Professional Documents
Culture Documents
Document ID SP-1208
Security Unrestricted
Revision 3.0
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 3.0
ii Revision History
The following is a brief summary of the 3 most recent revisions to this document. Details of all
revisions prior to these are held on file by the issuing department.
TABLE OF CONTENTS
i Document Authorisation .......................................................................................................... 1
ii Revision History ........................................................................................................................ 2
TABLE OF CONTENTS................................................................................................................... 3
1 Introduction ............................................................................................................................... 7
1.1 Purpose ....................................................................................................................... 7
1.2 Changes to the Specification....................................................................................... 7
1.3 Conflicting Requirements ............................................................................................ 7
1.4 Exceptions ................................................................................................................... 7
2 Specification Requirements ..................................................................................................... 8
2.1 Health, Safety and Environment (HSE) ....................................................................... 8
2.1.1 Scope ......................................................................................................................... 8
2.1.2 General....................................................................................................................... 8
2.1.3 HSE Advisor ............................................................................................................... 8
2.1.4 Specific Pipeline Activities .......................................................................................... 9
2.2 Quality Assurance ....................................................................................................... 9
2.2.1 Scope ......................................................................................................................... 9
2.2.2 General....................................................................................................................... 9
2.2.3 Quality Assurance Team ............................................................................................ 9
2.2.4 Company Inspection................................................................................................. 11
2.3 Materials Handling and Control ................................................................................. 12
2.3.1 Scope ....................................................................................................................... 12
2.3.2 General..................................................................................................................... 12
2.3.3 Pipe Inspection ......................................................................................................... 12
2.3.4 Pipe Handling ........................................................................................................... 13
2.3.5 Pipe Stacking ........................................................................................................... 13
2.3.6 Linepipe Specifications ............................................................................................. 13
2.3.7 Inspection of Materials other than Pipe .................................................................... 14
2.3.8 Handling of Materials other than Pipe ...................................................................... 14
2.3.9 Reconciliation ........................................................................................................... 14
2.4 R.O.W. and Trenching ............................................................................................... 15
2.4.1 Pipeline Right-of-Way and Working Strip ................................................................. 15
2.4.2 Staking, Clearing and Grading ................................................................................. 16
2.4.3 Trenching ................................................................................................................. 19
2.5 Stringing and Bending ............................................................................................... 22
2.5.1 Scope ....................................................................................................................... 22
2.5.2 Stringing ................................................................................................................... 23
2.5.3 Pipe Bending ............................................................................................................ 23
2.6 Welding and NDT ...................................................................................................... 24
2.6.1 Scope ....................................................................................................................... 24
2.6.2 Off-Plot Pipelines ...................................................................................................... 24
1 Introduction
1.1 Purpose
This document shall be used as the base specification for construction of all new carbon steel
and GRE pipelines required in PDO operations. Hydrostatic testing and Pre-commissioning of
new pipelines are covered separately in SP-1212 and DEP 31.40.50.30 respectively.
Appendix – F of this specification specifies requirements for construction of GRE pipelines.
This specification shall not be changed without approval from the Custodian (UIP, CFDH
Pipelines), who owns this specification. If you think any part of this specification is not correct,
write your comments on a copy of the User Comments Form. The form is included as the last
page of this specification.
1.4 Exceptions
The user shall obtain written approval prior to construction from the appropriate Technical
Authority within PDO for any deviation from or exception to the requirements of this Standard.
The appropriate technical authorities are set out in SP-2061.
Any work completed with unauthorised modifications may be rejected by the Company. Any
subsequent re-work shall be in accordance with this specification and shall be to the
Contractor’s expense.
2 Specification Requirements
2.1 Health, Safety and Environment (HSE)
2.1.1 Scope
This Section of the Specification covers the minimum HSE requirements required during
installation work.
2.1.2 General
The Contractor shall comply in all respects with all HSE Specifications listed in C-6 and C-9
documents of the Contract, paying particular attention to: The requirements for construction
and lifting equipment in CP-189, SP-1251, PR-1708 and PR-1709; the specification for
Aqueous Effluents SP-1006; SP-2000 “Road Transport” and GU-140.
As part of Contractor’s mobilisation, Contractor shall submit and obtain Company’s approval
for the HSE Plans and Procedures for the Work, prior to any Work commencing.
Contractor shall appoint one or more HSE Advisors, to be approved by the Company,
reporting directly to the Contractor’s Project Manager.
The HSE Advisor shall be fully conversant with the Work and shall have previous experience
and qualifications as specified in the HSE Regulations. Details of qualifications and
experience of the HSE Advisor(s) proposed by the Contractor shall be submitted to the
Company for approval before mobilisation of the HSE Advisor(s).
The responsibility of the HSE Advisor(s) is to ensure that all Contractor’s work and conditions
are in accordance with the Company’s HSE Regulations.
The Contractor’s HSE Advisor(s) shall make daily reports about all accidents, unsafe acts,
unsafe situations etc. noticed by himself or brought to his attention. The daily report shall be
transmitted to Contractor’s Project Manager on each morning following the reported day. A
copy shall be handed to the Company’s Site Engineer. The daily report is in addition to those
required by the Safety Regulations. Contractor’s Project Manager shall advise the Company’s
Site Engineer in writing within 24 hrs of the report being issued, what action has been taken to
prevent re-occurrence of any incidents reported.
The HSE Advisor(s) shall carry out his work from the moment the Contractor starts
mobilisation and until the date of completion.
Contractor shall provide a dedicated vehicle with VHF radio, for the sole use of the HSE
Advisor(s), for communications with Contractor’s Construction camp/head office.
Contractor shall specifically instruct all personnel of the dangers relating to the internal
inspection of pipelines. Only under special circumstances shall anyone be allowed to enter a
pipeline, and only after a specific procedure has been agreed and approved by the Company.
During construction of pipelines, the working strip shall be marked with road traffic signs and
specific warning signs relating to the construction activities. This applies particularly to road
crossings.
Generic pipeline construction hazards are identified in the Company’s Pipeline Construction
HSE Case. The Contractor shall make use of the information contained in the Pipeline
Construction HSE Case to identify and control HSE risks specific to the Work. Any additional
hazards identified through the HEMP process shall be advised to the Company for
incorporation in future issues of the Pipeline Construction HSE Case.
This Section of the Specification and SP-1171 “Specification for Quality Assurance of Design,
Construction and Engineering Works” covers the minimum requirements of Quality Assurance
required for the Work.
2.2.2 General
Before starting the Work, Contractor shall submit his proposed quality assurance procedures
and organisation to the Company for Company’s approval. Contractor’s proposed plan shall
include the internal procedures to report non conformances, how corrective action requests
are to be generated and how it will be demonstrated that such actions have been carried out
and are effective.
It is the duty of the Quality Assurance Team to ensure that the Work is carried out in
accordance with this Specification and other Contract Specifications. The Contractor shall
have a full time Quality Assurance Team and all necessary equipment at the Work Site. The
Team shall have no other work or responsibilities apart from Quality Assurance.
One Contractor’s Quality Assurance Engineer responsible for procedure preparation and
implementation, drawing and document control and supervision.
Quality Inspector’s duties include but not limited to the following activities:
- materials certification
- traceability of materials
- trench depth
- sand padding
- lowering in
- backfilling
- as-built drawings
- document control
2.2.3.1 Personnel
The Head of Quality Assurance shall have a detailed knowledge of welding and NDT and
other activities of pipeline construction. He shall have experience in quality assurance matters
and be suitably qualified.
All Contractor’s inspectors shall be fully conversant with and experienced in the aspects of the
Work for which they will be employed. They shall have previously worked on similar projects
in similar capacities. All Contractor inspectors shall be suitably qualified and a copy of all
qualification certificates relevant to the inspection function for which they are proposed by the
Contractor and shall be submitted for Company approval before mobilisation of the
Inspectors. All Contractor’s inspectors shall have a dedicated vehicle.
Following Company’s approval and the arrival of the Inspectors on site, Company has the
right to request all Inspectors to an examination to ensure their suitability for the work they are
required to do, and reject any Inspector who is found unsuitable, at the Company’s sole
discretion.
2.2.3.2 Organisation
The Head of Quality Assurance shall report directly to the Contractor’s Project Manager. His
duties shall be to liaise with the Company, organise the Contractor’s Inspectors so that they
carry out their duties in an efficient manner, and prepare all necessary reports. The Head of
Quality Assurance shall not carry out inspection work himself other than in supervision of the
Contractor’s Inspectors.
Contractor’s NDT supervisors and shrink sleeves manufacturers representative shall report
directly to the Head of Quality Assurance on quality assurance matters.
Company will employ a team of Inspectors throughout the contract period, to monitor all work
activities including safety aspects. These Company Inspectors are hereafter referred to as the
Inspectors.
The Inspectors will have authority to stop the work in the case of unsafe situations and non-
compliance with the HSE Specifications, as well as documented non compliance with agreed
installation or quality procedures which could impact on the future safety of the pipeline during
hydro testing or in service.
The inspectors will report non-compliances with this specification and other contract
standards to the CSR, who will advise the Contractor formally of any required corrective
action.
COASTAL BASED
PROJECT MANAGER
NDT SUB-CONTRACTOR
This Section of the Specification covers the minimum requirements for handling, storage and
administration of all materials, either Company or Contractor supplied, to be incorporated in
the Work.
2.3.2 General
2.3.2.1 Handling, including but not necessarily limited to receipt, checking, lifting, loading, transport,
unloading, stacking, and storage of materials shall be carried out by the Contractor in such a
manner as to avoid harm to personnel and any damage and loss of materials. Method and
means of transport and handling (including documentation) shall be subject to approval by the
Company.
2.3.2.2 Contractor’s material control and storage procedure shall be submitted to the Company within
two weeks of the start of mobilisation on site, for approval.
2.3.2.3 Contractor shall give the Company at least 24 hours notice in writing on each occasion when
he intends to start transporting Company supplied materials. A lapse greater than 24 hours
shall require re-notification. Pipe can be removed from Company’s yard 7 days per week
during daylight hours, unless otherwise specified by the Company. Contractor shall provide
the Company with a written confirmation of receipt of all materials (identified by type and
quantity) and a written reconciliation of all materials (identified by type and quality)
transported by them from Company’s storage yard on a weekly basis.
2.3.2.4 Contractor is required to supply lifting equipment for lifting materials at all locations. Lifting
equipment and operations shall be in accordance with CP-189.
2.3.2.5 Contractor shall appoint a dedicated site-based materials Controller whose sole function shall
be to control and report on the receipt, issue, and stock status of the Contractor and
Company supplied materials.
2.3.2.6 Contractor shall not be held responsible for manufacturing defects in Company supplied
materials, but shall be held responsible for any delays to the Work caused by Contractors
failure to report defects discovered during inspection by the Contractor within 24 hours of
such inspection.
2.3.2.7 Contractor’s procedures for material receipt and return of surplus materials shall conform to
Company’s materials procurement/administration procedures.
2.3.3.1 The Contractor shall visually inspect at the Company storage yards, all pipes internally and
externally for damages, surface defects and defective bevels. The Contractor shall satisfy
himself at this stage of the suitability of each pipe for welding and shall accept all
responsibility thereafter for all damages however caused.
2.3.3.2 Prior to haulage of pipe from Company’s storage yard, Company and Contractor shall carry
out a joint survey of pipe coating damage and bevel damages. On the basis of this survey,
Company will pay the Contractor a lump sum for repair of all bevel and coating damage,
based on the submitted unit rates in the Schedule of Rates, in accordance with this
specification. For bevel damages between 1 and 3 mm deep, the repair shall be by grinding.
For bevel damage depth greater than 3 mm, the repair shall be by re-bevelling.
2.3.4.1 Pipe shall not be allowed to drop or strike objects which may damage the pipe and/or coating
but shall be lifted, moved and lowered from one position to another by suitable equipment.
When lifting pipe, non-abrasive wide nylon pipe slings or special lifting hooks equipped with a
non-metallic bevel protectors curved to fit the curvature of the inside of the pipe shall be used.
Temporary attachments for handling or lifting shall not be welded to any pipe. A spreader bar
shall be used for all bulk pipe lifting/handling (excluding welding operations).
2.3.4.2 Trucks used to transport coated or bare pipes shall be free of any materials that might
damage or contribute to movement of the pipe during transport. Pipes shall be protected
against truck beds and side metallic posts by means of non-metallic soft materials. Pipes shall
be loaded and stacked on trucks in such a manner that flexing and shifting of the pipe during
transport is avoided. After loading, suitable non-metallic slings shall be used to tie the pipes
securely to the truck. During transport the tension of these slings shall be regularly checked.
Pipe ends shall be protected from contact with other metallic materials. Contractor shall
ensure that no bevel protectors are lost during transport. Pipes shall only be transported on
trucks (lifting equipment shall not be used to transport pipe).
2.3.4.3 Trucks used for loading of pipes will be checked by the Company prior to lifting the pipes to
ensure that the trucks and loading/load securing arrangements comply with the requirements
of PDO’s Transport Manual TOM/04/001, SP-2000 ‘Road Transport’ and government
regulations.
2.3.5.1 Ground surfaces to be used for stacking of pipe shall be reasonably flat. Stacked pipes shall
be raised above ground surfaces and prevented from movement by berms of screened sand
covered by polyethylene sheeting or by using timber covered with non-metallic soft materials.
When stacked, the bottom layer of pipes shall be wedged or clipped. Pipes of different
diameter, wall thickness, grade or manufacturer shall be stacked separately. Each stack shall
be properly marked to the satisfaction of the Company. It is advisable to stack CS pipes in
the East-West direction to avoid natural magnitization due to North-South magnentic polarity.
2.3.5.2 Epoxy-coated pipes shall be stacked during transport and storage using rubber or other
suitable separator strips.
2.3.5.3 Pipes shall not be stacked higher than 3.5 metres. Pipes shall be stacked in such a way that
no water is retained inside the pipe during storage.
2.3.6.1 Line-pipe shall be manufactured in accordance to DEP 31.40.20.35 and DEP 31.40.20.37 for
non critical and critical services respectively. These specify amendments/supplements to ISO
3183 Specification.
2.3.6.2 Minimum average pipe length shall be 11.50m as per above DEP. The minimum and
maximum length of pipe shall be between 9m and 18m long.
