SP 1208 Pipeline - Construction - Specification - (PCS-01)

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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September 2005
Version 2.0
TABLE OF CONTENTS
1 Introduction.............................................................................................................................. 5
1.1
Purpose...................................................................................................................... 5
1.2
Changes to the Specification.....................................................................................5
1.3
Conflicting Requirements........................................................................................... 5
1.4
Exceptions.................................................................................................................. 5
2 Specification Requirements................................................................................................... 6
2.1
Health, Safety and Environment (HSE).....................................................................6

2.1.1
Scope.......................................................................................................................... 6
2.1.2
General........................................................................................................................ 6
2.1.3
HSE Advisor................................................................................................................ 6
2.1.4
Specific Pipeline Activities............................................................................................7
2.2
Quality Assurance...................................................................................................... 7
2.2.1
Scope.......................................................................................................................... 7
2.2.2
General........................................................................................................................ 7
2.2.3
Quality Assurance Team.............................................................................................7
2.2.4
Company Inspection....................................................................................................9
2.3
Materials Handling and Control................................................................................10

2.3.1
Scope........................................................................................................................ 10
2.3.2
General......................................................................................................................10
2.3.3
Pipe Inspection..........................................................................................................10
2.3.4
Pipe Handling.............................................................................................................11
2.3.5
Pipe Stacking.............................................................................................................11
2.3.6
Linepipe Specifications..............................................................................................11
2.3.7
Inspection of Materials other than Pipe.....................................................................12
2.3.8
Handling of Materials other than Pipe.......................................................................12
2.3.9
Reconciliation............................................................................................................12
2.4
R.O.W. and Trenching.............................................................................................. 13

2.4.1
Pipeline Right-of-Way and Working Strip..................................................................13
2.4.2
Staking, Clearing and Grading..................................................................................14
2.4.3
Trenching................................................................................................................... 17
2.5
Stringing and Bending.............................................................................................. 20

2.5.1
Scope........................................................................................................................ 20
2.5.2
Stringing.................................................................................................................... 21
2.5.3
Pipe Bending.............................................................................................................21
2.6
Welding and NDT..................................................................................................... 22

2.6.1
Scope........................................................................................................................ 22
2.6.2
Off-Plot Pipelines.......................................................................................................22
2.6.3
On-Plot Pipework......................................................................................................23
2.7
Anti-Corrosion Field Joint Coating...........................................................................23

2.7.1
Scope........................................................................................................................ 23
2.7.2
Materials.................................................................................................................... 23
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2.7.3
Surface Preparation..................................................................................................24
2.7.4
Shrink Sleeve Application..........................................................................................24
2.7.5
F.B.E. Application.......................................................................................................25
2.7.6
Coating Repairs.........................................................................................................26
2.7.7
Testing, Inspection and Acceptance..........................................................................27
2.8
Lowering-In, Backfilling and Reinstatement.............................................................30

2.8.1
Scope........................................................................................................................ 30
2.8.2
Pre-Padding..............................................................................................................30
2.8.3
Lowering-in and Post-Padding..................................................................................30
2.8.4
Tie-ins........................................................................................................................31
2.8.5
Backfilling................................................................................................................... 31
2.8.6
Stabilising Sand Areas...............................................................................................32
2.8.7
Livestock Passageways............................................................................................32
2.8.8
Reinstatement...........................................................................................................32
2.9
Road and Wadi Crossings........................................................................................ 33

