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Melut Basin Oil Development Project (Downstream)

REPORT

PROJECT No.

052417
REF

CONSTRUCTABILITY

01-P-3-005
No OF SHEETS

16

DOCUMENT No

OFFICE CODE

PROJECT No

AREA

DIS

TYPE

NUMBER

05

2417

01

005

23/03/04

Issued For Approval

JC

KR

MRG

MRG

01/03/04

Issued for comment

PBF

PH

MRG

MRG

REV

DATE

BY

CHK

ENG

PM

DESCRIPTION

CLIENT

Melut Basin Oil Development Project (Downstream)


Constructability Report
TABLE OF CONTENTS
1

INTRODUCTION............................................................................................................................. 3
1.1
1.2

SUMMMARY RECOMMENDATIONS AND CONCLUSIONS ....................................................... 4


2.1
2.2
2.3

Summary ............................................................................................................................ 4
Recommendations............................................................................................................. 4
Conclusions ....................................................................................................................... 5

PIPELINE ACCESS........................................................................................................................ 6
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8

General ............................................................................................................................... 3
Purpose .............................................................................................................................. 3

Palouge to Al Renk ............................................................................................................ 6


Al Renk to Jebel Ain .......................................................................................................... 6
Jebel Ain to Rabak............................................................................................................. 6
Rabak to Khartoum............................................................................................................ 6
Khartoum to El Geili Refinery........................................................................................... 6
Al Geili to Atabara River ................................................................................................... 6
Atabara River to GNPOC Pump Station 6 (Haiya) .......................................................... 6
GNPOC Pump Station 6 to Port Sudan............................................................................ 6

MOVE AROUND SECTIONS ......................................................................................................... 7


4.1
4.2
4.3

Blue Nile River Crossing move around section. ............................................................ 7


Atabara River Crossing.................................................................................................... 7
White Nile Sugar Plantation (to be confirmed) ............................................................... 7

PINCH POINTS RESTRICTED WORKING WIDTH.................................................................... 8

CROSSINGS................................................................................................................................... 9
6.1
6.2
6.3

Major Crossings................................................................................................................. 9
Secondary Crossings........................................................................................................ 9
White Nile Sugar Plantation Irrigation Canal (to be confirmed) ................................... 9

ROCK SECTIONS ........................................................................................................................ 10


7.1

Existing Quarries ............................................................................................................. 10

PROXIMITY TO POPULATION CENTRES, IRRIGATION CHANNELS, POWER LINES AND


UTILITIES ..................................................................................................................................... 11

CONSTRUCTION CONSTRAINTS AND METHODOLOGIES .................................................... 12


9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9

General ............................................................................................................................. 12
Areas of concern or special construction methods .................................................... 12
Rock .................................................................................................................................. 12
Red Sea mountains ......................................................................................................... 14
Seasonal considerations/constraints, ground conditions .......................................... 14
Road, rail, irrigation crossings methodologies......................................................... 14
Unstable ground-areas ................................................................................................... 15
Areas suitable for temporary installations e.g. by yards, construction camps ........ 15
Transportation constraints bridges power lines....................................................... 15
9.9.1 Low clearance overhead bridges...................................................................... 15
9.9.2 Bridge weight loading limits ............................................................................. 15
9.9.3 High voltage power lines and pylons ............................................................... 16

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1
1.1

INTRODUCTION
General
JP Kenny Ltd has been contracted by Petrodar Operating Company (PDOC) to
prepare a Conceptual and Basic Engineering design for the oil export pipeline system
from the Central Processing Facility (CPF) at Palouge to the Red Sea, a distance of
approximately 1400 km.
Shareholders of PDOC, comprising of China National Petroleum Corporation (CNPC),
PETRONAS Carigali Nile (PC Nile), Gulf Petroleum, SUDAPET Limited and Al Thani
hold the rights for exploration and of the contract areas, Blocks 3 & 7. Those Blocks
are situated south east of the Republic of Sudan between longitude 31 & 34 and
latitude 8 & 10 with total area of around 72000 km2.
The Melut Basin Oil Development Project includes the Construction of Export Pipeline,
Pump Stations, Metering Station, Marine Terminal, SCADA & Tele-Communication
System together with all associated components i.e. valves, cathodic protection, check
points, sampling points, etc. Other associated Petrodar Projects comprise the initial
development of Field Production Facilities (FPF) for the following producing wells (Adar
Yale, Agordeed, and Palouge), Field Gathering Pipelines (FGP) and Central
Processing Facility (CPF).

