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Petroleum Development Oman L.L.C.

UNRESTRICTED Document ID: SP-1208
September 2005 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.

Pipeline Construction Specification 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 Date Author Scope / Remarks
No.

Version 2.0 September 2005 Jan Belt, Specification reviewed updated.
UIP/5 Requirements for GRE pipeline
construction included.

Version 1.0 April 2001 R J Harris, Text of Specification PCS-01
OIP/31 adapted and re-formatted.
References updated and text
edited. No significant technical
changes made.

SP-1208 Page i September 2005

Pipeline Construction Specification Version 2.0

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

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

SP-1208 Page ii September 2005

.............2 Contractor’s material control and storage procedure shall be submitted to the Company within two weeks of the start of mobilisation on site........3 Quality Assurance Team........ 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..3 1......... lifting..................3.............3 HSE Advisor...............6 Quality Assurance..................2 General....................... checking.......................7..... Lifting equipment and operations shall be in accordance with SP-1239....6 1.............................................................6 1............ unloading...2........................2 General....7.........4 1.......6 1.6..........................2 Organisation.............2..................7......................... Company and Contractor shall carry out a joint survey of pipe coating damage and bevel damages...............................6 1.....7 Materials Handling and Control.......1 Scope 2 1....... transport.................... On the basis of this survey......... based on the submitted unit rates in the Schedule of SP-1208 Page iii September 2005 ................ issue.. all pipes internally and externally for damages....6 1...................................3.............2 1....................................................2................ A lapse greater than 2 working days shall require re-notification............................3 1...............................7..5......1 The Contractor shall visually inspect at the Company storage yards.......................................................6 1.....5 Contractor shall appoint a dedicated site-based materials Controller whose sole function shall be to control and report on the receipt................. loading...7......2 General...................2 Prior to haulage of pipe from Company’s storage yard.................5.6......2..............................5..................................6................................................6 Contractor shall not be held responsible for manufacturing defects in Company supplied materials...........2.......4 Company Inspection..............3 1............. 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.............. stacking..1 Personnel.................5 1..................... and storage of materials shall be carried out by the Contractor in such a manner as to avoid any damage and loss of materials...3..6........................2 1...................................6 1....... for approval................6 1................................................3 Pipe Inspection..7.....................3................................................2...........................................................6 1....... Contractor shall provide the Company with a written confirmation of receipt of all materials (identified by type and quantity) and a written reconciliation of all materials (identified by type and quality) transported by them from Company’s storage yard on a weekly basis...4 Specific Pipeline Activities......3 1......................................6 1.....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.................6 1............................7.5...................7............ and stock status of the Contractor and Company supplied materials...... Method and means of transport and handling (including documentation) shall be subject to approval by the Company.............................................2.....7..............6............ Company will pay the Contractor a lump sum for repair of all bevel and coating damage..6........0 1.......................... including but not necessarily limited to receipt.......................................1 Scope 3 1............... unless otherwise specified by the Company................... Pipe can be removed from Company’s yard 7 days per week during daylight hours......................... surface defects and defective bevels.................................................Pipeline Construction Specification Version 2..................................7 Contractor’s procedures for material receipt and return of surplus materials shall conform to Company’s materials procurement/administration procedures...............1 Scope 6 1...........................................7......................................................7...........4 Contractor is required to supply lifting equipment for lifting materials at all locations.......................................7...................1 Handling..5 1................

........................... Any damage/defects shall be reported to the Company within 24 hours of receipt of SP-1208 Page iv September 2005 ...........37 for non critical and critical services respectively.....5.................4. Pipes shall be loaded and stacked on trucks in such a manner that flexing and shifting of the pipe during transport is avoided...........7. A spreader bar shall be used for all bulk pipe lifting/handling (excluding welding operations)....8 1.........6...................7...........1 Upon receipt of any materials............Pipeline Construction Specification Version 2.......5 Pipe Stacking.....6................8 1... Where concrete coating of linepipe is envisaged.....7......3 Trucks used for loading of pipes will be checked by the Company prior to lifting the pipes to ensure that the trucks and loading/load securing arrangements comply with the requirements of PDO’s Transport Manual TOM/04/001..8 1.7.3 Pipes shall not be stacked higher than 3.......8 1.....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......8 1.......7. When stacked.............................8 1...8 1........ Pipes shall be protected against truck beds and side metallic posts by means of non-metallic soft materials..8 1..............7......................7........................................40.............8 1................ wall thickness......5................8 1...... These specify amendments/supplements to ISO 3183 Specification.............. After loading... During transport the tension of these slings shall be regularly checked.6 1.......................35 and DEP 31....................5 metres.. the concrete coating cut back shall be increased by 100mm over and above the cut back left in the mill coated pipe............... Pipes shall be stacked in such a way that no water is retained inside the pipe during storage................ Pipes of different diameter....50m as per above DEP................ shall be provided with a factory-applied polyethylene / polypropylene coating or a factory applied fusion bonded epoxy powder coating.....7 Inspection of Materials other than Pipe...40............7............ the repair shall be by grinding........ the Contractor shall ensure that they conform to the required specification and are suitable for their intended application..................... 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.. When lifting pipe.......... Each stack shall be properly marked to the satisfaction of the Company..... the bottom layer of pipes shall be wedged or clipped......... Contractor shall ensure that no bevel protectors are lost during transport..1 Line-pipe shall be manufactured in accordance to DEP 31.......1 Pipe shall not be allowed to drop or strike objects which may damage the pipe and/or coating but shall be lifted........... the repair shall be by re-bevelling... The minimum and maximum length of pipe shall be between 9m and 13.......... grade or manufacturer shall be stacked separately.....................1 Ground surfaces to be used for stacking of pipe shall be reasonably flat............................. moved and lowered from one position to another by suitable equipment....... in accordance with this specification.....6..2 Epoxy-coated pipes shall be stacked during transport and storage using rubber or other suitable separator strips........10 1...............7........7.7.7........20............................. Pipes shall only be transported on trucks (lifting equipment shall not be used to transport pipe).....7........... For bevel damage depth greater than 3 mm...... SP-2000 ‘Road Transport’ and government regulations..... For bevel damages between 1 and 3 mm deep........................................7.......................................8 1....4........... Stacked pipes shall be raised above ground surfaces and prevented from movement by berms of screened sand covered by polyethylene sheeting or by using timber covered with non-metallic soft materials.........4 Pipe Handling.........................2 Minimum average pipe length shall be 11..................... Pipe ends shall be protected from contact with other metallic materials....0 Rates..... Temporary attachments for handling or lifting shall not be welded to any pipe...7..............6 Linepipe Specifications..................................7m long...................8 1.............5................3 Linepipes if required............ suitable non-metallic slings shall be used to tie the pipes securely to the truck......... Each polyethylene / polypropylene coated pipe shall be left bare for a distance of 150 ± 20 mm from each end..20... Each fusion-bonded epoxy powder coated pipe shall be left bare for a distance of 80 ± 15mm...............4.............

....................................10 1......................2.. detailing materials installed....7.......11 1...... shall be lifted by suitable equipment provided by the Contractor at Company’s storage yard and at all other locations... It is prohibited to store and transport fragile materials in more than one layer......................................................3 If no report is issued for damaged materials 24 hours after receipt (or in the case of 2..................9...........1.1 Scope..............................................10 1............2 On approval of the surplus list by the Company............................1 Scope.................2 In the case of materials delivered in their original sealed crates......... nozzles............7.......2 Staking..............10 1.................9 Reconciliation..7.............................7..........................................9......7...............................12 1................. Contractor shall provide suitable storage........ valves..............................7............1.........12 SP-1208 Page v September 2005 .......Pipeline Construction Specification Version 2....8.........................10 1..........O.............8.10 1...............................................7.................7... materials wasted and scrapped.......8.................8 Handling of Materials other than Pipe.....8 R.......................................................4 For materials which shall be stored cool and/or dry as required by the manufacturer or the Specifications.... fittings............................................................... transport and handling facilities in accordance with the requirements of the manufacturer and/or the Specifications.....................2 Survey....................1........................................ and Trenching................................................2 above........ suitable lifting hooks shall be used for lifting the materials..................................... Contractor shall only open the crates to examine the materials upon arrival at his own storage yard.....................................................1 Pipeline Right-of-Way and Working Strip....8.... 24 hours after arrival of materials at the Contractors storage yard)..........................11 1........... Contractor shall give reconciliation for all Company supplied materials issued...... Blinded openings of materials shall be kept closed until installation..........................3...10 1..... It is prohibited to use delicate parts such as hand wheels....... materials shall be secured by suitable non-metallic non-abrasive slings.......4 Planning/Approvals...1 At the end of the project................ Visual inspection shall be adequate for this purpose..........3 ROW Width ................................................... Contractor shall compile a list of the surplus materials........7....................8.... Timing of the issue of materials shall be as per the Company approved work schedule. and surplus materials........ description and MESC / SAP number when available.11 1............11 1....2 Materials other than pipe materials will be issued to the Contractor whenever possible in their original sealed shipping cases/crates......8................................7.....................8................................... Clearing and Grading...............8......... scraper traps etc.......................8........... Ground surfaces in storage areas shall be clean and flat..............10 1....7.............................W........................11 1................................1 Materials other than pipe materials such as.........7..................... indicating quantity............ When lifting lugs are provided on materials...... except in the case of damaged crates which shall be noted and the contents examined when Contractor takes receipt at Company’s storage yard.....11 1..................... for lifting of the materials........................................... The blinds shall be replaced by the Contractor in case of damage during transport or storage..........7...........8........11 1....................3 During transport.........................................5 Contractor shall provide a separate fenced storage area for Company supplied materials................11 1......................... Contractor shall return all surplus materials to Company’s storage yard.........7.... .........................10 1........ 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..... but not limited to........7......10 1........................10 1. etc.10 1.1.0 these materials and prior to transportation to the Contractor’s own storage yard.......8.............................8....................................... Stored materials shall be protected from ground surfaces by using timber covered with non-metallic soft materials....8...6 Distribution and supply of materials from Contractor’s storage yard to the worksites shall be limited to quantities required for approximately one day’s production...

.......... The skids and protective padding material shall be subject to Company (CSR) approval..........19 1......Pipeline Construction Specification Version 2.......................................2.....................6 Trench Width........9.8.....8........9...............................................19 1..................................... tracks...2 Stringing.........g..........6 Explosives (not used for blasting as part of the construction work)...19 1................... Length of individual pipe strings shall be subject to Company approval and shall generally not exceed 1 km.....9.2 Definitions.......8........... Dragging........... Pipes of different manufacturers shall not be mixed per line section without prior approval of the Company........ Contractor shall string all line pipe of one manufacturer before commencing the stringing of line pipe supplied by the second manufacturer.....................................4 Definition of Rock...12 1............19 SP-1208 Page vi September 2005 ....................................................18 1.... the number of pieces cut- off with less than one metre length is kept to a minimum...............8... at locations where an increased trench depth is required) can be accommodated without requiring an additional tie-in.........................................9.......... Pipe shall not be placed directly on the ground but on wooden skids with proper protective padding......................19 1..........................1 Scope.......................................... The distance between the trench edge and the pipe string shall be planned such that safe working space is provided....................................13 1.................2..................................8....................7 Grading the Working Strip..9................................................3 Pipe Bending............................18 1..........19 1.........3.... (See Section 2..........................9........3 Blasting............................0 1.....................................................18 1................15 1..........................3 Contractor shall be responsible for proper stringing and locating of the pipe by size...........................9.....4 Below and Aboveground Services.........................2........3 for requirements for slings and hooks). Wooden wedges shall be used to prevent movement of each strung pipe.2................2.18 1....8.............................................................................................................5 Sloping Trenches..............3.........8........... in view of the inherent increased risk of failure of skids due to movements of the pipe..................2...................................................9...15 1..................19 1....3...............19 1.......... 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...... etc...........14 1..........................8........2......15 1...............................5 Clearing the Working Strip............................. wall thickness..........................8.......4 Contractor shall string the pipe in such a manner so as to cause no interference with public roads.............2..........12 1...............15 1.............................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.................9....8.................2................................ Company may supply line pipe from different manufacturers..............7 Pipe shall be strung with the use of a spreader bar and two guide lines...........8..................9...................17 1.................................................................................. Special attention shall be paid to strings with one or more bends........ specification and manufacturer........................................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...........................2.3 Trenching.......2................................1 Scope 18 1.....9 Stringing and Bending...............................................................................3 Staking. skidding or dropping of the pipe is not permitted...........8......................................19 1.......3.........................2..............2 Where possible the skid elevations shall be planned such that minor differences between grade profile and bottom of trench profile (e.......... footpaths....14 1...................................5 Contractor shall layout and measure the pipes such that.................................2 Excavation.......................3.....................................3...2...............8.....................................................

. Manufacturers and Equipments (AVME) list of the company. Bends with ripples with a depth exceeding 0......................... to ensure that the installed pipe shall conform to the contours of the pre-padded trench........3........9........................................ This procedure shall be subject to Company’s approval.... the proposed work methods for coating application and coating repair.....................9.........................19 1................................................10................................ whichever is greater............5 Coating materials shall be kept dry and stored as long as possible in the manufacturer’s original packaging..................................... and in accordance with manufacturer’s instructions.... fully retaining bending shoes shall be used...9....... two weeks prior to application.....3..... Bends in pipe of diameter 8" or greater shall be made by using an internal (hydraulic or pneumatic) mandrel....22 1....2...21 1..........3 Surface Preparation...11.................................... Contractor shall provide a procedure for measuring ripples which shall be approved by the Company.... The procedure shall include amongst others....................4 The coating materials shall be properly packed and clearly marked with:. Contractor shall lay out and measure the pipe for bending such that the length of off-cuts is kept to a minimum... D being the pipeline diameter are not allowed unless approved by the Company....20 1............. before the start of the Work............................2..............5 mm............................8 The procedure for bending shall be such that the extremities of each joint remain straight over a minimum distance of 2 m or twice the pipe diameter.............................7 All bends shall be tested in the presence of the Company with a gauging plate of 97.. equipment.....................................3...............................10...2 Materials......1 Scope 21 1..........9.........................11........11.....................................................3....................11... at time of application by the Contractor....... submit and demonstrate to the Company a bending procedure.....0 1......... Roller type bending machines are preferred......................20 1.... degrees per pull and method and accuracy of measurement during pulling of the bend.................... shall not be older than the shelf life stated by the manufacturers............. step length............................................................2 Off-Plot Pipelines................................21 1..6 The list of Company approved wrap-around shrink sleeves is given in the Approved Vendors...............5 The cold bends shall be made by a smooth stretch bending machine.....20 1.20 1............... following a trigonometric survey to establish the number and degree of bends required............10......2....21 1.....2 Contractor shall.............3.................3.........................20 1.......................1 Contractor shall make all necessary bends required for proper construction of the pipeline.................... not exposed to direct sunlight........................... wrinkles and kinks are not acceptable.......................2.....................11..21 1............................................. application methods.........................1 Scope 20 1..21 1..............................................4 The radius of cold bends shall be not less than: .................. which shall conform to the recommendations of the manufacturer of the bending machine.......9.......11 Anti-Corrosion Field Joint Coating..22 SP-1208 Page vii September 2005 .......22 1....2....3 On-Plot Pipework............ dies and rolls of the bending equipment shall have soft surfaces to avoid damage to the pipe coating.........20 1..11............6 The pads.2 Contractor shall as a minimum follow manufacturer’s recommendations regarding material storage.............21 1..........................................1 Only materials supplied by Company approved manufacturers shall be used in the Work............................................. Where applicable..5% of the nominal internal diameter of the pipe prior to installation.........19 1............9...............21 1..............11..................................................................3...10 Welding and NDT.....................3 The materials................9..20 1.........3................3 Elastic bends with radius of curvature less than 500 x D.2.................. Contractor shall submit for Company approval and demonstrate to the Company. spares and tools.....9......11....................19 1.11...Pipeline Construction Specification Version 2...............

.............22 1...6 The sleeves shall be visually inspected for the following points:.....E.......23 1............4................................22 1.4....22 1....11.............2 The joint shall be heated to a temperature required by the procedure................. whichever are the most stringent............................................. whichever is the longer.32................. In all other cases burners or torches may be used.....5................................... Special attention must be given to the closure patch and overlapping areas....................40.............11....32.... The application procedure shall be in accordance with manufacturer’s instructions and the minimum requirements specified below.. Any field joint not coated within 4 hours of grit blasting shall be reblasted prior to the application of the coating......... gel time tests as per SP-1208 Page viii September 2005 ....B....................................................................................... The closure patch shall be positioned off to one side of the pipe............................................................3 The sleeve shall be wrapped entirely around the joint........ The epoxy material for the field joints shall be compatible with the linepipe coating and shall conform to the material requirements of DEP 31..30......... There shall be a minimum overlap of 50 mm onto the factory applied coating.......... and shall be demonstrated to the Company prior to field application by means of a procedure qualification test joint.....11................3......5..............30.......................... To check that the required preheat temperatures have been achieved..........................40...................................................11.....4....5........ For any powder that has temporarily experienced temperatures in excess of 27°C...........11...4.23 1.... and shall be demonstrated to the Company prior to field application by means of a procedure qualification test joint..2 The blast surface visual appearance shall conform to ISO 8501 grade Sa 2 1/2........11.... Application...........................................11.........3....... with respect to:... a digital contact thermometer shall be used..1 The mill applied epoxy coating of the linepipe shall be applied in accordance with DEP 31....... Induction heaters................11...................11...............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..............................11..........................4......................23 1. but must be returned to the normal storage temperature below 27°C at the end of the day. shall be carried out in accordance with SP-1246 and this specification..........................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......... ...........30..................3....11....... Surface preparation... Temperature recorders shall be used to monitor the storage temperature inside each container......... Torches may be used for tie-in welds at Company’s discretion.. the powder in the fluid bed can be kept at ambient temperatures up to 85°C.11....23 1..11........32.3...11....5 Coating of the field joint shall not take place until the weld has been non- destructively tested and approved by the Company...............23 1................................3 The resin powder shall be stored in waterproof containers which are insulated and cooled by refrigeration or air conditioning to a temperature not exceeding 27°C......... ring burners or propane torches of a suitable type may be used for pipe diameters smaller than 16"...2 Contractor shall propose the application procedure for Company approval...............4.......................4 The surface cleanliness shall conform to ISO 8502-1 to 4 and shall be such that the chloride contamination is less than 20 mg/m2. Induction heaters shall be used for pipe diameters of 16" and larger where the pre-heat temperature exceeds 100° C...... Contractor shall also submit test data to demonstrate that the applied coating satisfies the requirements DEP 31.................... the field joint area shall be blast cleaned...... whichever are the most stringent...................22 1.5 F.....Pipeline Construction Specification Version 2.11..............23 1....22 1........0 1.................4 Shrink Sleeve Application...............11........40...................... The application procedure shall be in accordance with manufacturer’s instructions and the minimum requirements specified below...............22 1.................22 1..1 Prior to coating....22 1.......... including blast cleaning......3...1 Contractor shall propose the application procedure for Company approval.....................5 The installed sleeve shall be left undisturbed for 4 hours or until the adhesive has been solidified......... During the daily powder coating operations..22 1....

...26 1....................... For smaller pipeline sizes.11............6......26 1............................................................11............4 The repair procedure for both mill and field applied fusion bonded epoxy powder coatings shall be selected based on the criterion of magnitude of the damaged area.........................0 manufacturer’s recommendation must be carried out on each box of powder before use............25 1........................... stripped and recoated to the original procedure..........4 The area of the pipe to be coated shall be preheated by induction heating coil to a maximum temperature of approximately 250°C. The actual temperature range shall be in accordance with the powder manufacturer’s recommendations.............. Company may accept powder application by a hand held device used by a skilled operator..:....11..................... using a technique which achieves an even coating thickness.................. In the event of contamination..25 1. If the ambient temperature falls....5.......7.........6 Coating Repairs.11...... capable of applying the powder at a uniform rate over the entire width of the area to be coated................................................11............6.............5.. etc...25 1...7 Testing............................................2 The coating repair procedure and the required materials for this.............5.......7....................26 1................. plus two more times during the day and when a new batch of grit is used........... it may be necessary to increase the preheating temperature slightly to provide adequate curing energy........26 1..................... hoses...... pinholes............... Powder application shall start as soon as the metal temperature is within the qualified temperature range...... the coating shall be rejected.......................... The frequency of testing as specified herein may be altered by the Company at Company’s sole discretion.................... Dirt or deleterious materials shall not contaminate the powder coated area during the application and curing stages......................23 1.................................................................. including the installation of repair sleeves when applicable..... a strip of transparent cellotape shall be applied to the surface.7... After the surface has been blast cleaned and dusted off..............e...........................6.7 All operators shall wear Company approved safety equipment to prevent inhalation of powder dust and contact with eyes.11.......................................................... shall be in accordance with a procedure submitted by the Contractor and approved by the Company..... i................. Smoking shall not be allowed in the vicinity of the coating operation...............6 The applied coating shall have a minimum dry film thickness of 400 ± 75 micron........................11.... i.....................................................23 1..1 The testing and inspection for acceptance of the coating system shall be carried out and recorded by the Contractor as instructed and witnessed by Company’s representative......Pipeline Construction Specification Version 2....25 1.25 1......................... Contractor shall use automatic coating machines...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.. such that the metal temperature does not drop below the specified lower temperature limit during coating application.3 The repair procedure for mill applied polyethylene / polypropylene coatings shall be selected based on the criterion of magnitude of the damaged area..................... Inspection and Acceptance. scratches or any other irregularities and shall be of uniform gloss and thickness.................. This shall be done on the first joint cleaned each day................25 1.......... If in the opinion of the Company the test has failed.11.... There shall be a minimum overlap of 50 mm onto the factory coating..........25 1................... Contractor shall undertake to perform additional cleaning to the specified standard....11..............5...........1 Coating repairs shall be executed on all coating damage and imperfections detected visually or by holiday testing..e.... and subsequently removed and examined for particle contamination..11.....................11.11............:........... The cured coating shall be free of blisters.............................................6.......25 1...... produced at least twice a day and additionally the SP-1208 Page ix September 2005 ...... Metal temperatures shall be checked by means of digital contact thermometers.......11.5 For pipeline sizes equal to or greater than 12"......3 The profile of the blast cleaned surfaces shall be tested by means of Testex Replica Tape (type X-course)..............................11.............. on the application unit shall be cleaned after each day’s work......8 The powder container..5..