2.3.7.1 Upon receipt of any materials, the Contractor shall ensure that they conform to the required
specification and are suitable for their intended application. Any damage/defects shall be
reported to the Company within 24 hours of receipt of these materials and prior to
transportation to the Contractor’s own storage yard. Visual inspection shall be adequate for
this purpose.
2.3.7.2 In the case of materials delivered in their original sealed crates, Contractor shall only open the
crates to examine the materials upon arrival at his own storage yard, except in the case of
damaged crates which shall be noted and the contents examined when Contractor takes
receipt at Company’s storage yard.
2.3.7.3 If no report is issued for damaged materials 24 hours after receipt (or in the case of 2.3.7.2
above, 24 hours after arrival of materials at the Contractors storage yard), then the materials
shall be considered free from damage and the Contractor shall be considered liable for any
damage reported or found at a later date.
2.3.8.1 Materials other than pipe materials such as, but not limited to, valves, fittings, scraper traps
etc., shall be lifted by suitable equipment provided by the Contractor at Company’s storage
yard and at all other locations. When lifting lugs are provided on materials, suitable lifting
hooks shall be used for lifting the materials. It is prohibited to use delicate parts such as hand
wheels, nozzles, etc. for lifting of the materials.
Temporary attachments for handling or lifting shall not be welded to any materials. Fittings
shall only be handled by suitable non-abrasive slings.
2.3.8.2 Materials other than pipe materials will be issued to the Contractor whenever possible in their
original sealed shipping cases/crates. Blinded openings of materials shall be kept closed until
installation. The blinds shall be replaced by the Contractor in case of damage during transport
or storage.
2.3.8.3 During transport, materials shall be secured by suitable non-metallic non-abrasive slings.
2.3.8.4 For materials which shall be stored cool and/or dry as required by the manufacturer or the
Specifications, Contractor shall provide suitable storage, transport and handling facilities in
accordance with the requirements of the manufacturer and/or the Specifications.
2.3.8.5 Contractor shall provide a separate fenced storage area for Company supplied materials.
Stored materials shall be protected from ground surfaces by using timber covered with non-
metallic soft materials. Ground surfaces in storage areas shall be clean and flat. It is
prohibited to store and transport fragile materials in more than one layer.
2.3.8.6 Distribution and supply of materials from Contractor’s storage yard to the worksites shall be
limited to quantities required for approximately one day’s production. Timing of the issue of
materials shall be as per the Company approved work schedule.
2.3.9 Reconciliation
2.3.9.1 At the end of the project, Contractor shall give reconciliation for all Company supplied
materials issued, detailing materials installed, materials wasted and scrapped, and surplus
materials. Contractor shall compile a list of the surplus materials, indicating quantity,
description and MESC / SAP number when available.
2.3.9.2 On approval of the surplus list by the Company, Contractor shall return all surplus materials to
Company’s storage yard.
2.4.1.1 Scope
This Section of the Specification covers the minimum requirements for the Pipeline Right-of-
Way (ROW) and the Working Strip.
2.4.1.2 Survey
The Company shall survey the route for the pipeline and prepare route maps from which the
centreline of the pipeline shall be staked out.
The actual centreline of the pipeline can in some instances deviate from the line staked e.g. at
station approaches. This should be taken into account where the word `centreline` is used in
the remainder of this Section.
The construction survey shall adopt the same marks and benchmarks as used in the
Engineering design unless otherwise approved by the Company.
The Right-of-Way for the pipeline is a corridor of 50 metres overall width and comprises:
The “Restricted Area”, a strip of land 25 meters wide on either side of the pipeline measured
from the centre line of the pipeline.
Where two or more pipelines are laid in parallel in the same corridor, the Right Of Way
corridor shall be enlarged by the space between the pipelines. The space between two
pipelines shall not be less than 2 meters from the existing or new pipeline.
Contractor may make use of a Working Strip, having a width of 31 metres (including a
continuous 6 metre wide vehicle access strip) from one edge of the Restricted Area.
Variations, if any, in this width caused by local conditions will be indicated on the drawings or
instructed to Contractor by the Company.
2.4.1.4 Planning/Approvals
Contractor shall, before starting any clearing operations, familiarise himself with any
requirements by the Authorities for work along the pipeline route or in connection with the use
of other lands or roads for construction purposes.
Contractor shall notify the Company 7 days in advance before start of work at road, pipeline,
cable, stream, river and wadi crossings and crossings of other existing structures, if any.
Contractor shall not commence work on such crossings before having obtained approval from
the Authorities and landowners concerned.
The crossings shall be installed to meet all requirements and conditions of the permits, issued
by the Authorities concerned.
In the absence of any specific requirements by the Authorities, Contractor shall comply with
the Company’s instructions.
Where the pipeline is laid close to any existing buried or above ground pipeline, flowline and
utility cables, the Contractor shall propose methods to safeguard the existing line (e.g. a
demarcation fence). No work is allowed in such an area without Company approval. Work
near live pipelines shall comply with the requirements of GU-501, ‘Guidelines for Excavating
and Working around Live Pipelines’ and paragraph 2.4.3.2–f) of this specification.
2.4.2.1 Scope
This Section of the Specification covers the minimum requirements for staking, clearing and
grading along the pipeline route as required for the Work.
Company will have obtained ‘approval in principle’ for laying the pipelines along the routes.
Contractor however will have to obtain permission from the concerned Authorities to execute
the work.
2.4.2.2 Definitions
a) ‘Clearing’ shall mean but is not necessarily limited to the cutting and disposal of
trees, farm crops, bushes and undergrowth.
b) ‘Grading’ shall mean but is not necessarily limited to removal and disposal of
rock, sand dunes, tree stumps and roots.
c) ‘Point of Intersection’ shall mean a point in which the centreline of the straight
sections of the pipeline route changes direction in the horizontal plane. In
general such a point will be outside the actual pipeline centreline because of
the bending radius to be applied.
2.4.2.3 Staking
a) The centreline of the pipeline shall be staked by the Contractor with markers
inter visible by binoculars or theolodite.
ii) The markers are angle-iron profiles or wooden posts with sequential
numbers, starting with no. 1 at start point of the pipeline. Reference
markers are marked with the letter ‘A’ or ‘B’. All markers extend
approximately 500 mm above grade. The ‘A’ and ‘B’ markers are located
at the same side of the centreline marker, ‘A’ being closest to the pipeline
centreline.
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.
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.
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.
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.
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 pulled from the ground, 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.
2.4.2.6 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.
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.
2.4.3 Trenching
2.4.3.1 Scope
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.
2.4.3.2 Excavation
a) Contractor shall excavate the pipeline trench on the staked centreline of the
pipeline.
II. Minimum depth of cover shall be measured from the top of the pipe to
the top of the undisturbed surface of the soil or top of graded Working
Strip which ever is smallest. Fill material in Working Strip shall not be
considered to add to the depth of cover. However, surface of fill
material placed to fill low points to accommodate pipe bending
limitations may be used to determine depth of cover subject to approval
by the Company of detailed location-specific design drawings including
soil stabilisation measures such as rip-rap or gabions.
III. ii) The minimum depth of cover at crossing of wadis, drainage ditches,
tarmac and graded roads, tracks and live stock crossings, whether or
not indicated on the route maps, shall be measured from the bottom of
wadis, ditches or from the top of roads and tracks as the case may be.
This depth shall be extended 5m outside the edge of the road, track,
wadi, ditch, etc. measured perpendicular to its axis.
d) Contractor shall excavate and grade the trench sufficiently deep and wide to
provide space for 150 mm of padding material after compaction all around the
pipe and for the continuous length of the pipeline.
e) The trench bottom and sides shall be kept free of all brush, skids, pipe
protectors, rocks, large clods, sticks, projecting rocks and other hard objects at
all times. Any such items encountered shall be removed prior to pre-padding
operations so that the pipe is not damaged, punctured or abraded.
f) Where the pipeline crossed other pipelines, sewers, water lines, cables,
conduits or other underground structures of any kind, Contractor shall excavate
and grade the trench to a depth in such a manner that the top of the pipeline
will be at a minimum of 500 mm below the bottom of the underground structure
crossed, subject to compliance with the minimum specified bending radius of
the pipe. If clearance of more than 500 mm is required by the Authorities
having jurisdiction, Contractor shall provide such increased clearance. The
construction over or under all existing structures such as roads, water lines,
telephone lines, and other pipelines shall be the responsibility of Contractor. In
the event that the pipeline crosses over existing structures, the same clearance
as described above shall be maintained and depth of cover as per paragraph
(c) above. For crossings of buried live pipelines, the requirements of GU-501
shall apply.
g) In locations where the trench is cut across roads, tracks, paths, walkways, etc.
Contractor shall provide temporary bridges or diversion road of adequate
strength and properly constructed to allow the passage of normal traffic with a
minimum of inconvenience and interruption. Whenever it is permissible to open
cut a road, Contractor shall remove and restore the surface in accordance with
the requirements of the Authorities having jurisdiction thereof or as directed by
the Company. Wherever possible, Contractor shall arrange to complete the
trenching, laying and backfilling of such crossings and to remove the temporary
bridging before the end of the regular work day in order to minimise hazard to
night traffic. Proper warning signals shall be placed and maintained while such
crossings are open. If the crossings are open at night, Contractor shall provide
and use warning lights or lanterns, all as required and approved by the
Authorities having jurisdiction and/or the Company.
h) Contractor shall provide and use sheet piles, struts, walling, jacks, pumps etc.,
as required to maintain the trench in good condition until the pipe is laid in
place and backfilled.
i) Contractor shall do hand work in the trench as is necessary to free the bottom
of the trench of loose rock and stones, and all other irregularities so as to leave
the trench bottom in a clean and suitable condition to receive the pipe.
j) If Contractor elects to carry out a rip survey, then the results of this survey shall
be made available to Company. The extent of rock encountered during
trenching shall be recorded on the as-built Alignment Sheets by the Contractor,
whether or not a rip survey is carried out.
2.4.3.3 Blasting
All activities including but not limited to storage, transportation of explosives and blasting shall
be carried out in accordance with the N.F.P.A. No. 495, BS 5607 and the instructions of the
Authorities and/or the requirements in this section, whichever are the most stringent.
Blasting shall be performed only by a specialist blasting contractor approved and registered
with the Company. A blasting procedure shall be submitted to the Company for review and
approval. The procedure shall detail the restrictions and special requirements for controlled
blasting to be applied when operating in the proximity of existing pipelines and structures, as
defined in clause b), following.
ii) Where blasting is to be carried out between 50 and 20 metres from any
existing pipeline or structure (either above or below ground), the
Contractor shall submit a procedure for controlled blasting, which shall
also detail safety precautions to safeguard existing pipelines or structures
(e.g. break holes, slit trenches, etc.). No trial blasting shall be performed
until the procedures are approved by the Company.
e) Blasting shall not be permitted in any location where possible danger exists to
the general public, property, existing utilities or other structures. In such
locations other methods of extracting rock shall be proposed by the Contractor
for approval by the Company.
For depth of cover purposes, rock in trench is defined as the rocky part of the specified trench
which cannot be removed by ditching machines, rock plough, back hoe or ripper, to be
decided after two passes of a D9 Caterpiller tractor (or one pass of a tandem D9) or equal,
equipped with proper ripping equipment.
Trenches having a longitudinal slope of more than 10% shall be provided with structures or
retaining barrier(s) as specified on the drawing TYP 3 0015 001 provided in Appendix E of
this specification. No retaining barriers are required in areas of sand dunes.
In the case of a single pipeline to be laid in the trench, the trench width shall normally be
outside diameter of the pipe plus 300 mm (i.e. 150 mm on each side of the pipe) unless
otherwise approved by the Company (refer drawing TYP 3 0002 001). In the case of more
than one pipeline to be laid in common trench, the trench width shall normally be the sum of
the diameters of the pipes plus 300 mm (i.e. 150 mm on each side of the pipe) plus 500 mm
clearance between the outside edges of adjacent pipes unless otherwise approved by the
Company.
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.
2.5.2 Stringing
2.5.2.1 No pipe shall be strung before the trench is excavated to full depth and accepted by the
Company to meet the requirements of this Specification. Pipe shall not be placed directly on
the ground but on wooden skids with proper protective padding or sand bags as deemed
acceptable by Company. The skids and protective padding material shall be subject to
Company (CSR) approval. Dragging, skidding or dropping of the pipe is not permitted.
Wooden wedges shall be used to prevent movement of each strung pipe.
2.5.2.2 Where possible the skid elevations shall be planned such that minor differences between
grade profile and bottom of trench profile (e.g. at locations where an increased trench depth is
required) can be accommodated without requiring an additional tie-in. The distance between
the trench edge and the pipe string shall be planned such that safe working space is
provided.
2.5.2.3 Contractor shall be responsible for proper stringing and locating of the pipe by size, wall
thickness, specification and manufacturer. Company may supply line pipe from different
manufacturers. Contractor shall string all line pipe of one manufacturer before commencing
the stringing of line pipe supplied by the second manufacturer. Pipes of different
manufacturers shall not be mixed per line section without prior approval of the Company.
2.5.2.4 Contractor shall string the pipe in such a manner so as to cause no interference with public
roads, footpaths, tracks, etc. Suitable gaps shall be left at intervals as necessary to permit the
passage of live stock and/or equipment across the Right-of-Way and as directed by the
Company.
2.5.2.5 Contractor shall layout and measure the pipes such that, the number of pieces cut-off with
less than one metre length is kept to a minimum.
2.5.2.6 The length of pipe string shall be planned with due consideration of thermal expansion and
other expected or accidental movement of the pipe string. Special attention shall be paid to
strings with one or more bends, in view of the inherent increased risk of failure of skids due to
movements of the pipe. Length of individual pipe strings shall be subject to Company
approval and shall generally not exceed 1 km.
2.5.2.7 Pipe shall be strung with the use of a spreader bar and two guide lines. (See Section 2.3 for
requirements for slings and hooks).
2.5.3.1 Contractor shall make all necessary bends required for proper construction of the pipeline,
following a trigonometric survey to establish the number and degree of bends required, to
ensure that the installed pipe shall conform to the contours of the pre-padded trench.
2.5.3.2 Contractor shall, before the start of the Work, submit and demonstrate to the Company a
bending procedure, which shall conform to the recommendations of the manufacturer of the
bending machine. This procedure shall be subject to Company’s approval. The procedure
shall include amongst others, step length, degrees per pull and method and accuracy of
measurement during pulling of the bend.
