, in service and for future decommissioning work using foam pigs, particular attention shall be paid to the need for effective internal cleaning of each completed GRE adhesive bonded joint after fit-up, and prior to curing, in order to ensure that no significant amount of adhesive protrudes from the inside seam of any glued joint. Reference is made ISO 14692-4 table 4.where it is specified under possible defects – excess adhesive shall not be more than 5% of inner diameter or 10mm which ever is less. The Contractor shall propose a method for cleaning the internal joints for Company review and approval in his detailed jointing procedure.

2.6.4

Each joint shall be inspected and certified by the QC Engineer to have been executed in accordance with the approved jointing procedures. Inspection or witnessing of the make up of any joints by the manufacturer’s field service engineer shall not absolve the Contractor of his responsibilities to provide a fit for purpose joint. As a minimum, the Contractor shall keep detailed records of make up and curing time, batch number of adhesive components as well as jointer ID and date/time for each joint.

2.6.5

Jointed pipes shall not be moved or handled during curing.

2.6.6

No more than 3 km of pipe shall be jointed prior to successful completion of the hydrotest of the first section of 50 joints of installed pipeline.

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2.6.7

All documents shall be submitted to the Company for approval. Procedures and operators shall be qualified to the requirements of the controlling specifications before commencement of any production jointing.

2.8

Lowering-in, Backfilling and Reinstatement

2.8.2

Pre-Padding

2.8.2.1 All trenches shall be fully pre-padded before lowering in or jointing in the trench. No padding shall be placed until Company has inspected and approved the trench bottom and the Contractor’s surveyor has confirmed that the trench bottom profile complies with the pipe manufacturer’s minimum bending radius requirements. 2.8.3

Lowering-in and Post-Padding

2.8.3.1 All pipes shall be lowered in within 96 hours of completion of jointing. The Contractor shall keep the lowering in operation within 1 km of the jointing operation. 2.8.3.3 A minimum of 3 sidebooms shall be used for lowering in strings of jointed pipe in excess of 50 meter. Cranes shall not be used for lowering in operations of pipe strings longer than 50 meters. The trench shall be maintained in a dry condition during lowering-in and backfill operations. During lowering in operations the pipe shall not be subject to bending in excess of the minimum allowable bending radius. A detailed procedure specifying the means of demonstrating compliance with the minimum bending radius requirement shall be submitted as part of the Contractor’s installation procedures, for Company approval, at least 3 weeks prior to the planned commencement of any lowering in operations. 2.8.3.4 The Contractor shall take measures to restrain the pipe in the trench by means of ‘plugging’, i.e. placing sand on top and around the pipe at regular intervals (one 6m ‘plug’ in the middle of every pipe) or by a Company approved equivalent method. The Contractor shall plan the work such that the lowering in and ‘plugging’ operations take place together during the coolest part of the day, (i.e. in the morning). Strings longer than 100 meter shall not be allowed to lie in the trench without sand plugging. This is to avoid ‘snaking’ and abrasion of the pipe due to thermal movement. 2.8.3.5 Sand padding ‘plugs’ shall be placed around and above the pipe, so as to fill the trench to a depth of 300 mm above the crown of the pipe, with the sand padding shaped to its natural angle of repose and with a minimum of 150 mm at any point around the pipe. No pipe shall be left overnight in the trench without sand padding around and above the pipe. (Joints shall be left fully exposed around the joint circumference for inspection until completion and acceptance of the hydrotest) 2.8.4

Tie-ins

2.8.4.1 Unless otherwise agreed by the Company, tie-ins of the pipeline sections shall take place in the trench by means of the same type of connections as the pipeline or if the pipeline connections are not of bonded type, by means of glued connections, using couplings if necessary. For tie-ins outside or above the trench, holding and lowering operations shall be undertaken in such a manner as to minimise stresses and bending in the pipe and avoid movement of the pipe from the skids. Due consideration shall be given to ambient temperature changes throughout the day and the resultant pipe length changes and induced stresses. 2.8.4.2 To minimise excessive internal protrusion of adhesives in bonded tie-in connections, care shall be taken not to place excess amounts of adhesive near the end of the bell, and to use the tip of the spigot to locate no more than the minimum required amount of adhesive at the internal joint seam location.