2.9.1
Scope........................................................................................................................ 33
2.9.2
Road Crossings.........................................................................................................33
2.9.3
Wadi-Crossings.........................................................................................................34
2.10
Concrete Coating for Wadi Crossings......................................................................35
2.10.1
Scope........................................................................................................................ 35
2.10.2
General......................................................................................................................35
2.10.3
Concrete Materials....................................................................................................36
2.10.4
Application.................................................................................................................36
2.10.5
Curing........................................................................................................................ 38
2.10.6
Inspection and Testing...............................................................................................38
2.10.7
Concrete Coating Repairs.........................................................................................39
2.11
Permanent Markers and Barriers.............................................................................40
2.11.1
Scope........................................................................................................................ 40
2.11.2
General......................................................................................................................40
2.11.3
Chainage Markers.....................................................................................................40
2.11.4
Block Valve Station Markers.....................................................................................40
2.11.5
Road Crossing Markers............................................................................................40
2.11.6
Wadi Crossing Markers.............................................................................................40
2.11.7
Pipeline Crossing Markers........................................................................................41
2.11.8
Cable Crossing Markers............................................................................................41
2.11.9
Markers at Horizontal Bends.....................................................................................41
2.11.10
Cathodic Protection Markers.....................................................................................41
2.11.11
Pearson Survey Hole Marker....................................................................................41
2.11.12
R.O.W. `STOP` Signs...............................................................................................41
2.11.13
Corrosion Monitoring Pit Marker...............................................................................41
2.11.14
Access Barriers.........................................................................................................41
2.12
Station Works........................................................................................................... 42
2.12.1
SP-1208
Scope........................................................................................................................ 42
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2.12.2
Earthworks................................................................................................................42
2.12.3
Civil and Mechanical Works......................................................................................43
2.12.4
Painting......................................................................................................................44
2.12.5
Instrumentation..........................................................................................................44
2.12.6
Electrical Works.........................................................................................................45
2.12.7
Fencing...................................................................................................................... 45
2.13
Cathodic Protection.................................................................................................. 45
2.13.1
Scope........................................................................................................................ 45
2.13.2
Materials.................................................................................................................... 46
2.13.3
Installation..................................................................................................................46
2.13.4
Temporary Cathodic Protection.................................................................................47
2.13.5
Pearson Survey.........................................................................................................47
2.13.6
Commissioning..........................................................................................................47
2.14
Quality and Treatment of Hydrotesting Water..........................................................47
2.15
Hydrostatic Testing................................................................................................... 47
2.16
Precommissioning Of Pipelines...............................................................................47
2.16.1
Scope........................................................................................................................ 47
2.16.2
General......................................................................................................................47
2.17
Work on Live Pipe Systems.....................................................................................49
2.17.1
Scope........................................................................................................................ 49
2.17.2
General......................................................................................................................49
2.18
As-Built Records and Hand-Over Documentation....................................................49
2.18.1
Scope........................................................................................................................ 49
2.18.2
Storage Format.........................................................................................................49
2.18.3
Storage Location.......................................................................................................50
2.18.4
Pipeline As-Built Documentation................................................................................50
2.18.5
Documents................................................................................................................50
2.18.6
Test, Calibration and Inspection Reports..................................................................50
2.18.7
Material Certificates...................................................................................................50
2.18.8
As-built Drawings and Pipeline Data Sheets.............................................................50
2.19
Effective Period........................................................................................................ 51
2.20
Review and Improvement........................................................................................ 51
Appendix A
Glossary of Definitions, Terms and Abbreviations.......................................52
Appendix B
Reference Documents.................................................................................53
Appendix C
Facilities For Company Personnel..............................................................57
Appendix D
List of Handover and As-built Documentation.............................................60
Appendix E
List of Typical Drawings for Pipeline Construction.......................................65
Appendix F
Construction Requirements For GRE Pipelines..........................................83
User Comment Form............................................................................................................ 92
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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:
1.4
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.
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
Contractors expense.
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2
2.1
2.1.1
Specification Requirements
Health, Safety and Environment (HSE)
Scope
This Section of the Specification covers the minimum HSE requirements required during
installation work.
2.1.2
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 Contractors mobilisation, Contractor shall submit and obtain Companys
approval for the HSE Plans and Procedures for the Work, prior to any Work
commencing.
2.1.3
HSE Advisor
Contractor shall appoint one or more HSE Advisors, to be approved by the Company,
reporting directly to the Contractors 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 Contractors work and conditions are
in accordance with the Companys HSE Regulations.
The Contractors 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 Contractors Project Manager on each morning following
the reported day. A copy shall be handed to the Companys Site Engineer. The daily
report is in addition to those required by the Safety Regulations. Contractors Project
Manager shall advise the Companys 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 Contractors Construction camp/head office.
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2.1.4
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 Companys 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.
2.2
2.2.1
Quality Assurance
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.
2.2.2
General
Before starting the Work, Contractor shall submit his proposed quality assurance
procedures and organisation to the Company for Companys approval. Contractors
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.
2.2.3
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 Contractors Quality Assurance Engineer responsible for procedure preparation and
implementation, drawing and document control and supervision.
Required number of Contractors 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 Inspectors duties include but not limited to the following activities:
2.2.3.1
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
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 Contractors 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 Contractors inspectors shall have a dedicated
vehicle.
Following Companys 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
Companys sole discretion.
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2.2.3.2
Organisation
The Head of Quality Assurance shall report directly to the Contractors Project Manager.
His duties shall be to liaise with the Company, organise the Contractors 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 Contractors Inspectors.
Contractors 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.
2.2.4
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 Contractors 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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2.3
2.3.1
Materials Handling and Control