2.5.3.3 Elastic bends with radius of curvature less than 500 x D, D being the pipeline diameter are not
allowed unless approved by the Company.
2.5.3.5 The cold bends shall be made by a smooth stretch bending machine. Bends with ripples with
a depth exceeding 0.5 mm, wrinkles and kinks are not acceptable. Contractor shall provide a
procedure for measuring ripples which shall be approved by the Company.
2.5.3.6 The pads, dies and rolls of the bending equipment shall have soft surfaces to avoid damage
to the pipe coating. Where applicable, fully retaining bending shoes shall be used. Roller type
bending machines are preferred. Bends in pipe of diameter 8" or greater shall be made by
using an internal (hydraulic or pneumatic) mandrel.
2.5.3.7 All bends shall be tested in the presence of the Company with a gauging plate of 97.5% of the
nominal internal diameter of the pipe prior to installation.
The longitudinal weld of the cold bend shall be located approximately within 10° from the
pipe’s neutral axis. The position of the longitudinal weld for successive pipe joints shall be
chosen such that the longitudinal welds are staggered and always occur in the top half of the
pipe (as specified in the welding specification).
2.5.3.8 The procedure for bending shall be such that the extremities of each joint remain straight over
a minimum distance of 2 m or twice the pipe diameter, whichever is greater. Contractor shall
lay out and measure the pipe for bending such that the length of off-cuts is kept to a
minimum.
This Section of the Specification covers the minimum requirements for the fabrication,
welding, and non-destructive testing of ‘on-plot’ piping and ‘off-plot’ pipelines for oil and gas
service, as required for the Work.
‘Off-Plot’ Pipelines are defined as all pipelines and pipe work covered by Codes ASME B31.4
or ASME B31.8 as specified in the drawings. This includes all pipeline work, block valve
stations and most parts of the pig trap stations.
The minimum requirements for welding are contained in Specification SP-1177 (for Class 1
Pipelines), SP-1174 (for Class 2 & 3 Pipelines) and SP-1097 (for Duplex Stainless Steel
Pipelines).
‘On-Plot’ Pipework is defined as all pipework and pipe runs covered by the code ASME B31.3
as specified in the drawings.
This Section of the Specification covers the minimum requirements for the external field
coating of pipeline weld joints and repair of damaged coating. Painting of station pipework,
valves, fittings etc. is specified in Section 2.12, Station Works.
Line-pipe is supplied with mill applied anti-corrosion coating unless specifically stated to the
contrary in the contract Scope of Work. The type of field joint coating that can be applied shall
be compatible with and have good adhesion to the mill applied coating:
-- For Polyethylene (PE) / Polypropylene (PP) coated line pipe, the field joint
coating shall be by heat shrink sleeves.
Contractor shall supply all equipment including spares and skilled manpower required for pipe
cleaning, application of coating, coating repair in the field, and inspection and testing of the
same in accordance with this Specification and DEP 31.40.30.37-Gen.
2.7.2 Materials
2.7.2.1 Only materials supplied by Company approved manufacturers shall be used in the Work.
2.7.2.3 The materials, at time of application by the Contractor, shall not be older than the shelf life
stated by the manufacturers.
2.7.2.4 The coating materials shall be properly packed and clearly marked with:
- Batch number
- Date of manufacture
- Storage temperatures
2.7.2.5 Coating materials shall be kept dry and stored as long as possible in the manufacturer’s
original packaging, not exposed to direct sunlight, and in accordance with manufacturer’s
instructions.
2.7.2.6 The list of Company approved wrap-around shrink sleeves is given in the Approved Vendors,
Manufacturers and Equipments (AVME) list of the company.
2.7.3.1 Prior to coating, the field joint area shall be blast cleaned. Surface preparation, including blast
cleaning, shall be carried out in accordance with SP-1246 and this specification.
Any weld spatter or sharp edges of the mill coating shall be removed by filing or light grinding
prior to blast cleaning. If the mill coating is disbonded along the edges, or if there is an
evidence of corrosion under the coating, the coating shall be cut-back until sound coating has
been obtained. Polyethylene coating shall be chamfered by torch and knife and F.B.E. coating
shall be feathered over a distance of 10-15 mm during grit blasting.
Abrasives for blast cleaning shall be certified in accordance with the relevant parts of ISO
11124 or ISO 11126. Certificates shall be maintained by the Contractor. The blasting nozzle
shall be fitted with a dead man’s handle so that the equipment will not operate unless the
handle is held.
2.7.3.2 The blast surface visual appearance shall conform to ISO 8501 grade Sa 2 1/2. Any field joint
not coated within 4 hours of grit blasting shall be reblasted prior to the application of the
coating.
2.7.3.3 The surface profile attained by the grit blasting shall conform to ISO 8503-2 and shall be 40-
75 microns peak to trough or as specified by field joint coating manufacturer.
2.7.3.4 The surface cleanliness shall conform to ISO 8502-1 to 4 and shall be such that the chloride
2
contamination is less than 20 mg/m .
2.7.3.5 Coating of the field joint shall not take place until the weld has been non-destructively tested
and approved by the Company.
2.7.4.1 Contractor shall propose the application procedure for Company approval. The application
procedure shall be in accordance with manufacturer’s instructions and the minimum
requirements specified below, whichever are the most stringent, and shall be demonstrated to
the Company prior to field application by means of a procedure qualification test joint.
2.7.4.2 The joint shall be heated to a temperature required by the procedure. Induction heaters, ring
burners or propane torches of a suitable type may be used for pipe diameters smaller than
16". Induction heaters shall be used for pipe diameters of 16" and larger where the pre-heat
temperature exceeds 100° C. In all other cases burners or torches may be used. Torches
may be used for tie-in welds at Company’s discretion. To check that the required preheat
temperatures have been achieved, a digital contact thermometer shall be used.
2.7.4.3 The sleeve shall be wrapped entirely around the joint. The closure patch shall be positioned
off to one side of the pipe. There shall be a minimum overlap of 50 mm onto the factory
applied coating.
2.7.4.4 The procedure for shrinking the sleeve shall ensure that all entrapped air is forced out at
either end using gloved hands and concave hand rollers. Special attention must be given to
the closure patch and overlapping areas.
2.7.4.5 The installed sleeve shall be left undisturbed for 4 hours or until the adhesive has been
solidified, whichever is the longer.
2.7.4.6 The sleeves shall be visually inspected for the following points:
a) Adhesive extruded from the ends of the sleeve indicates proper application. The ends
of the sleeve shall be firmly bonded to the surface of the coated pipe.
2.7.5.1 Coating repairs shall be executed on all coating damage and imperfections detected visually
or by holiday testing.
2.7.5.2 The coating repair procedure and the required materials for this, including the installation of
repair sleeves when applicable, shall be in accordance with a procedure submitted by the
Contractor and approved by the Company.
2.7.5.3 The repair procedure for mill applied polyethylene / polypropylene coatings shall be selected
based on the criterion of magnitude of the damaged area, i.e.:
c) for damages with a greater diameter than 100 mm, a thermoplastic wrap-
around shrink sleeve shall be used.
2.7.6.1 The testing and inspection for acceptance of the coating system shall be carried out and
recorded by the Contractor as instructed and witnessed by Company’s representative. The
frequency of testing as specified herein may be altered by the Company at Company’s sole
discretion.
2.7.6.2 The cleanliness of the blast cleaned surfaces for every field joint shall be inspected and shall
be in accordance with ISO 8501 grade Sa 2 1/2. After the surface has been blast cleaned and
dusted off, a strip of transparent cellotape shall be applied to the surface, and subsequently
removed and examined for particle contamination. This shall be done on the first joint cleaned
each day, plus two more times during the day and when a new batch of grit is used. If in the
opinion of the Company the test has failed, Contractor shall undertake to perform additional
cleaning to the specified standard.
2.7.6.3 The profile of the blast cleaned surfaces shall be tested by means of Testex Replica Tape
(type X-course), produced at least twice a day and additionally the first few joints and at each
change or replenishment of grit. Before applying the coating, the surface shall be free of rust
or residual grit. The surface profile shall be evaluated from the replicas in accordance with
manufacturer’s instructions, using a recently calibrated micrometer. As an alternative to the
above, the Company may allow the surface profile to be tested on site by a suitable profile
gauge in accordance with SP-1246.
2.7.6.4 Additionally, general checks at random shall be carried out such as monitoring of particle size
of copper slag, grit/shot used for blast cleaning, cleanliness of materials used for blast
cleaning and coating, and temperature control of the pipe surface.
2.7.6.5 Contractor shall supply all equipment required for inspection and testing including dry film
thickness gauges and holiday detectors. All equipment shall be approved by the Company
prior to use.
a) All shrink sleeves shall be visually inspected in accordance with Section 2.7.4
above.
- From each test sleeve one or more strips of 2.5 cm wide and 20 cm long
shall be cut perpendicular to the pipe axis and slowly peeled off, using an
approved peel strength gauge.
- The temperature of sleeve and pipe during such a peel test shall be as
per manufacturer’s recommendation, i.e. the time of day of the testing
shall be taken into account.
- The required peel strength for the above strip shall be in accordance with
the manufacturer’s temperature/strength correlation data. Repair shall be
carried out as per Section 2. 7.6.
c) Following the peel test, the Company may request the Contractor to remove
the entire sleeve to check the overall degree of adhesion and absence of bare
metal voids achieved. After removal of the shrink sleeve, the bulk of the
adhesive layer which remains on the pipe surface shall be essentially free from
voids. For acceptance criteria, reference shall be made to DEP 31.40.30.37.
Voids exposing bare metal shall not be acceptable and shall be reason to fail
the shrink sleeve application. In the event that the test fails, it shall be repeated
on the two sleeves adjacent to the tested sleeve. Tests shall continue until the
sleeves which are inspected are acceptable.
d) Company shall have the right to test one out of every hundred shrink sleeves
applied or one sleeve out of every days production if less than one hundred
sleeves are applied in any day.
2.7.6.7 Holiday detection of 100% of the surface area of all coated pipeline shall be carried out
immediately prior to lowering in the ditch. The holiday detection equipment which shall be
Company approved shall be set at 22000 Volts DC for PE coated pipes based on 5V per
micron of coating thickness. However, the voltage setting for holiday detection may be
lowered slightly at Company’s discretion if coating gets damaged. The electrode shall be a
conductive rubber or a spiral metal ring. Brush type electrodes shall not be used. The voltage
applied by the holiday detection equipment shall be measured by means of a voltage read
out. Alternatively a means of calibration of the applied voltage of holiday detection equipment
shall be provided to enable daily calibration of each piece of equipment. All holidays,
imperfections and damaged areas shall be identified with a waterproof marker at sufficient
distance from the defect to allow surface preparation and patching to take place without
detriment to the adhesion of the coating.
2.7.6.8 Company will carry out a ‘DCVG Survey’ to check the integrity of the buried coating. If coating
defects are found on any portion of the coating, Contractor shall excavate, repair and backfill
at Contractor’s expense.
This Section of the Specification covers the minimum requirements for pre and post padding,
lowering the pipe and backfilling, compacting and stabilising the trench as required for the
work.
2.8.2 Pre-Padding
2.8.2.1 All trenches shall be padded before lowering in of pipe string. No padding shall be placed until
the Company has inspected and approved the trench bottom.
2.8.2.2 To ensure that fine and clean padding material is used, the Contractor shall use mobile
screening plants that enable a continuous direct application of padding from the plant to the
trench. The type of screening plant is to be approved by Company prior to mobilisation to site
(minimum sieve size shall be 5 x 5 mm). Mobile screening plants are defined as screening
plants which move along the trench whilst they are in operation. Only in those areas where
mobile screening plants cannot be used due to access problems, pre-screened material may
be used after approval of the source by the Company. Pre-screened material shall be stored
in areas which have been cleared of rocks and stones and protected with plastic sheets to
prevent contamination with unacceptable padding materials.
2.8.2.3 The installed padding material shall be free of sharp rocks, stones, metal parts, roots, clods,
etc. and without sharp edges which could damage the pipeline. Base materials from which
pre and post padding material will be produced shall consist mainly of sandy material. More
than 75% by weight of the screened material should have grain size between 0.06 and 3.0
mm and no more than 25% by weight shall have a grain size between 3.0 and 5.0 mm. To
ensure compliance with the above requirements, the Contractor shall produce a grading curve
with typical screened material from the proposed source of sand or a representative section of
the working strip. If the base material is not sourced from the working strip, sources of
padding material shall first be approved by the Company. Suitable base material from the
working strip may not always be available or acceptable, in which case it shall be Contractor’s
responsibility to obtain suitable padding material from a source approved by the local
government authorities. Near residential areas and roads, padding material shall be dust free
(e.g. 'coarse sand' with a minimum grain size of 0.6 mm) in order to avoid inconvenience or
danger to the public.
2.8.2.4 The bottom of the trench shall be padded with sand throughout its length, whether in normal
ground or rock, so as to provide a minimum compacted padding thickness of 150 mm below
the invert of the pipe. Contractor shall keep the pre-padding operation within 1 km of the
lowering-in operation.
2.8.3.1 Welded pipe strings shall be lowered-in within 96 hours of completion of joint coating.
2.8.3.2 Immediately before commencing the lowering-in operation, the coating shall be checked for
holiday and if necessary, repaired to the satisfaction of the Company, as specified in Section
2.7.6. Only side booms shall be used for the lowering operation.
2.8.3.3 Wide non-abrasive slings or belts shall be used in all lowering-in operations and care shall be
taken when removing the slings from around the coated pipe after it has been lowered into
the trench. Any damage caused to the pipe and coating during lowering operations shall be
repaired before backfill commences.
2.8.3.4 The trench shall be maintained in a dry condition during lowering-in and backfill operations.
2.8.3.5 A minimum of 3 sidebooms shall be used for lowering in. Contractor shall submit to Company
a calculation to demonstrate that side booms used are sufficient to withstand the pipeline
section load. During lowering in operations the pipe shall not be subject to bending in excess
of the minimum allowable bending radius. A detailed procedure specifying the means of
demonstrating compliance with the minimum bending radius requirement shall be submitted
as part of the Contractor’s installation procedures, for Company approval, at least 3 weeks
prior to the planned commencement of any lowering in operations.