1.2

Purpose
The purpose of this document is to identify any constructional difficulties relating to the
pipeline and pump stations and to provide the reader with an overview of the pipeline
route construction issues

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2

SUMMMARY RECOMMENDATIONS AND CONCLUSIONS

2.1

Summary
For the larger part of the proposed route the pipeline will follow (within 2/3km)
government highways and railroads and therefore access for construction, materials
delivery and during operation should be acceptable. However as identified in the report
there will be a number of pinch points where alternative construction techniques will
need to be used; these alternative techniques are given in this report.
The need to schedule construction work outside the rainy season for certain stretches
of the pipeline is highlighted following observations of extensive flooding during site
visits during the rainy season. Careful planning will therefore be needed so that these
sections can be completed during the dry period of the year.
During the preliminary survey considerable route sections of rock bearing strata have
been identified and clearly more exploratory work needs to be carried prior to the
issuing of the EPC tenders. A point to highlight is that the use of explosives in the
vicinity of existing pipelines is not recommended practice and rock trenching should be
the preferred method. If explosives are used it should be in accordance with the
conditions stipulated within 05-2417-01-P-1-007 Pipeline Construction Specification.
Crossings of highways, railroads major rivers and irrigation canals are addressed and
problems are not anticipated using well proven established techniques.
During the preliminary survey, sections of unstable ground were noted, this should be
further investigated when the final route is staked out.
At this stage it is expected that a multi spread operation will be adopted to construct
the pipeline, however more details will be dependent on working patterns developed to
avoid working on certain sections during the wet season as noted above.

2.2

Recommendations
As noted in section 2.1 considerable sections of the proposed route is subject to
flooding in the rainy season. Therefore careful planning is essential to complete
pipeline installation outside this period. Furthermore the use of anti buoyancy concrete
coating will need consideration for the period before the pipeline is full of oil. The
sections where concrete coating may be required will be further identified following the
detailed survey and assimilation of local knowledge in the areas susceptible to
flooding.
Preliminary identification of rock bearing strata has been done, however further work is
required to obtain more precise information as to its extent.
Whilst access along the proposed route is generally good it is essential that the load
bearing capacity and headroom beneath highway bridges which follow the ROW and
will be used for construction traffic be ascertained as soon as possible. In addition all
high voltage cables and pylons under which any construction activity will take place
must have goal posts and bunting erected on both sides of access beneath these
cables/pylons to raise awareness of their presence.

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2.3

Conclusions
Bearing in mind the areas of concern which have been identified, especially the need
for planning work outside the rainy season, the route selected is considered to be
acceptable from the viewpoint of constructability, operation and maintenance.

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3

PIPELINE ACCESS
This section identifies the main access routes expected to be used during the
construction of the pipeline.

3.1

Palouge to Al Renk
A hard well graded dirt road to the west of the pipeline, within 200m of the Right of
Way (ROW) will provide pipeline access. Seasonal construction may be necessary due
to observed standing water over large areas.

3.2

Al Renk to Jebel Ain


A rough graded dirt road, heavily rutted currently exists. The pipeline will lie up to 8km
from this road and rainy season working would prove very difficult requiring extensive
grading and maintenance of access roads as well as the dirt road.

3.3

Jebel Ain to Rabak


Good access is available as an existing tarmac road runs within 2km of the ROW. Off
road conditions fair to good with hard ground and some agricultural/irrigation channels.

3.4

Rabak to Khartoum
There is good access on this section with a tarmac road running parallel to the pipeline
ROW at a maximum offset of 2-3km. Off road conditions are fair to good, access
routes to the ROW will require regular grading/maintenance.

3.5

Khartoum to El Geili Refinery


The pipeline runs up to 5km distance from the highway, hard ground in between to will
provide stable access.

3.6

Al Geili to Atabara River


A tarmac highway runs to the Atabara River bridge giving good access to the Pipeline
route. The tarmac road distance from the bridge to the pipeline crossing point being
some 24 km, north and south of the river.