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.
2.3.2
General
2.3.2.1
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.
2.3.2.2
Contractors material control and storage procedure shall be submitted to the Company
within two weeks of the start of mobilisation on site, for approval.
2.3.2.3
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 Companys 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 Companys storage
yard on a weekly basis.
2.3.2.4
Contractor is required to supply lifting equipment for lifting materials at all locations.
Lifting equipment and operations shall be in accordance with SP-1239.
2.3.2.5
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.
2.3.2.6
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.
2.3.2.7
Contractors procedures for material receipt and return of surplus materials shall
conform to Companys materials procurement/administration procedures.
2.3.3
Pipe Inspection
2.3.3.1
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.
2.3.3.2
Prior to haulage of pipe from Companys 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 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 rebevelling.
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2.3.4
Pipe Handling
2.3.4.1
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).
2.3.4.2
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).
2.3.4.3
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 PDOs Transport Manual TOM/04/001, SP-2000 Road Transport and
government regulations.
2.3.5
Pipe Stacking
2.3.5.1
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 nonmetallic 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.
2.3.5.2
Epoxy-coated pipes shall be stacked during transport and storage using rubber or other
suitable separator strips.
2.3.5.3
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.
2.3.6
Linepipe Specifications
2.3.6.1
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.
2.3.6.2
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.
2.3.6.3
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.
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2.3.7
Inspection of Materials other than Pipe
2.3.7.1
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 Contractors own storage yard. Visual
inspection shall be adequate for this purpose.
2.3.7.2
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 Companys storage yard.
2.3.7.3
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.
2.3.8
2.3.8.1
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 Companys
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.
2.3.8.2
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.
2.3.8.3
During transport, materials shall be secured by suitable non-metallic non-abrasive

slings.
2.3.8.4
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.
2.3.8.5
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.
2.3.8.6
Distribution and supply of materials from Contractors storage yard to the worksites shall
be limited to quantities required for approximately one days production. Timing of the
issue of materials shall be as per the Company approved work schedule.
2.3.9
2.3.9.1
Reconciliation
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.
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2.3.9.2
2.4
2.4.1
2.4.1.1
On approval of the surplus list by the Company, Contractor shall return all surplus
materials to Companys storage yard.
R.O.W. and Trenching

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.
2.4.1.2
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.
2.4.1.3
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.
2.4.1.4
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.
SP-1208
Page 9
September 2005
Version 2.0
In the absence of any specific requirements by the Authorities, Contractor shall comply
with the Companys 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 2.4.3.2f)
of this specification.
2.4.2
2.4.2.1
Staking, Clearing and Grading

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.
2.4.2.2
2.4.2.3
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.
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)
SP-1208
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.
Page 10
September 2005
Version 2.0
ii)
2.4.2.4
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 (leftside) 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.
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.
Below and Aboveground Services
SP-1208
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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2.4.2.5
2.4.2.6
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.
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.
SP-1208
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September 2005
Version 2.0
2.4.2.7
2.4.3
2.4.3.1
2.4.3.2
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.
Trenching
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.
Excavation
SP-1208
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.
Page 13
September 2005
Version 2.0
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)
SP-1208
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.
Page 14
September 2005
Version 2.0
2.4.3.3
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.
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)
SP-1208
Where blasting is to be carried out at or more than 50 metres away

from any existing pipelines or structures (either above or below
ground), the Contractor shall submit his proposed blasting
procedure and perform a trial blast for Company approval.
Page 15
September 2005
Version 2.0
2.4.3.4
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.
2.4.3.5
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.
2.4.3.6
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.
2.5
2.5.1
Stringing and Bending

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.
SP-1208
Page 16
September 2005
Version 2.0
2.5.2
Stringing
2.5.2.1
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.
2.5.2.2
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.
2.5.2.3
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.
2.5.2.4
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.
2.5.2.5
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.
2.5.2.6
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.
2.5.2.7
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).
2.5.3
Pipe Bending
2.5.3.1
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 prepadded trench.
2.5.3.2
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 Companys approval. The
procedure shall include amongst others, step length, degrees per pull and method and
accuracy of measurement during pulling of the bend.
2.5.3.3
Elastic bends with radius of curvature less than 500 x D, D being the pipeline diameter
are not allowed unless approved by the Company.
SP-1208
Page 17
September 2005
Version 2.0
2.5.3.4
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
2.5.3.5
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.
2.5.3.6
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.
2.5.3.7
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 pipes 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).
2.5.3.8
2.6
2.6.1
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