2.8.3.6 Contractor shall take measures to restrain the pipe in the trench by means of ‘plugging’, i.e.
placing sand on top and around the pipe at regular intervals (one 2m ‘plug’ on every welded
joint) or Company approved equivalent method. Contractor shall plan the work such that the
lowering in and ‘plugging’ operations take place during the hottest part of the day. Company
may, at its sole discretion, waive the requirement for ‘plugging’ and allow the post-padding
operation to be executed as one continuous operation, dependant on completion time and
ambient temperature considerations.
2.8.3.7 Sand padding shall be placed around and above the pipe, so as to fill the trench to a depth of
300 mm above the crown of the pipe, with the sand padding shaped to its natural angle of
repose and with a minimum of 150 mm at any point around the pipe. No pipe shall be left
overnight in the trench without sand padding around and above the pipe.
2.8.3.8 Where the trench has been excavated through or along drive-ways, walk ways, roads, etc.
and at live stock passage ways and other locations indicated on the drawings, the sand
padding shall be thoroughly compacted by watering and Company approved hand tools, to
achieve a compacted sand fill around the pipe and up to 300 mm above the crown of the pipe.
2.8.4 Tie-ins
Unless otherwise agreed by the Company, tie-ins shall take place in the trench. For tie-ins
outside the trench, holding and lowering operations shall be undertaken in such a manner as
to minimise stresses in the pipe and therefore avoid movement of the pipe from the skids, for
safety reasons. Due consideration shall be given to ambient temperature changes throughout
the day and the resultant pipe length changes/stresses.
2.8.5 Backfilling
2.8.5.1 The trench shall not be backfilled until the Company has approved the sand padding around
and above the pipe and has approved starting the backfilling operation. Any settlement that
occurs after installation or when loaded with hystrostatic test water shall not impose stress on
the pipe because of differential settlement. The properties of the backfill materials shall
permit the CP system to work effectively. The permeability of the replaced material shall be
similar to that of the unexcavated material to prevent tunnel erosion in the case of heavy
rains. Backfilling shall be performed as soon as possible after padding has been approved.
2.8.5.2 In areas containing buried cables, backfilling shall not be performed until all tiles have been
replaced and protected and/or all cables have been supported to Company’s satisfaction. The
backfill around all underground services shall be thoroughly compacted by hand.
2.8.5.3 The material used for initial backfill shall be from the screening plant or other loose material
not greater than 100 mm in diameter, all subject to Company approval. The fill material shall
be placed in such a manner as to avoid disturbing the sand padding and excessive
penetration (more than 150 mm) of rocks into the sand layer. Contractor shall demonstrate
that his proposed method of backfilling achieves this requirement. The initial backfill shall be
placed in the trench to a level slightly above surrounding ground.
2.8.5.4 After the initial backfill, the remaining excavated material shall be neatly crowned over the
trench (the windrow), except in wadi areas. Where rock is excessively large, in Company’s
opinion, shall be removed from site and not used as windrow material. On either side of road
crossings, the windrow shall be tapered from full height to ground level to improve the visibility
of drivers on the ROW.
2.8.5.5 Trenches crossing ditches shall be backfilled with the material excavated from the trench at
the location. If the excavated material, in Company’s opinion is not suitable for backfilling,
Contractor shall provide and use suitable material from another source. Ditches with lined or
otherwise improved surfaces shall be resurfaced in a manner satisfactory to and approved by
the Company and the Authorities. Backfill in or on banks of ditches, wadis shall be compacted
as necessary to prevent soil erosion or other damage which might be caused by the
construction of the pipeline.
2.8.5.6 Where the trench has been excavated through or along drive-ways, walks, roads, etc., and at
live stock passage ways and other locations indicated on the drawings, the initial backfill shall
be thoroughly compacted by mechanically tamping the material into place. The surface of
such areas shall be stabilised and/or restored to its original condition to the satisfaction of the
Company and the Authorities.
Where wadis or roads are graded, trenched or otherwise disturbed, the Contractor shall
restore the property to its original contour and condition even to the extent of hauling in and
placing new fill materials, gravel and stabilising materials or compounds, or by using special
compaction methods, as necessary to obtain the approval of the Company and the
Authorities.
2.8.5.7 ‘Sloping trenches’ (see Section 2.4.3.5) shall be backfilled as shown on Standard Drawing
TYP 3 0015 001.
To ensure the retention of sand cover in active sand areas (i.e. where the windrow consists of
sand only), the backfill shall be stabilised, preferably with a 150 mm layer of marl or other
stable material. The width of stabilisation shall be 3 metres on each side of the pipeline (plus
0.6 metres for every 3 metres of dune height if the line passes through a sand dune).
2.8.8 Reinstatement
2.8.8.1 Contractor shall clean-up the Working Strip and all working areas used by the Contractor
regularly during the course of the work, and shall restore the lands traversed, to the
satisfaction of the Company. Areas of soft sand in the continuous 6 m wide vehicle access
strip shall be removed and replaced by approved infill material so as to leave the vehicle
access strip in a safe condition for driving. The vehicle access strip shall be deviated at road
crossings in order to give a visual indication to drivers of the presence of the road.
2.8.8.2 The excess soil in the working strip shall be levelled in a manner satisfactory to the Company.
All loose rock exposed by the construction operations which is scattered over the working
strip or adjacent property shall be removed and placed over the windrow. However, rocks
larger than 750mm in diameter shall not be placed directly on the backfill material, but may be
placed next to the windrow.
2.8.8.3 All creeks, water courses, wells, syphons, drains, streams, wadis, ditches and irrigation
channels shall be reinstated by the Contractor to their former condition and their banks shall,
if deemed necessary by the Company, be pitched with stone and/or faced with special
protection to prevent washing out or erosion.
2.8.8.4 All enclosures, walls, gates, etc. shall be restored by the Contractor to at least as good a
condition as they were prior to the commencement of the Contractor’s operations to approval
of the Company.
2.8.8.5 All private roads, bridges and other private structures used by the Contractor for access or
haulage shall be restored by the Contractor to a condition equal to or better than that which
existed prior to the commencement of the Contractor’s operations.
2.8.8.6 Construction roads, used at escarpments, may be required by the Company to be left as they
are.
2.8.8.7 Construction markers shall not be removed, unless requested by the Company.
2.8.8.8 All rubbish/debris left over after removal of camp facilities shall be removed to designated
scrap dumps. The sites shall be levelled and cleared in accordance with the Regulations for
Pipeline Contractor Camps in the Interior and to Company’s satisfaction.
This Section of the Specification covers the minimum requirements for road and wadi
crossings as required for the work.
2.9.2.1 The carbon steel pipeline shall cross all roads and highways, without the installation of
casings. All road crossings shall be made by the open cut method. Trench less methods such
as horizontal drilling, pipe jacking may be considered for major road crossing to avoid
disruption of traffic. If directional drilling is used, tests are to be conducted to confirm the
integrity of the coating, the method for which is to be agreed prior to the installation of the
pipe.
2.9.2.2 The construction of road crossings shall meet the requirements of API RP 1102 latest issue
and shall be installed as shown on the drawings. The crossings shall be installed to meet at
all times the requirements and conditions set forth by the Authorities having jurisdiction.
2.9.2.3 Contractor shall install an off-set diversion road, when specifically permitted or required to do
so by the Company and/or responsible Authorities and provide adequate maintenance to
ensure safe passage of vehicles. The diversion shall not cross the pipeline where it has
already been installed.
2.9.2.4 Contractor shall at all times and at every unfinished road crossing provide adequate and
proper traffic aids, such as warning signs, and other safeguards to the satisfaction of the
Company and the Authorities to ensure safety of the public. All warning signs shall be in both
Arabic and English language.
2.9.2.5 Contractor shall comply with the following minimum requirements of the Directorate General
of Roads for major road crossings:
c) Approvals must be obtained from all Utility Authorities and the Ministry of Land Affairs
and Municipalities prior to seeking permission from the Directorate General of Roads.
d) Final approval of any proposed road works must be obtained from the Royal Oman
Police.
2.9.3 Wadi-Crossings
2.9.3.1 ‘Wadi’ shall mean dry river bed which could be temporarily filled with water following rain. The
wadis will be identified on the Alignment Sheets as ‘Flood plains’, ‘Wadi type ‘A’’, ‘Wadi type
‘B’’, or ‘Wadi type ‘C’’. Pipe installed in ‘Flood plains’ does not require casing protection, but
shall be stabilised at 3 meter intervals by means of bags of dry cement/sand mix placed on
top of the pipeline. The Contractor shall demonstrate by calculations that the weight of the
cement bags and soil overburden (excluding the windrow and post padding) is sufficient to
counteract the buoyancy force of the pipeline in empty condition. Wadis may be classified
based on judgement and careful evaluation of the crossing location with due consideration to
wadi’s width, bed slope, past discharge history and erosion potential at the crossing location.
The wadi types are described below.
a) Type ‘A’ wadis are those where low velocity flow is expected after heavy rains.
At these wadi crossings, line pipe without concrete protection shall be installed
(TYP 3 0008 001) with a minimum cover of 1500 mm.
b) Type ‘B” wadis are those where erosion due to high velocity flow is expected
after heavy rains At these wadi crossings, line pipe with continuous concrete
protection shall be installed (TYP 3 0009 001) with a minimum cover of 1500
mm.
c) Type ‘C” wadis are those where heavy erosion due to high velocity flow is
expected after heavy rains combined with the existence of large stones and
boulders. At these wadi crossings, line pipe with continuous concrete protection
shall be installed (TYP 3 0010 001) with a minimum cover of 1500 mm.
Additionally, the pipeline trench shall be protected with gabions placed at the
surface.
2.9.3.2 Wadi crossings shall be installed to meet at all times the requirements and conditions issued
by the Authorities having jurisdiction in the area.
2.9.3.3 All concrete coated pipes shall be electrically tested on site prior to installation in order to
demonstrate that there is no contact between the reinforcing steel and the pipe steel. The
concrete shall be applied in accordance with Section 2.10, following.
2.9.3.4 At locations where concrete protection has been applied, the trench shall be backfilled with
coarse gravel and rock with a minimum dimension of 50 mm up to a level 500 mm below
grade level.
2.9.3.5 For type `C` wadi-crossing, gabions consisting of packages of boulders with dimensions
between 100 and 200 mm contained in galvanised, coated steel wire mesh, shall be placed
on top, up to grade level over the full width of the trench. The type of wire mesh shall be
approved by the Company prior to use. Additional requirement of gapions on both sides of
the pipeline and 150mm thick concrete slap, inclusive of wire mesh, top and 4-6 meters both
sides of the pipeline shall be considered for pipelines with high H2S levels and MOL/SOGL (in
view of the recent cyclones), reference for these additional requirements are to be made to
drawing no. RBB-3-0118-002-1A-1-A.
2.9.3.6 Normally the windrow shall not be installed over the pipeline through the wadi section.
However for wide wadi crossings, greater than 100m, the windrow shall be installed
intermittently in order to mark the location of the pipeline (Windrow lengths shall be
approximately 25m at 75m intervals).
This Section of the Specification covers the minimum requirements for concrete coating of the
pipeline at Wadi crossings type B and C as required for the work.
2.10.2 General
2.10.2.1 Contractor shall be responsible for the supply and installation of all concrete coatings,
including all associated handling and transport of linepipe etc. Contractor shall furnish all
materials, equipment, labour, supervision, worksite and services incidental to and necessary
for the application of concrete in accordance with this specification and all subject to
Company approval.
2.10.2.2 The concrete shall have a minimum dry density of 2400 kg/m 3 after 28 days. The minimum
thickness shall depend on the pipe outside diameter as specified below:
Up to 6.625" : 40 mm
6.625" to 12.75" : 50 mm
over 12.75" : 60 mm
2.10.2.3 The mill identity of each pipe length shall be preserved and records kept during and after the
coating process. A certified permanent record shall be supplied to the Company showing the
serial number, average outside diameter, length and all weights.
2.10.2.4 The concrete coating of line pipe shall be applied either in an approved coating plant or in the
field before welding of linepipes, at Contractor’s option. Field application shall be by dry mix
gunite technique or Company approved equivalent. The plant application procedure and the
coating plant may involve methods other than guniting and shall be Company approved.
The Contractor shall prepare, and submit to the Company for approval, a minimum of 1 month
before commencement of the work, a detailed coating procedure specification containing, but
not limited to, the following.
2.10.3.1 The cement shall be ordinary Portland cement conforming to BS EN197 or ASTM C150.
Cement which is held in stock for longer than three months, or any cement which shows signs
of deterioration, partial setting or other defects or which fails when tested, shall be rejected.
2.10.3.2 Aggregates shall be naturally occurring washed sand and shall be hard, dense, durable,
clean, sharp and graded evenly from fine to coarse, as per the grading limits specified below,
and be in compliance with BS 882. If in the opinion of the Company, the aggregate contains
an undesirable proportion of chemicals, dust, clay, organic matter or other undesirable
constituents, the consignment shall be rejected. The grading of aggregate when plotted
against sieve size shall be within the limits tabulated below:
passing a no. 8 65 - 90
passing a no. 16 45 - 75
passing a no. 30 30 - 50
passing a no. 50 10 - 22
2.10.3.3 Water for use in concrete shall be clean and free from all substances which may be injurious
to concrete or steel. It shall satisfy the requirements of BS 3148 and contain no staining or
colouring.
2.10.3.4 Reinforcement of concrete coating shall be by one layer of electrically welded galvanised
steel mesh fabric reinforcement to BS 4483. Maximum mesh dimensions shall be 38mm x
38mm x 2 mm wire diameter. The minimum overlap between two consecutive rolls of mesh
shall be 50 mm except at field joints where no overlap is required. The reinforcement shall be
placed at the centre of the concrete coating layer by using P.V.C. spacer blocks or a
Company approved equivalent. The reinforcement shall be clean, free from scale, mud,
grease, hardened rebound or anything likely to destroy adhesion or promote corrosion.
2.10.4 Application
2.10.4.1 Prior to concrete coating, Contractor shall apply a protective layer or ‘barrier coat’ to epoxy
coated pipe. The type of barrier coat to be used shall be a two component fibre reinforced
cementetious coating such as FBE Brushcrete, Fosroc H.I.M, Epoxytar, Rezex water based
epoxy coating ES2 or equivalent. Contractor shall demonstrate to the satisfaction of the
Company that the proposed barrier coat prevents the occurrence of holidays in the epoxy
coating due to the concrete application process, and promotes a good bond between the
epoxy and concrete coating.