3.7

Atabara River to GNPOC Pump Station 6 (Haiya)


Tarmac road access does not exist. The ground (some low sand dunes/flats) is,
generally good for access but will require regular grading and maintenance.

3.8

GNPOC Pump Station 6 to Port Sudan


Access over this section ranges from good to poor and is restricted due to the distance
from the tarmac road which ends at the town of Gebait. Rail access is good to KP
1309 but then leaves the ROW which continues through to the Red Sea coastal range
to join the Khartoum to Port Sudan highway at KP 1352. From here access is good to
the Marine Terminal.

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4

MOVE AROUND SECTIONS


There are the only two move around sections on the pipeline. Other crossings e.g.
Kenana Irrigation Canal have adjacent tarmac roads.

4.1

Blue Nile River Crossing move around section.


The Blue Nile crossing will be a move around operation, this requires the complete
spread to be transported by road from south of the river to the north bank (dependant
on spread travel direction). The crossing of the river will be achieved by HDD
(Horizontal Directional Drilling), the ends will be tied in after the section has been
hydro-tested. The section of pipe used for the crossing should be pre-tested prior to
installation or pull-back operation.
Careful planning will be required to achieve minimum disruption of the front end
welding operations within the scheduled working day. Equipment move around will
start after completion of the working day (this could also minimise traffic congestion
problems due to Blue Nile bridges being located in a busy Khartoum district/area,
distance from pipeline to bridge is approximately 34km) and the overnight move will
allow a next morning start-up, continuing the mainline progress minimising
unscheduled stoppages.

4.2

Atabara River Crossing


The Atabara River Crossing will be carried out by HDD. The section of pipe used for
the crossing should be pre-tested prior to installation or pull-back operation. A move
around will be required, as the north side/south side bridge to ROW distance is
approximately 20kms, and no roads link the location of the crossing with the Atabara
bridge. The bridge itself will need to be checked for load limitations. Traffic congestion
problems should not be an issue at this location.
It should be noted that at certain times of the year, December March (the location
was visited on January 26th, 2004), the river bed can be dry. Although ground bearing
and stability issues would have to be addressed, it may be possible to run some
equipment directly across the river bed. However, crops are planted on the river bed
over this period.

4.3

White Nile Sugar Plantation (to be confirmed)


A major irrigation canal is proposed to be built for the White Nile Sugar Plantation. The
location of the crossing is

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5

PINCH POINTS RESTRICTED WORKING WIDTH


Where these sections are located varies from open country, between an existing
pipeline and rising ground to corridors through population centres.
Construction can be achieved by short sections of pipe being welded, from two or
three joint sections up to eight joints or more. These sections can be left adjacent to
the mainline section, to be lifted and tied-in prior to lower and lay. This will allow extra
width that would otherwise be taken up by welding a continuous string along the ROW.
Typical examples are where the ditch will need to excavated by hydraulic backhoe
(mounted) to areas adjacent to graveyards/cemeteries as in the approaches to the
town of Rabak. Restricted width working is not limited to these two examples.
An example of where alternative construction methods are required can be seen at the
approach to the Assayala Sugar Complex. Although ROW working width is more than
adequate it will be seen that an irrigation ditch to the west of the pipeline (south to
north direction) and a wet area, extending along and adjacent to the ROW east side,
could give cause for concern. Movement of heavy equipment could prove detrimental
causing the ground to be cut up and rutted leading to equipment access problems,
reinstatement etc. An alternative construction option would be to push-pull this section,
this would provide the required reduction in working width to allow trenching operations
without encroaching on the agricultural areas.

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6
6.1

CROSSINGS
Major Crossings
Blue Nile River crossing at KP 602, HDD (width of river approximately 330m at this
point).
Atabara River crossing at KP 925 approx. HDD (width of river approximately 350m at
this point).

6.2

Secondary Crossings
River crossing at KP 63, open cut, auger bore, pipe jack.
Kenana sugar factory irrigation canal at KP 309, auger bore, pipe jack.
Main highway, North Rabak at KP 323, highway on 5m high embankment, auger bore.
Two small irrigation channels 5m wide at KP250 - KP 323, open cut.
Two small irrigation channels at KP 334, open cut.
Sondos scheme irrigation channel KP 368, dry at time of visit, open cut, auger bore.
Irrigation channel at KP 593, 7m wide, auger bore.