........ If the base material is not sourced from the working strip... and temperature control of the pipe surface..... 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....06 and 3. All equipment shall be approved by the Company prior to use. roots....7..... grit/shot used for blast cleaning......... Backfilling and Reinstatement .... The surface profile shall be evaluated from the replicas in accordance with manufacturer’s instructions......26 1.. the Company may allow the surface profile to be tested on site by a suitable profile gauge in accordance with SP-1246.27 1.............. stones............29 1........ the Contractor shall use mobile screening plants that enable a continuous direct application of padding from the plant to the trench... Before applying the coating............12.............. 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................7 Fusion Bonded Epoxy Testing....... the surface shall be free of rust or residual grit.............7...................... All holidays....................28 1......11...... 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)...29 1.................2.......... 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......0 mm and no more than 25% by weight shall have a grain size between 3....12 Lowering-In..................11.6 Shrink Sleeves Testing..........5 Contractor shall supply all equipment required for inspection and testing including dry film thickness gauges and holiday detectors..... 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....... etc..7......26 1..... sources of SP-1208 Page x September 2005 ....... pre-screened material may be used after approval of the source by the Company...... Contractor shall excavate..............29 1.7..............12......1 All trenches shall be padded before lowering in of pipe string...2 To ensure that fine and clean padding material is used...............................0 first few joints and at each change or replenishment of grit...7..28 1....8 Holiday detection of 100% of the surface area of all coated pipeline shall be carried out immediately prior to lowering in the ditch................................12..26 1.................... If coating defects are found on any portion of the coating..12...7.11.....1 Scope 29 1..11...........0 mm...... Brush type electrodes shall not be used............... cleanliness of materials used for blast cleaning and coating................ and without sharp edges which could damage the pipeline..11...................11.................... the voltage setting for holiday detection may be lowered slightly at Company’s discretion if coating gets damaged. 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.. using a recently calibrated micrometer.4 Additionally..Pipeline Construction Specification Version 2................ To ensure compliance with the above requirements..................... However. metal parts.........0 and 5.2 Pre-Padding.......27 1..... repair and backfill at Contractor’s expense...................... No padding shall be placed until the Company has inspected and approved the trench bottom...............................................2......2............................................. Only in those areas where mobile screening plants cannot be used due to access problems....... ....... As an alternative to the above.......... The voltage applied by the holiday detection equipment shall be measured by means of a voltage read out........12.......... More than 75% by weight of the screened material should have grain size between 0.......9 Company will carry out a ‘Pearson Survey’ to check the integrity of the buried coating...3 The installed padding material shall be free of sharp rocks.. general checks at random shall be carried out such as monitoring of particle size of copper slag...... Mobile screening plants are defined as screening plants which move along the trench whilst they are in operation.......... clods....29 1..................... Base materials from which pre and post padding material will be produced shall consist mainly of sandy material...... The electrode shall be a conductive rubber or a spiral metal ring..

. all subject to Company approval...................12............ 'coarse sand' with a minimum grain size of 0......................3.................................... at its sole discretion...... Contractor shall keep the pre-padding operation within 1 km of the lowering-in operation.. Contractor shall plan the work such that the lowering in and ‘plugging’ operations take place during the hottest part of the day...............2....31 1...............................5... the sand padding shall be thoroughly compacted by watering and Company approved hand tools........................3.............12.......29 1.......................3 Lowering-in and Post-Padding............ in which case it shall be Contractor’s responsibility to obtain suitable padding material from a source approved by the local government authorities..... repaired to the satisfaction of the Company... padding material shall be dust free (e.. etc........31 1.......... whether in normal ground or rock.5..... as specified in Section 2.........Pipeline Construction Specification Version 2...... Backfilling shall be performed as soon as possible after padding has been approved.... i........................................12......................5 Backfilling........4 The trench shall be maintained in a dry condition during lowering-in and backfill operations..7 Where the trench has been excavated through or along drive-ways.....................................................e...............0 padding material shall first be approved by the Company...... roads.......12...............29 1.........3.....31 1...12..............4 The bottom of the trench shall be padded with sand throughout its length.....29 1...........................................7....2 Immediately before commencing the lowering-in operation...5 Contractor shall take measures to restrain the pipe in the trench by means of ‘plugging’...................... The backfill around all underground services shall be thoroughly compacted by hand........ Any damage caused to the pipe and coating during lowering operations shall be repaired before backfill commences..................................29 1................ walk ways............. and at live stock passage ways and other locations indicated on the drawings.12.12................. so as to provide a minimum compacted padding thickness of 150 mm below the invert of the pipe.....................................................5.. waive the requirement for ‘plugging’ and allow the post-padding operation to be executed as one continuous operation...........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................. dependant on completion time and ambient temperature considerations.....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.....2 In areas containing buried cables................3......3.... No pipe shall be left overnight in the trench without sand padding around and above the pipe.31 1.......................6 Sand padding shall be placed around and above the pipe....3 The material used for initial backfill shall be from the screening plant or other loose material not greater than 100 mm in diameter................29 1..31 1..................................................... so as to fill the trench to a depth of 300 mm above the crown of the pipe...............31 1....................... Near residential areas and roads.......... the coating shall be checked for holiday and if necessary................3.31 1. Company may........... Suitable base material from the working strip may not always be available or acceptable..........................................................................6............................. placing sand on top and around the pipe at regular intervals (one 2m ‘plug’ on every welded joint) or Company approved equivalent method..12........................12.........................12......... backfilling shall not be performed until all tiles have been replaced and protected and/or all cables have been supported to Company’s satisfaction.3.............12...........g..............31 1..........6 mm) in order to avoid inconvenience or danger to the public..................12.................12....29 1.............. 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 SP-1208 Page xi September 2005 .... to achieve a compacted sand fill around the pipe and up to 300 mm above the crown of the pipe...............12.............4 Tie-ins......1 Welded pipe strings shall be lowered-in within 96 hours of completion of joint coating................................ with the sand padding shaped to its natural angle of repose and with a minimum of 150 mm at any point around the pipe.....

the windrow shall be tapered from full height to ground level to improve the visibility of drivers on the ROW..........6 Construction roads...12................................ If the excavated material........ 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..Pipeline Construction Specification Version 2...12....32 1.............. to the satisfaction of the Company...............2 The excess soil in the working strip shall be levelled in a manner satisfactory to the Company..............12................ Where rock is excessively large....4 After the initial backfill................8...5......5............34 1..............32 1..................3 All creeks..8.........12. streams.. used at escarpments.......................... be pitched with stone and/or faced with special protection to prevent washing out or erosion. the remaining excavated material shall be neatly crowned over the trench (the windrow).....8 All rubbish/debris left over after removal of camp facilities shall be removed to designated scrap dumps.......0 layer......................7 ‘Sloping trenches’ (see Section 2........ the initial backfill shall be thoroughly compacted by mechanically tamping the material into place..............5 All private roads............... walks... roads.12..................8 Reinstatement... 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.....................12...................................... and shall restore the lands traversed.................................................... except in wadi areas.32 1........... ......................................................... etc........................34 1................31 1..............1 Contractor shall clean-up the Working Strip and all working areas used by the Contractor regularly during the course of the work.......... unless requested by the Company....8..................12.. in Company’s opinion... drains......... wells......12....... Backfill in or on banks of ditches.....8...............................31 1.....32 1...... bridges and other private structures used by the Contractor for access or haulage shall be restored by the Contractor to a condition equal to or better than that which existed prior to the commencement of the Contractor’s operations... The initial backfill shall be placed in the trench to a level slightly above surrounding ground......... The sites shall be levelled and cleared in accordance with SP-1208 Page xii September 2005 ..34 1........12...... but may be placed next to the windrow..........12.........32 1.. in Company’s opinion is not suitable for backfilling.7 Livestock Passageways............ Ditches with lined or otherwise improved surfaces shall be resurfaced in a manner satisfactory to and approved by the Company and the Authorities........8....12........ walls.....6 Where the trench has been excavated through or along drive-ways..... rocks larger than 750mm in diameter shall not be placed directly on the backfill material..............8........8.. However...... Contractor shall provide and use suitable material from another source...... Contractor shall demonstrate that his proposed method of backfilling achieves this requirement. water courses.................... ditches and irrigation channels shall be reinstated by the Contractor to their former condition and their banks shall......................... wadis. etc...........................32 1...........34 1................7 Construction markers shall not be removed......12...... shall be restored by the Contractor to at least as good a condition as they were prior to the commencement of the Contractor’s operations to approval of the Company. if deemed necessary by the Company........... shall be removed from site and not used as windrow material..4 All enclosures..34 1.... On either side of road crossings............... wadis shall be compacted as necessary to prevent soil erosion or other damage which might be caused by the construction of the pipeline..... syphons........ may be required by the Company to be left as they are...12.........5....4..... 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... and at live stock passage ways and other locations indicated on the drawings..12.5) shall be backfilled as shown on Standard Drawing TYP 3 0015 001...............5 Trenches crossing ditches shall be backfilled with the material excavated from the trench at the location............ gates.....8.3......... The surface of such areas shall be stabilised and/or restored to its original condition to the satisfaction of the Company and the Authorities.....32 1..5.....32 1..........................12................6 Stabilising Sand Areas...................

................ shall be placed on top......... Pipe installed in ‘Flood plains’ does not require casing protection.............13........0 the Regulations for Pipeline Contractor Camps in the Interior and to Company’s satisfaction...3.............................37 SP-1208 Page xiii September 2005 .....36 1....... 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........................................... pipe jacking may be considered for major road crossing to avoid disruption of traffic........................3......... ‘Wadi type ‘A’’................. All warning signs shall be in both Arabic and English language....34 1............2 Wadi crossings shall be installed to meet at all times the requirements and conditions issued by the Authorities having jurisdiction in the area.........35 1.............. The wadis will be identified on the Alignment Sheets as ‘Flood plains’.................................................. up to grade level over the full width of the trench...............13.........13......34 1.. The diversion shall not cross the pipeline where it has already been installed..............................34 1.. coated steel wire mesh..............13.. Trench less methods such as horizontal drilling............................... 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.............13...13..........3 Contractor shall install an off-set diversion road...14 Concrete Coating for Wadi Crossings............................35 1....... bed slope.........13...3 Wadi-Crossings....................... All road crossings shall be made by the open cut method........................... The wadi types are described below..............37 1......... or ‘Wadi type ‘C’’...1 Scope 34 1...... the windrow shall be installed intermittently in order to mark the location of the pipeline (Windrow lengths shall be approximately 25m at 75m intervals)...............................5 Contractor shall comply with the following minimum requirements of the Directorate General of Roads for major road crossings:.................Pipeline Construction Specification Version 2.............. but shall be stabilised at 3 meter intervals by means of bags of dry cement/sand mix placed on top of the pipeline..................5 For type `C` wadi-crossing. The crossings shall be installed to meet at all times the requirements and conditions set forth by the Authorities having jurisdiction........................13 Road and Wadi Crossings................ following..................34 1....................13............................................ ‘Wadi type ‘B’’................4 Contractor shall at all times and at every unfinished road crossing provide adequate and proper traffic aids......13.. The type of wire mesh shall be approved by the Company prior to use.3.............10......2.......2 Road Crossings......13.......13................35 1........................ gabions consisting of packages of boulders with dimensions between 100 and 200 mm contained in galvanised............ The concrete shall be applied in accordance with Section 2.. However for wide wadi crossings........................................... greater than 100m..........4 At locations where concrete protection has been applied......1 The carbon steel pipeline shall cross all roads and highways..... past discharge history and erosion potential at the crossing location........3......... ...... Wadis may be classified based on judgement and careful evaluation of the crossing location with due consideration to wadi’s width.. 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....................34 1................35 1.......13.3.....34 1................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.........34 1..........13...3.13......2...... and other safeguards to the satisfaction of the Company and the Authorities to ensure safety of the public.....6 Normally the windrow shall not be installed over the pipeline through the wadi section............35 1......2.... without the installation of casings................................34 1......2................ such as warning signs......................2..1 ‘Wadi’ shall mean dry river bed which could be temporarily filled with water following rain...............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...................

............... supervision......14...............3.. Contractor shall furnish all materials.............. or any cement which shows signs of deterioration...4................1 Scope 37 1. It shall satisfy the requirements of BS 3148 and contain no staining or colouring.. length and all weights..... No rebound material shall be mixed into any batch.................... sharp and graded evenly from fine to coarse.3 Concrete Materials.. proportioning and mixing of the materials shall be such that a concrete coating is provided with the minimum specified strength and density.. Cement which is held in stock for longer than three months... hardened rebound or anything likely to destroy adhesion or promote corrosion...............37 1.................. The type of barrier coat to be used shall be a two component fibre reinforced cementetious coating such as FBE Brushcrete.0 1....39 1...1 Contractor shall be responsible for the supply and installation of all concrete coatings............. The minimum thickness shall depend on the pipe outside diameter as specified below:37 1.....14........................................ worksite and services incidental to and necessary for the application of concrete in accordance with this specification and all subject to Company approval......................39 1..37 1..................................................................... The reinforcement shall be placed at the centre of the concrete coating layer by using P. and be in compliance with BS 882....................2 Aggregates shall be naturally occurring washed sand and shall be hard...............3....4 The concrete coating of line pipe shall be applied either in an approved coating plant or in the field..... Contractor shall apply a protective layer or ‘barrier coat’ to epoxy coated pipe.......Pipeline Construction Specification Version 2........3 Water for use in concrete shall be clean and free from all substances which may be injurious to concrete or steel.................. Maximum mesh dimensions shall be 38mm x 38mm x 2 mm wire diameter. as per the grading limits specified below.. partial setting or other defects or which fails when tested......14...........39 1... If in the opinion of the Company........14...........4 Reinforcement of concrete coating shall be by one layer of electrically welded galvanised steel mesh fabric reinforcement to BS 4483...................2 General......................3 The mill identity of each pipe length shall be preserved and records kept during and after the coating process.. Field application shall be by dry mix gunite technique or Company approved equivalent......... clay.........................V...I........................14.. at Contractor’s option.... 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..................................... Epoxytar........39 1...................... The plant application procedure and the coating plant may involve methods other than guniting and shall be Company approved.......... shall be rejected...... Rezex water based epoxy coating ES2 or equivalent........................... free from scale..2 Batching.................................... average outside diameter...2................ durable.2...... the aggregate contains an undesirable proportion of chemicals..................... grease...........37 1.......... spacer blocks or a Company approved equivalent...2...............3....3....1 The cement shall be ordinary Portland cement conforming to BS EN197 or ASTM C150......................39 1....14..................14........37 1.......14...... the consignment shall be rejected..........................14............................... labour......14..............14...... The reinforcement shall be clean.....4 Application........... dust..............14.2 The concrete shall have a minimum dry density of 2400 kg/m3 after 28 days........... The minimum overlap between two consecutive rolls of mesh shall be 50 mm except at field joints where no overlap is required...2....... equipment..........4..................... dense..39 1.........M.. Fosroc H...... The grading of aggregate when plotted against sieve size shall be within the limits tabulated below: ......39 1...........C..... mud. organic matter or other undesirable constituents.. clean............... No batch of cement and aggregate shall be used in the work if it has stood for more than half an hour after mixing..........14... including all associated handling and transport of linepipe etc...... A certified permanent record shall be supplied to the Company showing the serial number......................................14............. and promotes a good bond between the epoxy and concrete coating....1 Prior to concrete coating......40 SP-1208 Page xiv September 2005 ...

...........4 The mixing equipment shall be capable of providing a uniform mix.......6........... spray.......14........14...42 1....14............................... pieces of cement bag...........3 For factory applied coating......... Contractor may optt not to wait for the test results and immediately initiate the stripping and subsequent coating repair work...............42 1.... Written evidence of such experience shall be furnished to the Company.......4........... draught.......... 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............42 SP-1208 Page xv September 2005 ...............14............. 0..5............. for a minimum period of 7 days by wrapping with suitable hessian or polyethylene sheeting........................ Contractor shall remove cores from the suspected pipe.....................5...............6...........14.3 Contractor shall pay attention to the moisture content of the sand used for guniting........14.....6 to 1.1 The finished concrete coating shall be completely protected from wind.......4....... Other operators of the guniting crew shall have a minimum of one year’s experience........... If concrete is faulty...4......................................5 Curing42 1.......7.......14....14.......5....... a distance of approx....... 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..... prior to concrete application.. 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.4....2 The concrete coated pipe shall not be lifted or transported from the curing area during the 7 day curing period....42 1............. At both ends of each pipe................30 m from the end shall be completely left free of concrete to facilitate field joints.....5...14........................e.........40 1.... etc...1 Every length of coated pipe shall be inspected visually and by spiral ring holiday detector and repaired.........14............Pipeline Construction Specification Version 2.8 The outer surface of the concrete coating shall be smooth.......... In case the moisture content falls outside the critical range of 5 to 8%.0 1........ Mix temperature shall not exceed 32°C........14. inspect and where necessary repair the corrosion coating or reapply the concrete coating..........6 Inspection and Testing.......... If the compressive strength tests of the cores fail to meet the specified strengths.......... etc....................... If the sand is too wet........................ Also during this period the pipe shall not be exposed to direct sunlight and/or temperature below freezing point....14...40 1.. he shall have at least 3 years experience in work of a similar nature..... After a period of 4 hours from placement and for the 7 days curing period...........40 1..40 1............................ Contractor shall remove the defective coatings by Company approved method.......................40 1.... 0.............................10... in accordance with Section 2......5 Concrete shall not be placed until:..... Contractor shall make the sand suitably damp either by spraying the dry sand with water or mixing wet sand with specially supplied dry sand.......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.............. any other curing methods apart from that mentioned in 2. 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... flakes from the mixer drum..............2 The concrete shall be visually inspected immediately after the application and after approximately 3 days...4..... Anti-Corrosion Coatings. without corrugations and concentric with the steel pipe.. the surface of the pipe.... the hose will block and a mortar layer will build up inside the gun......... The nozzle shall be held in the optimum position for placement at all times i.............. Further regulating of the water supply should be kept to a minimum to ensure uniform concrete quality... the concrete surface shall be kept wet....42 1....42 1.............40 1........4.2 m from and at right angles to. The concrete shall taper back from these points at a two-to-one slope until the required thickness of coating is reached.........6 Since the technique of guniting relies significantly on the skill of the nozzle man.......14.... rain.......... The dry mix used for guniting shall be screened to prevent inclusion of stone.....1 may be adopted subject to approval of the Company......

....44 SP-1208 Page xvi September 2005 ... Should the damaged area be more than 0.........................42 1................. Repairs shall be made by chiselling the crack out to width of not less than 25 mm throughout the length of the crack......43 1..........................7.....Pipeline Construction Specification Version 2.1 m2 and less than 0......6................44 1..........................................6...43 1............................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...........3 Chainage Markers.. On a regular basis. All other defects shall only be repaired once the concrete has hardened................................ shall be made every day.............6...........43 1.. made from mild steel........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...................2.............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..6........14....7..........15 Permanent Markers and Barriers.......................................................................................14............14.... An area of less than 0.......................... the coating shall be removed around the entire periphery of the line pipe throughout the entire damaged area and repaired............. where applicable.43 1....14..........7 Concrete Coating Repairs... vertical or overhead) and gunited.6 Wadi Crossing Markers..................................44 1.......14..3 Concrete cracks that are in excess of 1...15.15.. The repairs shall be kept moist and allowed to remain undisturbed for a period of not less than 36 hours.......... shall be repaired.............................. one at the start of work........ cores shall be taken from each test panel after it has cured in a similar manner as the coated pipe.....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.............................0 1............44 1............14.....10....15..........7 Effective electrical separation between reinforcing steel and pipe shall be determined for each pipe joint by electrical tests................................ to be decided by the Company...............15..................2.................33 m2 per joint.......................33 m2 per joint.2 General....15................................... These test panels shall be positioned alongside the work and in a position similar to the work (horizontal................ or where cracks are over 330 mm in length longitudinally along the pipe irrespective of width........ Further curing shall be in accordance with the Specification...........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.1 m2 per joint where the concrete remaining on the joint is sound shall be accepted without repairs....................... 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 mm in width and extend over 180° circumferentially around the pipe.....................6.......................5 Road Crossing Markers.......7....................44 1....... 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..14............. 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....................................5%).....................14...... and one during the day as instructed by the Company....43 1..44 1...............42 1...43 1........ 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........14...14..............................44 1..................4 Block Valve Station Markers.3 Test panels.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.........1 Scope 44 1. Concrete coatings not in accordance with the dimensional requirements shall be repaired or stripped and recoated at the discretion of the Company............................15...................................................... Should the area affected be more than 0.........................43 1....7....