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.
2.6.2
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).
SP-1208
Page 18
September 2005
Version 2.0
2.6.3
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.
2.7
2.7.1
Anti-Corrosion Field Joint Coating

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.
2.7.2
Materials
2.7.2.1
Only materials supplied by Company approved manufacturers shall be used in the

Work.
2.7.2.2
Contractor shall as a minimum follow manufacturers 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.
2.7.2.3
The materials, at time of application by the Contractor, shall not be older than the shelf
life stated by the manufacturers.
2.7.2.4
The coating materials shall be properly packed and clearly marked with:
SP-1208
The manufacturers name
Material qualification and identification
Batch number
Date of manufacture
Test certificates and test data
Storage temperatures
Material Safety Data Sheet
Page 19
September 2005
Version 2.0
2.7.2.5
Coating materials shall be kept dry and stored as long as possible in the manufacturers
original packaging, not exposed to direct sunlight, and in accordance with
manufacturers instructions.
2.7.2.6
The list of Company approved wrap-around shrink sleeves is given in the Approved
Vendors, Manufacturers and Equipments (AVME) list of the company.
2.7.3
2.7.3.1
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 mans handle so that the equipment will not operate
unless the handle is held.
2.7.3.2
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.
2.7.3.3
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.
2.7.3.4
The surface cleanliness shall conform to ISO 8502-1 to 4 and shall be such that the
2
chloride contamination is less than 20 mg/m .
2.7.3.5
Coating of the field joint shall not take place until the weld has been non-destructively
tested and approved by the Company.
2.7.4
Shrink Sleeve Application
2.7.4.1
Contractor shall propose the application procedure for Company approval. The
application procedure shall be in accordance with manufacturers 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.
2.7.4.2
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 Companys discretion. To check
that the required preheat temperatures have been achieved, a digital contact
thermometer shall be used.
2.7.4.3
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.
2.7.4.4
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.
SP-1208
Page 20
September 2005
Version 2.0
2.7.4.5
The installed sleeve shall be left undisturbed for 4 hours or until the adhesive has been
solidified, whichever is the longer.
2.7.4.6
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.
2.7.5
F.B.E. Application
2.7.5.1
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.
2.7.5.2
Contractor shall propose the application procedure for Company approval. The
application procedure shall be in accordance with manufacturers 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 Companys 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
Manufacturers representative shall be present on site full time during field applied
epoxy coating work.
2.7.5.3
The resin powder shall be stored in waterproof containers which are insulated and
cooled by refrigeration or air conditioning to a temperature not exceeding 27C.
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 85C, but must be returned to the normal storage
temperature below 27C at the end of the day. For any powder that has temporarily
experienced temperatures in excess of 27C, gel time tests as per manufacturers
recommendation must be carried out on each box of powder before use.
2.7.5.4
The area of the pipe to be coated shall be preheated by induction heating coil to a
maximum temperature of approximately 250C. The actual temperature range shall be
in accordance with the powder manufacturers 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.
SP-1208
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September 2005
Version 2.0
2.7.5.5
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.
2.7.5.6
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.
2.7.5.7
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.
2.7.5.8
The powder container, hoses, etc. on the application unit shall be cleaned after each
days work.
2.7.6
Coating Repairs
2.7.6.1
Coating repairs shall be executed on all coating damage and imperfections detected
visually or by holiday testing.
2.7.6.2
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.
2.7.6.3
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.
SP-1208
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September 2005
Version 2.0
2.7.6.4
2.7.7
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
2.7.7.1
The testing and inspection for acceptance of the coating system shall be carried out and
recorded by the Contractor as instructed and witnessed by Companys representative.
The frequency of testing as specified herein may be altered by the Company at
Companys sole discretion.
2.7.7.2
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.
2.7.7.3
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 manufacturers 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.
2.7.7.4
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.
2.7.7.5
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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September 2005
Version 2.0
2.7.7.6
2.7.7.7
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 manufacturers 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
manufacturers 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.
Fusion Bonded Epoxy Testing

a)
SP-1208
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.
Page 24
September 2005
Version 2.0
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 manufacturers 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 204C, 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).
2.7.7.8
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 Companys
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.
2.7.7.9
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 Contractors expense.
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2.8
2.8.1
Lowering-In, Backfilling and Reinstatement