6.3

White Nile Sugar Plantation Irrigation Canal (to be confirmed)


A major irrigation canal is proposed to be built for the White Nile Sugar Plantation. The
location and size of the canal/crossing is currently unknown and further information
should be sought. Until further information is available the crossing should be treated
as a move around section.

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7

ROCK SECTIONS
First rock appears in exposures and hills at Jebel Ain KP 236 through KP 251 and KP
259.
Potential rock at KP 318, a borehole will determine.
Sub-surface rock at KP 600, and rock appears to be more prevalent north of Blue Nile
although Nubian sandstone sedimentary layer, known to cover extensive areas south,
should be rippable. Indications of rock exposures etc., continue north
Rock approximately 0.5/1.00m below surface at Al Geili refinery, continues
sporadically through to GNPOC Pump Station 6 at Haiya and continues to Singkat.
Overall First Pass estimate of rock is between 250km and 300km. More precise
information will follow with detailed survey. Rock ditch in Red Sea Mountains appears
45 50km (included in overall estimate).
The major portion of the pipeline through the Red Sea Mountains lies in a valley.
Wadis where the ditch will be in sand gravel cobbles, sporadic short rock sections.

7.1

Existing Quarries
The only quarry observed was at Jebel Ain where a small drill and shoot crew were
working. No other operations were observed, but it is understood that there are sandgravel pits along the line, albeit at some distance,

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8

PROXIMITY TO POPULATION CENTRES, IRRIGATION CHANNELS, POWER LINES


AND UTILITIES
The main population centres are, from south to north:

Al Renk: By-pass

Rabak: Corridor through town, power lines, utilities (underground: not known),
irrigation channels, up to 7m wide on entering Assalaya sugar plantation

Khartoum: By-pass, power lines, utilities (underground unknown), some irrigation


canals on Khartoum/Blue Nile approach, south to north direction.

No other major population centre along the route. A number of villages by-passed
or corridor located through. More will emerge from the detailed survey.

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9
9.1

CONSTRUCTION CONSTRAINTS AND METHODOLOGIES


General
Over the length of the pipeline the terrain, to the eye, is flat. Running north from
Palouge roughly parallel to the White Nile, turning north west above the Sondos
agricultural scheme to skirt the urban areas of Khartoum to the east crossing the Blue
Nile at Km:602 and heading toward the Al Geili refinery at KP 687. Immediately to the
north east of the refinery the Melut pipeline will join and run parallel to the GNOPC
pipeline, 28 NB and also will fall into the proximity of a product pipeline, both these
pipelines have their terminals in the Port Sudan area. The Melut pipeline is
gradually rising in elevation as it proceeds north west (approx) reaching a maximum of
910-920 m asl. at the town of Summit. Summit is at the approaches to mountains and
from this point a gradual fall in elevation will occur all the way to the Red Sea coastal
plain and the terminal, approx elevation 20m + (this will need to be verified subject to
final location of the terminal).
The full length of the pipeline lends itself to the use of double jointed pipe, at no point,
even through the Red Sea mountains, would it be necessary to use single joints other
than for some short sections of circa/approx 150 + 200ms and careful attention to
alignment and bending could render these unnecessary leaving single joints for use at
crossings etc.
The terrain and alignment of the pipeline is such that minimal sag and overbends are
required and these will be relatively of shallow or slow degrees other than at major
river crossings/major canal crossings, this also applies to left or right side bends.
Maximum use of flexible bends should be used (can be used effectively) in the Wadi
and washout areas where extra pipeline cover will be required, careful contouring of
ditch floor can make bending unnecessary or, at least, minimal.

9.2

Areas of concern or special construction methods


Over the full length of the pipeline, 1367 kms, there is only one particular area of
concern and that is in the southern end. The concern relates, not so much as terrain,
but to the effects on the terrain by seasonal precipitation; these areas run from the
Assayala sugar scheme all the way south to Palouge. During a visit in November
2003 at the end of the rainy season by the pipeline routing team, it was noticed that
large areas, extending directly from the edges of the road were under several inches of
water, tall grasses and low scrub made visual inspection difficult but when distant
areas were viewed through binoculars it was seen that the extent of the water cover
was considerable. Conventional pipeline construction methods under these conditions
cannot be considered and therefore, seasonal construction will need to be imposed
(records and local knowledge tell us these areas dry out, thereby allowing conventional
construction methods).
Special construction methods are related to narrow ROW widths and fall within
accepted construction practice, see section 5, pinch points restricted width working.
Main sections will be at Rabak, Assayala Sugar Scheme, Singkat Town.