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2.8.4.3 All tie-in connections to metallic systems shall be by means of flanged connections. Tieins to other GRE pipe systems may be made by flanged connections or by means of bonded couplings. 2.8.5

Backfilling

2.8.5.1 The trench shall not be backfilled until the Company has approved the sand padding around and above the pipe and has confirmed its approval for the backfilling operation to commence. Backfilling shall be performed as soon as possible after padding has been approved, but not prior to the successful completion of the hydrotest. 2.8.7

Livestock Passageways Unless otherwise indicated on the drawings, livestock passageways shall be installed at intervals of approximately 2 km and may be combined with graded road and track crossings. The livestock passageways shall be constructed by means of a cased pipeline crossing in accordance with drawing TYP-3-0017-001 buried at a minimum depth of 1500 mm to the top of the casing pipe. The width of the crossing shall be 2.5 m and the total length shall be 6.5 m. Access barriers shall be installed on the ends of the crossing to indicate the safe crossing width of the livestock passageway for light vehicles.

2.8.9

Anchor Blocks & Thrust blocks

2.8.9.1 The need for concrete anchor or thrust blocks in the pipeline system will be determined during detailed design, depending on the expected operational pressure surges, temperature changes, nature of the ground and the geometry of the pipeline layout. Approval shall be obtained from the relevant linepipe and fittings manufacturers, if changes are required. 2.8.9.2 Anchor blocks should normally be located in line with fittings, tie-ins to steel pipe and to exposed runs of pipe. The concrete should be poured in situ on to undisturbed or compacted soil. Where parts of the pipe or fitting joints are to be encapsulated by the block, hydrostatic pre-testing of the joint assembly should be completed first. Alternatively blocks may be cast before pipe laying and the pipes fastened with brackets inlaid with an elastomeric strip. All anchor blocks shall be installed and cured prior to commencement of any hydrotesting activities on the pipeline. 2.8.9.3 For GRE lines, a layer of elastomeric material 6 – 10 mm thick shall be wrapped around sections of pipes or fittings before concrete is applied. Concrete shall not be poured directly on to unprotected GRE surfaces. 2.8.9.4 No more than half the circumference of the pipe or fitting shall be cast into the concrete thrust block. Thrust block casting around entire fittings or joints shall be avoided.

2.9

Road and Wadi Crossings

2.9.2

Road Crossing with Casing Where GRE pipelines are required to cross under roads and highways, the pipe shall be protected by installation within a steel or HDPE casing pipe with a minimum cover of 1500 mm to the top of the casing pipe. Detailed installation methods of cased pipe shall be in accordance with the Manufacturer’s recommendations for the particular pipeline material and shall be agreed with the Company. The following requirements shall apply for GRE pipe: •

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covered by standard drawing TYP-3-0017-001. Signs indicating maximum axle loadings shall be provided at each crossing.

2.9.3

•

The assembled pipeline section in crossing shall be subjected to an air leak tightness test before its installation into the casing.

•

Cased pipes shall be fitted with spacers (minimum 4 per pipe length at a maximum spacing of 3000 mm) to ensure the pipe is centred and to prevent damage during installation.

•

The ends of the casing shall be sealed with flexible bellows of approved design to be fitted over the casing ends and the pipe to prevent influx of backfill material into the annulus. Filling the entire annular space with polyurethane foam is also acceptable.

•

Steel casing pipe shall be externally coated to prevent corrosion, with a Company

•

Prior to backfilling, suitable devices may be attached to both carrier pipe and casing pipe on each side of the crossing to enable monitoring of differential movement between the casing and the carrier pipeline.

Wadi-Crossings All wadi crossings in GRE pipelines shall be through steel or HDPE casings with sufficient negative buoyancy to prevent the casing and pipe from floating in empty condition. Continuous buoyancy compensation and impact protection may be provided by means properly designed concrete coating of the casing pipe along the full length of the Wadi crossing. Casings shall be externally protected against corrosion using an appropriate coating system. Requirement for installation of the GRE pipe into the casing is covered in 2.9.2, above. Concrete coating of the casing pipe is required in accordance with Section 2.10 of the main text.