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.
2.8.2
Pre-Padding
2.8.2.1
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.
2.8.2.2
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.
2.8.2.3
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 Contractors 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.
2.8.2.4
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.
2.8.3
Lowering-in and Post-Padding
2.8.3.1
Welded pipe strings shall be lowered-in within 96 hours of completion of joint coating.
2.8.3.2
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.
2.8.3.3
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.
SP-1208
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September 2005
Version 2.0
2.8.3.4
The trench shall be maintained in a dry condition during lowering-in and backfill
operations.
2.8.3.5
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.
2.8.3.6
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.
2.8.3.7
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.
2.8.4
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.
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 approved starting the backfilling operation.
Backfilling shall be performed as soon as possible after padding has been approved.
2.8.5.2
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 Companys
satisfaction. The backfill around all underground services shall be thoroughly compacted
by hand.
2.8.5.3
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.
2.8.5.4
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
Companys 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.
SP-1208
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September 2005
Version 2.0
2.8.5.5
Trenches crossing ditches shall be backfilled with the material excavated from the
trench at the location. If the excavated material, in Companys 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.
2.8.5.6
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.
2.8.5.7
2.8.6
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).
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 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.
2.8.8
Reinstatement
2.8.8.1
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.
2.8.8.2
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.
SP-1208
Page 28
September 2005
Version 2.0
2.8.8.3
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.
2.8.8.4
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 Contractors operations to
approval of the Company.
2.8.8.5
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 Contractors operations.
2.8.8.6
Construction roads, used at escarpments, may be required by the Company to be left as

they are.
2.8.8.7
Construction markers shall not be removed, unless requested by the Company.
2.8.8.8
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 Companys satisfaction.
2.9
2.9.1
Road and Wadi Crossings

Scope
This Section of the Specification covers the minimum requirements for road and wadi
crossings as required for the work.
2.9.2
Road Crossings
2.9.2.1
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.
2.9.2.2
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.
2.9.2.3
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.
2.9.2.4
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.
2.9.2.5
Contractor shall comply with the following minimum requirements of the Directorate
General of Roads for major road crossings:
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.
SP-1208
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September 2005
Version 2.0
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.
2.9.3
2.9.3.1
Wadi-Crossings
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 wadis 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.
2.9.3.2
Wadi crossings shall be installed to meet at all times the requirements and conditions
issued by the Authorities having jurisdiction in the area.
2.9.3.3
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.
2.9.3.4
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.
2.9.3.5
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.
SP-1208
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September 2005
Version 2.0
2.9.3.6
2.10
2.10.1
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

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.
2.10.2
General
2.10.2.1
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.
2.10.2.2
The concrete shall have a minimum dry density of 2400 kg/m 3 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/mm 2 at 7 days and 30 N/mm 2 at 28 days.
2.10.2.3
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.
2.10.2.4
The concrete coating of line pipe shall be applied either in an approved coating plant or
in the field, at Contractors 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;
inspection and testing (including procedures and pro-forma)
Page 31
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2.10.3
Concrete Materials
2.10.3.1
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.
2.10.3.2
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.

2.10.3.3
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.
2.10.3.4
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.
2.10.4
2.10.4.1
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.
SP-1208
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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 manufacturers 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.
2.10.4.2
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.
2.10.4.3
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.
2.10.4.4
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 32C.
2.10.4.5
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 35C.
2.10.4.6
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 years 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.
2.10.4.7
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.
2.10.4.8
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.
SP-1208
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2.10.5
Curing
2.10.5.1
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.
2.10.5.2
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.
2.10.5.3
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.
2.10.6
Inspection and Testing
2.10.6.1
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.
2.10.6.2
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.
2.10.6.3
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.
2.10.6.4
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.
SP-1208
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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.
2.10.6.5
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.
2.10.6.6
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%).
2.10.6.7
Effective electrical separation between reinforcing steel and pipe shall be determined for
each pipe joint by electrical tests.
2.10.7
Concrete Coating Repairs
2.10.7.1
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.
2.10.7.2
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 m 2 and less than
0.33 m 2 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 m 2 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.
2.10.7.3
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.
SP-1208
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2.10.7.4
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.
2.11
2.11.1
Permanent Markers and Barriers

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.
2.11.2
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.
2.11.3
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.
2.11.4
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.
2.11.5
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.
2.11.6
Wadi Crossing Markers