........................16...16.......17............................... Contractor shall sub-contract the supply/installation to a Company approved supplier/contractor...............17.....4 Painting.3 m length...............15........................................................................15..........0 1.3..16....1....15.................................................15....................................50 1.....17.......................................................47 1..................................47 1...................................e....1......................................49 1....7 Fencing...........16....................................................................48 1..............................17............................................................15................16....49 1.............2 Concrete/ Block work..........16...........................................................12 R........5 Instrumentation...................................................17...........................................14............................................................................46 1...............3 Painting of access barriers shall be in black and yellow bands of 0............9 Markers at Horizontal Bends...........................................................49 1.14..........................P supervisor who shall have the prior approval of the Company...................................................................O...........................................15..........................8 Cable Crossing Markers............................. `STOP` Signs...3......2 The cathodic protection design shall be in accordance with SP-1128 Specification for Cathodic Protection Design’...46 1........10 Cathodic Protection Markers...........15...........3 When a complete new C........................1 General.........................49 1....3 Civil and Mechanical Works... then the Contractor shall employ a qualified C........13 Corrosion Monitoring Pit Marker...................................1 Scope 46 1..........................16.....50 1....................47 1........14..Pipeline Construction Specification Version 2......................................12....... but allowing inspection vehicles to pass when required....................6 Electrical Works........... System shall be carried out concurrently with the main pipeline laying work.......3...........49 1....... solar stations...............................................................49 1.W...................................................17.......45 1.......................................1............... Station Works....45 1............................................................ Final configuration shall be approved by the Company Site Representative........................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...P.......7 Pipeline Crossing Markers....45 1.............15............45 1......................................................45 1.....16 Station Works............ Paintings shall be carried out in accordance with Section 2.................................11 Pearson Survey Hole Marker....................45 1........17 Cathodic Protection.................2 Earthworks............P test points connects to an existing system....................16................................................ At these crossings...............................................................16............... in order to mobilise a Company CP Inspector.........16......................4 Contractor shall give the Company 5 days notice prior to installation of special C......................16................45 1.3.............................3........................4 Process Pipework........ access barriers shall be constructed in accordance with Standard Drawing GEN-2-1633-01....................47 1. T/R units and ground bed anode systems.........45 1...................2 Materials..................................................14 Access Barriers.....45 1.................1 Impresssed Current Cathodic Protection .......48 1........................50 SP-1208 Page xvii September 2005 ................................................. Details of various design aspects are indicated in the standard drawings specified in SP-1136 ‘Specification for Cathodic Protection Standard Drawings’.........................................................15...........................15...........15.......................................................3 Structural Steel.................49 1...47 1..................................................................17.............P items i.................................................... removable barriers shall be installed to prevent normal access from the crossing to the Right-of-Way..................................................................................45 1...................45 1......................1 Installation of the C...1 When specified on the drawings............................. When solar panels are required..................................................3 Installation......................................................

unless shown otherwise on the drawings (Ref................50 1... the connection pad may be attached by welding a pad on the foreign services (Ref....................... after installation of the pipeline...........51 1.....................................17........................52 1.... Standard Test Post...........21............................50 1.....1 Scope 52 1...............0 1...3.............P......5 Where Foreign Service Bonding Facilities are required on foreign services.........................................................53 SP-1208 Page xviii September 2005 ... Standard Test Post shall be installed (Ref...17..... Contractor shall excavate.............17...............20...... STD- 7-3007)..........17.............. for the precommissioning work including but not limited to detailed procedures..5........... at the following locations:.........17.................2 At approximately 2 km intervals...4 Temporary Cathodic Protection................5 Pearson Survey.... testing facilities shall be installed in accordance with SP-1129... as shown on the Drawings..................................................20 Precommissioning Of Pipelines......... cables shall be installed in accordance with SP-1129...........51 1.... STD-7-6003...........................8 Drain Point Facilities shall be installed as shown on the Drawings (Ref............2 General.6 Current Measuring Stations shall be installed on the pipeline every 10 km............. STD-7-3006).......... If coating defects are found on any portion of the coating................... Contractor shall install Pearson Survey Earthing Points adjacent to each 2 km C............................................21 Work on Live Pipe Systems................................ STD-7- 3003)....................................Pipeline Construction Specification Version 2.......17..3............. Contractor’s proposals shall include complete information regarding the following aspects:...........................................51 1............................... a C.............................51 1.....50 1..........................2....P..................................1 Contractor shall make detailed proposals...........2 General............51 1........................3 Cable connections to the pipeline (Ref...... STD-7-3001).. STD-7-2001) shall also be required.17...........21.................................. for Company approval......20...............................................1 Company will carry out a ‘Pearson Survey’..50 1.........17.......... Welding and NDT....50 1........... STD-7-6001..................6 Commissioning..............52 1.......................6..................................... repair and backfill at Contractor’s expense....................51 1......................................20.................................9 Insulating joints/flanges shall be installed in accordance with Drawings (Ref.............53 1......... including procedure and welder qualification shall be in accordance with Section 2.............................................3..17......... Welding of the attachments to the pipeline.....................4 All C........................................18 Quality and Treatment of Hydrotesting Water..........................3..................... and STD-7- 6004).5....19 Hydrostatic Testing. in accordance with drawing GEN-2-1633-01.......... In order to achieve good earthing for this survey...... and within 50m of a power line (Ref.P... ...3............P......2 These earthing points shall be constructed during the main pipelay work.......................17...........17........................3....10 All C...............50 1.........11 Ground beds..........................................51 1................. STD-7-6002. when required and shown on the Drawings........................51 1....7 A Grounding Facility shall be installed at power line crossings and where the pipeline runs parallel to..................................3....3.....1 Scope 53 1................................................ to check the integrity of the buried pipeline coating.....17.............51 1..... programme and schedule for Work..............................................51 1............................................................................17...........51 1........ Cable to pipeline connections shall be made prior to hydrostatic testing.................................3.......................52 1..... as shown on the drawings...3.17.......17. STD-7-3004)....... STD-7-3005)..... Cable markers shall be installed in accordance with drawing STD-7-7001.. shall be installed in accordance with SP-1129(Ref........... for cross bonding.

54 1..................................2...............................................64 Appendix E List of Typical Drawings for Pipeline Construction.................3 Storage Location..........53 1...................................105 SP-1208 Page xix September 2005 ...............................0 1..................22............................54 1....1 The work permit system shall apply to all work on live pipe systems...........22.........................................................................8 As-built Drawings and Pipeline Data Sheets...22...........2 Storage Format.........................53 1.................... Calibration and Inspection Reports.......22....................................21....38....................... Welding on pressurised pipes shall be carried out in accordance with SP-1167......................................................4 Pipeline As-Built Documentation...................................... Contractor shall do all that is necessary to obtain work permits and to execute the Work in adherence to the work permit...........................................................................................................24 Review and Improvement......................................................................................10................................................................23 Effective Period...................22......................6 Test..........5 Documents................Pipeline Construction Specification Version 2................................22 As-Built Records and Hand-Over Documentation..................................................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..........................21..22.............................................21.......69 Appendix F CONSTRUCTION REQUIREMENTS FOR GRE PIPELINES...................7 Material Certificates.............22...................61 Appendix D: List of Handover and As-built Documentation....55 1................................................................ A vendor’s representative shall be present at all times during the use of such tools and equipment...............22......54 1...........53 1.................................2...........................3 Hot tapping on live pipe systems shall be carried out in accordance with DEP 31..... Terms and Definitions.................................................................... Terms and Abbreviations...................................................................................................................................................................................................................................................1 Scope 53 1....................56 ii.... Abbreviations....................95 User Comment Form....60.......................56 Appendix B Reference Documents........................................................................................................................56 i.......54 1............................................................53 1...................................................................53 1.............................................54 1.......................55 Appendix A Glossary of Definitions....2..55 1.57 Appendix C: Facilities For Company Personnel...

Purchase Orders and Variations thereto.0 April 2001.50. CFDH Pipelines). 1. the following priority of documents shall apply: . the existing SP-1247 (Dec. Contractual Scope of Work. Send the copy with your comments and personal details to Document Control Section (DCS).2 Changes to the Specification This specification shall not be changed without approval from the Custodian (UIP. who owns this specification. Any work completed with unauthorised modifications may be rejected by the Company.40. SP-1208 Page 1 September 2005 . . 1. . This document and PDO/Group standards referred to in this document. Project Specification and Requisition Sheets. The appropriate technical authorities are set out in GU-272.3 Conflicting Requirements In case of conflicting requirements between documents relating to an inquiry or order.30 respectively. write your comments on a copy of the User Comments Form. . If you think any part of this specification is not correct. Any subsequent re-work shall be in accordance with this specification and shall be to the Contractor’s expense.4 Exceptions The user shall obtain written approval prior to construction from the appropriate Technical Authority within PDO for any deviation from or exception to the requirements of this Standard.1 Purpose This document shall be used as the base specification for construction of all new carbon steel pipelines required in PDO operations.0 1 Introduction 1. This revision updates the earlier Pipeline Construction Specification (SP-1208) Version 1.2002) stands withdrawn. International Standards and Specifications referred to in this document. The form is included as the last page of this specification. 1. Appendix – F of this specification specifies requirements for construction of GRE pipelines.Pipeline Construction Specification Version 2. With the inclusion of requirements for GRE pipeline construction in this revision. Hydrostatic testing and Pre-commissioning of new pipelines are covered separately in SP-1212 and DEP 31.

The HSE Advisor(s) shall carry out his work from the moment the Contractor starts mobilisation and until the date of completion.1 Scope This Section of the Specification covers the minimum HSE requirements required during installation work. paying particular attention to: The requirements for construction and lifting equipment in SP-1143.0 2 Specification Requirements 1. As part of Contractor’s mobilisation. A copy shall be handed to the Company’s Site Engineer.5. The HSE Advisor shall be fully conversant with the Work and shall have previous experience and qualifications as specified in the HSE Regulations. 1. 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). SP-1251 and PR-1508.3 HSE Advisor Contractor shall appoint one or more HSE Advisors. what action has been taken to prevent re-occurrence of any incidents reported. prior to any Work commencing. unsafe acts.5 Health. The daily report is in addition to those required by the Safety Regulations. The Transport Operations manual TOM/04/001 as well as SP-2000 “Road Transport” and GU-140. unsafe situations etc.5. The work of the HSE Advisor(s) is to ensure that all Contractor’s work and conditions are in accordance with the Company’s HSE Regulations.2 General The Contractor shall comply in all respects with all HSE Specifications listed in C-6 and C-9 documents of the Contract. SP-1239. for communications with Contractor’s Construction camp/head office. reporting directly to the Contractor’s Project Manager. the specification for Aqueous Effluents SP-1006.5. The Contractor’s HSE Advisor(s) shall make daily reports about all accidents. noticed by himself or brought to his attention. SP-1208 Page 2 September 2005 . Pipeline Construction Specification Version 2. The daily report shall be transmitted to Contractor’s Project Manager on each morning following the reported day. for the sole use of the HSE Advisor(s). Contractor shall submit and obtain Company’s approval for the HSE Plans and Procedures for the Work. Contractor’s Project Manager shall advise the Company’s Site Engineer in writing within 24 hrs of the report being issued. to be approved by the Company. Contractor shall provide a dedicated vehicle with VHF radio. 1. Safety and Environment (HSE) 1.

sand padding. 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 General Before starting the Work. The Team shall have no other work or responsibilities apart from Quality Assurance. Generic pipeline construction hazards are identified in the Company’s Pipeline Construction HSE Case. 1.4 Specific Pipeline Activities Contractor shall specifically instruct all personnel of the dangers relating to the internal inspection of pipelines. During construction of pipelines. Only under special circumstances shall anyone be allowed to enter a pipeline.6. lowering.1 Scope This Section of the Specification and SP-1171 “Specification for Quality Assurance of Design.0 1. how corrective action requests are to be generated and how it will be demonstrated that such actions have been carried out and are effective. drawing and document control and supervision.6. 1. The Contractor shall have a full time Quality Assurance Team and all necessary equipment at the Work Site.5. Contractor shall submit his proposed quality assurance procedures and organisation to the Company for Company’s approval. Construction and Engineering Works” covers the minimum requirements of Quality Assurance required for the Work. and only after a specific procedure has been agreed and approved by the Company. 1. 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.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. Contractor’s proposed plan shall include the internal procedures to report non conformances. Required number of Contractor’s Inspectors (depending on contract size and geographical spread of the work sites) to cover welding/jointing. tie-ins. backfilling. hydro testing and pre commissioning activities.6. NDT. SP-1208 Page 3 September 2005 . the working strip shall be marked with road traffic signs and specific warning signs relating to the construction activities. The Quality Assurance Team should as a minimum consist of: One Contractor’s Quality Assurance Engineer responsible for procedure preparation and implementation. joint coating/painting. Pipeline Construction Specification Version 2. This applies particularly to road crossings.6 Quality Assurance 1.

shrink sleeve application (CS pipelines) . SP-1208 Page 4 September 2005 . reports and general documentation . All Contractor’s inspectors shall have a dedicated vehicle. field welding / jointing . 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. check pot life of adhesives (GRE pipelines) . They shall have previously worked on similar projects in similar capacities. welding / jointing procedures as the case may be . NDT procedures (CS pipelines) . Following Company’s approval and the arrival of the Inspectors on site. painting/coating (CS pipework) .Pipeline Construction Specification Version 2. Company has the right to request all Inspectors to an examination to ensure their suitability for the work they are required to do. trench depth . document control 1. traceability of materials . He shall have experience in quality assurance matters and be suitably qualified.0 Quality Inspector’s duties include but not limited to the following activities: . materials certification . post padding / plugging . backfilling .1 Personnel The Head of Quality Assurance shall have a detailed knowledge of welding and NDT and other activities of pipeline construction. All Contractor’s inspectors shall be fully conversant with and experienced in the aspects of the Work for which they will be employed.6. lowering in . identification numbering systems . sand padding .3. at the Company’s sole discretion. and reject any Inspector who is found unsuitable. as-built drawings . incoming materials inspection and acceptance .

who will advise the Contractor formally of any required corrective action. The Head of Quality Assurance shall not carry out inspection work himself other than in supervision of the Contractor’s Inspectors. Figure 1 Quality Assurance Organisation SP-1208 Page 5 September 2005 . His duties shall be to liaise with the Company. 1. 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. The Inspectors will have authority to stop the work in the case of unsafe situations and non-compliance with the HSE Specifications. organise the Contractor’s Inspectors so that they carry out their duties in an efficient manner. to monitor all work activities including safety aspects. in accordance with the NDT flowchart included in the Procedures. Interpretation of weld radiographs shall be performed by Contractor’s Specialist sub Contractor and the Inspectors independently.0 1.Pipeline Construction Specification Version 2.6.2 Organisation The Head of Quality Assurance shall report directly to the Contractor’s Project Manager.3.4 Company Inspection Company will employ a team of Inspectors throughout the contract period. These Company Inspectors are hereafter referred to as the Inspectors. The Quality Assurance organisation shall be similar to that shown in Figure 1.6. and prepare all necessary reports. The inspectors will report non-compliances with this specification and other contract standards to the CSR. Contractor’s NDT supervisors and shrink sleeves manufacturers representative shall report directly to the Head of Quality Assurance on quality assurance matters. Non-compliance certificates and other forms are also to be included in the Procedures.

1 Scope This Section of the Specification covers the minimum requirements for handling.4 Contractor is required to supply lifting equipment for lifting materials at all locations. and stock status of the Contractor and Company supplied materials.7. for approval. 1. 1. Company and Contractor shall carry out a joint survey of pipe coating damage and bevel damages.7. 1.7. 1. storage and administration of all materials.2.3. lifting.7. stacking. surface defects and defective bevels.7.3. Contractor shall provide the Company with a written confirmation of receipt of all materials (identified by type and quantity) and a written reconciliation of all materials (identified by type and quality) transported by them from Company’s storage yard on a weekly basis. On the basis of this survey.7 Materials Handling and Control 1. 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 Prior to haulage of pipe from Company’s storage yard. loading.3 Pipe Inspection 1. either Company or Contractor supplied. to be incorporated in the Work. A lapse greater than 2 working days shall require re- notification.6 Contractor shall not be held responsible for manufacturing defects in Company supplied materials.2 Contractor’s material control and storage procedure shall be submitted to the Company within two weeks of the start of mobilisation on site.7 Contractor’s procedures for material receipt and return of surplus materials shall conform to Company’s materials procurement/administration procedures.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.1 The Contractor shall visually inspect at the Company storage yards. 1.7.2.7.7. and storage of materials shall be carried out by the Contractor in such a manner as to avoid any damage and loss of materials. Lifting equipment and operations shall be in accordance with SP- 1239. 1. 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. Company will pay the Contractor a lump sum for repair of all bevel and coating damage.2.2.1 Handling.5 Contractor shall appoint a dedicated site-based materials Controller whose sole function shall be to control and report on the receipt.7. transport. 1.2 General 1.7. unloading. issue. 1. including but not necessarily limited to receipt. Pipe can be removed from Company’s yard 7 days per week during daylight hours.2. checking. 1.2. unless otherwise specified by the Company. based on the submitted unit SP-1208 Page 6 September 2005 .0 1.7. Pipeline Construction Specification Version 2.7.2. all pipes internally and externally for damages. Method and means of transport and handling (including documentation) shall be subject to approval by the Company.

the repair shall be by re-bevelling. For bevel damage depth greater than 3 mm.Pipeline Construction Specification Version 2. the repair shall be by grinding.0 rates in the Schedule of Rates. For bevel damages between 1 and 3 mm deep. SP-1208 Page 7 September 2005 . in accordance with this specification.

20.6.7. Each fusion-bonded epoxy powder coated pipe shall be left bare for a distance of 80 ± 15mm. When lifting pipe. the bottom layer of pipes shall be wedged or clipped. grade or manufacturer shall be stacked separately.6. moved and lowered from one position to another by suitable equipment.3 Linepipes if required.7. Pipes shall only be transported on trucks (lifting equipment shall not be used to transport pipe).37 for non critical and critical services respectively. Pipes shall be stacked in such a way that no water is retained inside the pipe during storage. Pipe ends shall be protected from contact with other metallic materials. 1.1 Ground surfaces to be used for stacking of pipe shall be reasonably flat. 1.Pipeline Construction Specification Version 2. Where concrete SP-1208 Page 8 September 2005 .5. wall thickness.7. shall be provided with a factory-applied polyethylene / polypropylene coating or a factory applied fusion bonded epoxy powder coating.0 1. After loading.6.7.5.40.2 Epoxy-coated pipes shall be stacked during transport and storage using rubber or other suitable separator strips.7. 1. These specify amendments/supplements to ISO 3183 Specification.7m long.3 Trucks used for loading of pipes will be checked by the Company prior to lifting the pipes to ensure that the trucks and loading/load securing arrangements comply with the requirements of PDO’s Transport Manual TOM/04/001.6 Linepipe Specifications 1.1 Line-pipe shall be manufactured in accordance to DEP 31.3 Pipes shall not be stacked higher than 3.7. 1. Temporary attachments for handling or lifting shall not be welded to any pipe.2 Minimum average pipe length shall be 11.4 Pipe Handling 1.4.2 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. 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.20. Stacked pipes shall be raised above ground surfaces and prevented from movement by berms of screened sand covered by polyethylene sheeting or by using timber covered with non-metallic soft materials. 1.7. When stacked.7. Pipes shall be protected against truck beds and side metallic posts by means of non-metallic soft materials. 1. 1. A spreader bar shall be used for all bulk pipe lifting/handling (excluding welding operations).7. Each stack shall be properly marked to the satisfaction of the Company.5.50m as per above DEP. SP- 2000 ‘Road Transport’ and government regulations.7.7. Pipes of different diameter. The minimum and maximum length of pipe shall be between 9m and 13. Contractor shall ensure that no bevel protectors are lost during transport. suitable non-metallic slings shall be used to tie the pipes securely to the truck.1 Pipe shall not be allowed to drop or strike objects which may damage the pipe and/or coating but shall be lifted.4. Each polyethylene / polypropylene coated pipe shall be left bare for a distance of 150 ± 20 mm from each end.5 metres. 1. During transport the tension of these slings shall be regularly checked.4.5 Pipe Stacking 1.7. Pipes shall be loaded and stacked on trucks in such a manner that flexing and shifting of the pipe during transport is avoided.35 and DEP 31.40.

SP-1208 Page 9 September 2005 . the concrete coating cut back shall be increased by 100mm over and above the cut back left in the mill coated pipe.0 coating of linepipe is envisaged.Pipeline Construction Specification Version 2.

7. nozzles. 1. 1.0 1. shall be lifted by suitable equipment provided by the Contractor at Company’s storage yard and at all other locations.7. Temporary attachments for handling or lifting shall not be welded to any materials. Visual inspection shall be adequate for this purpose. 1.8.7.2 above.7. materials shall be secured by suitable non-metallic non- abrasive slings. Fittings shall only be handled by suitable non-abrasive slings.3 During transport.9 Reconciliation SP-1208 Page 10 September 2005 . Stored materials shall be protected from ground surfaces by using timber covered with non-metallic soft materials.7. for lifting of the materials.7.7.7 Inspection of Materials other than Pipe 1.7. etc.1 Upon receipt of any materials.. 1.8. suitable lifting hooks shall be used for lifting the materials. 1.7.7. The blinds shall be replaced by the Contractor in case of damage during transport or storage.7.5 Contractor shall provide a separate fenced storage area for Company supplied materials.1 Materials other than pipe materials such as.8. 1. but not limited to.7. Any damage/defects shall be reported to the Company within 24 hours of receipt of these materials and prior to transportation to the Contractor’s own storage yard. 1. fittings.8.2 Materials other than pipe materials will be issued to the Contractor whenever possible in their original sealed shipping cases/crates. the Contractor shall ensure that they conform to the required specification and are suitable for their intended application.8. scraper traps etc. transport and handling facilities in accordance with the requirements of the manufacturer and/or the Specifications.7.4 For materials which shall be stored cool and/or dry as required by the manufacturer or the Specifications.8 Handling of Materials other than Pipe 1.2 In the case of materials delivered in their original sealed crates.3. 24 hours after arrival of materials at the Contractors storage yard).7. except in the case of damaged crates which shall be noted and the contents examined when Contractor takes receipt at Company’s storage yard. Contractor shall provide suitable storage. Contractor shall only open the crates to examine the materials upon arrival at his own storage yard. Timing of the issue of materials shall be as per the Company approved work schedule. It is prohibited to use delicate parts such as hand wheels. 1. 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.Pipeline Construction Specification Version 2.8.7. valves.7. 1. Ground surfaces in storage areas shall be clean and flat. It is prohibited to store and transport fragile materials in more than one layer. When lifting lugs are provided on materials. Blinded openings of materials shall be kept closed until installation.6 Distribution and supply of materials from Contractor’s storage yard to the worksites shall be limited to quantities required for approximately one day’s production.3 If no report is issued for damaged materials 24 hours after receipt (or in the case of 2.

Contractor shall not commence work on such crossings before having obtained approval from the Authorities and landowners concerned. Contractor shall notify the Company 7 days in advance before start of work at road. Variations. having a width of 31 metres (including a continuous 6 metre wide vehicle access strip) from one edge of the Restricted Area.2 On approval of the surplus list by the Company. issued by the Authorities concerned. Pipeline Construction Specification Version 2. cable.W.9. in this width caused by local conditions will be indicated on the drawings or instructed to Contractor by the Company.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 crossings shall be installed to meet all requirements and conditions of the permits.1. indicating quantity. at station approaches.1 Scope This Section of the Specification covers the minimum requirements for the Pipeline Right-of-Way (ROW) and the Working Strip. if any.4 Planning/Approvals Contractor shall.8. river and wadi crossings and crossings of other existing structures.1.7. a strip of land 25 meters wide on either side of the pipeline measured from the centre line of the pipeline.3 ROW Width The Right-of-Way for the pipeline is a corridor of 50 metres overall width and comprises: The “Restricted Area”.8 R.8.8. Where two or more pipelines are laid in parallel in the same corridor. and surplus materials.8.9. description and MESC / SAP number when available.1 Pipeline Right-of-Way and Working Strip 1. This should be taken into account where the word `centreline` is used in the remainder of this Section. 1. if any. and Trenching 1.g. materials wasted and scrapped.1 At the end of the project.O. Contractor shall give reconciliation for all Company supplied materials issued. 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. detailing materials installed. 1.7. Contractor shall compile a list of the surplus materials.8. 1. the Right Of Way corridor shall be enlarged by the space between the pipelines. Contractor may make use of a Working Strip. before starting any clearing operations. pipeline.0 1. 1. The actual centreline of the pipeline can in some instances deviate from the line staked e. SP-1208 Page 11 September 2005 . stream.1. 1. The space between two pipelines shall not be less than 2 meters from the existing or new pipeline. Contractor shall return all surplus materials to Company’s storage yard.