To this end one or more sections of a test joint shall each be coated with a proposed barrier
coat, in accordance with manufacturer’s recommendations. The number of applications, film
thickness and curing time shall be representative for the application in the production process.
The test joint shall be concrete coated, whereupon the concrete is immediately washed off
and each test section subjected to a holiday test and an adhesion test both in accordance
with Section 2. 7.
2.10.4.2 Batching, proportioning and mixing of the materials shall be such that a concrete coating is
provided with the minimum specified strength and density. No batch of cement and aggregate
shall be used in the work if it has stood for more than half an hour after mixing. No rebound
material shall be mixed into any batch.
2.10.4.3 Contractor shall pay attention to the moisture content of the sand used for guniting. If the
sand is too wet, the hose will block and a mortar layer will build up inside the gun. If the sand
is too dry the cement will not adhere to the sand grains on mixing and excessive separation
will occur in the hose. In case the moisture content falls outside the critical range of 5 to 8%,
Contractor shall make the sand suitably damp either by spraying the dry sand with water or
mixing wet sand with specially supplied dry sand.
2.10.4.4 The mixing equipment shall be capable of providing a uniform mix. The dry mix used for
guniting shall be screened to prevent inclusion of stone, flakes from the mixer drum, pieces of
cement bag, etc. Mix temperature shall not exceed 32°C.
a) The line pipe corrosion coating has been holiday detected and approved by the
Company.
b) The barrier coat (if required) has been applied and cured.
c) Reinforcement has been adequately secured in the correct position with use of
spacer blocks, to prevent displacement during concrete application.
d) Shading has been installed to prevent the line pipe temperature exceeding
35°C.
2.10.4.6 Since the technique of guniting relies significantly on the skill of the nozzle man, he shall have
at least 3 years experience in work of a similar nature. Other operators of the guniting crew
shall have a minimum of one year’s experience. Written evidence of such experience shall be
furnished to the Company. Contractor shall have a minimum of five years experience in
guniting or alternatively shall subcontract the guniting work to a specialist Sub Contractor with
similar minimum experience level. The guniting crew shall demonstrate their ability to
consistently coat pipe to this specification by guniting at least three separate quarter length
pipe samples prior to start of production.
2.10.4.7 Before directing the guniting nozzle onto the pipe surface the nozzle man shall ensure that
the proportioning of water and dry mix is correct. Further regulating of the water supply should
be kept to a minimum to ensure uniform concrete quality. The nozzle shall be held in the
optimum position for placement at all times i.e. 0.6 to 1.2 m from and at right angles to, the
surface of the pipe.
2.10.4.8 The outer surface of the concrete coating shall be smooth, without corrugations and
concentric with the steel pipe. At both ends of each pipe, a distance of approx. 0.30 m from
the end shall be completely left free of concrete to facilitate field joints. The concrete shall
taper back from these points at a two-to-one slope until the required thickness of coating is
reached.
2.10.5 Curing
2.10.5.1 The finished concrete coating shall be completely protected from wind, draught, rain, spray,
etc. for a minimum period of 7 days by wrapping with suitable hessian or polyethylene
sheeting. Also during this period the pipe shall not be exposed to direct sunlight and/or
temperature below freezing point. After a period of 4 hours from placement and for the 7 days
curing period, the concrete surface shall be kept wet.
2.10.5.2 The concrete coated pipe shall not be lifted or transported from the curing area during the 7
day curing period. The Contractor shall take precautions to prevent detrimental movement of
line pipe after concrete coating to minimise handling stresses whilst concrete is hardening
and curing.
2.10.5.3 For factory applied coating, any other curing methods apart from that mentioned in 2.10.5.1
may be adopted subject to approval of the Company.
2.10.6.1 Every length of coated pipe shall be inspected visually and by spiral ring holiday detector and
repaired, in accordance with Section 2.7, Anti-Corrosion Coatings, prior to concrete
application.
2.10.6.2 The concrete shall be visually inspected immediately after the application and after
approximately 3 days. If concrete is faulty, Contractor shall remove cores from the suspected
pipe. If the compressive strength tests of the cores fail to meet the specified strengths,
Contractor shall remove the defective coatings by Company approved method, inspect and
where necessary repair the corrosion coating or reapply the concrete coating. Contractor may
optt not to wait for the test results and immediately initiate the stripping and subsequent
coating repair work.
2.10.6.3 Test panels, made from mild steel, shall be made every day, one at the start of work, and one
during the day as instructed by the Company. These test panels shall be positioned alongside
the work and in a position similar to the work (horizontal, vertical or overhead) and gunited.
On a regular basis, to be decided by the Company, cores shall be taken from each test panel
after it has cured in a similar manner as the coated pipe.
2.10.6.4 Core samples shall be obtained using a diamond core cutter set to ensure that the cut is
perpendicular to the surface and fitted with a positive depth of cut limit to ensure that the core
barrel shall not penetrate closer than 6 mm to the corrosion coat of the line pipe, where
applicable.
The minimum diameter of the core shall be at least three times the nominal maximum
aggregate size. The length to diameter ratio of the core when trimmed for testing shall not be
less than one-to-one. Sampling, storing, testing and calculation shall be in accordance with
the provisions of BS 1881. Cores shall be cut four days after concreting and stored in a curing
tank until tested.
Samples shall be tested as specified in BS 1881. The compressive strength of each specimen
shall be calculated using the computed cross-sectional area based on the average diameter
of the specimen. For acceptance, each core shall have the minimum density and compressive
strength as specified in Section 2.10.2.2.
Company may accept any other method of testing that Contractor can demonstrate to give a
consistently reliable measure of strength attained by the concrete coating. Cube tests will be
accepted for crushing strength instead of core samples, but the required compressive
strengths will be 20% greater than specified for core tests. The Contractor shall arrange for an
independent agency acceptable to the Company to test these cubes.
2.10.6.5 The thickness of applied concrete coating shall be measured on every joint at three or more
points to check compliance with the minimum requirements as per Section 2.10.2.2. The
three points shall be spaced at approximately equal intervals with distance between the end
points at least eighty (80) percent of the coated length. Concrete coatings not in accordance
with the dimensional requirements shall be repaired or stripped and recoated at the discretion
of the Company.
2.10.6.6 Factory applied coated pipes shall be weighed and weight of each coated pipe shall have a
tolerance of +10% on any one joint and a tolerance of –4% on the total length as calculated
from the specified density and thickness. Weighing devices used to determine the weights of
the coated joints shall be certified in writing to provide an accuracy of one half on one percent
(0.5%).
2.10.6.7 Effective electrical separation between reinforcing steel and pipe shall be determined for each
pipe joint by electrical tests.
2.10.7.1 Concrete coating that is found to be defective at the time of coating shall be immediately
stripped from the pipe and the pipe recoated. All other defects shall only be repaired once the
concrete has hardened.
2.10.7.2 Defective concrete coating areas affected by spalling due to compression or shearing caused
by impact against other objects which have caused a loss of not more than twenty five
percent (25%) of the total thickness of the coating shall be repaired. An area of less than 0.1
m2 per joint where the concrete remaining on the joint is sound shall be accepted without
repairs. Should the area affected be more than 0.1 m 2 and less than 0.33 m2 per joint, the
concrete remaining in place over that area shall be undercut so as to provide a key lock for
the same basic material as the coating. Should the damaged area be more than 0.33 m 2 per
joint, the coating shall be removed around the entire periphery of the line pipe throughout the
entire damaged area and repaired.
Repairs shall be made by satisfactorily restoring the reinforcing, removing all cracked or
broken concrete at the point of coating damage, wetting the fresh surface of the broken
coating (unless the coating is still too ‘green’ to require it), and troweling a stiff mixture of
cement, water and aggregate, of the same materials and proportions as the coating, into and
through the reinforcing. This mixture shall be built up until the surface is level with the coating
around the repair. The pipe shall then be allowed to moist cure for a minimum of four days.
The resulting coating shall be equal in weight, density, uniformity, strength and characteristics
to the originally applied coating.
2.10.7.3 Concrete cracks that are in excess of 1.5 mm in width and extend over 180° circumferentially
around the pipe, or where cracks are over 330 mm in length longitudinally along the pipe
irrespective of width, shall be repaired. Repairs shall be made by chiselling the crack out to
width of not less than 25 mm throughout the length of the crack. The crack shall be repaired
with materials similar to that from which the coating is made and in a manner similar to that
outlined above.
2.10.7.4 Core sample holes shall be repaired with materials similar to that from which the coating is
made and in a manner similar to that outlined above. The repairs shall be kept moist and
allowed to remain undisturbed for a period of not less than 36 hours. Further curing shall be in
accordance with the Specification.
This Section of the Specification covers the minimum requirement for the supply and
installation of permanent pipeline markers and access barriers, as required for the Work.
2.11.2 General
The Contractor shall supply and install permanent pipeline markers along the pipeline route
as close as possible to the windrow. Construction details of all types of markers are shown on
the drawings. Each marker consists of a post sealed with a cap end, mounted with two
marker plates as per the drawings. Marker plate no. 1 shows general information about the
pipeline involved, whereas marker plate no.2 shows relevant information for each location.
The different types of pipeline markers are listed below. As-built chainage shall be indicated
on the marker plates with an accuracy of one meter. (The start point of the pipeline, KP 0,
shall be the pipeline isolation valve in the scraper trap station).
Crude : red
Gas : blue
Water : green
The marker plates shall be parallel with the pipeline i.e. they shall face the R.O.W. access
road. Separate markers are required on parallel lines.
Chainage markers shall be installed along the pipeline at each one (1) kilometre chainage
station. A chainage marker is not required if the distance between its location and any other
type of pipeline marker, as mentioned hereafter in this section is less than 200 metres.
Block valve station markers shall be installed along the pipeline at each block valve station. A
schematic diagram of the block valve station pipe work layout shall be installed on the block
valve station fencing.
Road crossing markers shall be installed at both sides of each paved or graded road
crossing. Location shall be 5metres from the borders of the road.
Wadi crossing markers shall be installed at both sides of each wadi crossing.
Pipeline crossing markers shall be installed at each crossing with an existing underground or
above ground pipeline. (This does not apply to flowlines).
Cable crossing markers shall be installed at each crossing with an existing underground
cable.
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.
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.
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.
A marker shall be installed adjacent to each of the corrosion monitoring pit, in the case where
the pit is not located inside a station. The marker shall be inside the pit with fencing.
2.11.13.1 When specified on the drawings, access barriers shall be constructed in accordance with
Standard Drawing GEN-2-1633-01.
2.11.13.2 Breaks in the barriers shall be provided at each road/track/livestock crossing and at least
once every two kilometres to coincide with livestock crossings. At these crossings, removable
barriers shall be installed to prevent normal access from the crossing to the Right-of-Way, but
allowing inspection vehicles to pass when required. Final configuration shall be approved by
the Company Site Representative.
2.11.13.3 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.
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
- 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
- Hydrotesting
- Use of explosives
- Access barriers
Contractor shall supply all materials and equipment unless stated otherwise in the Schedules.
2.12.2 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.
2.12.3.1 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 GU-628 and SP-2039, 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.
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.
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.
f) In the event that anchors are required, these shall be installed at the locations
shown in the drawings. The anchor flange with a pipe joint welded at both ends
shall be completely installed prior to start of civil work. The anchor flange to be
embedded in the concrete shall be coated in accordance with Section 2.12.4
below. Pipe coating shall be tested with the holiday detector prior to embedding
in concrete. The concrete work shall be backfilled and left to cure a minimum of
three weeks before further joints are allowed to be welded to the anchor flange
assembly.
2.12.4 Painting
a) All above and below ground steel surfaces (with the exception of polyethylene
or epoxy coated pipework and items supplied in a manufacturer’s finish) shall
be prepared and painted in accordance with this Specification.
b) Valves and insulating joints shall be supplied with a single coat primer only, in
accordance with SP-1246.
Handrails black
2.12.5 Instrumentation
Contractor shall carry out instrumentation works in accordance with PR-1094 and DEP
62.10.08.11 GEN.
b) All work shall be carried out in accordance with the following Specifications:
2.12.7 Fencing
a) The fencing required for the Work shall be of the medium security type, and be
supplied and constructed in accordance with SP1279-P. The exact
requirements for each location are shown in the drawings.
2.13.1.1 The cathodic protection design shall be in accordance with SP-1128 Specification for
Cathodic Protection Design’. Details of various design aspects are indicated in the standard
drawings specified in SP-1136 ‘Specification for Cathodic Protection Standard Drawings’.
2.13.1.2 When a complete new C.P test points connects to an existing system, then the Contractor
shall employ a qualified C.P supervisor who shall have the prior approval of the Company.
When solar panels are required, Contractor shall sub-contract the supply/installation to a
Company approved supplier/contractor.
2.13.1.3 Contractor shall give the Company 5 days notice prior to installation of special C.P items i.e.
solar stations, T/R units and ground bed anode systems, in order to mobilise a Company CP
Inspector.
2.13.2 Materials
Contractor shall procure all materials required for the Work, unless stated otherwise in the
Schedules. Specifications for materials shall be as shown on the drawings. The following
Company Specifications are applicable:
2.13.3 Installation
2.13.3.1 Installation of the C.P. System shall be carried out concurrently with the main pipeline laying
work.
2.13.3.2 At approximately 2 km intervals, as shown on the drawings, a C.P. Standard Test Post shall
be installed (Ref. STD-7-3001). Welding of the attachments to the pipeline, including
procedure and welder qualification shall be in accordance with Section 2.6, Welding and NDT.
2.13.3.3 Cable connections to the pipeline (Ref. STD-7-2001) shall also be required, as shown on the
Drawings, at the following locations:
- pipeline crossings
- negative connections
- earthing electrodes
- insulating joints
Where the required connections at pipeline crossings, current measurement stations, etc. are
within 200m of the planned location of a C.P. test station/pup piece point, the latter may be
relocated to coincide with the connection, subject to prior Company approval.
2.13.3.4 All C.P. testing facilities shall be installed in accordance with SP-1129.
2.13.3.5 Where Foreign Service Bonding Facilities are required on foreign services, for cross bonding,
the connection pad may be attached by welding a pad on the foreign services (Ref. STD-7-
3005).