Wadi crossing markers shall be installed at both sides of each wadi crossing.
SP-1208
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2.11.7
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).
2.11.8
Cable Crossing Markers

Cable crossing markers shall be installed at each crossing with an existing underground
cable.
2.11.9
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.
2.11.10
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.
2.11.11
Pearson Survey Hole Marker

A marker shall be installed adjacent to each Pearson Survey earthing hole. Ref. GEN2-1632-01.
2.11.12
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.
2.11.13
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.
2.11.14
Access Barriers
2.11.14.1
When specified on the drawings, access barriers shall be constructed in accordance with
Standard Drawing GEN-2-1633-01.
2.11.14.2
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.
2.11.14.3
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.
SP-1208
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2.12
2.12.1
Station Works
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.
2.12.2
Earthworks
SP-1208
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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2.12.3
2.12.3.1
2.12.3.2
Civil and Mechanical Works

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.
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.
2.12.3.3
Structural Steel
All structural steelworks shall be in accordance with SP1279-G.
2.12.3.4
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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2.12.4
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.
Painting
a)
All above and below ground steel surfaces (with the exception of
polyethylene or epoxy coated pipework and items supplied in a
manufacturers 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
black/yellow
Handrails
black
(In special instances Camouflaged paint may be required).

e)
2.12.5
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.
SP-1208
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2.12.6
2.12.7
2.13
2.13.1
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:
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
Impresssed Current Cathodic Protection
2.13.1.1
2.13.1.2
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.
2.13.1.3
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.
2.13.1.4
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.
SP-1208
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2.13.2
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:
2.13.3
SP-1129 (Construction, Installation and Commissioning)
SP-1130 (Materials and Equipment)
SP-1136 (Standard Drawings)
PR-1234 (Safe Working Procedures)
Installation
2.13.3.1
Installation of the C.P. System shall be carried out concurrently with the main pipeline
laying work.
2.13.3.2
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.
2.13.3.3
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.
2.13.3.4
All C.P. testing facilities shall be installed in accordance with SP-1129.
2.13.3.5
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).
2.13.3.6
Current Measuring Stations shall be installed on the pipeline every 10 km, unless shown
otherwise on the drawings (Ref. STD-7-3004).
2.13.3.7
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).
SP-1208
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2.13.3.8
Drain Point Facilities shall be installed as shown on the Drawings (Ref. STD-7-3003).
2.13.3.9
Insulating joints/flanges shall be installed in accordance with Drawings (Ref. STD-73007).
2.13.3.10
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.
2.13.3.11
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).
2.13.4
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.
2.13.5
Pearson Survey
2.13.5.1
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 Contractors expense.
2.13.5.2
These earthing points shall be constructed during the main pipelay work, in accordance
with drawing GEN-2-1633-01.
2.13.6
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.
2.14
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.
2.15
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.
2.16
2.16.1
Precommissioning Of Pipelines
Scope
SP-1208
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September 2005
Version 2.0
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.
2.16.2
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.
2.16.2.1
Contractor shall make detailed proposals, for Company approval, for the
precommissioning work including but not limited to detailed procedures, programme and
schedule for Work. Contractors proposals shall include complete information regarding
the following aspects:
SP-1208
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.
Page 44
September 2005
Version 2.0
2.17
2.17.1
Work on Live Pipe Systems

Scope
This Section of the Specification covers the minimum requirement for work on live pipe
systems as required for the Work.
2.17.2
General
2.17.2.1
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.
2.17.2.2
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 vendors
representative shall be present at all times during the use of such tools and equipment.
2.17.2.3
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 SP1167.
2.18
2.18.1
As-Built Records and Hand-Over Documentation

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.
2.18.2
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.
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
SP-1208
Page 45
September 2005
Version 2.0
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.
2.18.3
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.
2.18.4
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.
2.18.5
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.
2.18.6
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.
2.18.7
Material Certificates
Contractor shall make available Mill and Test Certificates, where applicable, for all
materials supplied by Contractor and incorporated in the permanent facilities.
2.18.8
As-built Drawings and Pipeline Data Sheets
SP-1208
Page 46
September 2005
Version 2.0
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 manufacturers 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.
2.19
Effective Period
The requirements of this specification shall remain in force indefinitely unless
superseded by an authorised revision.
2.20
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
Page 47
September 2005
Version 2.0
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/Supplie
r
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
Page 48
August September 2005
Version 2.0
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
pipelines
and working around live
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
excavation
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
Page 49
Version 2.0
Specification for welding of Class 2 Pipelines (Flowlines)
SP-1208
Page 50
SP-1174
Version 2.0
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,
Programme (STOP)
SP-1259
Safety,
Training
Observation
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
Page 51
Version 2.0
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
Page 52
DEP 31.40.50.30-Gen
Version 2.0
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
SpecificationforLinepipe
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
Products Tests for the Assessment of Surface Cleanliness
Products - Surface Roughness Characteristics of Blast-Cleaned Steel
Substrates
Products - Specification for Metallic Blast-Cleaning Abrasives
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 Varemb
CH-1211 Geneva 20, Switzerland
SP-1208
Page 53
Version 2.0
APPENDIX C: FACILITIES FOR COMPANY PERSONNEL