8. ‘A’ being closest to the pipeline centreline. a demarcation fence).2. clearing and grading along the pipeline route as required for the Work.Pipeline Construction Specification Version 2. flowline and utility cables.8.2. perpendicular to the previous pipeline direction. Work near live pipelines shall comply with the requirements of ERD 38-11. ‘Guidelines for Excavating and Working around Live Pipelines’ and paragraph 2. 1. Reference markers are established at the Points of Intersection. 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. tree stumps and roots. No work is allowed in such an area without Company approval. Contractor shall comply with the Company’s instructions.3 Staking a) The centreline of the pipeline shall be staked by the Contractor with markers inter visible by binoculars or theolodite. farm crops. Contractor however will have to obtain permission from the concerned Authorities to execute the work.8. 1.1 Scope This Section of the Specification covers the minimum requirements for staking.2 Definitions a) ‘Clearing’ shall mean but is not necessarily limited to the cutting and disposal of trees. Company will have obtained ‘approval in principle’ for laying the pipelines along the routes. b) ‘Grading’ shall mean but is not necessarily limited to removal and disposal of rock.2 Staking. Clearing and Grading 1. In general such a point will be outside the actual pipeline centreline because of the bending radius to be applied. i) Markers are located at the centreline of the pipeline where straight.3.2.2–f) of this specification. 1 at start point of the pipeline. starting with no. the Contractor shall propose methods to safeguard the existing line (e. 1. bushes and undergrowth. Reference markers are marked with the letter ‘A’ or ‘B’. b) Prior to the clearing operations Contractor shall stake: i) Markers in the centreline of the pipeline at distances of maximum 100 metres for straight line sections and maximum 10 metres for horizontal bends. All markers extend approximately 500 mm above grade. Where the pipeline is laid close to any existing buried or above ground pipeline. SP-1208 Page 12 September 2005 .0 In the absence of any specific requirements by the Authorities.4.8. ii) The markers are angle-iron profiles or wooden posts with sequential numbers. The ‘A’ and ‘B’ markers are located at the same side of the centreline marker.g. but in any case not less than one at the centre of every bend. sand dunes. at 25 metre steps from the pipeline centreline.

Pipeline Construction Specification Version 2.0

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

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

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

1.8.2.4 Below and Aboveground Services

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

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

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

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

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

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

SP-1208 Page 13 September 2005

Pipeline Construction Specification Version 2.0

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 0005-
001 in Appendix E.

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

1.8.2.5 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).

1.8.2.6 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 Page 14 September 2005

Pipeline Construction Specification Version 2.0

1.8.2.7 Grading the Working Strip

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

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

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

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

1.8.3 Trenching

1.8.3.1 Scope

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

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

1.8.3.2 Excavation

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

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

SP-1208 Page 15 September 2005

90 0. tracks and live stock crossings. cables. Fill material in Working Strip shall not be considered to add to the depth of cover. In the event that the pipeline crosses over existing structures. REQUIRING B 31. pipe protectors. track. Wadi. For crossings of buried live pipelines. wadi. 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. Contractor shall provide such increased clearance. telephone lines. ditch. etc. measured perpendicular to its axis. punctured or abraded.8) GROUND BLASTING OR ROCK CUTTING Location Class 1 0. Any such items encountered shall be removed prior to pre-padding operations so that the pipe is not damaged.60 Location Class 3 and 4 0.90 0. rocks. and other pipelines shall be the responsibility of Contractor. skids. SP-1208 Page 16 September 2005 . 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.80 Roads. However. The construction over or under all existing structures such as roads.50 1. ditches or from the top of roads and tracks as the case may be. sticks. whether or not indicated on the route maps. large clods. 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. drainage ditches. ii) The minimum depth of cover at crossing of wadis. If clearance of more than 500 mm is required by the Authorities having jurisdiction. f) Where the pipeline crossed other pipelines. the requirements of ERD38-11 shall apply. e) The trench bottom and sides shall be kept free of all brush. tarmac and graded roads.Pipeline Construction Specification Version 2. This depth shall be extended 5m outside the edge of the road.0 c) The trench shall be excavated so as to provide a minimum depth of cover as specified in the table below. conduits or other underground structures of any kind.60 Location Class 2 0. shall be measured from the bottom of wadis. and live stock passageways 1. unless specified otherwise in the Contract scope of work or drawings. water lines. sewers. water lines. the same clearance as described above shall be maintained and depth of cover as per paragraph (c) above. MINIMUM COVER (M) LOCATION CLASS (as defined in ASME IN NORMAL IN ROCK.80 0. projecting rocks and other hard objects at all times.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.

Wherever possible. transportation of explosives and blasting shall be carried out in accordance with the N. No. If the crossings are open at night.P. 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 required to maintain the trench in good condition until the pipe is laid in place and backfilled. whether or not a rip survey is carried out. h) Contractor shall provide and use sheet piles. the Contractor shall submit his proposed blasting procedure and perform a trial blast for Company approval.F.3.Pipeline Construction Specification Version 2.3 Blasting All activities including but not limited to storage. b) Areas to be blasted are categorised as follows: i) 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). BS 5607 and the instructions of the Authorities and/or the requirements in this section. walling. If an inspector is appointed.A. A blasting procedure shall be submitted to the Company for review and approval.8. walkways.. whichever are the most stringent. all as required and approved by the Authorities having jurisdiction and/or the Company. Whenever it is permissible to open cut a road. he will be present at all blasting operations to monitor compliance with the approved blasting procedures. 495.0 g) In locations where the trench is cut across roads. etc. then the results of this survey shall be made available to Company. j) If Contractor elects to carry out a rip survey. The extent of rock encountered during trenching shall be recorded on the as-built Alignment Sheets by the Contractor. Contractor shall provide and use warning lights or lanterns. Proper warning signals shall be placed and maintained while such crossings are open. i) Contractor shall do hand work in the trench as is necessary to free the bottom of the trench of loose rock and stones. struts. Blasting shall be performed only by a specialist blasting contractor approved and registered with the Company. Contractor shall remove and restore the surface in accordance with the requirements of the Authorities having jurisdiction thereof or as directed by the Company. following. paths. a) A qualified blasting inspector may be appointed by the Company. Contractor shall arrange to complete the trenching. and all other irregularities so as to leave the trench bottom in a clean and suitable condition to receive the pipe. jacks. 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. SP-1208 Page 17 September 2005 . 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. as defined in clause b). 1. pumps etc. tracks.

to be decided after two passes of a D9 Caterpiller tractor (or one pass of a tandem D9) or equal.3.e. the trench width shall normally be outside diameter of the pipe plus 300 mm (i. rock in trench is defined as the rocky part of the specified trench which cannot be removed by ditching machines.e.9 Stringing and Bending 1.8. 1. pipelines running parallel) shall be kept to a minimum and must be approved by the Company as part of the Contractors proposed blasting procedure. slit trenches. c) Blasting shall be carried out prior to stringing the pipes. back hoe or ripper.6 Trench Width In the case of a single pipeline to be laid in the trench. 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. Pipeline Construction Specification Version 2. In such locations other methods of extracting rock shall be proposed by the Contractor for approval by the Company.0 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. existing utilities or other structures.g.). iii) No blasting is allowed within 20 metres of any existing pipeline or structure (either above or below ground). break holes. 1.5 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. In the case of more than one pipeline to be laid in common trench. 1. the trench width shall normally be the sum of the diameters of the pipes plus 300 mm (i.8. In no case shall the peak particle velocity exceed 10 mm/sec. etc. 150 mm on each side of the pipe) unless otherwise approved by the Company (refer drawing TYP 3 0002 001).g. e) Blasting shall not be permitted in any location where possible danger exists to the general public. No trial blasting shall be performed until the procedures are approved by the Company. equipped with proper ripping equipment. property. No retaining barriers are required in areas of sand dunes.1 Scope This Section of the Specification covers the minimum requirements for stringing the line pipe along the trench side and for cold bending of metallic pipe as required for the work. 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. SP-1208 Page 18 September 2005 .8. which shall also detail safety precautions to safeguard existing pipelines or structures (e. rock plough.3.3. 1.4 Definition of Rock For depth of cover purposes.9.

Company may supply line pipe from different manufacturers. 1. step length. 1.1 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.g.9.3.9. 1. 1. in view of the inherent increased risk of failure of skids due to movements of the pipe.2. to ensure that the installed pipe shall conform to the contours of the pre-padded trench.3 for requirements for slings and hooks).Pipeline Construction Specification Version 2. submit and demonstrate to the Company a bending procedure. 1. footpaths. D being the pipeline diameter are not allowed unless approved by the Company. degrees per pull and method and accuracy of measurement during pulling of the bend.9.2. Suitable gaps shall be left at intervals as necessary to permit the passage of live stock and/or equipment across the Right-of-Way and as directed by the Company.1 Contractor shall make all necessary bends required for proper construction of the pipeline.2. the number of pieces cut-off with less than one metre length is kept to a minimum.7 Pipe shall be strung with the use of a spreader bar and two guide lines. The procedure shall include amongst others. 1. 1. The skids and protective padding material shall be subject to Company (CSR) approval.5 Contractor shall layout and measure the pipes such that.2.9. following a trigonometric survey to establish the number and degree of bends required. The distance between the trench edge and the pipe string shall be planned such that safe working space is provided. 1.2 Where possible the skid elevations shall be planned such that minor differences between grade profile and bottom of trench profile (e.3 Pipe Bending 1.3.3 Contractor shall be responsible for proper stringing and locating of the pipe by size. Wooden wedges shall be used to prevent movement of each strung pipe. Dragging.0 1.3.9. 1.9. wall thickness. Pipes of different manufacturers shall not be mixed per line section without prior approval of the Company.9. This procedure shall be subject to Company’s approval.2.2 Contractor shall. tracks.9.2 Stringing 1.9.3 Elastic bends with radius of curvature less than 500 x D. skidding or dropping of the pipe is not permitted. at locations where an increased trench depth is required) can be accommodated without requiring an additional tie-in. specification and manufacturer.9. before the start of the Work. Length of individual pipe strings shall be subject to Company approval and shall generally not exceed 1 km. etc.9.2. Special attention shall be paid to strings with one or more bends. which shall conform to the recommendations of the manufacturer of the bending machine. Contractor shall string all line pipe of one manufacturer before commencing the stringing of line pipe supplied by the second manufacturer.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. Pipe shall not be placed directly on the ground but on wooden skids with proper protective padding. (See Section 2.2.4 Contractor shall string the pipe in such a manner so as to cause no interference with public roads. SP-1208 Page 19 September 2005 .9.

This includes all pipeline work.9. 40 D for pipe OD of over 400mm The radius of hot bends shall not be less than: .10 Welding and NDT 1.5% of the nominal internal diameter of the pipe prior to installation. Pipeline DN150 to DN 250: 5D . 30 D for pipe OD of 200mm to 400mm .9. as required for the Work. wrinkles and kinks are not acceptable.1 Scope This Section of the Specification covers the minimum requirements for the fabrication. The minimum requirements for welding are contained in Specification SP-1177 (for Class 1 Pipelines).3. block valve stations and most parts of the pig trap stations. Pipeline DN100 and below: 10D . SP-1174 (for Class 2 & 3 Pipelines) and SP-1097 (for Duplex Stainless Steel Pipelines). 1.9. fully retaining bending shoes shall be used.4 The radius of cold bends shall be not less than: . welding. Bends in pipe of diameter 8" or greater shall be made by using an internal (hydraulic or pneumatic) mandrel. Contractor shall lay out and measure the pipe for bending such that the length of off-cuts is kept to a minimum.3. Roller type bending machines are preferred. Pipeline Construction Specification Version 2.5 mm.3.10. 1.8 The procedure for bending shall be such that the extremities of each joint remain straight over a minimum distance of 2 m or twice the pipe diameter.8 as specified in the drawings. 1.10.5 The cold bends shall be made by a smooth stretch bending machine.6 The pads. 1. SP-1208 Page 20 September 2005 .7 All bends shall be tested in the presence of the Company with a gauging plate of 97.9. 25 D for pipe OD of less than 200mm . and non-destructive testing of ‘on-plot’ piping and ‘off-plot’ pipelines for oil and gas service. The longitudinal weld of the cold bend shall be located approximately within 10° from the pipe’s neutral axis.4 or ASME B31.2 Off-Plot Pipelines ‘Off-Plot’ Pipelines are defined as all pipelines and pipe work covered by Codes ASME B31. 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).0 1. Bends with ripples with a depth exceeding 0. Where applicable. 1. Contractor shall provide a procedure for measuring ripples which shall be approved by the Company.3. dies and rolls of the bending equipment shall have soft surfaces to avoid damage to the pipe coating.3. whichever is greater. Pipeline DN 300 and above: 3D 1.9.

2.11. The type of field joint coating that can be applied shall be compatible with and have good adhesion to the mill applied coating: . 1. Material Safety Data Sheet SP-1208 Page 21 September 2005 . The manufacturer’s name . 1. Batch number . valves.3 The materials.10. Contractor shall submit for Company approval and demonstrate to the Company. Contractor shall supply all equipment including spares and skilled manpower required for pipe cleaning. coating repair in the field.1 Only materials supplied by Company approved manufacturers shall be used in the Work. .4 The coating materials shall be properly packed and clearly marked with: . Pipeline Construction Specification Version 2. fittings etc. Test certificates and test data .11.2 Materials 1. spares and tools.11. Date of manufacture . Material qualification and identification .11.2.2. 1. application methods. For Polyethylene (PE) / Polypropylene (PP) coated line pipe. equipment.11 Anti-Corrosion Field Joint Coating 1.3 On-Plot Pipework ‘On-Plot’ Pipework is defined as all pipework and pipe runs covered by the code ASME B31. the field joint coating shall be by FBE field joint coating. Station Works.12. Line-pipe is supplied with mill applied anti-corrosion coating unless specifically stated to the contrary in the contract Scope of Work.1 Scope This Section of the Specification covers the minimum requirements for the external field coating of pipeline weld joints and repair of damaged coating. application of coating. shall not be older than the shelf life stated by the manufacturers.3 as specified in the drawings. at time of application by the Contractor. and inspection and testing of the same in accordance with this Specification. is specified in Section 2. The minimum requirements are contained in Specification SP-1173. Painting of station pipework.2 Contractor shall as a minimum follow manufacturer’s recommendations regarding material storage. two weeks prior to application. the proposed work methods for coating application and coating repair.11. 1. Storage temperatures . For Fusion Bonded Epoxy (FBE) coated line pipe.0 1. the field joint coating shall be by heat shrink sleeves.11.2. 1.

1.11.2. Any weld spatter or sharp edges of the mill coating shall be removed by filing or light grinding prior to blast cleaning. 1. The application procedure shall be in accordance with manufacturer’s instructions and the minimum requirements specified below.2 The blast surface visual appearance shall conform to ISO 8501 grade Sa 2 1/2.0 1.6 The list of Company approved wrap-around shrink sleeves is given in the Approved Vendors.4 Shrink Sleeve Application 1.3.4. whichever are the most stringent.5 Coating of the field joint shall not take place until the weld has been non- destructively tested and approved by the Company.11.11.4 The surface cleanliness shall conform to ISO 8502-1 to 4 and shall be such 2 that the chloride contamination is less than 20 mg/m . Induction heaters.11.2 The joint shall be heated to a temperature required by the procedure. 1. coating shall be feathered over a distance of 10-15 mm during grit blasting.11.B.3 The surface profile attained by the grit blasting shall conform to ISO 8503-2 and shall be 40-75 microns peak to trough or as specified by field joint coating manufacturer. 1.11. including blast cleaning.3 The sleeve shall be wrapped entirely around the joint.E. the coating shall be cut-back until sound coating has been obtained. There shall be a minimum overlap of 50 mm onto the factory applied coating.3 Surface Preparation 1. Induction heaters shall be used for pipe diameters of 16" and larger where the pre-heat temperature exceeds 100° C. shall be carried out in accordance with SP-1246 and this specification.11.1 Prior to coating. The blasting nozzle shall be fitted with a dead man’s handle so that the equipment will not operate unless the handle is held. Any field joint not coated within 4 hours of grit blasting shall be reblasted prior to the application of the coating. The closure patch shall be positioned off to one side of the pipe. Manufacturers and Equipments (AVME) list of the company. and shall be demonstrated to the Company prior to field application by means of a procedure qualification test joint. If the mill coating is disbonded along the edges. 1.4. To check that the required preheat temperatures have been achieved. and in accordance with manufacturer’s instructions. a digital contact thermometer shall be used. Surface preparation.1 Contractor shall propose the application procedure for Company approval. or if there is an evidence of corrosion under the coating.11.11.3.11. In all other cases burners or torches may be used. 1. Certificates shall be maintained by the Contractor.2. 1.11. Torches may be used for tie-in welds at Company’s discretion. not exposed to direct sunlight.4. ring burners or propane torches of a suitable type may be used for pipe diameters smaller than 16". Polyethylene coating shall be chamfered by torch and knife and F. 1.11. 1.3.Pipeline Construction Specification Version 2.3.5 Coating materials shall be kept dry and stored as long as possible in the manufacturer’s original packaging. Abrasives for blast cleaning shall be certified in accordance with the relevant parts of ISO 11124 or ISO 11126. the field joint area shall be blast cleaned.3. SP-1208 Page 22 September 2005 .

If the ambient temperature falls. Special attention must be given to the closure patch and overlapping areas.32.11. impact resistance . then the Contractor shall perform field tests followed by full laboratory testing of the coating in accordance with DEP 31. cathodic disbondment In the event that the Contractor cannot demonstrate that the coating satisfies these requirements.5 F. Powder application shall start as soon as the metal temperature is SP-1208 Page 23 September 2005 .5. and shall be demonstrated to the Company prior to field application by means of a procedure qualification test joint.32.5.0 1.5 The installed sleeve shall be left undisturbed for 4 hours or until the adhesive has been solidified. A Manufacturer’s representative shall be present on site full time during field applied epoxy coating work. During the daily powder coating operations.30.Pipeline Construction Specification Version 2.30.11. 1.3 The resin powder shall be stored in waterproof containers which are insulated and cooled by refrigeration or air conditioning to a temperature not exceeding 27°C. 1. The actual temperature range shall be in accordance with the powder manufacturer’s recommendations.1 The mill applied epoxy coating of the linepipe shall be applied in accordance with DEP 31. hot water resistance .11. 1.40. the powder in the fluid bed can be kept at ambient temperatures up to 85°C.5.11. gel time tests as per manufacturer’s recommendation must be carried out on each box of powder before use.30.4. whichever are the most stringent. 1.11. whichever is the longer. The epoxy material for the field joints shall be compatible with the linepipe coating and shall conform to the material requirements of DEP 31.4.11. The external appearance of the sleeves shall be smooth and without dimples.32.32. 1. 1.40. it may be necessary to increase the preheating temperature slightly to provide adequate curing energy. Temperature recorders shall be used to monitor the storage temperature inside each container.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.4 The area of the pipe to be coated shall be preheated by induction heating coil to a maximum temperature of approximately 250°C. with respect to: .11. in Company’s opinion. The application procedure shall be in accordance with manufacturer’s instructions and the minimum requirements specified below. but must be returned to the normal storage temperature below 27°C at the end of the day. The ends of the sleeve shall be firmly bonded to the surface of the coated pipe. Contractor shall also submit test data to demonstrate that the applied coating satisfies the requirements DEP 31.11.40.6 The sleeves shall be visually inspected for the following points: a) Adhesive extruded from the ends of the sleeve indicates proper application.4.B.40. For any powder that has temporarily experienced temperatures in excess of 27°C.5. b) There shall be no sign of punctures or pinholes.30. Application 1.2 Contractor shall propose the application procedure for Company approval. hardness .E.

0 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.Pipeline Construction Specification Version 2. SP-1208 Page 24 September 2005 .

5.6.0 1. The cured coating shall be free of blisters.11. 1.Pipeline Construction Specification Version 2. the coating shall be rejected. a thermoplastic repair stick shall be used.7 All operators shall wear Company approved safety equipment to prevent inhalation of powder dust and contact with eyes. Contractor shall use automatic coating machines.2 The coating repair procedure and the required materials for this.8 The powder container.11. There shall be a minimum overlap of 50 mm onto the factory coating. stripped and recoated to the original procedure.11. capable of applying the powder at a uniform rate over the entire width of the area to be coated. including the installation of repair sleeves when applicable.11. shall be in accordance with a procedure submitted by the Contractor and approved by the Company.11.6 Coating Repairs 1. 1.40. 1.11. d) minor flaws of polyethylene / polypropylene coating may be smoothed down using a torch and a hot iron. hoses. using a technique which achieves an even coating thickness. 1. Company may accept powder application by a hand held device used by a skilled operator. Polyethylene / polypropylene coating repair materials shall as a minimum be in accordance with DEP 31.31. For smaller pipeline sizes.: a) for pinholes and damages with a diameter or width of 10 mm maximum. a patch of thermoplastic heat shrink materials shall be used. Dirt or deleterious materials shall not contaminate the powder coated area during the application and curing stages.11.6 The applied coating shall have a minimum dry film thickness of 400 ± 75 micron.e. SP-1208 Page 25 September 2005 .6.5 For pipeline sizes equal to or greater than 12".1 Coating repairs shall be executed on all coating damage and imperfections detected visually or by holiday testing.11. 1. i.5.5. pinholes. etc. on the application unit shall be cleaned after each day’s work.30.3 The repair procedure for mill applied polyethylene / polypropylene coatings shall be selected based on the criterion of magnitude of the damaged area. In the event of contamination. scratches or any other irregularities and shall be of uniform gloss and thickness. Smoking shall not be allowed in the vicinity of the coating operation.5.6. c) for damages with a greater diameter than 100 mm. a thermoplastic wrap- around shrink sleeve shall be used. 1. b) for damages from 10 mm width to 100 mm diameter.