2.13.3.6 Current Measuring Stations shall be installed on the pipeline every 10 km, unless shown
otherwise on the drawings (Ref. STD-7-3004).
2.13.3.7 A Grounding Facility shall be installed at power line crossings and where the pipeline runs
parallel to, and within 50m of a power line (Ref. STD-7-3006).
2.13.3.8 Drain Point Facilities shall be installed as shown on the Drawings (Ref. STD-7-3003).
2.13.3.9 Insulating joints/flanges shall be installed in accordance with Drawings (Ref. STD-7-3007).
2.13.3.10 All C.P. cables shall be installed in accordance with SP-1129. Cable to pipeline connections
shall be made prior to hydrostatic testing. Cable markers shall be installed in accordance with
drawing STD-7-7001.
2.13.3.11 Ground beds, when required and shown on the Drawings, shall be installed in accordance
with SP-1129(Ref. STD-7-6001, STD-7-6002, STD-7-6003, and STD-7-6004).
In the case that the pipeline is to be buried in a highly corrosive soil and when the installation
of the permanent cathodic protection system cannot be finalized before the pipeline is buried
(pipelines with long construction periods) a temporary cathodic protection system shall be
installed. Such a system shall be designed in the same way as a permanent cathodic
protection system with the exception that material quantities and quality shall be adequate to
cover a lifetime equal to the time of the pipeline construction until the expected
commissioning of the permanent cathodic protection system. Anode connections shall be
constructed such that they can easily be connected / disconnected during and/or after
commissioning of the permanent system.
2.13.5.1 Company will carry out a ‘DCVG Survey’, after installation of the pipeline, to check the
integrity of the buried pipeline coating.. If coating defects are found on any portion of the
coating, Contractor shall excavate, repair and backfill at Contractor’s expense.
2.13.6 Commissioning
Contractor is required to provide a PDO approved C.P. Contractor to commission the C.P.
system after installation in accordance with documents SP-1129 and PR-1169. The
Contractor should inform the name of sub-contractor they intend to use to execute the
commissioning not less than 28 days prior to commencement of commissioning.
The minimum requirements for hydrostatic testing operations, i.e. cleaning, gauging, filling,
hydrostatic testing and dewatering of pipeline and station works as required for the Work are
covered under a separate specification SP-1212: Hydrostatic Testing of New Pipelines.
The minimum requirements for precommissioning of oil and gas pipelines including but not
limited to bulk dewatering, final dewatering, cleaning, drying and preservation of oil and gas
pipelines as required for the Work are covered under a separate DEP 31.40.50.30.
2.16.2 General
The Contractor shall carry out the pre-commissioning activities of pipelines in accordance with
the requirements of the Scope of Work, this specification and DEP 31.40.50.30. Pre-
commissioning records shall be in accordance with chapters 6 and 8 of DEP 31.40.50.30.
Hydrotest water shall be disposed of in accordance with SP-1006.
Contractor shall supply all materials, consumables, equipment, spares, labour, supervision
and other services incidental to and necessary for the successful performance of the pre-
commissioning work in a manner satisfactory to the Company.
2.16.2.1 Contractor shall make detailed proposals, for Company approval, for the precommissioning
work including but not limited to detailed procedures, programme and schedule for Work.
Contractor’s proposals shall include complete information regarding the following aspects:
- complete summary and lay out of the temporary pipework, equipment and facilities
including spares for each section to be pre-commissioned.
- the method(s) to be employed to preserve the dryness and cleanliness of the line.
- a summary of the amount of material and consumables and the number and
qualifications of personnel, to be used for the precommissioning work.
- calculations and any other evidence necessary to demonstrate that the work will be
executed in accordance with the requirements of the Contract. The sizing of drying
equipment and calculations of the time required for drying shall be based on a film
thickness of residual water of not less than 0.1 mm. Lower values may be assumed
if the Contractor can demonstrate, to the Company's satisfaction, their validity from
previous experience.
This Section of the Specification covers the minimum requirement for work on live pipe
systems as required for the Work.
2.17.2 General
2.17.2.1 The work permit system shall apply to all work on live pipe systems. Contractor shall do all
that is necessary to obtain work permits and to execute the Work in adherence to the work
permit.
2.17.2.2 Specialised tools and equipment as required for the performance of work on live pipe systems
shall only be acquired form the Company approved vendors. A vendor’s representative shall
be present at all times during the use of such tools and equipment.
2.17.2.3 Hot tapping on live pipe systems shall be carried out in accordance with DEP 31.38.60.10.
Welding on pressurised pipes shall be carried out in accordance with SP-1167.
This Section of the Specification covers the minimum requirements for keeping and
maintaining records, drawings and documents of all aspects of the pipeline project. These
requirements supplement those contained in SP-1131, to which reference should be made for
the definitions and general requirements. The scope includes new pipeline construction and
modifications to existing lines and related facilities.
Where any conflict occurs with the requirements of SP-1131, this specification shall take
precedence.
Retention of information as hard copy shall be minimised and wherever possible master
copies of documentation shall be acquired and stored in a suitable electronic format. Route
survey data shall be presented in accordance with XTO documents TS18v1-0: Pipeline Data
Specification and TS19v1-0: Flowline Data Specification. All master documents should be
classified, coded and compiled on to a minimum number of fully indexed compact discs or
other media that may be specified by the Company. Controlled and separately stored back-up
copies of key items shall be maintained. All NDT data shall be presented to Company in
electronic format.
Documentation available only as hard copy shall be scanned for archiving. In the cases where
the required storage life is short (e.g. less than 2 years), or the document is not suitable for
scanning, exceptions to this requirement should be agreed by the responsible Project
Engineer in consultation with the relevant CFDH or nominated discipline engineer.
Hard copies of whichever master documents are required for day to day operation and
maintenance, or for permanent reference to support future engineering activities during the
operational life, may be made as required provided documents maintained ‘As-Built’ are
formally issued as controlled copies.
Master copies of all textual documentation after handover shall be held by the pipeline owner
(Asset Manager) in a properly managed archive. This shall include storage of pipeline
radiographs for the prescribed retention period before disposal. Autocad drawings shall be
stored and referenced in CCMS in accordance with Company practice.
Controlled hard copies of documents required for pipeline operation and maintenance
(Operating Manuals, Design Reference Manual, PEFS etc. as per Appendix D) should be
provided to Operations as part of the handover package. Issue of further documents should
be authorised and controlled by the Asset Manager.
A detailed listing shall be filed within CCMS Business Records of the storage location of all
master documents for each pipeline. This list, along with copies of all key drawings within
CCMS and the basic pipeline design and operating data held in SAP, shall be linked to the
relevant pipeline location in GIS to enable the data to be readily identified and/or retrieved.
Original pipeline drawings and other documents required to be maintained ‘As-Built’ (see
Appendix D) shall be updated during the construction and commissioning phase in line with
SP-1131, Section 4. Subsequent revisions of the master documents shall be authorised and
all As-Built copies issued on a properly controlled basis in accordance with CP-102.
2.18.5 Documents
The Contractor shall prepare summary sheets (3 copies) containing a full list of the
documentation sets provided to the Company Site Representative prior to demobilising.
Contractor shall record the name of the Company Site Representative who received the
documentation on the sheet and retain one copy for Contractor’s own records and pass one
copy of the sheet to the Company Site Representative and one copy to the Company coastal
based Project Engineer.
Unless otherwise stated, Contractor shall provide originals of documents plus two copies.
Contractor shall make available inspection, calibration and testing reports, (including welding
procedures, NDT procedures, radiographs, ultrasonic test reports, hydrostatic testing and
drying reports), as specified in applicable Sections of the Specification.
Contractor shall make available Mill and Test Certificates, where applicable, for all materials
supplied by Contractor and incorporated in the permanent facilities.
Contractor shall return to the Company one copy of each drawing (provided by the Company)
corrected with as-built information for those drawings in the Drawing List which are indicated
to be revised as as-built. These as-built drawings shall be submitted for approval to the
Company within 2 weeks of the Completion Date and shall be approved by the Company
before Acceptance of Work.
- Measured top of pipe level at each installed joint location, with chainage
- The chainage, elevation, size, type, shape of all roads, wadis, pipes, cables and
other objects crossing and/or obstructing the pipeline.
- The identification and the location of circumferential welds and pipe lengths with the
manufacturer’s number, heat number, sequence number and length installed.
Contractor shall provide a site-based experienced, full-time ‘As-Built’ surveyor, with valid
driving licence and vehicle, throughout the duration of the Contract. He shall maintain the
Pipeline Data Sheets (originals provided by the Company) and shall collect and maintain all
data required for the ‘As-Built’ drawings. Refer to Pipeline Data Base requirements in
Appendix D.
‘As-Built’ drawings shall be prepared during the progress of the Construction Work and
Contractor shall provide a drawing office, personnel, and all necessary equipment and
facilities, to the approval of the Company, for the purpose of producing as-built drawings.
Preliminary ‘As-Built’ drawings shall be submitted to the Company for approval on a weekly
basis within 2 weeks of the completion of backfilling of the trench on that part of the pipeline
route contained on the drawing concerned.
The requirements of this specification shall remain in force indefinitely unless superseded by
an authorised revision.
It is intended that the present version (3.0) of this specification will be reviewed and updated
once in every three years. The review authority will be UIP (CFDH Pipelines).
A1.2 Abbreviations
REFERENCE REF #
PDO STANDARDS
Code of Practice
Corporate Document Management CP-102
Health Safety and Environment Management System CP-122
Lifting And Hoisting CP-189
Specification
Specification for Aqueous Effluents SP-1006
Specification for Waste Management SP-1009
Specification for Site Preparation, Abandonment and SP-1012
Restoration
Specification for welding of Duplex Stainless Steel Pipelines SP-1097
Electrical Installation Practice SP-1099
Electrical Standard Drawings SP-1105
Specification for Earthing and Bonding SP-1109
Specification for Cathodic Protection Design SP-1128
Specification for Construction, 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, 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
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 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, Offices, Laboratories, SP-1256
Workshops and Industrial Safety Specification
HSE Specification, Safety, 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, Road Transport SP-2000
Mechanical Standard Drawings SP-2039
Technical Authority System SP-2061
GRP Specification (Qualification and Manufacturing) SP-2092
Specification for Polyethylene Liners in Carbon Steel SP-2094
Flowlines & Pipelines
Procedure
Instrumented Protective Functions Test Procedure PR-1094
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
Lifting and Hoisting Procedure Inspection Testing and PR-1708
Certification
Lifting and Hoisting Procedure Lift Planning Execution PR-1709
Electrical Safety Rules PR-1947
Guideline
C-09 HSE Requirements and Guidance for use GU-140
Environmental Assessment Guideline GU-195
Guidelines for the protection of buried sections of surface GU-368
laid Pipelines/Flowlines
Guidelines for Project Certification and Completion GU-623
Management System (CCMS) Users
Civil & Building Standard Drawings Index GU-628
REFERENCE REF #
SHELL STANDARDS
Index to DEP publications DEP 00.00.05.05-Gen.
Piping – General requirements DEP 31.38.01.11-Gen
Piping classes – exploration and production DEP 31.38.01.15-Gen.
Hot tapping on pipelines, piping and equipment DEP 31.38.60.10-Gen
Design of pipeline pig trap systems DEP 31.40.10.13-Gen.
Pipeline overpressure protection DEP 31.40.10.14-Gen
Upheaval buckling of pipelines DEP 31.40.10.16-Gen
GRP Pipelines and piping systems (amendments / DEP 31.40.10.19-Gen.
supplements to ISO 14692)
Line pipe induction bends (amendments / supplements DEP 31.40.20.33-Gen
to ISO 15590 – 1)
Linepipe for non-critical service DEP 31.40.20.35-Gen
(Amendments/supplements to ISO 3183-1)
Linepipe for critical service DEP 31.40.20.37-Gen
(Amendments/supplements to ISO 3183-3)
Pipeline Fittings (amendments / supplements to MSS SP DEP 31.40.21.30-Gen
– 75)
Pig signallers: Intrusive type DEP 31.40.21.33-Gen
Carbon and low alloy steel pipeline flanges for use in oil DEP 31.40.21.34-Gen
and gas operations (amendments / supplements to MSS
SP – 44)
Concrete coating of linepipe DEP 31.40.30.30-Gen.
External polyethylene and polypropylene coating for line DEP 31.40.30.31-Gen
pipe
Thermoplastic lined pipelines DEP 31.40.30.34-Gen
External Field Joint And Rehabilitation Coating Systems DEP 31.40.30.37-Gen
For Line Pipe
AMERICAN STANDARDS
Process Piping ASME B31.3
Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids ASME B31.4
Gas Transmission and Distribution Piping Systems ASME B31.8
Issued by:
American Society of Mechanical Engineers
Publications and Distribution Section
1220 L Street Northwest
Washington DC 20005, USA
BRITISH STANDARDS
Code of Practice for the Safe Use of Explosives in the Construction Industry BS 5607
Issued by:
British Standards Institution
389 Chiswick High Road
London, W4 4AL, UK
INTERNATIONAL STANDARDS
Preparation of Steel Substrates before Application of Paints and Related
Products – Visual Assessment of Surface Cleanliness 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 - 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 - Specification for Metallic Blast-Cleaning Abrasives
Preparation of Steel Substrates before Application of Paints and Related ISO 11126
Products - 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, fittings and flanges for ISO 15590-1
pipeline transportation systems – Part 1: Induction Bends
Issued by:
International Organization for Standardization
1,Rue de Varembé
CH-1211 Geneva 20, Switzerland
This Section of the Specification covers the minimum requirements for facilities for Company
personnel at Contractor’s Construction Camp and is supplementary to the Regulations for
Pipeline Contractor Camps in the Interior.
C.2 Accommodation
C.2.1 Where the Contractor is required in the Contract Scope of Work to provide his own camp,
Contractor shall provide and maintain in its camp, good quality accommodation for the
number of Company’s senior personnel stated in the Scope of Work. Company may choose
to use this accommodation for personnel other than Company personnel.
C.2.2 Where the Contractor is required in the Contract Scope of Work to provide accommodation
for the Company’s personnel, the minimum accommodation requirements for each of
Company’s aforementioned senior personnel shall be:
a) Bed-sitting room of 14.0 square metres floor area. This shall be furnished with:
C.2.3 Contractor shall replace all linen twice per week, clean all accommodation daily, and keep all
accommodation in good repair.