C.1
Scope
This Section of the Specification covers the minimum requirements for facilities for
Company personnel at Contractors 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 Companys 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 Companys personnel, the minimum accommodation
requirements for each of Companys 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
SP-1208
Page 54
Version 2.0
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 Companys use shall be subject to Companys
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 Companys 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 Companys 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
SP-1208
Page 55
Version 2.0
C.4.3
The offices shall be interconnected. At each spread camp, the Contractor shall provide
and maintain for Companys sole use such materials and equipment (computer,
stationary, etc.) as may be required for the Companys clerical work at the camp.
C.4.4
As and when required, Contractor shall make available for Companys 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 Companys use shall be subject to
Companys 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 manufacturers local

representatives 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 Companys
Site Representatives 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.
SP-1208
Page 56
Version 2.0
1.1
Drawing control register
DC
(See remarks)
N/A
1.2
Pipeline inspection reports
CC
Service life
Electronic or Paper
1.3
Equipment reports
Vendor
Service life
Electronic or Paper
1.4
Operating manual
DC
Service life
Electronic
1.5
Design reference manual
DC
Service life
Electronic
1.6
Soil investigation report
SC
2 years
1.7
Environmental data
SC
2 years
1.8
Studies - feasibility/conceptual/ front end
DC
1.9
Technical audit/HAZOP reports
1.10
Close-out reports
2.0
General Drawings
2.1
Originator *
Remarks
Location
General Reports
Keep As-Built
1.0
Document Category
Custodian **
Storage format
LIST OF HANDOVER AND AS-BUILT DOCUMENTATION

Retention time
APPENDIX D:
N/A
Retained until drawings are as-built and stored in

EDMS.
Archive
Archived items to be referenced in EDMS.
Archive
EDMS
Essential data for each line held in PACER,

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

accessed via GIS
Paper
Archive
Storage reference in EDMS.
Paper
Archive
Project completion
(see remarks)
N/A
N/A
Conceptual data underlying chosen design options

to be retained with DRM (1.5 above)
DC
(See remarks)
Electronic
EDMS
Retained until close out of HAZOP actions.
PE
2 years
Electronic
EDMS
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
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
SP-1208
Page 57
Version 2.0
Storage format
Keep As-Built
Location
Mechanical Documents
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 **
4.0
Document Category
Originator *
Retention time
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
SP-1208
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Storage format
Keep As-Built
Location
Shutdown matrices
DC
Service life
Electronic/Paper
EDMS
7.5
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
SP-1208
Page 59
Custodian **
7.4
Document Category
Originator *
Retention time
Remarks
Version 2.0
Welding/NDT progress chart
CC
2 years
Paper
Archive
9.3
NDT reports/Test packs
CC
Service life
Electronic or Paper
Archive