If in the opinion of the Company the test has failed.11. 1. using a recently calibrated micrometer.7. As an alternative to the above.4 The repair procedure for both mill and field applied fusion bonded epoxy powder coatings shall be selected based on the criterion of magnitude of the damaged area. All contamination shall be removed from the surface by cleaning with solvent or water detergent and using a combination of wire brushes and scrapers. 1. a strip of transparent cellotape shall be applied to the surface. i. The surface shall then be abraded using coarse emery paper or a flexible grinding disc.7. A rapid curing two pack is preferred to enable repairs prior to lowering the pipe in the trench. to a nominal thickness of 500 microns dry film thickness. Before applying the coating. After the surface has been blast cleaned and dusted off.3 The profile of the blast cleaned surfaces shall be tested by means of Testex Replica Tape (type X-course). The frequency of testing as specified herein may be altered by the Company at Company’s sole discretion.11. the Company may allow the surface profile to be tested on site by a suitable profile gauge in accordance with SP-1246.6.7.0 1.11. to the original specification.5 Contractor shall supply all equipment required for inspection and testing including dry film thickness gauges and holiday detectors.11. All equipment shall be approved by the Company prior to use.7. Inspection and Acceptance 1. 1.11. and temperature control of the pipe surface.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.e.1 The testing and inspection for acceptance of the coating system shall be carried out and recorded by the Contractor as instructed and witnessed by Company’s representative. other than scratches. Contractor shall undertake to perform additional cleaning to the specified standard. The mixing instructions supplied with the two pack epoxy by the manufacturer must be strictly adhered to. The damaged coating shall be removed around the entire circumference by grit blasting. are above the maximum limit for liquid epoxy repair shall be repaired by using FBE coating method for field joints. b) Damages. SP-1208 Page 26 September 2005 . with a diameter or width greater than 100 mm. ensuring that the coating surrounding the defect is also abraded but not removed. grit/shot used for blast cleaning.Pipeline Construction Specification Version 2. the surface shall be free of rust or residual grit. This shall be done on the first joint cleaned each day.11. 1.4 Additionally. plus two more times during the day and when a new batch of grit is used. produced at least twice a day and additionally the first few joints and at each change or replenishment of grit. and manufactured by a Company approved manufacturer. 1. cleanliness of materials used for blast cleaning and coating. and scratches over 100 mm in length shall be repaired by a two pack liquid epoxy. and subsequently removed and examined for particle contamination. Application is carried out using a clean palette knife or filling knife. The surface profile shall be evaluated from the replicas in accordance with manufacturer’s instructions.: a) Holidays or minor coatings damages upto 100 mm in diameter or width. compatible with the original FBE coating.7.7 Testing.11. general checks at random shall be carried out such as monitoring of particle size of copper slag.

5 cm wide and 20 cm long shall be cut perpendicular to the pipe axis and slowly peeled off. 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. b) Destructive testing on shrink sleeves shall be executed as follows: . c) Following the peel test. In the event that the test fails.7.11. 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.6. using an approved peel strength gauge. the time of day of the testing shall be taken into account.Pipeline Construction Specification Version 2. . SP-1208 Page 27 September 2005 .7. In the event of failure.6 Shrink Sleeves Testing a) All shrink sleeves shall be visually inspected in accordance with Section 2. Tests shall continue until the sleeves which are inspected are acceptable. i. From each test sleeve one or more strips of 2. Sleeves for testing will be chosen by the Company.e. The temperature of sleeve and pipe during such a peel test shall be as per manufacturer’s recommendation. After removal of the shrink sleeve. The required peel strength for the above strip shall be in accordance with the manufacturer’s temperature/strength correlation data.0 1. Peel off exposing bare metal constitutes a failure. the joint on either side shall also be tested. Failed joints and other joints rejected on the basis of the test results shall be stripped and recoated to the original specification. Voids exposing bare metal shall not be acceptable and shall be reason to fail the shrink sleeve application.4 above. the bulk of the adhesive layer which remains on the pipe surface shall be essentially free from voids.7 Fusion Bonded Epoxy Testing a) Every day at least one representative epoxy coated field joint shall be subjected to an adhesion test. This test shall be carried out on the same day that the coating is applied. Repair shall be carried out as per Section 2. .7. The test area of the passed joints shall be repaired with the liquid epoxy system as per 2. it shall be repeated on the two sleeves adjacent to the tested sleeve. 1. Contractor shall attempt to force the coating from the substrate with the Stanley knife. 7. upto a maximum of 6 mm x 6 mm.6. although a certain amount of voids may be allowed at the discretion of the Company.11. Starting at the point of the vee. . With a Stanley knife.7. two cuts shall be made through the coating to the substrate to form a vee with an intersection at about 30 degrees.

repair and backfill at Contractor’s expense. The voltage applied by the holiday detection equipment shall be measured by means of a voltage read out. which shall be calibrated at regular intervals (at least daily).8 Holiday detection of 100% of the surface area of all coated pipeline shall be carried out immediately prior to lowering in the ditch. MIBK (Methyl Iso Butyl Ketone).7. 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. or others (ref SP-1246) as per powder manufacturer’s recommendation and the outcome of the laboratory test.9 Company will carry out a ‘Pearson Survey’ to check the integrity of the buried coating. 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.Pipeline Construction Specification Version 2. c) The gel time of fusion bonded epoxy powders shall be tested daily. The electrode shall be a conductive rubber or a spiral metal ring. 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. SP-1208 Page 28 September 2005 .7. 1. 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. on the basis of the test results shall be stripped and recoated to the original specification.11. However. by spreading a sample of approximately 0.0 b) Every day at least one representative epoxy coated field joint shall be subjected to a cure test. Brush type electrodes shall not be used. In the event of failure. the epoxy powder shall exhibit a gel time within the range of 25 to 50 seconds. the joints on either side shall also be subjected to a cure test. At a temperature of 204°C.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. 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. the voltage setting for holiday detection may be lowered slightly at Company’s discretion if coating gets damaged. Contractor shall provide a fully cured laboratory prepared sample. This is done by rubbing a smooth coated area. No softening of the coating shall be noticeable by comparing the rubbed area with the adjacent non rubbed area of the joint. 1. During the test. The test shall be carried out on the same day that the coating is applied. free from overspray and surface powder contamination. Failed joints and other joints rejected. all in accordance to Company approved procedure. All holidays. 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). If coating defects are found on any portion of the coating.11. Contractor shall excavate. the coated substrate must be cooled down to ambient temperature.

1 Scope This Section of the Specification covers the minimum requirements for pre and post padding. Contractor shall keep the pre-padding operation within 1 km of the lowering-in operation.3. whether in normal ground or rock.3. the Contractor shall use mobile screening plants that enable a continuous direct application of padding from the plant to the trench. 1. Base materials from which pre and post padding material will be produced shall consist mainly of sandy material. the coating shall be checked for holiday and if necessary.2. 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.0 mm. Pipeline Construction Specification Version 2. 1.1 All trenches shall be padded before lowering in of pipe string.g.12.12. Only in those areas where mobile screening plants cannot be used due to access problems. Mobile screening plants are defined as screening plants which move along the trench whilst they are in operation.12.0 mm and no more than 25% by weight shall have a grain size between 3.12. If the base material is not sourced from the working strip. 1.3 The installed padding material shall be free of sharp rocks.2 Immediately before commencing the lowering-in operation. More than 75% by weight of the screened material should have grain size between 0.12 Lowering-In.7.6.2.0 and 5. in which case it shall be Contractor’s responsibility to obtain suitable padding material from a source approved by the local government authorities. stones. and without sharp edges which could damage the pipeline. padding material shall be dust free (e.6 mm) in order to avoid inconvenience or danger to the public. clods. Suitable base material from the working strip may not always be available or acceptable.12.4 The bottom of the trench shall be padded with sand throughout its length.12. compacting and stabilising the trench as required for the work.0 1.12. 1. repaired to the satisfaction of the Company. 1. 1. lowering the pipe and backfilling.12. 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). 'coarse sand' with a minimum grain size of 0. To ensure compliance with the above requirements. pre-screened material may be used after approval of the source by the Company.12.2 To ensure that fine and clean padding material is used. Near residential areas and roads.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 SP-1208 Page 29 September 2005 . so as to provide a minimum compacted padding thickness of 150 mm below the invert of the pipe. Backfilling and Reinstatement 1.2. as specified in Section 2.12.1 Welded pipe strings shall be lowered-in within 96 hours of completion of joint coating.2 Pre-Padding 1. roots.3 Lowering-in and Post-Padding 1. 1. sources of padding material shall first be approved by the Company.2. etc.06 and 3. 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.3. metal parts. No padding shall be placed until the Company has inspected and approved the trench bottom.

0 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.Pipeline Construction Specification Version 2. SP-1208 Page 30 September 2005 .

1.Pipeline Construction Specification Version 2. walk ways. etc. i. the remaining excavated material shall be neatly crowned over the trench (the windrow). 1. placing sand on top and around the pipe at regular intervals (one 2m ‘plug’ on every welded joint) or Company approved equivalent method. No pipe shall be left overnight in the trench without sand padding around and above the pipe. the sand padding shall be thoroughly compacted by watering and Company approved hand tools. except in wadi areas.3 The material used for initial backfill shall be from the screening plant or other loose material not greater than 100 mm in diameter. Contractor shall plan the work such that the lowering in and ‘plugging’ operations take place during the hottest part of the day.12. Due consideration shall be given to ambient temperature changes throughout the day and the resultant pipe length changes/stresses. 1. all subject to Company approval.e.5 Contractor shall take measures to restrain the pipe in the trench by means of ‘plugging’. 1. On either side of road crossings. 1.3.4 After the initial backfill.12. Where rock is excessively large.2 In areas containing buried cables.3.12. 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.0 1. for safety reasons. at its sole discretion.12. For tie- ins outside the trench. The initial backfill shall be placed in the trench to a level slightly above surrounding ground.5 Backfilling 1.1 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. roads. Backfilling shall be performed as soon as possible after padding has been approved.12. Company may. shall be removed from site and not used as windrow material.12. with the sand padding shaped to its natural angle of repose and with a minimum of 150 mm at any point around the pipe. 1. 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. waive the requirement for ‘plugging’ and allow the post-padding operation to be executed as one continuous operation.5. so as to fill the trench to a depth of 300 mm above the crown of the pipe.3.12. tie-ins shall take place in the trench.5. to achieve a compacted sand fill around the pipe and up to 300 mm above the crown of the pipe.4 The trench shall be maintained in a dry condition during lowering-in and backfill operations. 1. SP-1208 Page 31 September 2005 . 1.12.7 Where the trench has been excavated through or along drive-ways. Contractor shall demonstrate that his proposed method of backfilling achieves this requirement. in Company’s opinion. the windrow shall be tapered from full height to ground level to improve the visibility of drivers on the ROW. The backfill around all underground services shall be thoroughly compacted by hand.12. dependant on completion time and ambient temperature considerations. and at live stock passage ways and other locations indicated on the drawings.5.3.4 Tie-ins Unless otherwise agreed by the Company. backfilling shall not be performed until all tiles have been replaced and protected and/or all cables have been supported to Company’s satisfaction.12.5.6 Sand padding shall be placed around and above the pipe.

1 Contractor shall clean-up the Working Strip and all working areas used by the Contractor regularly during the course of the work.8.5. the backfill shall be stabilised.0 1.7 ‘Sloping trenches’ (see Section 2. in Company’s opinion is not suitable for backfilling.6 metres for every 3 metres of dune height if the line passes through a sand dune).2 The excess soil in the working strip shall be levelled in a manner satisfactory to the Company.Pipeline Construction Specification Version 2. 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. 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.e.3.5m. livestock passageways shall be installed at intervals of approximately 2 km and may be combined with graded road and track crossings. roads.5 m. etc.5.6 Stabilising Sand Areas To ensure the retention of sand cover in active sand areas (i. or by using special compaction methods. The surface of such areas shall be stabilised and/or restored to its original condition to the satisfaction of the Company and the Authorities.12. and shall restore the lands traversed. Where wadis or roads are graded. 1. If the excavated material.5 m cover over the total pipeline length of 6. Access barriers shall be installed on the ends of the crossing to indicate the safe crossing width of the livestock passageway for light vehicles. walks. to the satisfaction of the Company.. Backfill in or on banks of ditches.8. 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.12. The width of the live stock passage shall be 2. 1. trenched or otherwise disturbed.12.6 Where the trench has been excavated through or along drive-ways. rocks larger than 750mm in diameter shall SP-1208 Page 32 September 2005 .12. the Contractor shall restore the property to its original contour and condition even to the extent of hauling in and placing new fill materials. Compaction of the livestock passageways shall be such that the passing of light vehicles will not have any detrimental effect on the passageway. Contractor shall provide and use suitable material from another source. gravel and stabilising materials or compounds.12.7 Livestock Passageways Unless otherwise indicated on the drawings. 1.5. where the windrow consists of sand only).12. The livestock passageways shall be constructed with a minimum of 1.12. and at live stock passage ways and other locations indicated on the drawings.4. However. wadis shall be compacted as necessary to prevent soil erosion or other damage which might be caused by the construction of the pipeline. 1.5 Trenches crossing ditches shall be backfilled with the material excavated from the trench at the location. Ditches with lined or otherwise improved surfaces shall be resurfaced in a manner satisfactory to and approved by the Company and the Authorities.5) shall be backfilled as shown on Standard Drawing TYP 3 0015 001.12.8 Reinstatement 1. as necessary to obtain the approval of the Company and the Authorities. 1. 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. the initial backfill shall be thoroughly compacted by mechanically tamping the material into place. 1.

Pipeline Construction Specification Version 2. but may be placed next to the windrow. SP-1208 Page 33 September 2005 .0 not be placed directly on the backfill material.

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.8.8. All warning signs shall be in both Arabic and English language. gates. All road crossings shall be made by the open cut method.2. used at escarpments.12.1 Scope This Section of the Specification covers the minimum requirements for road and wadi crossings as required for the work.12. ditches and irrigation channels shall be reinstated by the Contractor to their former condition and their banks shall. 1. 1. and other safeguards to the satisfaction of the Company and the Authorities to ensure safety of the public.2. wadis.12.4 All enclosures.13.2 Road Crossings 1. without the installation of casings.7 Construction markers shall not be removed.8.5 Contractor shall comply with the following minimum requirements of the Directorate General of Roads for major road crossings: SP-1208 Page 34 September 2005 .8 All rubbish/debris left over after removal of camp facilities shall be removed to designated scrap dumps. unless requested by the Company. etc.8.0 1.13 Road and Wadi Crossings 1. Pipeline Construction Specification Version 2. wells.1 The carbon steel pipeline shall cross all roads and highways. walls. 1. 1.2.13. The sites shall be levelled and cleared in accordance with the Regulations for Pipeline Contractor Camps in the Interior and to Company’s satisfaction. 1. water courses. 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 crossings shall be installed to meet at all times the requirements and conditions set forth by the Authorities having jurisdiction. such as warning signs.5 All private roads. be pitched with stone and/or faced with special protection to prevent washing out or erosion. drains. 1.8.2.4 Contractor shall at all times and at every unfinished road crossing provide adequate and proper traffic aids. if deemed necessary by the Company. The diversion shall not cross the pipeline where it has already been installed. 1. may be required by the Company to be left as they are.13. pipe jacking may be considered for major road crossing to avoid disruption of traffic.2.3 Contractor shall install an off-set diversion road. streams. 1.13. Trench less methods such as horizontal drilling.3 All creeks. shall be restored by the Contractor to at least as good a condition as they were prior to the commencement of the Contractor’s operations to approval of the Company.13.13. syphons. bridges and other private structures used by the Contractor for access or haulage shall be restored by the Contractor to a condition equal to or better than that which existed prior to the commencement of the Contractor’s operations. 1.12.12.12. 1. 1.6 Construction roads.8.13.

2 Wadi crossings shall be installed to meet at all times the requirements and conditions issued by the Authorities having jurisdiction in the area.13.13. SP-1208 Page 35 September 2005 . 1. bed slope. line pipe with continuous concrete protection shall be installed (TYP 3 0010 001) with a minimum cover of 1500 mm. or ‘Wadi type ‘C’’.3.10. At these wadi crossings. Wadis may be classified based on judgement and careful evaluation of the crossing location with due consideration to wadi’s width. the pipeline trench shall be protected with gabions placed at the surface. a) Type ‘A’ wadis are those where low velocity flow is expected after heavy rains. a Bank Guarantee.3 Wadi-Crossings 1. Diversion roads must be constructed with compacted non-plastic materials. Additionally. 1.3. reinstatement and standards of construction to the Directorate General of Roads for approval before commencing work on site. 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. e) Contractor shall be required to give to the Directorate General of Roads. 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. 1.Pipeline Construction Specification Version 2. This requirement applies to each individual crossing point. At these wadi crossings. which must not degenerate into dust during use.13. line pipe without concrete protection shall be installed (TYP 3 0008 001) with a minimum cover of 1500 mm.13.0 a) Contractor shall submit details of all proposed diversions. ‘Wadi type ‘A’’. The concrete shall be applied in accordance with Section 2. b) Reinstatement of roads must be to the same standard as existing roads. methods of crossings.3.13. 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.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.1 ‘Wadi’ shall mean dry river bed which could be temporarily filled with water following rain. 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. line pipe with continuous concrete protection shall be installed (TYP 3 0009 001) with a minimum cover of 1500 mm. Pipe installed in ‘Flood plains’ does not require casing protection. 1. ‘Wadi type ‘B’’. d) Final approval of any proposed road works must be obtained from the Royal Oman Police. but shall be stabilised at 3 meter intervals by means of bags of dry cement/sand mix placed on top of the pipeline.4 At locations where concrete protection has been applied. The wadis will be identified on the Alignment Sheets as ‘Flood plains’. b) Type ‘B” wadis are those where erosion due to high velocity flow is expected after heavy rains At these wadi crossings. The wadi types are described below. following.3. past discharge history and erosion potential at the crossing location.

5 For type `C` wadi-crossing.0 1. gabions consisting of packages of boulders with dimensions between 100 and 200 mm contained in galvanised.Pipeline Construction Specification Version 2.3. The type of wire mesh shall be approved by the Company prior to use. up to grade level over the full width of the trench. shall be placed on top.13. coated steel wire mesh. SP-1208 Page 36 September 2005 .

75" : 60 mm The concrete shall be Grade 30 to BS 8110 with a characteristic crushing strength of 21 N/mm2 at 7 days and 30 N/mm2 at 28 days. repair procedures. type. labour. .3 The mill identity of each pipe length shall be preserved and records kept during and after the coating process. methods of control. the following. average outside diameter.14.14 Concrete Coating for Wadi Crossings 1. 1. placement of steel reinforcement.6 Normally the windrow shall not be installed over the pipeline through the wadi section. Field application shall be by dry mix gunite technique or Company approved equivalent. 1. 1. The Contractor shall prepare.625" to 12. Pipeline Construction Specification Version 2.3. a detailed coating procedure specification containing. the windrow shall be installed intermittently in order to mark the location of the pipeline (Windrow lengths shall be approximately 25m at 75m intervals). at Contractor’s option. Contractor-supplied materials: specifications. concrete coating procedures covering the concrete mix. concrete application.. coating equipment and facilities and identifying the ranges of parameters to be used.1 Contractor shall be responsible for the supply and installation of all concrete coatings.2. The plant application procedure and the coating plant may involve methods other than guniting and shall be Company approved. equipment.625" : 40 mm 6.2. worksite and services incidental to and necessary for the application of concrete in accordance with this specification and all subject to Company approval. including all associated handling and transport of linepipe etc.2 General 1.14. but not limited to. 1.4 The concrete coating of line pipe shall be applied either in an approved coating plant or in the field.14.2.14. and submit to the Company for approval.0 1. Reference is made to Company Specification SP-1282 for concrete production. length and all weights. Contractor shall furnish all materials. supplier. supervision. a minimum of 1 month before commencement of the work.13. A certified permanent record shall be supplied to the Company showing the serial number. 1. The minimum thickness shall depend on the pipe outside diameter as specified below: Up to 6. greater than 100m. etc.1 Scope This Section of the Specification covers the minimum requirements for concrete coating of the pipeline at Wadi crossings type B and C as required for the work. .14.75" : 50 mm over 12.14. SP-1208 Page 37 September 2005 .2.2 The concrete shall have a minimum dry density of 2400 kg/m3 after 28 days. However for wide wadi crossings. curing.

Pipeline Construction Specification Version 2. inspection and testing (including procedures and pro-forma) SP-1208 Page 38 September 2005 .0 .

Epoxytar. 16 45 .Pipeline Construction Specification Version 2.14.14. grease. durable. 50 10 .3 Water for use in concrete shall be clean and free from all substances which may be injurious to concrete or steel. sharp and graded evenly from fine to coarse. 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.75 passing a no. The reinforcement shall be clean. 4 95 . mud. clean.3 Concrete Materials 1.100 passing a no.M. Maximum mesh dimensions shall be 38mm x 38mm x 2 mm wire diameter. Cement which is held in stock for longer than three months.4.0 1. 1.I.2 Aggregates shall be naturally occurring washed sand and shall be hard.C. It shall satisfy the requirements of BS 3148 and contain no staining or colouring. 8 65 . If in the opinion of the Company. The reinforcement shall be placed at the centre of the concrete coating layer by using P. Contractor shall apply a protective layer or ‘barrier coat’ to epoxy coated pipe. partial setting or other defects or which fails when tested. as per the grading limits specified below. 1. dust. and promotes a good bond between the epoxy and concrete coating.50 passing a no. SP-1208 Page 39 September 2005 . organic matter or other undesirable constituents. shall be rejected. spacer blocks or a Company approved equivalent.1 The cement shall be ordinary Portland cement conforming to BS EN197 or ASTM C150.4 Reinforcement of concrete coating shall be by one layer of electrically welded galvanised steel mesh fabric reinforcement to BS 4483.90 passing a no.3.1 Prior to concrete coating.14.3. 1.14. 100 2-8 Stockpiles of aggregates shall be covered by tarpaulins. 30 30 . clay.14. the consignment shall be rejected. The type of barrier coat to be used shall be a two component fibre reinforced cementetious coating such as FBE Brushcrete. hardened rebound or anything likely to destroy adhesion or promote corrosion. the aggregate contains an undesirable proportion of chemicals. free from scale.14.22 passing a no.3. Rezex water based epoxy coating ES2 or equivalent. dense.14.V. or any cement which shows signs of deterioration.3. 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. Fosroc H. The minimum overlap between two consecutive rolls of mesh shall be 50 mm except at field joints where no overlap is required. 1. and be in compliance with BS 882.4 Application 1.