C.2.4 All accommodation provided for the Company’s use shall be subject to Company’s approval.
C.3 Messing
C.3.1 Where the Contractor is required in the Contract Scope of Work to provide messing,
Contractor shall provide and maintain complete and clean messing facilities for the Company
personnel and shall provide adequate good quality meals with soft drinks at such meals. The
menu should have at least one alternative main course.
C.3.2 Contractor shall provide an adequate laundry service for the personal clothing of the
Company personnel.
C.3.3 Contractor shall keep the Company personnel refrigerators stocked with a selection of soft
drinks.
C.4.1 Contractor shall furnish, clean and maintain good quality office equipment and
accommodation at each spread camp for 5 members of the Company’s personnel.
C.4.2 Unless otherwise agreed by the Company, office space for these persons shall have a
minimum floor area of 16 square metres for each office and each office shall be supplied with
the following for sole use by the Company’s personnel:
C.4.3 The offices shall be interconnected. At each spread camp, the Contractor shall provide and
maintain for Company’s sole use such materials and equipment (computer, stationary, etc.)
as may be required for the Company’s clerical work at the camp.
C.4.4 As and when required, Contractor shall make available for Company’s use at the main spread
camp site, a furnished conference room of minimum floor area 24 square metres and with
seating for a minimum of 15 persons.
C.4.5 All offices and office services, provided for Company’s use shall be subject to Company’s
approval.
C.4.6 Contractor shall provide 2 administration clerks who is proficient in English, typing and
general office procedures, for Company use seven days per week at site and five days per
week at coast throughout the duration of the Contract
C.4.7 Contractor shall provide a suitable Digital camera with two 128 MB memory sticks and photo
editing software for the exclusive use of the Company Site Representative.
C.5.1 Throughout the construction period Contractor shall fuel, service, clean, maintain and repair
the vehicles which Company uses on the Work Site, up to the number given in the Scope of
Work.
C.5.2 Maintenance procedures shall be strictly in accordance with vehicle manufacturer’s local
representative’s recommendations for the specific terrain and climatic conditions involved. A
daily status check for all cars being used is required. Contractor shall maintain vehicles of the
Company with due diligence and utmost care to ensure safety of the vehicles. Contractor
shall keep a record of all checks and services for each Company vehicle.
C.5.3 Contractor shall provide an English speaking driver with the necessary experience to obtain a
PDO driving licence for Company use seven days per week for the duration of the Contract.
C.5.4 Where Contractor is required in the Scope of Work to provide vehicles for the use of
Company personnel, they shall at the start of the Contract be either new or have less than
10,000 Km mileage. The vehicles shall be 4 wheel Drive, preferably Mitsubishi Pajero V6
(LWB) or Company approved equivalent.
C.6.1 Contractor shall make available separate recreational facilities for the Company personnel,
with a floor area of minimum 24 square metres, and furnished with easy chairs.
C.6.2 In each camp a 29” colour TV connected to a sattalite dish, sattalite reciver, and DVD Player
shall be available for the sole use of Company personnel.
C.6.3 Magazines and daily newspapers shall be provided by the Contractor as per Company’s Site
Representative’s requirements.
C.6.4 At each Contractor Camp, facilities shall be provided for outdoor sports (football, tennis, etc.),
type to be agreed with Company Site Representative.
As-
Originator *
Custodians
Retention
Location
Storage
format
Keep
Built
time
**
1.0 General Reports
1.1 Drawing control register DC OXO1x, OXO4x, (See remarks) N/A N/A Retained until drawings are as-built and stored in
OXO61, UEC15, UIP4 CCMS.
1.2 Pipeline inspection reports CC OXO61, UEC15, UIP4 Service life Electronic or Paper CIRRAS-RBA Archived items to be referenced in CCMS.
1.3 Equipment reports Vendor OXO1x,OXO4x, OXO61, Service life Electronic or Paper 3 Archive Archived items to be referenced in CCMS.
UEC15,UIP4
1.4 Operating manual DC OXO1x, OXO4x, Service life Electronic 3 CCMS Essential data for each line held in CIRRAS-RBA,
OXO61, UEC15, UIP4 accessed via GIS. All data specified in minimum
data requirements shall be entered into the
Company Asset Register (SAP)
1.5 Design reference manual DC OXO1x, OXO4x, Service life Electronic 3 CCMS Essential data for each line held in CIRRAS-RBA,
A) Pipeline Design basis – At minimum to OXO61, UEC15, UIP4 accessed via GIS
cover :
• Design Code
• Design Life
• Design Factor
• Pipeline Class
• M.A.O.P
• Design temperature (min / max)
• Design Flowrate
• Material grade
• Outside Diameter
• Length
• MAOP
• Nominal Wall Thickness
• Internal Diameter Summary
• Minimum bend radius
As-
Originator *
Custodians
Retention
Location
Storage
format
Keep
Built
time
**
• Wall thickness variations & locations
• Internal & external coatings (types,
locations, thickness, inc field joints)
• Liner thickness (applicable for PE lined
pipeline)
• Number of vents (for PE lined pipeline)
• Road and wadi crossings details
(locations)
• Summary of in line components &
dimensions (valves, pig traps, tees,
wyes)
B) Pipeline corrosion management plan at
minimum should contain the followings:
1.6 Soil investigation report SC OXO1x, OXO4x 2 years Paper Archive Storage reference in CCMS.
1.7 Environmental data SC OXO1x, OXO4x 2 years Paper Archive Storage reference in CCMS.
1.8 Studies - feasibility/conceptual/ front end DC OXO1x, OXO4x , Project N/A N/A Conceptual data underlying chosen design
OXO61, UEC15 completion (see options to be retained with DRM (1.5 above)
remarks)
1.9 Technical audit/HAZOP reports DC OXO1x, OXO4x (See remarks) Electronic CCMS Retained until close out of HAZOP actions.
2.1 Plot plans DC OXO1x, OXO4x, Service life Electronic/Paper 3 CCMS Drawing reference in GIS. Note, benchmark
OXO61, UEC15 locations included in plot plans.
As-
Originator *
Custodians
Retention
Location
Storage
format
Keep
Built
time
**
2.2 Hazardous area classification drawing DC OXO1x, OXO4x Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
2.3 Process flow schemes DC OXO1x, OXO4x, Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
OXO61, UEC15
2.4 Utility flow schemes DC OXO1x, OXO4x, Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
OXO61, UEC15
2.5 Process and engineering flow scheme DC OXO1x, OXO4x, Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
OXO61, UEC15, UIP4
2.6 Utility and engineering flow scheme DC OXO1x, OXO4x Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
2.7 Material identification diagram DC OXO1x, OXO4x Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
3.1 Road and paving plan DC OXO1x, OXO4x Service life Electronic/Paper 3 CCMS
3.2 Foundation location plan DC OXO1x, OXO4x Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
3.3 Fencing and grading plan DC OXO1x, OXO4x Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
3.4 Non-standard pipe supports, guides and DC OXO1x, OXO4x Service life Electronic/Paper CCMS Drawing reference in GIS.
anchors
4.1 Piping key plans DC OXO1x, OXO4x, Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
OXO61, UEC15, UIP4
4.2 Piping plans DC OXO1x, OXO4x, Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
OXO61, UEC15, UIP4
4.3 Equipment data sheets Vendor OXO1x, OXO4x, Service life Electronic or Paper Archive Archived items to be referenced in CCMS.
Vendor drawings for end closures, valves, OXO61, UEC15, UIP4
insulating couplings, barred tees, Pig signaller
4.6 Material/equipment requisitions DC/PE OXO1x, OXO4x See remarks Electronic SAP Retain for longer of guarantee period or 2 years.
Reference in CCMS
5.1 Pipeline routing key plan DC OXO1x, OXO4x, Service life Electronic 3 CCMS Drawing reference in GIS.
OXO61, UEC15, UIP4
As-
Originator *
Custodians
Retention
Location
Storage
format
Keep
Built
time
**
5.2 Route maps XTO/2 OXO1x, OXO4x, Service life Electronic or Paper 3 GIS Ref. TS18V1-0.doc & TS-19V1-0.doc
OXO61, UEC15, UIP4
5.3 Alignment sheets DC OXO1x, OXO4x, Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
OXO61, UEC15, UIP4
5.4 Station approach drawings DC OXO1x, OXO4x, Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
OXO61, UEC15, UIP4
6.1 Single line diagram DC OXO1x, OXO4x, OXO62 Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
6.2 Power cable layout layout drawing DC OXO1x, OXO4x, OXO62 Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
6.3 Earthing layout drawing DC OXO1x, OXO4x, OXO62 Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
6.4 Lighting layout drawing DC OXO1x, OXO4x, OXO62 Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
6.5 Cable schedule DC OXO1x, OXO4x, OXO62 Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
6.6 Trench layout DC OXO1x, OXO4x, OXO62 Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
6.7 Electrical material requisitions DC/PE OXO1x, OXO4x, OXO62 See remarks Electronic SAP As 4.6, above.
7.1 Instrument location plan DC OXO1x, OXO4x, OXO63 Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
7.2 Instrument data sheets DC OXO1x, OXO4x, Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
OXO63
7.3 List of alarm and trip settings DC OXO1x, OXO4x, Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
OXO63
7.4 Shutdown matrices DC OXO1x, OXO4x, OXO63 Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
7.5 Functional logic diagram DC OXO1x, OXO4x, Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
OXO63
7.6 Loop diagrams DC OXO1x, OXO4x, OXO63 Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
As-
Originator *
Custodians
Retention
Location
Storage
format
Keep
Built
time
**
7.7 Alarm annunciator system DC OXO1x, OXO4x, OXO63 Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
7.8 Control room layout DC OXO1x, OXO4x, OXO63 Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
7.9 List of telemetry points DC OXO1x, OXO4x, OXO63 Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
7.10 Control room instrument cable layout DC OXO1x, OXO4x, OXO63 Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
7.11 Junction box layout DC OXO1x, OXO4x, OXO63 Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
7.12 Instrument requisitions DC/PE OXO1x, OXO4x, OXO63 See remarks Electronic 3 SAP As 4.6, above
8.1 Ground bed layouts DC OXO1x, OXO4x, Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
OXO61, UEC15, UIP4
8.2 Wiring diagrams/cable sizes DC OXO1x, OXO4x Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
8.3 Cabling routing layout DC OXO1x, OXO4x Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
8.4 Transformer rectifier plot layout DC OXO1x, OXO4x, Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
OXO61, UEC15, UIP4
8.5 Layout of CP facilities DC OXO1x, OXO4x, Service life Electronic/Paper 3 CCMS Drawing reference in GIS.
OXO61, UEC15, UIP4
8.6 CP survey report SC OXO1x, OXO4x, Service life Electronic or Paper Archive Archived items to be referenced in CCMS.
OXO61, UEC15, UIP4
8.7 CP material specification report SC OXO1x, OXO4x Service life Electronic or Paper Archive Archived items to be referenced in CCMS.
8.8 CP installation specification SC OXO1x, OXO4x Service life Electronic or Paper Archive Archived items to be referenced in CCMS.
8.9 CP requisitions DC OXO1x, OXO4x Service life Electronic SAP As 4.6, above.
9.1 Welding and NDT procedures CC OXO1x, OXO4x Service life Electronic or Paper Archive Archived items to be referenced in CCMS.
9.2 Welding/NDT progress chart CC OXO1x, OXO4x 2 years Paper Archive Storage reference in CCMS.
As-
Originator *
Custodians
Retention
Location
Storage
format
Keep
Built
time
**
9.3 NDT reports/Test packs CC OXO1x, OXO4x Service life Electronic or Paper Archive Archived items to be referenced in CCMS.
Relevant data to be entered in PACER.
9.4 Radiographs CC OXO1x, OXO4x 2 years Film Archive Storage reference in CCMS.
9.5 Commissioning documentation OTL OXO1x, OXO4x, 2 years Paper Archive Storage reference in CCMS.
OXO61, UEC15, UIP4
9.6 Hydrotest certificates CC OXO1x, OXO4x, Service life Electronic or Paper Archive Archived items to be referenced in CCMS.
OXO61, UEC15, UIP4 Relevant data to be entered in PACER.
9.7 Insulating coupling test forms CC OXO1x, OXO4x Service life Electronic or Paper Archive Archived items to be referenced in CCMS.
Relevant data to be entered in PACER.
9.8 Instrument calibration certificates CC OXO1x, OXO4x 2 years Paper Archive Storage reference in CCMS.
9.9 Launcher and receiver inspection form CC OXO1x, OXO4x, Service life Electronic or Paper Archive Archived items to be referenced in CCMS.
OXO61, UEC15, UIP4
9.10 Punch list PE OXO1x, OXO4x (See remarks) N/A N/A Retained until actions cleared.
9.11 CP Installation inspection report CC OXO1x, OXO4x Service life Paper Archive Storage reference in CCMS.
9.12 Construction drawings CC OXO1x, OXO4x (See remarks) N/A N/A Retained until master drawings are updated.
9.13 Misc. site correspondence, records, MOM etc. CC OXO1x, OXO4x Project N/A N/A Selected documents of contractual significance
completion may be archived for 2 years.
10.0 Vendor Documents
10.1 Vendor drawings for end closures, valves, Vendor OXO1x, OXO4x, Service life Electronic or Paper Archive Storage reference in CCMS.
insulating couplings, barred tees OXO61, UEC15, UIP4
10.2 Material certification, reports and test data for Vendor/T OXO1x, OXO4x Service life Electronic or Paper Archive Archived items to be referenced in CCMS.
linepipe and fittings. PI Surplus material documentation held by TSP.
10.3 Material certification, reports and test data for Vendor/T OXO1x, OXO4x Service life Electronic or Paper Archive Archived items to be referenced in CCMS.
static and rotating equipment PI
10.4 Certification, reports and test data for surplus Vendor/T OXO1x, OXO4x Until required Electronic or Paper Archive Archived items to be referenced in CCMS.
materials PI
10.5 Operating instruction manuals Vendor OXO1x, OXO4x, Service life Electronic or Paper Archive Archived items to be referenced in CCMS.
OXO61, UEC15, UIP4
As-
Originator *
Custodians
Retention
Location
Storage
format
Keep
Built
time
**
10.6 Maintenance instruction manuals Vendor OXO1x, OXO4x, Service life Electronic or Paper Archive Archived items to be referenced in CCMS.