2.15

System Hydrotesting and Certification

2.15.1 Scope 2.15.1.1 On completion of installation, the GRE pipeline system shall be flushed, hydro tested and certified in accordance with DEP 31.40.10.19, ISO-14692-4 and this specification. 2.15.1.2 The testing of each test section shall commence as soon as possible and, so far as is practicable within the programme, shall be undertaken progressively throughout the construction of the line. The first 500 meter of jointed pipe shall be tested within two weeks of completion in order to provide confidence that the workmanship and installation procedures are fit for purpose. If the 500 meter section hydrotest is satisfactory, then the lengths of each subsequent test section shall be decided by the Contractor. If the test on the first 500 meter fails, then the next 500 meter section shall also be tested separately. The pipeline shall be tested in 500 meter sections until such time that the Contractor demonstrates his ability to install a 500 meter section without hydrotest failures. 2.15.1.3 Only soft foam pigs shall be used for cleaning, filling and dewatering of GRE pipelines. 2.15.1.4 No gauging of GRE pipelines is required as online pigging is not envisaged for GRE pipelines. 2.15.2 Hydrostatic Testing

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The minimum requirements of hydrostatic testing operations relating to safety, materials and equipment used, cleaning, filling, temperature stabilisation, pressurisation, air content verification, testing, depressurising, dewatering and hydrotest documentation applicable for metallic pipelines (SP-1212) shall also be reviewed and taken into account when preparing the hydrotest procedures for GRE pipelines. Any ambiguities or lack of clarity between these requirements specified and the requirements of DEP 31.40.10.19 shall be identified to the Company for the purposes of specification improvement. However, in the case of clearly contradictory requirements (e.g. tightness test calculations), the additional requirements of this specification shall prevail over other specifications. 2.15.2.1 Short term Strength Test The pipeline shall be subjected to one(1) hour strength test to a pressure equal to 1.5 times the design pressure. The pressure shall be maintained at the test pressure + 100 kPa by bleeding or adding water as required. If a leak is suspected the pressure shall be reduced to the pipeline design pressure before carrying out a visual examination. No personnel shall come closer than 5 meters from the pipeline before the pressure has been reduced to design pressure. Subsequently, a “step test” shall be performed. In this test the test section shall be repressurised to the leak tightness test pressure and after each hour the pressure shall be recorded and the section re-pressurised by adding water. The quantity of water required to bring the section back to the test pressure shall be recorded. This shall continue for a period of 24hours. If the quantity of water added shows a decreasing trend then it may be considered that the pipeline is tight. If the quantity of water added remains constant then it must be assumed that the pipeline is not leak tight. No work shall be carried out to repair leaks until the pressure has been reduced to a safe pressure i.e. static head plus 100 kPa. During the test, deadweight tester readings shall be recorded every 30 minutes and pipe, soil and air temperature recorded every 1.5 hours. 2.15.2.2 Tightness Test The pipeline shall be subjected to a 24 hour tightness test, immediately following the strength test, at the pressure indicated on the drawings. (This should be 110% of design pressure). No water shall be added or removed during the test. The test shall demonstrate, to Company’s satisfaction that there are no leaks in the pipeline. This shall be achieved by visual inspection of each joint every 4 hours during the hydrotest period. A tightness test check calculation shall be made to verify that no large leaks have been missed. Allowance shall be made for instrument inaccuracies and also the pressure changes as a result of average temperature changes, calculated from the formula given in DEP 31.40.10.19 (assuming a fully restrained line section). The average temperature of the pipe may be used for this calculation. The temperature measurements taken on the exposed pipe may be included in determining the average pipe temperature. In the event of there being any doubt about the tightness of the line, as determined from the visual inspections, the test shall be extended or repeated to Company’s satisfaction at no additional cost to Company. The tightness test calculation shall be provided to the Company for information. During the test, the pressure shall be recorded continuously, deadweight tester readings shall be recorded every 30 minutes and pipe, soil and air temperatures recorded at maximum 3 hour intervals. The temperature recording interval shall be reduced to 30 minute duration for the first and last 2 hours of the 24 hours to assist with the pressure/temperature variation check calculation.

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2.15.3 GRE and Steel Station Pipework Station Pipework shall be subjected to a combined strength/tightness test of 4 hour duration, at the test pressure shown on the Drawings. The first one hour of the test shall not exceed a pressure 1.5 times the design pressure of any GRE component. The remainder of the test shall not exceed 1.1 times the design pressure of any GRE component. The pipework may be tied-in and retested as part of a pipeline section in order to avoid an additional test head, an additional tie-in joint or bulk water loss etc.

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USER COMMENT FORM If you find something that is incorrect, ambiguous or could be better in this document, write your comments and suggestions on this form. Send the form to the Document Control Section (DCS). They make a record of your comment and send the form to the correct CFDH. The form has spaces for your personal details. This lets DCS or the CFDH ask you about your comments and tell you about the decision. Procedure Details

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