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.4.8 The outer surface of the concrete coating shall be smooth. to prevent displacement during concrete application.0 To this end one or more sections of a test joint shall each be coated with a proposed barrier coat.14. 0. film thickness and curing time shall be representative for the application in the production process.6 to 1. 1. Mix temperature shall not exceed 32°C. In case the moisture content falls outside the critical range of 5 to 8%.4 The mixing equipment shall be capable of providing a uniform mix.14. At both ends of each pipe. No rebound material shall be mixed into any batch. in accordance with manufacturer’s recommendations. 0.6 Since the technique of guniting relies significantly on the skill of the nozzle man. 1.2 m from and at right angles to. The dry mix used for guniting shall be screened to prevent inclusion of stone. the hose will block and a mortar layer will build up inside the gun. 1.14. 1.4. d) Shading has been installed to prevent the line pipe temperature exceeding 35°C. 1. If the sand is too wet.Pipeline Construction Specification Version 2.4. the surface of the pipe.14.4. c) Reinforcement has been adequately secured in the correct position with use of spacer blocks. without corrugations and concentric with the steel pipe. 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.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. b) The barrier coat (if required) has been applied and cured. The test joint shall be concrete coated.14. The number of applications. No batch of cement and aggregate shall be used in the work if it has stood for more than half an hour after mixing.e.4. 7. The guniting crew shall demonstrate their ability to consistently coat pipe to this specification by guniting at least three separate quarter length pipe samples prior to start of production. 1. flakes from the mixer drum.2 Batching.30 m from the end shall be completely left free of SP-1208 Page 40 September 2005 . a distance of approx. Contractor shall make the sand suitably damp either by spraying the dry sand with water or mixing wet sand with specially supplied dry sand.14.3 Contractor shall pay attention to the moisture content of the sand used for guniting. he shall have at least 3 years experience in work of a similar nature. Other operators of the guniting crew shall have a minimum of one year’s experience. 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. 1. etc.14. proportioning and mixing of the materials shall be such that a concrete coating is provided with the minimum specified strength and density. pieces of cement bag.5 Concrete shall not be placed until: a) The line pipe corrosion coating has been holiday detected and approved by the Company.4. Written evidence of such experience shall be furnished to the Company. 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.

Pipeline Construction Specification Version 2. SP-1208 Page 41 September 2005 . The concrete shall taper back from these points at a two-to-one slope until the required thickness of coating is reached.0 concrete to facilitate field joints.

5. 1. inspect and where necessary repair the corrosion coating or reapply the concrete coating. draught. Contractor may optt not to wait for the test results and immediately initiate the stripping and subsequent coating repair work. The length to diameter ratio of the core when trimmed for testing shall not be less than one-to-one. for a minimum period of 7 days by wrapping with suitable hessian or polyethylene sheeting.5 Curing 1.1 may be adopted subject to approval of the Company.1 The finished concrete coating shall be completely protected from wind. If the compressive strength tests of the cores fail to meet the specified strengths. made from mild steel.6.14. SP-1208 Page 42 September 2005 . etc. shall be made every day. The minimum diameter of the core shall be at least three times the nominal maximum aggregate size.5. The compressive strength of each specimen shall be calculated using the computed cross-sectional area based on the average diameter of the specimen. Anti-Corrosion Coatings. vertical or overhead) and gunited.14. Cores shall be cut four days after concreting and stored in a curing tank until tested. 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. the concrete surface shall be kept wet.1 Every length of coated pipe shall be inspected visually and by spiral ring holiday detector and repaired.5. rain.7. in accordance with Section 2.4 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.10. After a period of 4 hours from placement and for the 7 days curing period.14. one at the start of work. Samples shall be tested as specified in BS 1881.2 The concrete coated pipe shall not be lifted or transported from the curing area during the 7 day curing period. testing and calculation shall be in accordance with the provisions of BS 1881.14. Contractor shall remove the defective coatings by Company approved method. spray.14. 1. each core shall have the minimum density and compressive strength as specified in Section 2.6. 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.14.14. Also during this period the pipe shall not be exposed to direct sunlight and/or temperature below freezing point. cores shall be taken from each test panel after it has cured in a similar manner as the coated pipe.5.2. to be decided by the Company.0 1.6 Inspection and Testing 1.Pipeline Construction Specification Version 2.3 Test panels. 1.6.6. Contractor shall remove cores from the suspected pipe.3 For factory applied coating. where applicable.14.14. 1.10. any other curing methods apart from that mentioned in 2.2. 1. 1. prior to concrete application. For acceptance. Sampling. On a regular basis.2 The concrete shall be visually inspected immediately after the application and after approximately 3 days. If concrete is faulty. storing.

Pipeline Construction Specification Version 2. 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.10.1 m 2 per joint where the concrete remaining on the joint is sound shall be accepted without repairs.2. 1. 1. Cube tests will be accepted for crushing strength instead of core samples.0 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.14.14. All other defects shall only be repaired once the concrete has hardened. 1. Should the damaged area be more than 0.7.3 Concrete cracks that are in excess of 1. density. shall be repaired.14.5 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. Repairs shall be made by satisfactorily restoring the reinforcing.33 m2 per joint.14. but the required compressive strengths will be 20% greater than specified for core tests.6.1 Concrete coating that is found to be defective at the time of coating shall be immediately stripped from the pipe and the pipe recoated. 1. of the same materials and proportions as the coating. Repairs shall be made by chiselling the crack out to width of not less than 25 mm throughout the length of the crack. The pipe shall then be allowed to moist cure for a minimum of four days.5 mm in width and extend over 180° circumferentially around the pipe. This mixture shall be built up until the surface is level with the coating around the repair.14. or where cracks are over 330 mm in length longitudinally along the pipe irrespective of width.1 m2 and less than 0. water and aggregate. SP-1208 Page 43 September 2005 .6.14.33 m2 per joint. An area of less than 0.7 Concrete Coating Repairs 1.7. 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. uniformity. The resulting coating shall be equal in weight.6. the coating shall be removed around the entire periphery of the line pipe throughout the entire damaged area and repaired.14. 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. strength and characteristics to the originally applied coating. The Contractor shall arrange for an independent agency acceptable to the Company to test these cubes. removing all cracked or broken concrete at the point of coating damage.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. Should the area affected be more than 0. Concrete coatings not in accordance with the dimensional requirements shall be repaired or stripped and recoated at the discretion of the Company. 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.7 Effective electrical separation between reinforcing steel and pipe shall be determined for each pipe joint by electrical tests.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. 1. 1.7. and troweling a stiff mixture of cement. into and through the reinforcing.2. wetting the fresh surface of the broken coating (unless the coating is still too ‘green’ to require it).5%).

Construction details of all types of markers are shown on the drawings. Further curing shall be in accordance with the Specification.O. The different types of pipeline markers are listed below. as mentioned hereafter in this section is less than 200 metres.e.6 Wadi Crossing Markers Wadi crossing markers shall be installed at both sides of each wadi crossing.7. 1. access road.15 Permanent Markers and Barriers 1.0 1. Separate markers are required on parallel lines.2 General The Contractor shall supply and install permanent pipeline markers along the pipeline route as close as possible to the windrow.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. 1.15. mounted with two marker plates as per the drawings. 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. 1. The repairs shall be kept moist and allowed to remain undisturbed for a period of not less than 36 hours.15. whereas marker plate no.2 shows relevant information for each location.15. 1. 1.5 Road Crossing Markers Road crossing markers shall be installed at both sides of each paved or graded road crossing.4 Block Valve Station Markers Block valve station markers shall be installed along the pipeline at each block valve station.1 Scope This Section of the Specification covers the minimum requirement for the supply and installation of permanent pipeline markers and access barriers. A schematic diagram of the block valve station pipe work layout shall be installed on the block valve station fencing. shall be the pipeline isolation valve in the scraper trap station). Pipeline Construction Specification Version 2.14. they shall face the R. As-built chainage shall be indicated on the marker plates with an accuracy of one meter. 1. Location shall be 5metres from the borders of the road. as required for the Work.3 Chainage Markers Chainage markers shall be installed along the pipeline at each one (1) kilometre chainage station. KP 0. 1 shows general information about the pipeline involved.15.15.15. Each marker consists of a post sealed with a cap end.W. (The start point of the pipeline. SP-1208 Page 44 September 2005 . Marker plate no. A chainage marker is not required if the distance between its location and any other type of pipeline marker.

Pipeline Construction Specification Version 2.0

1.15.7 Pipeline Crossing Markers

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

1.15.8 Cable Crossing Markers

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

1.15.9 Markers at Horizontal Bends

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

1.15.10 Cathodic Protection Markers

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

1.15.11 Pearson Survey Hole Marker

A marker shall be installed adjacent to each Pearson Survey earthing hole. Ref. GEN-2-
1632-01.

1.15.12 R.O.W. `STOP` Signs

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

1.15.13 Corrosion Monitoring Pit Marker

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

1.15.14 Access Barriers

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

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

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

SP-1208 Page 45 September 2005

Pipeline Construction Specification Version 2.0

1.16 Station Works
1.16.1 Scope

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

- Earthworks

- Civil and Mechanical Work

- Painting

- Instrumentation

- Electrical Works

- Fencing

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

- Materials

- Cathodic Protection

- Supply of hydrotest water

- Hydrotesting

- Work on `live` systems

- Use of explosives

- Access barriers

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

1.16.2 Earthworks

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

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

SP-1208 Page 46 September 2005

Pipeline Construction Specification Version 2.0

1.16.3 Civil and Mechanical Works

1.16.3.1 General

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

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

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

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

1.16.3.2 Concrete/ Block work

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

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

c) Anchor bolts, pipe sleeves, anchor rails, insert and sliding plates shall be
built in as formwork proceeds. They shall be positioned accurately and be
firmly fixed such that no movement shall occur during the concrete pour. If
provision is to be made to allow for slight adjustment in position of anchor
(holding-down) bolts, this shall be clearly indicated on the detail foundation
drawings with the method(s) to be applied.

Anchor bolts, etc. shall be properly protected against damage and
corrosion. Threaded parts shall be greased and securely protected from
damage before pouring of concrete. Anchor bolts shall be as shown on the
drawings. All embedded parts shall be free from oil, loose scale, rust,
paint, grease or other harmful matter.

1.16.3.3 Structural Steel

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

1.16.3.4 Process Pipework

a) Fabrication and welding of process pipework and fittings shall be in
accordance with SP-1173 Specification for Welding of On-Plot Pipework.

The on-plot Specification states that all welding shall be by the uphill
technique. In certain circumstances, downhill welding may be considered
for filling and capping runs, any proposals for which shall be reviewed on a
case by case basis by the Company welding TA-2 and endorsed by the
CFDH Welding.

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.

SP-1208 Page 47 September 2005

08. in stations or on the pipeline. SP-1208 Page 48 September 2005 . these shall be installed at the locations shown in the drawings. e) Surface preparation and painting shall be in accordance with SP-1246. All welds shall be subject to MPI and the final cap to nipple weld shall be radiographed. The proposed location for temporary vents shall be U. pipework.12.T. 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. f) In the event that anchors are required. 1. 1. All items shall be colour white.11 GEN. The anchor flange to be embedded in the concrete shall be coated in accordance with Section 2. fittings and valves. checked for laminations and to confirm adequate wall thickness.4 Painting a) All above and below ground steel surfaces (with the exception of polyethylene or epoxy coated pipework and items supplied in a manufacturer’s finish) shall be prepared and painted in accordance with this Specification. prior to welding or cutting. c) Underground steelwork.5 Instrumentation Contractor shall carry out instrumentation works in accordance with SP-1088 and DEP 62. including those inside corrosion monitoring pits.4 below.16. these shall be provided with prior approval of the Company. shall be coated in accordance with SP- 1246. The anchor flange with a pipe joint welded at both ends shall be completely installed prior to start of civil work. pipework.4 below. in accordance with SP-1246.10.16. Pipe coating shall be tested with the holiday detector prior to embedding in concrete.Pipeline Construction Specification Version 2. 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). A MPI check shall also be made to confirm the absence of surface breaking defects. The size of such vents shall be 1 inch. d) Above-ground steelwork. Thereafter the cap.0 e) If temporary vents are required by Contractor for hydrostatic testing. fitting and valves shall be painted in accordance with SP-1246. nipple and weldolet shall be painted as specified in Section 12. b) Valves and insulating joints shall be supplied with a single coat primer only.

17. he shall obtain prior approval of the Company and restore the relevant part to its original condition upon instruction of the Company.3 When a complete new C. 1. Contractor shall sub-contract the supply/installation to a Company approved supplier/contractor.17. SP-1208 Page 49 September 2005 .17. and be supplied and constructed in accordance with SP1279-P.17. 1.P items i.2 The cathodic protection design shall be in accordance with SP-1128 Specification for Cathodic Protection Design’. 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 1.0 1.1. 1.P supervisor who shall have the prior approval of the Company. Pipeline Construction Specification Version 2. T/R units and ground bed anode systems. The exact requirements for each location are shown in the drawings.4 Contractor shall give the Company 5 days notice prior to installation of special C. including standard drawings from SP-1105.7 Fencing a) The fencing required for the Work shall be of the medium security type. b) If Contractor requires an opening in an existing fence for construction purposes.1.17.1 1.17 Cathodic Protection 1. then the Contractor shall employ a qualified C. Details of various design aspects are indicated in the standard drawings specified in SP-1136 ‘Specification for Cathodic Protection Standard Drawings’. When solar panels are required.e. solar stations.6 Electrical Works a) This section refers to permanent electrical works as specified in the Drawings (normally earthing and bonding only).P test points connects to an existing system. in order to mobilise a Company CP Inspector.16.1. Electrical Standard Drawings.1.1 Impresssed Current Cathodic Protection 1.16.

permanent reference cells . 1. STD-7-2001) shall also be required. the connection pad may be attached by welding a pad on the foreign services (Ref.3.17.2 At approximately 2 km intervals.6 Current Measuring Stations shall be installed on the pipeline every 10 km.3 Cable connections to the pipeline (Ref.3 Installation 1. STD-7-3001).0 1. etc. subject to prior Company approval.17.6. as shown on the drawings. unless stated otherwise in the Schedules.5 Where Foreign Service Bonding Facilities are required on foreign services. test station/pup piece point.17. SP-1208 Page 50 September 2005 .3. earthing electrodes .4 All C.1 Installation of the C.2 Materials Contractor shall procure all materials required for the Work.3. 1. buried or overhead high voltage powerline . pipeline crossings .P. Specifications for materials shall be as shown on the drawings. 1. current measurement stations. Welding and NDT. negative connections . insulating joints Where the required connections at pipeline crossings. Installation and Commissioning) • SP-1130 (Materials and Equipment) • SP-1136 (Standard Drawings) • PR-1234 (Safe Working Procedures) 1. System shall be carried out concurrently with the main pipeline laying work. STD-7-3004). STD-7-3005).17. 1.3. at the following locations: . Standard Test Post shall be installed (Ref.17.17. for cross bonding.3. current measuring stations . 1.3.P. Welding of the attachments to the pipeline. unless shown otherwise on the drawings (Ref. testing facilities shall be installed in accordance with SP-1129. STD-7-3006).P. the latter may be relocated to coincide with the connection. including procedure and welder qualification shall be in accordance with Section 2.17.Pipeline Construction Specification Version 2. are within 200m of the planned location of a C. 1. and within 50m of a power line (Ref. as shown on the Drawings. The following Company Specifications are applicable: • SP-1129 (Construction.3.17.17. a C.P.7 A Grounding Facility shall be installed at power line crossings and where the pipeline runs parallel to.

in accordance with drawing GEN-2-1633-01.17. to check the integrity of the buried pipeline coating.P. Cable to pipeline connections shall be made prior to hydrostatic testing. STD-7-6003.1 Company will carry out a ‘Pearson Survey’. Standard Test Post. cleaning. SP-1208 Page 51 September 2005 .17. 1. Anode connections shall be constructed such that they can easily be connected / disconnected during and/or after commissioning of the permanent system.P. after installation of the pipeline. 1. i. cables shall be installed in accordance with SP-1129. repair and backfill at Contractor’s expense. Contractor shall install Pearson Survey Earthing Points adjacent to each 2 km C. 1. Contractor shall excavate. 1.0 1. gauging. shall be installed in accordance with SP-1129(Ref. Contractor to commission the C.P. In order to achieve good earthing for this survey.3.e.5. 1.10 All C. 1.3. 1. 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.18 Quality and Treatment of Hydrotesting Water The minimum requirements for the quality and treatment of flushing and hydrostatic testing water as required for the Work is stipulated in SP-1212: Hydrostatic Testing of New Pipelines.6 Commissioning Contractor is required to provide a PDO approved C.17. when required and shown on the Drawings. and STD-7-6004).5.8 Drain Point Facilities shall be installed as shown on the Drawings (Ref.17. STD-7-6001.17. 1. 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.17. Cable markers shall be installed in accordance with drawing STD-7-7001.P. STD-7-6002. STD-7- 3003).2 These earthing points shall be constructed during the main pipelay work.17.9 Insulating joints/flanges shall be installed in accordance with Drawings (Ref. filling.17. 1.4 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.3.19 Hydrostatic Testing The minimum requirements for hydrostatic testing operations.11 Ground beds.5 Pearson Survey 1. If coating defects are found on any portion of the coating.3. Pipeline Construction Specification Version 2.17. system after installation in accordance with documents SP-1129 and PR-1169. STD-7-3007). 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.

30. . programme and schedule for Work. equipment and facilities including spares for each section to be pre-commissioned. . their validity from previous experience.20 Precommissioning Of Pipelines 1.50. Contractor shall supply all materials. spares.50. calculations and any other evidence necessary to demonstrate that the work will be executed in accordance with the requirements of the Contract. . Hydrotest water shall be disposed of in accordance with SP-1006. . supervision and other services incidental to and necessary for the successful performance of the pre-commissioning work in a manner satisfactory to the Company. . any tie-in work to be carried out after pre-commissioning. test/calibration procedures for all main equipment and instrumentation.1 Scope The minimum requirements for precommissioning of oil and gas pipelines including but not limited to bulk dewatering.2 General The Contractor shall carry out the pre-commissioning activities of pipelines in accordance with the requirements of the Scope of Work. the method or combination of methods to be employed . complete summary and lay out of the temporary pipework. Pipeline Construction Specification Version 2. branch off takes. cleaning. Lower values may be assumed if the Contractor can demonstrate. drying and preservation of oil and gas pipelines as required for the Work are covered under a separate DEP 31. SP-1208 Page 52 September 2005 . etc. . 1.40.40. to the Company's satisfaction. precommissioning of valves. Pre-commissioning records shall be in accordance with chapters 6 and 8 of DEP 31.20. for the precommissioning work including but not limited to detailed procedures.20. precise definition of the sections to be precommisioned .0 1. equipment.20.2.30.30. tests to verify the success of the operation.50. 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 0.40. . the method(s) to be employed to preserve the dryness and cleanliness of the line.1 Contractor shall make detailed proposals. labour. consumables. this specification and DEP 31. a summary of the amount of material and consumables and the number and qualifications of personnel.1 mm. 1. final dewatering. to be used for the precommissioning work. Contractor’s proposals shall include complete information regarding the following aspects: . for Company approval.