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
SP-1208
Page 60
Remarks
Location
Originator *
valves,
Keep As-Built
Storage format
9.2
Document Category
Custodian **
Retention time
Abbreviations
**
CC
Construction Contractor
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.
SP-1208
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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
TYP-3-0001-001
ROW and working strip details
TYP-3-0002-001
Trench Dimensions
TYP-3-0003-001
Cold field bending details
TYP-3-0004-001
Road crossing over existing above ground pipeline
TYP-3-0005-001
Road crossing over existing under ground pipeline
TYP-3-0006-001
Pipeline crossing tarmac road
TYP-3-0007-001
Live stock passageway crossing
TYP-3-0008-001
Pipeline crossing Wadi Type A
TYP-3-0009-001
Pipeline crossing Wadi Type B
10
TYP-3-0010-001
Pipeline crossing Wadi Type C
11
TYP-3-0011-001
Pipeline crossing existing above ground pipeline
12
TYP-3-0012-001
Pipeline crossing existing under ground pipeline
13
TYP-3-0013-001
Pipeline crossing existing under ground cables
14
TYP-3-0014-001
Pipeline in parallel
transmission line
15
TYP-3-0015-001
Retaining Barriers in sloping trenches
16
TYP-3-0016-001
Pipeline Markers & signs
17
TYP-3-0017-001
GRE pipeline crossing road
and
crossing
high
voltage
The drawings are for information only.
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NOTES:
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
Contractors supervisors and all manufacturers 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 manufacturers
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 Companys 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 manufacturers 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 manufacturers
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 manufacturers 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 Contractors 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 Manufacturers 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 manufacturers 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.
SP-1208
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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 Contractors surveyor has confirmed that the trench bottom profile complies with
the pipe manufacturers 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 Contractors 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
Manufacturers recommendations for the particular pipeline material and shall be agreed
with the Company. The following requirements shall apply for GRE pipe:
SP-1208
Specific construction requirements shall be in accordance with the project scope

of work and alignment drawings. The construction of cased crossings is
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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.
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2.15.2 Hydrostatic Testing

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 Companys 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 Companys
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
SP-1208
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Version 2.0
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.
SP-1208
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Version 2.0
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.
SP-1208
Page 98
Version 2.0
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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SP-1208
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Version 2.0
SP-1208
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SP 1208 Pipeline - Construction - Specification - (PCS-01)

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SP 1208 Pipeline - Construction - Specification - (PCS-01)

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Petroleum Development Oman L.L.C.

Document ID: SP-1208

Pipeline Construction Specification

Pipeline Construction Specification

Authorised For Issue

Specification reviewed updated.

Text of Specification PCS-01

Pipeline Construction Specification

Changes to the Specification.....................................................................................5

Health, Safety and Environment (HSE).....................................................................6

Specific Pipeline Activities............................................................................................7

Quality Assurance Team.............................................................................................7

Materials Handling and Control................................................................................10

Inspection of Materials other than Pipe.....................................................................12

Handling of Materials other than Pipe.......................................................................12

R.O.W. and Trenching.............................................................................................. 13

Pipeline Right-of-Way and Working Strip..................................................................13

Staking, Clearing and Grading..................................................................................14

Stringing and Bending.............................................................................................. 20

Welding and NDT..................................................................................................... 22

Anti-Corrosion Field Joint Coating...........................................................................23

Pipeline Construction Specification

Shrink Sleeve Application..........................................................................................24

Testing, Inspection and Acceptance..........................................................................27

Lowering-In, Backfilling and Reinstatement.............................................................30

Lowering-in and Post-Padding..................................................................................30

Stabilising Sand Areas...............................................................................................32

Road and Wadi Crossings........................................................................................ 33

Concrete Coating for Wadi Crossings......................................................................35

Inspection and Testing...............................................................................................38

Concrete Coating Repairs.........................................................................................39

Permanent Markers and Barriers.............................................................................40

Block Valve Station Markers.....................................................................................40

Road Crossing Markers............................................................................................40

Wadi Crossing Markers.............................................................................................40

Pipeline Crossing Markers........................................................................................41

Cable Crossing Markers............................................................................................41

Markers at Horizontal Bends.....................................................................................41

Cathodic Protection Markers.....................................................................................41

Pearson Survey Hole Marker....................................................................................41

R.O.W. `STOP` Signs...............................................................................................41

Corrosion Monitoring Pit Marker...............................................................................41

Pipeline Construction Specification

Civil and Mechanical Works......................................................................................43

Temporary Cathodic Protection.................................................................................47

Quality and Treatment of Hydrotesting Water..........................................................47

Work on Live Pipe Systems.....................................................................................49

As-Built Records and Hand-Over Documentation....................................................49

Pipeline As-Built Documentation................................................................................50

Test, Calibration and Inspection Reports..................................................................50

As-built Drawings and Pipeline Data Sheets.............................................................50

Review and Improvement........................................................................................ 51

Glossary of Definitions, Terms and Abbreviations.......................................52

Facilities For Company Personnel..............................................................57

List of Handover and As-built Documentation.............................................60

List of Typical Drawings for Pipeline Construction.......................................65

Construction Requirements For GRE Pipelines..........................................83

User Comment Form............................................................................................................ 92

Pipeline Construction Specification

Pipeline Construction Specification

Pipeline Construction Specification

Changes to the Specification

Contractual Scope of Work, Purchase Orders and Variations thereto.