9.3

Rock
Visual observations and appraisal of rock along the length of the pipeline route begins
at Jebel Ain. These comprise surface exposures of igneous rock and small hills of
about 10m + in height and several larger hills of 100m height with attendant scattered

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boulders; some of which are in excess of 6 m across (it should be noted that although
this area is the first location of rock subsequent bore holes may prove otherwise).
From Jebel Ain through to the south bank of the Blue Nile crossing, rock exposure
ranges from minimal to non existent, it is well to remember that this is an area
remarkable for the, so named, Nubian sandstone, stratas/aquifer.
North side of the Blue Nile crossing at KP 616 small surface excavations, 2 & 3
meters deep, display layers of sedimentary deposits, sandstone and siltstones. These
are in multiple, thin layers, well fractured and should be easily ripped (if not dug
directly) by backhoe or chain trencher. These sedimentary deposits are not apparent
from visual observation of the natural or undisturbed ground, from this area to the
approach of the Al Geili refinery there are no obvious indications of rock.
Once at Al Geili rock will be encountered at varying depths below ground surface.
Observations of trench excavation in the area display rock of varying degrees of
hardness and strength being broken out with the assistance of backhoe mounted
hydraulic jack hammers. From this point, north to north west, moving toward Atabara
numerous rock exposures occur, mostly igneous, from shallow rises of 0.5m to hills of
50-60m in height. The pipeline is routed to skirt or run between these maintaining the
level/flat profile of the pipeline.
Blasting has been used through this section, this can be seen from the waste which
has been windrowed over the existing GNPOC pipeline. Some of the blocks are large,
up to 1.5 mts across.
From KP 835, North West to the south bank of the Atabara river there are no visual
indications of rock.
Travelling further, northwest from the north side of the Atabara River surface
exposures start at KP 1007, sporadic, barely visible, and continue. A large
exposure/group of hills to the immediate north west of the pipeline of several hundred
meters in height (200-220m) at KP 1023 indicates a presence of rock, but observations
of residue from earlier excavations does not indicate rock to be within pipeline ditch
depth. From KP1113 to KP1150 signs of rock are minimal to non-existent and consist
of what appears to be buried boulders. Furthermore, inspection of the backfill windrow
over the GNPOC pipeline tends to corroborate this from KP:1150 on towards Haiya
where the rock exposures and GNPOC pipeline backfill windrow shows further
evidence of heavy rock excavation, possible blasting. It should be noted that when
considering rippability, tractors weighing in excess of 60 tons with 500 hp are used,
e.g. cat-D10, D9L, Komatsu-375, lesser sized units are not considered serious ripping
units. Rock exposures increasingly become consistent although no-show sections of
several kilometers length exist and this continues on through Summit to Singkat. At
Singkat the Melut pipeline follows the GNPOC pipeline corridor through the centre of
the township. See section 5 Pinch Points Restricted working width.
From KP 1278 the pipeline is within the Red Sea Mountains corridor and the line is
routed along the valley floor keeping to the edges of the bordering hills. Short sections
of rocky ground are traversed but apart from the narrow section at KP1308 most
excavation will be in sand and gravel with cobbles. Ground surface through these
sections is littered with rock fragments over 0.5m+ in size but indications are that most
can be ripped if not dug directly.

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From KP1311 problems associated with excavation in rock should no longer exist. An
exception will occur in the region of KP1320 where two pinch points occur between the
GNPOC pipeline and rock hills north of the line, ripping and jackhammers will be able
to excavate these sections which are only tens of metres in length.
From these points to the Port Sudan Terminal exposures of rock cease.
9.4

Red Sea mountains


The pipeline across the Red Sea mountain range will continue from KP 1000 and up
to KP 1256 follow within 2km of the highway and the railroad. At this point it will
continue along the railroad corridor as the highway veers off. At KP 1264 the pipeline
will rejoin the highway corridor and skirt Sitka to the west and follow a location
between the highway and railroad up to KP 1282 where it will continue adjacent to the
road/railroad corridors after passing the village of Gebeit. The pipeline will continue in
this location until KP1304 where it will leave the railroad and follow a road at KP 1323
and bear east up to KP 1355 and then north east towards the new Marine Terminal.