2.38. this specification shall take precedence. SP-1208 Page 53 September 2005 .1 Scope This Section of the Specification covers the minimum requirements for keeping and maintaining records.21.60. The scope also covers responsibility for document preparation and custody. coded and compiled on to a minimum number of fully indexed compact discs or other media that may be specified by the Company.1 The work permit system shall apply to all work on live pipe systems. These requirements supplement those contained in SP-1131.2 Specialised tools and equipment as required for the performance of work on live pipe systems shall only be acquired form the Company approved vendors. 1. storage format and the storage location.22.2. 1. drawings and documents of all aspects of the pipeline project.22 As-Built Records and Hand-Over Documentation 1.21. These requirements are developed as a comprehensive list of documentation specific to pipeline projects and listed in Appendix D of this specification.2.2 General 1.1 Scope This Section of the Specification covers the minimum requirement for work on live pipe systems as required for the Work. All master documents should be classified.22. 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. Route survey data shall be presented in accordance with XTO documents TS18v1-0: Pipeline Data Specification and TS19v1-0: Flowline Data Specification. The scope includes new pipeline construction and modifications to existing lines and related facilities. 1. Welding on pressurised pipes shall be carried out in accordance with SP-1167. Where any conflict occurs with the requirements of SP-1131.0 1.2 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. Pipeline Construction Specification Version 2. A vendor’s representative shall be present at all times during the use of such tools and equipment.10. Controlled and separately stored back-up copies of key items shall be maintained.21 Work on Live Pipe Systems 1. the recommended storage period before disposal. 1. The types of documents/drawings required for handover of a pipeline are detailed in subsequent sections.21. This Appendix also include.21.21. to which reference should be made for the definitions and general requirements. the minimum recommended retention period for each type of document and the appropriate form in which storage should take place.3 Hot tapping on live pipe systems shall be carried out in accordance with DEP 31. Contractor shall do all that is necessary to obtain work permits and to execute the Work in adherence to the work permit. 1.

shall be linked to the relevant pipeline location in GIS to enable the data to be readily identified and/or retrieved. 1.22. ultrasonic test reports. 1. Design Reference Manual.0 Documentation available only as hard copy shall be scanned for archiving. Controlled hard copies of documents required for pipeline operation and maintenance (Operating Manuals. as specified in applicable Sections of the Specification. Material Certificates for Contractor Supplied materials .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. where applicable. SP-1208 Page 54 September 2005 . 1. along with copies of all key drawings within EDMS and the basic pipeline design and operating data held in SAP. Calibration and Inspection Reports . Test.Pipeline Construction Specification Version 2. radiographs. exceptions to this requirement should be agreed by the responsible Project Engineer in consultation with the relevant CFDH or nominated discipline engineer.5 Documents The required documents to be provided by the Contractor are: . Contractor shall provide originals of documents plus two copies. This list. or the document is not suitable for scanning. less than 2 years). (including welding procedures.22. As-built Drawings and Pipeline Data Sheets Unless otherwise stated. Calibration and Inspection Reports Contractor shall make available inspection. In the cases where the required storage life is short (say. Hard copies of whichever master documents are required for day to day operation and maintenance.22. hydrostatic testing and drying reports). or for permanent reference to support future engineering activities during the operational life. 1.22. Issue of further documents should be authorised and controlled by the Asset Manager. PEFS etc. NDT procedures. Autocad drawings shall be stored and referenced in EDMS in accordance with Company practice. may be made as required provided documents maintained ‘As-Built’ are formally issued as controlled copies. as per Appendix D) should be provided to Operations as part of the handover package. A detailed listing shall be filed within EDMS Business Records of the storage location of all master documents for each pipeline.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. calibration and testing reports. This shall include storage of pipeline radiographs for the prescribed retention period before disposal. for all materials supplied by Contractor and incorporated in the permanent facilities.7 Material Certificates Contractor shall make available Mill and Test Certificates.22.6 Test. Subsequent revisions of the master documents shall be authorised and all As-Built copies issued on a properly controlled basis in accordance with CP-102. 1.

with chainage . The review authority will be UIP (CFDH Pipelines).0) of this specification will be reviewed and updated once in every three years. 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. with chainage . 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. to the approval of the Company. . changes in pipe grade. 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. . Cover and grade elevations at 12 meter intervals. Other relevant data including the chainage of block-valves. for the purpose of producing as-built drawings. diameter. wadis. The chainage. The identification and the location of circumferential welds and pipe lengths with the manufacturer’s number. . anchors. pipes. Refer to Pipeline Data Base requirements in Appendix D. Contractor shall provide a site-based experienced. personnel. ‘As-Built’ drawings shall be prepared during the progress of the Construction Work and Contractor shall provide a drawing office. SP-1208 Page 55 September 2005 . The location and degree of all points of intersection. with chainage . cables and other objects crossing and/or obstructing the pipeline. Measured trench depth at each 12 meter intervals. with valid driving licence and vehicle. wall thickness.22. Pipeline Construction Specification Version 2. elevation. 1.24 Review and Improvement It is intended that the present version (2. and depth at which it was encountered. and all necessary equipment and facilities. full-time ‘As-Built’ surveyor. size. . cathodic protection appliances.23 Effective Period The requirements of this specification shall remain in force indefinitely unless superseded by an authorised revision. The locations of all temporary vents.8 As-built Drawings and Pipeline Data Sheets Contractor shall return to the Company one copy of each drawing (provided by the Company) corrected with as-built information for those drawings in the Drawing List which are indicated to be revised as as-built. etc.0 1. Type of rock/soil encountered in trench preparation. Measured top of pipe level at each installed joint location. instrumentation. . heat number. shape of all roads. throughout the duration of the Contract. The position of all permanent markers. The as-built information shall include but not be limited to: . 1. . type. sequence number and length installed.

commissioning or management of a project. TERMS AND ABBREVIATIONS i. may Indicates a possible course of action. Consultant or Contractor that uses this document. 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 SP-1208 Page 56 August September 2005 . procurement. User The Company. Manufacturer/Supplier The party which manufactures or supplies equipment and services to perform the duties specified by the Company. Terms and Definitions Company Petroleum Development Oman LLC. The Company may also include an agent or consultant authorised to act for. Procurement. should Indicates a recommendation.0 APPENDIX A GLOSSARY OF DEFINITIONS. or operation or maintenance of a facility. Abbreviations BCD Business Control Document CFDH Corporate Functional Discipline Head CP Cathodic Protection CSR Company Site Reprensative EPC Engineering. shall Indicates a requirement. the Company. The Company may undertake all or part of the duties of the Contractor. ii.Pipeline Construction Specification Version 2. engineering. Corporate Functional The person within the Company responsible for the Discipline Head discipline to which the standard belongs. Contractor The party which carries out all or part of the design. construction. and on behalf of.

Abandonment and SP-1012 Restoration Mounting of Plant Instruments SP-1088 Specification for welding of Duplex Stainless Steel Pipelines SP-1097 Electrical Installation Practice SP-1099 Electrical Safety Rules SP-1104 Electrical Standard Drawings SP-1105 Specification for Earthing and Bonding SP-1109 Specification for Cathodic Protection Design SP-1128 Specification for Construction. REFERENCE REF # PDO STANDARDS Code of Practice Corporate Document Management CP-102 Health Safety and Environment Management System CP-122 Specification Civil and Building Standard Drawings ERD 10-11 Mechanical Standard Drawings ERD 38-04 Guidelines for excavation and working around live pipelines ERD 38-11 Specification for Qualification. Construction SP-1171 and Engineering works Specification for welding of on-plot Pipework SP-1173 Specification for welding of Class 2 Pipelines (Flowlines) SP-1174 SP-1208 Page 57 August September 2005 . the latest edition of each publication shall be used. reference is made to the following publications.Pipeline Construction Specification Version 2. application and inspection of ERD 48-04 shrink sleeves for corrosion protection Specification for Aqueous Effluents SP-1006 Specification for Waste Management SP-1009 Specification for Site Preparation. Installation and SP-1129 Commissioning of Cathodic Protection System Specification for Cathodic Protection Materials and SP-1130 Equipment 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 SP-1147 Pipelines Specification for welding on pressurised pipes SP-1167 Specification for Quality Assurance of Design. together with any amendments/supplements/revisions thereto. Unless specifically designated by date.0 APPENDIX B REFERENCE DOCUMENTS In this SP.

Laboratories. 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 C-09 HSE Requirements and Guidance for use GU-140 Environmental Assessment Guideline GU-195 Guideline for the Granting of Engineering Technical GU-272 Authorities Guidelines for the protection of buried sections of surface GU-368 laid Pipelines/Flowlines SP-1208 Page 58 August September 2005 .0 REFERENCE REF # PDO STANDARDS Specification for Welding of Class 1 Pipelines SP-1177 Specification for Application and selection of Standard Pipe SP-1187 Supports 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 SP-1246 production facilities (Part 1 – 5) Training requirements for lifting operations personnel SP-1251 HSE Specification. Camps. Training Observation Programme SP-1259 (STOP) Specification for Civil and Building Construction SP-1279 Specification for Reinforced Concrete – Production & SP-1282 Construction Guidelines HSE Specification.Pipeline Construction Specification Version 2. SP-1256 Workshops and Industrial Safety Specification HSE Specification. Offices. Safety.

38.21.Pipeline Construction Specification Version 2.4 / B31.40.40.0 REFERENCE REF # SHELL STANDARDS Index to DEP publications DEP 00.12-Gen Inspection and Functional testing of instruments DEP 62.40. External polyethylene and polypropylene coating for line DEP 31.16-Gen GRP Pipelines and piping systems (amendments / DEP 31.30.40.01.30-Gen.30.40.30.40.30.40.20.40.37-Gen (Amendments/supplements to ISO 3183-3) Pipeline Fittings (amendments / supplements to MSS DEP 31. Pipeline overpressure protection DEP 31. Hot tapping on pipelines.05.15-Gen.40.00.30-Gen Pipeline Repairs (supplements to ASME B31.01.32-Gen.10.60.40.38.10.14-Gen Upheaval buckling of pipelines DEP 31.21.40.11-Gen Piping classes – exploration and production DEP 31.34-Gen Precommissioning of pipelines DEP 31.08.10.20.19-Gen.10-Gen Design of pipeline pig trap systems DEP 31.50.40.40. piping and equipment DEP 31.35-Gen (Amendments/supplements to ISO 3183-1) Linepipe for critical service DEP 31.38.10.40.60.34-Gen and gas operations (amendments / supplements to MSS SP – 44) Concrete coating of linepipe DEP 31.40.40.05-Gen.33-Gen to ISO 15590 – 1) Linepipe for non-critical service DEP 31.33-Gen Carbon and low alloy steel pipeline flanges for use in oil DEP 31. supplements to ISO 14692) Line pipe induction bends (amendments / supplements DEP 31.31-Gen pipe External fusion-bonded epoxy powder coating for line DEP 31.30-Gen SP – 75) Pig signallers: Intrusive type DEP 31.11-Gen SP-1208 Page 59 August September 2005 . Piping – General requirements DEP 31.20.10.8) DEP 31.21. pipe Thermoplastic lined pipelines DEP 31.13-Gen.

Inc. 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. UK INTERNATIONAL STANDARDS Preparation of Steel Substrates before Application of Paints and Related Products – Visual Assessment of Surface Cleanliness ISO 8501-1 Preparation of Steel Substrates before Application of Paints and Related Products – Tests for the Assessment of Surface Cleanliness ISO 8502-1 to 4 Preparation of Steel Substrates before Application of Paints and Related Products . Northeast Vienna.127 Park street.Pipeline Construction Specification Version 2.8 Issued by: American Society of Mechanical Engineers Publications and Distribution Section 1220 L Street Northwest Washington DC 20005. W4 4AL. VA 22180.Surface Roughness Characteristics of Blast-Cleaned Steel ISO 8503-1 to 4 Substrates Preparation of Steel Substrates before Application of Paints and Related ISO 11124 Products .Rue de Varembé CH-1211 Geneva 20.4 Gas Transmission and Distribution Piping Systems ASME B31.3 Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids ASME B31. Switzerland SP-1208 Page 60 August September 2005 .Specification for Metallic Blast-Cleaning Abrasives Preparation of Steel Substrates before Application of Paints and Related ISO 11126 Products . fittings and flanges for ISO 15590-1 pipeline transportation systems – Part 1: Induction Bends Issued by: International Organization for Standardization 1.Specification for Non-Metallic Blast-Cleaning Abrasives ISO 14692 Petroleum and Natural Gas Industries – Glass Reinforced Plastics (GRP) Piping Petroleum and Natural Gas Industries – Induction bends. 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. USA Specification for Linepipe API Std 5L Standard for welding pipelines and related facilities API Std 1104 Recommended practice for liquid petroleum pipelines crossing railroads and API RP 1102 highways Issued by: American Petroleum Institute Publications and Distribution Section 1220 L Street Northwest Washington DC 20005.0 AMERICAN STANDARDS Process Piping ASME B31.

This shall be furnished with: one standard bed and mattress. electricity. one chest of drawers. C. C. fly screens. Pipeline Construction Specification Version 2.2 Accommodation C. Contractor shall provide and maintain in its camp. adequate heating and air-conditioning. one writing desk with drawers and with a matching chair.0 square metres floor area.2 metres one full length wardrobe.0 APPENDIX C: FACILITIES FOR COMPANY PERSONNEL C. each 0. one bedside light. two coffee tables. one waste paper basket. 1. one refrigerator. glasses. one 14” portable colour TV+ DVD Player one bedside rug. cups and saucers. electrical power points. one electric kettle. one bedside table. of minimum width 1.2. b) Private toilet/shower of minimum 3. the minimum accommodation requirements for each of Company’s aforementioned senior personnel shall be: a) Bed-sitting room of 14. ashtrays.2 Where the Contractor is required in the Contract Scope of Work to provide accommodation for the Company’s personnel.5 metres long and 1 metre wide.1 Scope This Section of the Specification covers the minimum requirements for facilities for Company personnel at Contractor’s Construction Camp and is supplementary to the Regulations for Pipeline Contractor Camps in the Interior. good quality accommodation for the number of Company’s senior personnel stated in the Scope of Work.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 61 August September 2005 .1 Where the Contractor is required in the Contract Scope of Work to provide his own camp.5 square metres floor area (minimum width 1. general lighting. Company may choose to use this accommodation for personnel other than Company personnel.2.75 metres square. two easy chairs. sewerage.

C.3 Contractor shall keep the Company personnel refrigerators stocked with a selection of soft drinks.1 Where the Contractor is required in the Contract Scope of Work to provide messing. C.0 c) All necessary bed and bathroom linen. C. C.2. electricity.3. and ashtrays. C.4.1 Contractor shall furnish. Pipeline Construction Specification Version 2. waste paper baskets. C. 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. C. in trays. The menu should have at least one alternative main course. office space for these persons shall have a minimum floor area of 45 square metres and shall be supplied with the following for sole use by the Company’s personnel: four desks.3 Messing C.4 Offices and Office Services C.2 Contractor shall provide an adequate laundry service for the personal clothing of the Company personnel.2 Unless otherwise agreed by the Company. 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.3. electrical power points.4. clean and maintain good quality office equipment and accommodation at each spread camp for 5 members of the Company’s personnel. 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.3 Contractor shall replace all linen twice per week. five handheld radios office telephones internet / email facilities two digital camera one refrigerator SP-1208 Page 62 August September 2005 .3.4 All accommodation provided for the Company’s use shall be subject to Company’s approval. and keep all accommodation in good repair. general lighting. clean all accommodation daily.2.

preferably Mitsubishi Pajero V6 (LWB) or Company approved equivalent. C.2 In each camp a 29” colour TV with DVD player shall be available for the sole use of Company personnel. Contractor shall keep a record of all checks and services for each Company vehicle. C. etc.6. service. C.5. they shall at the start of the Contract be either new or have less than 10. etc. provided for Company’s use shall be subject to Company’s approval. tennis. with a floor area of minimum 24 square metres. C. Contractor shall maintain vehicles of the Company with due diligence and utmost care to ensure safety of the vehicles.6 Recreational facilities C.5. typing and general office procedures.1 Throughout the construction period Contractor shall fuel. a furnished conference room of minimum floor area 24 square metres and with seating for a minimum of 15 persons.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.4. C.2 Maintenance procedures shall be strictly in accordance with vehicle manufacturer’s local representative’s recommendations for the specific terrain and climatic conditions involved. C.).6. maintain and repair the vehicles which Company uses on the Work Site.6.4 Where Contractor is required in the Scope of Work to provide vehicles for the use of Company personnel. stationary.5.4.0 C.4. Contractor shall make available for Company’s use at the main spread camp site.3 The offices shall be interconnected. up to the number given in the Scope of Work.3 Magazines and daily newspapers shall be provided by the Contractor as per Company’s Site Representative’s requirements.6. type to be agreed with Company Site Representative. facilities shall be provided for outdoor sports (football. C.1 Contractor shall make available separate recreational facilities for the Company personnel. the Contractor shall provide and maintain for Company’s sole use such materials and equipment (computer.4.5 All offices and office services.000 Km mileage. Pipeline Construction Specification Version 2.4 At each Contractor Camp. At each spread camp. C. C. 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.4 As and when required. and furnished with easy chairs. The vehicles shall be 4 wheel Drive. SP-1208 Page 63 August September 2005 .4. C. A daily status check for all cars being used is required. C.6 Contractor shall provide an administration clerk who is proficient in English.) as may be required for the Company’s clerical work at the camp. for Company use seven days per week throughout the duration of the Contract.5 Vehicles and Maintenance C.

2. benchmark locations included in plot plans.2 Hazardous area classification drawing DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS.0 General Reports 1.7 Environmental data SC 2 years Paper Archive Storage reference in EDMS.2 Pipeline inspection reports CC Service life Electronic or Paper Archive Archived items to be referenced in EDMS. accessed via GIS 1.7 Material identification diagram DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS. 2.5 Process and engineering flow scheme DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS.1 Road and paving plan DC Service life Electronic/Paper ✓ EDMS 3.5 Design reference manual DC Service life Electronic ✓ EDMS Essential data for each line held in PACER. 2. 2. 1.6 Soil investigation report SC 2 years Paper Archive Storage reference in EDMS. 1.3 Equipment reports Vendor Service life Electronic or Paper ✓ Archive Archived items to be referenced in EDMS.feasibility/conceptual/ front end DC Project completion N/A N/A Conceptual data underlying chosen design options (see remarks) to be retained with DRM (1. guides and anchors DC Service life Electronic/Paper EDMS Drawing reference in GIS. 3.0 General Drawings 2. 1.4 Utility flow schemes DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS.0 APPENDIX D: LIST OF HANDOVER AND AS-BUILT DOCUMENTATION Storage format Document Category Remarks Originator * Retention time Keep As-Built Custodian ** Location 1.6 Utility and engineering flow scheme DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS. Note. 3.2 Foundation location plan DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS. 2. 1.4 Non-standard pipe supports.9 Technical audit/HAZOP reports DC (See remarks) Electronic EDMS Retained until close out of HAZOP actions. 1.3 Process flow schemes DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS.1 Plot plans DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS. accessed via GIS 1. 3.10 Close-out reports PE 2 years Electronic EDMS 2.5 above) 1.0 Civil Documents 3.4 Operating manual DC Service life Electronic ✓ EDMS Essential data for each line held in PACER.8 Studies .1 Drawing control register DC (See remarks) N/A N/A Retained until drawings are as-built and stored in EDMS.Pipeline Construction Specification Version 2. 4.0 Mechanical Documents SP-1208 Page 64 August September 2005 . 2. 1.3 Fencing and grading plan DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS.

doc 5.2 Route maps XTO/2 Service life Electronic or Paper ✓ GIS Ref.2 Power cable layout layout drawing DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS.1 Pipeline routing key plan DC Service life Electronic ✓ EDMS Drawing reference in GIS.3 Alignment sheets DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS. 6. SP-1208 Page 65 August September 2005 . 7.3 Equipment data sheets Vendor Service life Electronic or Paper Archive Archived items to be referenced in EDMS.Pipeline Construction Specification Version 2. 6.7 Electrical material requisitions DC/PE See remarks Electronic EMA As 4.4 Isometrics DC Project completion N/A N/A 4. 6. 4.0 Pipeline Documents 5.3 List of alarm and trip settings DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS.0 Instrument Documents 7. 7.4 Station approach drawings DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS. 7.2 Piping plans DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS. 5.3 Earthing layout drawing DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS.5 Cable schedule DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS. Reference in EDMS 5.0 Storage format Document Category Remarks Originator * Retention time Keep As-Built Custodian ** Location 4. TS18V1-0.6 Material/equipment requisitions DC/PE See remarks Electronic EMA Retain for longer of guarantee period or 2 years.6 Trench layout DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS. 4.1 Single line diagram DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS.doc & TS-19V1-0. 6. above. 5.2 Instrument data sheets DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS.1 Piping key plans DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS.5 Tie-in schedule DC Project completion N/A ✓ N/A 6.5 Material take off DC Project completion N/A N/A 4.0 Electrical Documents 6.1 Instrument location plan DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS.4 Shutdown matrices DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS. 6. 4.4 Lighting layout drawing DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS. 5.6. 7. 6.

8.6. above.3 Cabling routing layout DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS. 7. 8.0 Pipeline Construction Documents 9. 7.10 Control room instrument cable layout DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS.9 List of telemetry points DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS. 8. 7. 7.2 Wiring diagrams/cable sizes DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS. 8.0 Cathodic Protection Documents 8.8 Control room layout DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS.2 Welding/NDT progress chart CC 2 years Paper Archive Storage reference in EDMS. 9. above 8.8 CP installation specification SC Service life Electronic or Paper Archive Archived items to be referenced in EDMS. 8.5 Functional logic diagram DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS. SP-1208 Page 66 August September 2005 . 8.6 Loop diagrams DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS.4 Transformer rectifier plot layout DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS.7 CP material specification report SC Service life Electronic or Paper Archive Archived items to be referenced in EDMS. 7.5 Layout of CP facilities DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS.9 CP requisitions DC Service life Electronic EMA As 4.Pipeline Construction Specification Version 2. 7.0 Storage format Document Category Remarks Originator * Retention time Keep As-Built Custodian ** Location 7.1 Ground bed layouts DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS.6. 8.7 Alarm annunciator system DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS. 7. 8.11 Junction box layout DC Service life Electronic/Paper ✓ EDMS Drawing reference in GIS.1 Welding and NDT procedures CC Service life Electronic or Paper Archive Archived items to be referenced in EDMS.6 CP survey report SC Service life Electronic or Paper Archive Archived items to be referenced in EDMS. 9.12 Instrument requisitions DC/PE See remarks Electronic ✓ EMA As 4.

9.6 Maintenance instruction manuals Vendor Service life Electronic or Paper Archive Archived items to be referenced in EDMS. 9. MOM etc. barred tees 10.0 Storage format Document Category Remarks Originator * Retention time Keep As-Built Custodian ** Location 9. 9. materials 10. Relevant data to be entered in PACER. Surplus linepipe and fittings. reports and test data for Vendor/TPI Service life Electronic or Paper Archive Archived items to be referenced in EDMS.8 Instrument calibration certificates CC 2 years Paper Archive Storage reference in EDMS. insulating couplings. 9. reports and test data for static Vendor/TPI Service life Electronic or Paper Archive Archived items to be referenced in EDMS. records. Relevant data to be entered in PACER.1 Vendor drawings for end closures.11 CP Installation inspection report CC Service life Paper Archive Storage reference in EDMS. 9.2 Material certification. 10. 9.7 Insulating coupling test forms CC Service life Electronic or Paper Archive Archived items to be referenced in EDMS. 10.3 Material certification. Vendor Service life Electronic or Paper Archive Storage reference in EDMS. Abbreviations CC Construction Contractor SP-1208 Page 67 August September 2005 . 10. 10. 9. 9. reports and test data for surplus Vendor/TPI Until required Electronic or Paper Archive Archived items to be referenced in EDMS. valves.4 Radiographs CC 2 years Film Archive Storage reference in EDMS. material documentation held by TSP.5 Operating instruction manuals Vendor Service life Electronic or Paper Archive Archived items to be referenced in EDMS.0 Vendor Documents 10. and rotating equipment 10. site correspondence.4 Certification. 9.10 Punch list PE (See remarks) N/A N/A Retained until actions cleared. 9.6 Hydrotest certificates CC Service life Electronic or Paper Archive Archived items to be referenced in EDMS.3 NDT reports/Test packs CC Service life Electronic or Paper Archive Archived items to be referenced in EDMS.9 Launcher and receiver inspection form CC Service life Electronic or Paper Archive Archived items to be referenced in EDMS. CC Project completion N/A N/A Selected documents of contractual significance may be archived for 2 years. Relevant data to be entered in PACER.7 SPIR forms Vendor Service life Electronic or Paper Archive Archived items to be referenced in EDMS.12 Construction drawings CC (See remarks) N/A N/A Retained until master drawings are updated.Pipeline Construction Specification Version 2.13 Misc.5 Commissioning documentation OTL 2 years Paper Archive Storage reference in EDMS.

Pipeline Construction Specification Version 2. SP-1208 Page 68 August September 2005 .0 Storage format Document Category Remarks Originator * Retention time Keep As-Built Custodian ** Location 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.

Drawing Title No. 1 TYP-3-0001-001 O ROW and working strip details 2 TYP-3-0002-001 O Trench Dimensions 3 TYP-3-0003-001 O Cold field bending details 4 TYP-3-0004-001 O Road crossing over existing above ground pipeline 5 TYP-3-0005-001 O Road crossing over existing under ground pipeline 6 TYP-3-0006-001 O Pipeline crossing tarmac road 7 TYP-3-0007-001 O Live stock passageway crossing 8 TYP-3-0008-001 O Pipeline crossing Wadi Type A 9 TYP-3-0009-001 O Pipeline crossing Wadi Type B 10 TYP-3-0010-001 O Pipeline crossing Wadi Type C 11 TYP-3-0011-001 O Pipeline crossing existing above ground pipeline 12 TYP-3-0012-001 O Pipeline crossing existing under ground pipeline 13 TYP-3-0013-001 O Pipeline crossing existing under ground cables Pipeline in parallel and crossing high voltage 14 TYP-3-0014-001 O transmission line 15 TYP-3-0015-001 O Retaining Barriers in sloping trenches 16 TYP-3-0016-001 O Pipeline Markers & signs 17 TYP-3-0017-001 O GRE pipeline crossing road The drawings are for information only.0 APPENDIX E LIST OF TYPICAL DRAWINGS FOR PIPELINE CONSTRUCTION Sr. SP-1208 Page 69 August September 2005 . Rev. Sketch No.Pipeline Construction Specification Version 2.

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A

A

TYPICAL ROAD CROSSING OVER EXISTING UNDER GROUND PIPELINE

SECTION A-A

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Pipeline Construction Specification Version 2.0 SP-1208 Page 86 August September 2005 .

0 SP-1208 Page 87 August September 2005 .Pipeline Construction Specification Version 2.

Pipeline Construction Specification Version 2.0 SP-1208 Page 88 August September 2005 .

0 SP-1208 Page 89 August September 2005 .Pipeline Construction Specification Version 2.

Pipeline Construction Specification Version 2.0 SP-1208 Page 90 August September 2005 .

Pipeline Construction Specification Version 2.0 SP-1208 Page 91 August September 2005 .

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Pipeline Construction Specification Version 2.0 SP-1208 Page 93 August September 2005 .

Pipeline Construction Specification Version 2.0 SP-1208 Page 94 August September 2005 .

0 APPENDIX F CONSTRUCTION REQUIREMENTS FOR GRE PIPELINES 1.40. 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. Apart from PE linings.2. (Under non-EPC contracts the pipe vendor representatives and. other manufacturer’s representatives for other Company supplied materials. GRE pipelines shall be installed in accordance with this specification and ISO 14692-4.3 Quality Assurance Team 2. field service engineers working for the Contractor under EPC contracts shall report directly to the Head of Quality Assurance on quality assurance matters.34 / ERD 43-15 and ERD 43-16 apply for procurement and installation of these materials.Pipeline Construction Specification Version 2.1 Personnel The Head of Quality Assurance shall have a detailed knowledge of installation and inspection of GRE pipelines.1 Background and Scope This Appendix specifies additional requirements for the construction of all new GRE pipeline systems in PDO operations. trenching etc. Whilst these general topics may be applied to the installation of any non-metallic linepipe material. Specification Requirements 2.2 Organisation Contractor’s supervisors and all manufacturer’s representatives of GRE pipe vendor.30.g. Wherever applicable.2 Quality Assurance 2. SP-1208 Page 95 August September 2005 . Activities that are largely common to both material groups. only additional requirements and modifications pertaining to construction of GRE pipelines are given in this Appendix. if applicable.3. e. GRE is the only non-metallic pipe material which has been used by PDO for Class 1 pipelines in Hydrocarbon service. HSE. 2.3. clearing. 2.. specific requirements and guidelines in the current version of this Appendix are primarily concerned with GRE pipelines. shall report to the Company CSR).2. Current PDO specifications DEP 31. Construction of LLRTP and LLGRE pipelines shall be carried out as per requirements provided by the vendor and approved by the Company. are included in the main text of this specification. He shall have general experience in quality assurance matters and be suitably qualified. taking due account of the limitations noted in the GRE linepipe purchase requisition and associated stress analysis executed by the GRE linepipe vendor. Introduction 1. including thermoplastic liners. PE lining and RTP linepipe have been in regular use for Class 2 pipelines (mostly flowlines) for a number of years.2.

The inspection shall include a detailed check for damage or dimensional non-conformances of bells and spigots. Pipes shall be loaded and stacked on trucks in such a manner that flexing and shifting of the pipe during transport is avoided.4 Pipe Handling 2. 100mm x 50mm timber (spacer stripping) may be used for both purposes.3.3. and for long storage periods a suitable cover should be fitted on each stack. Typically.3. 2.Pipeline Construction Specification Version 2.3 Pipe Inspection 2. dimensional non-conformance. the inspection shall be done before removal of the material from the Company’s storage yards.1 Ground surfaces to be used for stacking of pipe shall be reasonably flat. Pipe shall not be laid directly on the ground. After loading.4. such as timber of 100mm x 50mm section. gouges. the Contractor shall comply with GRE pipe manufacturer’s recommendations for pipe stacking. Any shortages. The Company shall review and approve the test results prior to start of construction. During transport the tension of these slings shall be regularly checked. including scratches.5. crushing. Pipes shall be protected against truck beds and side metallic protrusions by means of non-metallic soft materials.3.3 Materials Handling and Control 2. 2. 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.3.2 Pipes may be stacked to a height of 1.5. SP-1208 Page 96 August September 2005 . Where strapping down of stacks is necessary. the Company will determine which requirements shall apply. Additionally.3. piping and fittings are acceptable for installation. Supports between layers should be in vertical alignment. 2. 2.4. The Contractor shall ensure that no pipe end protectors can be lost during transport. For Company supplied materials. In the case of a conflict or ambiguity. missing end protectors or damage. Chains. cables or clamps shall not be used. Pipes shall be laid on suitable supports. suitable non-metallic slings shall be used to tie the load securely to the truck. Non- abrasive wide nylon or canvas pipe slings of minimum width 200mm shall be used for lifting pipe. moved and lowered from one position to another by suitable equipment.5 Pipe Stacking 2. shall be reported to the Company within 24 hours of receipt.1 The Contractor shall visually inspect and dimensionally check each pipe and fitting.5m provided suitable supports are provided both at the sides of the stack and between layers.0 2. located no more than 3m apart and a minimum of 1m from the pipe ends.3.3. End protectors may be punctured with a 5mm drill to prevent them blowing off the pipes. Whereafter the Contractor shall accept responsibility for all material losses and damage however caused. concrete floors or on to rails. 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 General Contractor shall confirm to the Company at an early stage in the project that the testing methods of factory made GRE spools.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. nylon straps should be used. cracking etc.3.1 Pipe shall not be allowed to drop or strike objects which may damage the pipe but shall be lifted. 2.3.

SP-1208 Page 97 August September 2005 . wall thickness.0 2. pressure class.5.3 Pipes of different diameter.3. Each stack shall be properly marked to the satisfaction of Company. material grade or manufacturer shall be stacked separately.Pipeline Construction Specification Version 2.

The Contractor’s surveyor shall survey the trench and submit a formal report with photographs.6 Handling and Control of Consumable Products 2.3 Trenching 2. at all times until the trench is completely backfilled.3. Local high and low points in the trench bottom shall be levelled off to provide a smooth continuous profile.4. 2.3 No consumables shall be stored or used beyond its stated shelf life. 2.3.1 Adhesives.4.W. A continuous record of temperatures of adhesive storage conditions shall be maintained.O. Adhesives shall be kept in refrigerated conditions if the storage period is in excess of one month. 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. hardeners.2 For reasons of safety. SP-1208 Page 98 August September 2005 . A fulltime dedicated crew shall be employed by the contractor to maintain the trench in a rock- free condition before and after pre-padding has been installed. survey data and a detailed profile drawing with invert levels at 12 m spacing.0 2.3. stones and all other irregularities so as to leave the trench bottom in a clean and suitable condition to receive the pipe.4 R. i) The Contractor shall do hand work in the trench as is necessary to free the bottom of the trench of loose rock. and Trenching 2. 2. providing evidence that this requirement is achieved.3.6. resins and additives shall be stored in accordance with the manufacturer’s written instructions in a cool air conditioned area. Contractor shall demonstrate compliance with site storage procedures for all consumables in accordance with detailed consumable handling procedures.4 GRE fittings shall be stored inside or in their original crates out of direct sunlight.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. catalysts and accelerators shall be stored separately in accordance with manufacturer’s instructions. whichever is shorter. or as specified by the manufacturer. Solvents shall be similarly segregated as required by the relevant Material Safety Data Sheets.3.Pipeline Construction Specification Version 2.6.6. away from direct sunlight and excessive humidity.6. 2.3.

may be achieved by elastic bending.1 Small changes in direction. due to right-of-way restrictions. At locations where the pipeline comes above ground.3.6. including moving of bend locations shall be subject to written approval of the Company and the linepipe manufacturer. as specified in the design drawings and approved by the linepipe manufacturer and the Company. 2. Inspection or witnessing of the make up of any joints by the manufacturer’s field service engineer shall not absolve the Contractor of his responsibilities to provide a fit for purpose joint.Pipeline Construction Specification Version 2. Separate procedures shall be prepared for shop fabrication.0 2.6. 2. fabricated elbows shall be used.5 Pipe Stringing and Bending 2. As a minimum. However.4 Each joint shall be inspected and certified by the QC Engineer to have been executed in accordance with the approved jointing procedures.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. The Contractor shall propose a method for cleaning the internal joints for Company review and approval in his detailed jointing procedure.5. Company specification and standards.3. in order to ensure that no significant amount of adhesive protrudes from the inside seam of any glued joint.where it is specified under possible defects – excess adhesive shall not be more than 5% of inner diameter or 10mm which ever is less. Where this is not possible. in service and for future decommissioning work using foam pigs. e. the Contractor shall keep detailed records of make up and curing time. 2. site jointing work and repair work. it is required to accommodate the expansion of bends through proper design and stress analysis.3 Bends 2. provided the bend radius is greater than the specified minimum elastic bending radius specified by the pipe manufacturer for the supplied linepipe. in the vertical as well as the horizontal plane.6 Jointing 2. These shall be in accordance with the Manufacturer’s instructions. particular attention shall be paid to the need for effective internal cleaning of each completed GRE adhesive bonded joint after fit-up. 2. In this section. 2. Any changes to the design layout of the pipeline.1 This section of the specification covers requirements for the jointing of GRE pipelines.6. the bottom of the trench shall be flat for a minimum distance of 25 m. elastic bends are not permitted. SP-1208 Page 99 August September 2005 . batch number of adhesive components as well as jointer ID and date/time for each joint. and prior to curing. This may require revised stress analyses to be executed for the pipeline. expansion cushions shall be installed as per design behind each bend and extending to approximately 5 m each side of the bend. All joint types shall be qualified and approved by the Company before its use in production joints.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. Reference is made ISO 14692-4 table 4.5.g.2 To allow for large expansion at bends such as those caused by wide temperature fluctuations or hydrotest conditions.3 In order to ensure piggability of the pipeline during hydrotest water filling. Special attention is required at transitions between above ground and buried installation to avoid elastic bending. The requirements for qualification and production jointing of all types joints including laminated joints are specified in ISO 14692-4.6. 2. 2.5.6.5 Jointed pipes shall not be moved or handled during curing.

2.2.8.3.3. by means of glued connections.e.4 The Contractor shall take measures to restrain the pipe in the trench by means of ‘plugging’. This is to avoid ‘snaking’ and abrasion of the pipe due to thermal movement. The trench shall be maintained in a dry condition during lowering-in and backfill operations. Due consideration shall be given to ambient temperature changes throughout the day and the resultant pipe length changes and induced stresses.1 Unless otherwise agreed by the Company.8.1 All trenches shall be fully pre-padded before lowering in or jointing in the trench. The Contractor shall plan the work such that the lowering in and ‘plugging’ operations take place together during the coolest part of the day.Pipeline Construction Specification Version 2. During lowering in operations the pipe shall not be subject to bending in excess of the minimum allowable bending radius.8. For tie-ins outside or above the trench.4.6.8. 2.5 Sand padding ‘plugs’ shall be placed around and above the pipe.0 2.2 Pre-Padding 2. for Company approval.8. (Joints shall be left fully exposed around the joint circumference for inspection until completion and acceptance of the hydrotest) 2. No padding shall be placed until Company has inspected and approved the trench bottom and the Contractor’s surveyor has confirmed that the trench bottom profile complies with the pipe manufacturer’s minimum bending radius requirements. 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. Cranes shall not be used for lowering in operations of pipe strings longer than 50 meters. so as to fill the trench to a depth of 300 mm above the crown of the pipe.8.7 All documents shall be submitted to the Company for approval.8. Backfilling and Reinstatement 2. at least 3 weeks prior to the planned commencement of any lowering in operations. The Contractor shall keep the lowering in operation within 1 km of the jointing operation.e. i. (i.8 Lowering-in. 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. Procedures and operators shall be qualified to the requirements of the controlling specifications before commencement of any production jointing.4.3. using couplings if necessary.8. in the morning). 2.4 Tie-ins 2. 2.2 To minimise excessive internal protrusion of adhesives in bonded tie-in connections. with the sand padding shaped to its natural angle of repose and with a minimum of 150 mm at any point around the pipe. 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. Strings longer than 100 meter shall not be allowed to lie in the trench without sand plugging. SP-1208 Page 100 August September 2005 .3. A detailed procedure specifying the means of demonstrating compliance with the minimum bending radius requirement shall be submitted as part of the Contractor’s installation procedures.8.8. No pipe shall be left overnight in the trench without sand padding around and above the pipe. 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.3 Lowering-in and Post-Padding 2.3 A minimum of 3 sidebooms shall be used for lowering in strings of jointed pipe in excess of 50 meter. 2.1 All pipes shall be lowered in within 96 hours of completion of jointing. care shall be taken not to place excess amounts of adhesive near the end of the bell. 2.

Concrete shall not be poured directly on to unprotected GRE surfaces. 2. Access barriers shall be installed on the ends of the crossing to indicate the safe crossing width of the livestock passageway for light vehicles. The construction of cased crossings is SP-1208 Page 101 August September 2005 . Approval shall be obtained from the relevant linepipe and fittings manufacturers.0 2.9.Pipeline Construction Specification Version 2. The width of the crossing shall be 2. 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.3 For GRE lines. depending on the expected operational pressure surges. The concrete should be poured in situ on to undisturbed or compacted soil. 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.9.9 Anchor Blocks & Thrust blocks 2.8. 2. Detailed installation methods of cased pipe shall be in accordance with the Manufacturer’s recommendations for the particular pipeline material and shall be agreed with the Company. a layer of elastomeric material 6 – 10 mm thick shall be wrapped around sections of pipes or fittings before concrete is applied.5 m and the total length shall be 6.4. but not prior to the successful completion of the hydrotest. Thrust block casting around entire fittings or joints shall be avoided.5 m.9. 2.7 Livestock Passageways Unless otherwise indicated on the drawings. tie-ins to steel pipe and to exposed runs of pipe. Where parts of the pipe or fitting joints are to be encapsulated by the block.8.2 Anchor blocks should normally be located in line with fittings.5 Backfilling 2.8. temperature changes. 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.9 Road and Wadi Crossings 2.8. 2.4 No more than half the circumference of the pipe or fitting shall be cast into the concrete thrust block.8.8.9.9.2 Road Crossing with Casing Where GRE pipelines are required to cross under roads and highways. Backfilling shall be performed as soon as possible after padding has been approved.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.8.8. The following requirements shall apply for GRE pipe: • Specific construction requirements shall be in accordance with the project scope of work and alignment drawings. 2. 2. livestock passageways shall be installed at intervals of approximately 2 km and may be combined with graded road and track crossings. if changes are required. All anchor blocks shall be installed and cured prior to commencement of any hydrotesting activities on the pipeline.8.5. Tie- ins to other GRE pipe systems may be made by flanged connections or by means of bonded couplings. nature of the ground and the geometry of the pipeline layout.3 All tie-in connections to metallic systems shall be by means of flanged connections.1 The need for concrete anchor or thrust blocks in the pipeline system will be determined during detailed design. 2.

the GRE pipeline system shall be flushed. Signs indicating maximum axle loadings shall be provided at each crossing. 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.2.19. • Steel casing pipe shall be externally coated to prevent corrosion. 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. If the test on the first 500 meter fails. • 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. Concrete coating of the casing pipe is required in accordance with Section 2.1 On completion of installation. 2. 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.15.15 System Hydrotesting and Certification 2.1. then the lengths of each subsequent test section shall be decided by the Contractor.Pipeline Construction Specification Version 2. 2. shall be undertaken progressively throughout the construction of the line.9. Requirement for installation of the GRE pipe into the casing is covered in 2.15. • The assembled pipeline section in crossing shall be subjected to an air leak tightness test before its installation into the casing. 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.1.3 Only soft foam pigs shall be used for cleaning. 2.0 covered by standard drawing TYP-3-0017-001.40. hydro tested and certified in accordance with DEP 31.9.1 Scope 2.2 The testing of each test section shall commence as soon as possible and.4 No gauging of GRE pipelines is required as online pigging is not envisaged for GRE pipelines. Casings shall be externally protected against corrosion using an appropriate coating system. filling and dewatering of GRE pipelines. Filling the entire annular space with polyurethane foam is also acceptable.10 of the main text. • 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.3 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.15. ISO-14692-4 and this specification. with a Company • Prior to backfilling.15. 2. 2. above.15.2 Hydrostatic Testing SP-1208 Page 102 August September 2005 .15.1. then the next 500 meter section shall also be tested separately. 2. If the 500 meter section hydrotest is satisfactory.10. so far as is practicable within the programme.1.

soil and air temperature recorded every 1. Any ambiguities or lack of clarity between these requirements specified and the requirements of DEP 31.10. The quantity of water required to bring the section back to the test pressure shall be recorded. The tightness test calculation shall be provided to the Company for information. (This should be 110% of design pressure). at the pressure indicated on the drawings. Subsequently.40. No water shall be added or removed during the test. A tightness test check calculation shall be made to verify that no large leaks have been missed.g. depressurising.40. No work shall be carried out to repair leaks until the pressure has been reduced to a safe pressure i. static head plus 100 kPa. pressurisation. tightness test calculations). 2.19 shall be identified to the Company for the purposes of specification improvement. No personnel shall come closer than 5 meters from the pipeline before the pressure has been reduced to design pressure. air content verification. In the event of there being any doubt about the tightness of the line.1 Short term Strength Test The pipeline shall be subjected to one(1) hour strength test to a pressure equal to 1. The average temperature of the pipe may be used for this calculation.15. The temperature measurements taken on the exposed pipe may be included in determining the average pipe temperature. the test shall be extended or repeated to Company’s satisfaction at no additional cost to Company. In this test the test section shall be re- pressurised to the leak tightness test pressure and after each hour the pressure shall be recorded and the section re-pressurised by adding water. immediately following the strength test. cleaning. 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. soil and air temperatures recorded at maximum 3 hour intervals. as determined from the visual inspections.5 times the design pressure.0 The minimum requirements of hydrostatic testing operations relating to safety. temperature stabilisation.2. During the test. The pressure shall be maintained at the test pressure + 100 kPa by bleeding or adding water as required. However. testing. If a leak is suspected the pressure shall be reduced to the pipeline design pressure before carrying out a visual examination. This shall be achieved by visual inspection of each joint every 4 hours during the hydrotest period. a “step test” shall be performed. calculated from the formula given in DEP 31. the additional requirements of this specification shall prevail over other specifications. During the test. SP-1208 Page 103 August September 2005 .5 hours.2 Tightness Test The pipeline shall be subjected to a 24 hour tightness test. deadweight tester readings shall be recorded every 30 minutes and pipe.e. filling. 2. If the quantity of water added shows a decreasing trend then it may be considered that the pipeline is tight. materials and equipment used. Allowance shall be made for instrument inaccuracies and also the pressure changes as a result of average temperature changes. to Company’s satisfaction that there are no leaks in the pipeline.10. in the case of clearly contradictory requirements (e. The test shall demonstrate.15.19 (assuming a fully restrained line section). This shall continue for a period of 24hours.Pipeline Construction Specification Version 2. The temperature recording interval shall be reduced to 30 minute duration for the first and last 2 hours of the 24 hours to assist with the pressure/temperature variation check calculation. deadweight tester readings shall be recorded every 30 minutes and pipe.2. the pressure shall be recorded continuously. If the quantity of water added remains constant then it must be assumed that the pipeline is not leak tight.

The remainder of the test shall not exceed 1. The pipework may be tied-in and retested as part of a pipeline section in order to avoid an additional test head.Pipeline Construction Specification Version 2.0 2. at the test pressure shown on the Drawings.15.5 times the design pressure of any GRE component. SP-1208 Page 104 August September 2005 . an additional tie-in joint or bulk water loss etc.1 times the design pressure of any GRE component.3 GRE and Steel Station Pipework Station Pipework shall be subjected to a combined strength/tightness test of 4 hour duration. The first one hour of the test shall not exceed a pressure 1.

: To CFDH: CFDH Actions Recd.0 USER COMMENT FORM If you find something that is incorrect.: Ref. Send the form to the Document Control Section (DCS). ambiguous or could be better in this document. They make a record of your comment and send the form to the correct CFDH. This lets DCS or the CFDH ask you about your comments and tell you about the decision.: Document Date: Inits. revise at next issue:  Accept.: Recd. The form has spaces for your personal details. Ind. Date: Date: Reject:  Ind. Ind.: Signature: Date: Phone: Document Control Section Actions Comment Number: Date: CFDH Ref. Procedure Details Title: Issue Date: Number: Page Number: Heading Number: Figure Number: Comments: Suggestions: User’s personal details Name: Ref.: Accept. Decision: Inits. write your comments and suggestions on this form.Pipeline Construction Specification Version 2. issue temporary amendment  Comments: Originator Advised: Date: Inits.: Control Section Advised: SP-1208 Page 105 August September 2005 .