9.5

Seasonal considerations/constraints, ground conditions


It is essential that construction of the section of pipeline which traverses the Red Sea
mountains be carried out during the dry season to avoid the hazard of flash floods
which can develop rapidly in this region with catastrophic consequences. Where
possible routing should closely follow highway and railroad routes as these have
withstood washout over the years and will offer the probable optimum location.. As
noted earlier in this report the ground conditions along the pipeline route comprise
loose sand and gravel which could offer little resistance to floodwater

9.6

Road, rail, irrigation crossings methodologies


Throughout the total pipeline length, 1,367 kms it is considered that there will be two
horizontally directionally drilled (HDD) crossings, one at the Atabara River and one at
the Blue Nile, a possibility exists, at the Assalaya Sugar Scheme to use this method as
an alternative/expedient to conventional auger bore/pipe jack.
Irrigation canals such as those at Kenana and Sondos would be bored by rail mounted
auger bore systems where an entry launching pit would be excavated, the auger
system installed, allowing the pipe joints to be progressively jacked and welded until
showing in the exit pit at the other side of the crossing,
For short, bored crossings a suspended auger bore system could be utilised whereby
the line pipe, in a pre-welded section, could be directly installed in a single operation.
This method is applicable to road, rail and some irrigation canals.
A considerable number of crossings of road and irrigation canals could be achieved by
open cut construction where a road or channel is ditched through the short section laid
and backfilled to await tie-in to the main line.
A great number of the irrigation canals lay above the natural ground levels of the
surrounding areas, (most are gravity systems requiring head to flood the channels and
fields) this being so, does not require excessive extra cover and in many cases, will
allow open cut installation methods.

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Rail crossings, by their nature of being in service continually will require boring by one
means or another, all rail crossings visited by the routing team were capable of being
bored conventionally, no rock bores were observed.
9.7

Unstable ground-areas
Although it is known that seismically active areas exist as shown on the Sudan
National Geological maps, along and through the Red Sea mountains records would
need to be checked as to the incidence and/or frequency of activity.
Alluvial fans along the foot of bordering hills, while having the appearance of stability,
have been avoided, these fans consist of waste or washed out material from
surrounding high ground and while many lay dormant for years, can slump or slide with
serious consequences for any installed pipeline, excessive rain for example can
instigate slides in areas that contain alluvial fans.
Some low sand dunes are located along the pipeline route, as long as the ROW is cut
low enough to allow for increased depth of cover over the pipeline. This should not
prove problematic, much as in the use of extra cover is applied to the pipeline in Wadis
and Wadi crossings to minimise the risk of exposure by scouring so the pipeline in
dunes has exposure by the actions of wind minimised/prevented.

9.8

Areas suitable for temporary installations e.g. by yards, construction camps


Having given consideration to the requirements for these installations and the need to
minimise unnecessary work, and land usage, it appears to be in the interests of all
parties concerned to make use of the areas adjacent to the proposed pump station
locations, thereby centralising delivery and dispatch points such as pipe joint delivery,
double joint process, pipe to ROW dispatch and construction camp to minimise
unnecessary transportation of the workforce to separate locations.
Having these facilities localised would also minimise demobilisation and reinstatement
costs upon contract completion.

9.9

Transportation constraints bridges power lines


Travelling through the route of the pipeline it was observed that other than access
considerations, see section 3, very few obstacles occurred and these are identified
below:

9.9.1

Low clearance overhead bridges


None except at Khartoum (east bridge), and overhead clearance appears adequate.
However this needs to be checked.

9.9.2

Bridge weight loading limits

Blue Nile bridge (East bridge)

Atabara River bridge (East bridge)

Both need to be checked

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Melut Basin Oil Development Project (Downstream)


Constructability Report
9.9.3

High voltage power lines and pylons


Minimal number of locations and these are adjacent to rail crossings and villages.
Goal posts and bunting to be erected.
Where offloading of rail cars (pipe delivery)) takes place, initial dump site should be
placed on side of rail sidings away from power lines to minimise the risk of contact by
front end loaders or crainage.

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