At minimum the design data should contain: OXO61, UEC15 UEC13,
UIP4
Abbreviations
CC Construction Contractor
DC Design Contractor
SC Specialist Contractor
** The Project Engineer shall distribute the documents to the respective Custodians as per Company policy.
Sr.
Sketch No. Rev. Drawing Title
No.
NOTES:
SECTION A-A
Distance to be
confirmed by
Material and
Corrosion
Engineer TA-
2 Level
Distance to be
confirmed by
Material and
Corrosion
Engineer TA-
2 Level
Distance to be
confirmed by
Material and
Corrosion
Engineer TA-
2 Level
Note: R.O.W for Main Oil and Gas Lines, as per Royal Decree no. 2/99, shall have an inviolable area 25 meters wide on either side of their center line.
The above dimensions shall be in line with the referenced Royal Decree.
F.1. Introduction
F.1.1 Background and Scope
This Appendix specifies additional requirements for the construction of all new GRE pipeline
systems in PDO operations. Construction of LLRTP and GRE pipelines shall be carried out as
per requirements provided by the vendor and approved by the Company.
The numbering system in this Appendix is designed to allow for easy reference back to the
main text by using the same numbering system contained therein. Wherever applicable, only
additional requirements and modifications pertaining to construction of GRE pipelines are
given in this Appendix.
Activities that are largely common to both material groups, e.g. HSE, clearing, trenching etc.,
are included in the main text of this specification. Whilst these general topics may be applied
to the installation of any non-metallic linepipe material, including thermoplastic liners, specific
requirements and guidelines in the current version of this Appendix are primarily concerned
with GRE pipelines.
Apart from PE linings, GRE is the only non-metallic pipe material which has been used by
PDO for Class 1 pipelines in Hydrocarbon service. PE lining and RTP linepipe have been in
regular use for Class 2 pipelines (mostly flowlines) for a number of years. Current PDO
specifications DEP 31.40.30.34 / SP-2092 and SP-2094 apply for procurement and
installation of these materials. GRE pipelines shall be installed in accordance with this
specification and ISO 14692-4, taking due account of the limitations noted in the GRE linepipe
purchase requisition and associated stress analysis executed by the GRE linepipe vendor.
F.2.2.3.1 Personnel
The Head of Quality Assurance shall have a detailed knowledge of installation and inspection
of GRE pipelines. He shall have general experience in quality assurance matters and be
suitably qualified.
F.2.2.3.2 Organisation
Contractor’s supervisors and all manufacturer’s representatives of GRE pipe vendor, field
service engineers working for the Contractor under EPC contracts shall report directly to the
Head of Quality Assurance on quality assurance matters. (Under non-EPC contracts the pipe
vendor representatives and, if applicable, other manufacturer’s representatives for other
Company supplied materials, shall report to the Company CSR).
Contractor shall confirm to the Company at an early stage in the project that the testing
methods of factory made GRE spools, piping and fittings are acceptable for installation. The
Company shall review and approve the test results prior to start of construction.
F.2.3.3.1 The Contractor shall visually inspect and dimensionally check each pipe and fitting.
For Company supplied materials, the inspection shall be done before removal of the material
from the Company’s storage yards. Thereafter the Contractor shall accept responsibility for all
material losses and damage however caused. The inspection shall include a detailed check
for damage or dimensional non-conformances of bells and spigots. Any shortages,
dimensional non-conformance, missing end protectors or damage, including scratches,
gouges, crushing, cracking etc. shall be reported to the Company within 24 hours of receipt.
F.2.3.4.1 Pipe shall not be allowed to drop or strike objects which may damage the pipe but
shall be lifted, moved and lowered from one position to another by suitable equipment. Non-
abrasive wide nylon or canvas pipe slings of minimum width 200mm shall be used for lifting
pipe. Chains, cables or clamps shall not be used.
F. 2.3.4.2 Trucks used to transport pipes shall be flat-bottomed and free of any projections or
loose materials that might damage or contribute to movement of the pipe during transport.
Pipes shall be protected against truck beds and side metallic protrusions by means of non-
metallic soft materials. Pipes shall be loaded and stacked on trucks in such a manner that
flexing and shifting of the pipe during transport is avoided. After loading, suitable non-metallic
slings shall be used to tie the load securely to the truck. During transport the tension of these
slings shall be regularly checked. The Contractor shall ensure that no pipe end protectors can
be lost during transport. Pipes shall only be transported on trucks (side booms and other
lifting equipment shall not be used to transport pipe on site for distances in excess of 50
meters).
F.2.3.5.1 Ground surfaces to be used for stacking of pipe shall be reasonably flat. Pipe shall
not be laid directly on the ground, concrete floors or on to rails. Pipes shall be laid on suitable
supports, such as timber of 100mm x 50mm section. End protectors shall remain in place
during storage and care shall be taken to ensure adjacent socket and spigot ends are kept
out of contact. End protectors may be punctured with a 5mm drill to prevent them blowing off
the pipes.
F.2.3.5.2 Pipes may be stacked to a height of 1.5m provided suitable supports are provided
both at the sides of the stack and between layers. Typically, 100mm x 50mm timber (spacer
stripping) may be used for both purposes. Supports between layers should be in vertical
alignment, located no more than 3m apart and a minimum of 1m from the pipe ends. Where
strapping down of stacks is necessary, nylon straps should be used, and for long storage
periods a suitable cover should be fitted on each stack. Additionally, the Contractor shall
comply with GRE pipe manufacturer’s recommendations for pipe stacking. In the case of a
conflict or ambiguity, the Company will determine which requirements shall apply.
F.2.3.5.3 Pipes of different diameter, wall thickness, pressure class, material grade or
manufacturer shall be stacked separately. Each stack shall be properly marked to the
satisfaction of Company.
F.2.3.6.1 Adhesives, resins and additives shall be stored in accordance with the manufacturer’s
written instructions in a cool air conditioned area, away from direct sunlight and excessive
humidity. Adhesives shall be kept in refrigerated conditions if the storage period is in excess
of one month, or as specified by the manufacturer, whichever is shorter. Contractor shall
demonstrate compliance with site storage procedures for all consumables in accordance with
detailed consumable handling procedures. A continuous record of temperatures of adhesive
storage conditions shall be maintained.
F.2.3.6.2 For reasons of safety, hardeners, catalysts and accelerators shall be stored
separately in accordance with manufacturer’s instructions. Solvents shall be similarly
segregated as required by the relevant Material Safety Data Sheets.
F.2.3.6.3 No consumables shall be stored or used beyond its stated shelf life.
F.2.3.6.4 GRE fittings shall be stored inside or in their original crates out of direct sunlight.
F.2.4.3.2 Excavation
d) The Contractor shall excavate and grade the trench sufficiently deep and wide to provide
a minimum of 500 mm working space on both sides of the pipe (where jointing is done in
the trench) and space for 150 mm of padding material after compaction all around the
pipe and for the continuous length of the pipeline. The trench profile after excavation shall
be such that the radius of curvature in any plane is greater than the minimum allowable
bending radius specified by the linepipe vendor. Local high and low points in the trench
bottom shall be levelled off to provide a smooth continuous profile. The Contractor’s
surveyor shall survey the trench and submit a formal report with photographs, survey data
and a detailed profile drawing with invert levels at 12 m spacing, providing evidence that
this requirement is achieved.
i) The Contractor shall do hand work in the trench as is necessary to free the bottom of the
trench of loose rock, stones and all other irregularities so as to leave the trench bottom in
a clean and suitable condition to receive the pipe. A fulltime dedicated crew shall be
employed by the contractor to maintain the trench in a rock-free condition before and after
pre-padding has been installed, at all times until the trench is completely backfilled.
F.2.5.3.1 Small changes in direction, in the vertical as well as the horizontal plane, may be
achieved by elastic bending, provided the bend radius is greater than the specified minimum
elastic bending radius specified by the pipe manufacturer for the supplied linepipe. Where this
is not possible, e.g. due to right-of-way restrictions, fabricated elbows shall be used, as
specified in the design drawings and approved by the linepipe manufacturer and the
Company. Special attention is required at transitions between above ground and buried
installation to avoid elastic bending. At locations where the pipeline comes above ground, the
bottom of the trench shall be flat for a minimum distance of 25 m. In this section, elastic bends
are not permitted. Any changes to the design layout of the pipeline, including moving of bend
locations shall be subject to written approval of the Company and the linepipe manufacturer.
This may require revised stress analyses to be executed for the pipeline.
F.2.5.3.2 To allow for large expansion at bends such as those caused by wide temperature
fluctuations or hydrotest conditions, expansion cushions shall be installed as per design
behind each bend and extending to approximately 5 m each side of the bend. However, it is
required to accommodate the expansion of bends through proper design and stress analysis.
F.2.6 Jointing
F.2.6.1 This section of the specification covers requirements for the jointing of GRE pipelines. The
requirements for qualification and production jointing of all types joints including laminated
joints are specified in ISO 14692-4.
F.2.6.2 The Contractor shall prepare a Method Statement covering the jointing work to be carried out
and a detailed procedure for each type and size of joint and fitting to be joined. These shall be
in accordance with the Manufacturer’s instructions, Company specification and standards.
Separate procedures shall be prepared for shop fabrication, site jointing work and repair work.
All joint types shall be qualified and approved by the Company before its use in production
joints.
F.2.6.3 In order to ensure piggability of the pipeline during hydrotest water filling, in service and for
future decommissioning work using foam pigs, particular attention shall be paid to the need
for effective internal cleaning of each completed GRE adhesive bonded joint after fit-up, and
prior to curing, in order to ensure that no significant amount of adhesive protrudes from the
inside seam of any glued joint. Reference is made ISO 14692-4 table 4.where it is specified
under possible defects – excess adhesive shall not be more than 5% of inner diameter or
10mm which ever is less. The Contractor shall propose a method for cleaning the internal
joints for Company review and approval in his detailed jointing procedure.
F.2.6.4 Each joint shall be inspected and certified by the QC Engineer to have been executed in
accordance with the approved jointing procedures. Inspection or witnessing of the make up of
any joints by the manufacturer’s field service engineer shall not absolve the Contractor of his
responsibilities to provide a fit for purpose joint. As a minimum, the Contractor shall keep
detailed records of make up and curing time, batch number of adhesive components as well
as jointer ID and date/time for each joint.
F.2.6.6 No more than 3 km of pipe shall be jointed prior to successful completion of the hydrotest of
the first section of 50 joints of installed pipeline.
F.2.6.7 All documents shall be submitted to the Company for approval. Procedures and operators
shall be qualified to the requirements of the controlling specifications before commencement
of any production jointing.
F.2.8.2.1 All trenches shall be fully pre-padded before lowering in or jointing in the trench. No
padding shall be placed until Company has inspected and approved the trench bottom and
the Contractor’s surveyor has confirmed that the trench bottom profile complies with the pipe
manufacturer’s minimum bending radius requirements.
F.2.8.3.1 All pipes shall be lowered in within 96 hours of completion of jointing. The Contractor
shall keep the lowering in operation within 1 km of the jointing operation.
F.2.8.3.3 A minimum of 3 sidebooms shall be used for lowering in strings of jointed pipe in
excess of 50 meter. Cranes shall not be used for lowering in operations of pipe strings longer
than 50 meters. The trench shall be maintained in a dry condition during lowering-in and
backfill operations. During lowering in operations the pipe shall not be subject to bending in
excess of the minimum allowable bending radius. A detailed procedure specifying the means
of demonstrating compliance with the minimum bending radius requirement shall be
submitted as part of the Contractor’s installation procedures, for Company approval, at least 3
weeks prior to the planned commencement of any lowering in operations.
F.2.8.3.4 The Contractor shall take measures to restrain the pipe in the trench by means of
‘plugging’, i.e. placing sand on top and around the pipe at regular intervals (one 6m ‘plug’ in
the middle of every pipe) or by a Company approved equivalent method. The Contractor shall
plan the work such that the lowering in and ‘plugging’ operations take place together during
the coolest part of the day, (i.e. in the morning). Strings longer than 100 meter shall not be
allowed to lie in the trench without sand plugging. This is to avoid ‘snaking’ and abrasion of
the pipe due to thermal movement.
F.2.8.3.5 Sand padding ‘plugs’ shall be placed around and above the pipe, so as to fill the
trench to a depth of 300 mm above the crown of the pipe, with the sand padding shaped to its
natural angle of repose and with a minimum of 150 mm at any point around the pipe. No pipe
shall be left overnight in the trench without sand padding around and above the pipe. (Joints
shall be left fully exposed around the joint circumference for inspection until completion and
acceptance of the hydrotest)
F.2.8.4 Tie-ins
F.2.8.4.1 Unless otherwise agreed by the Company, tie-ins of the pipeline sections shall take
place in the trench by means of the same type of connections as the pipeline or if the pipeline
connections are not of bonded type, by means of glued connections, using couplings if
necessary. For tie-ins outside or above the trench, holding and lowering operations shall be
undertaken in such a manner as to minimise stresses and bending in the pipe and avoid
movement of the pipe from the skids. Due consideration shall be given to ambient
temperature changes throughout the day and the resultant pipe length changes and induced
stresses.
F.2.8.4.3 All tie-in connections to metallic systems shall be by means of flanged connections.
Tie-ins to other GRE pipe systems may be made by flanged connections or by means of
bonded couplings.
F.2.8.5 Backfilling
F.2.8.5.1 The trench shall not be backfilled until the Company has approved the sand padding
around and above the pipe and has confirmed its approval for the backfilling operation to
commence. Backfilling shall be performed as soon as possible after padding has been
approved, but not prior to the successful completion of the hydrotest.
F.2.8.9.1 The need for concrete anchor or thrust blocks in the pipeline system will be
determined during detailed design, depending on the expected operational pressure surges,
temperature changes, nature of the ground and the geometry of the pipeline layout. Approval
shall be obtained from the relevant linepipe and fittings manufacturers, if changes are
required.
F.2.8.9.2 Anchor blocks should normally be located in line with fittings, tie-ins to steel pipe and
to exposed runs of pipe. The concrete should be poured in situ on to undisturbed or
compacted soil. Where parts of the pipe or fitting joints are to be encapsulated by the block,
hydrostatic pre-testing of the joint assembly should be completed first. Alternatively blocks
may be cast before pipe laying and the pipes fastened with brackets inlaid with an elastomeric
strip. All anchor blocks shall be installed and cured prior to commencement of any
hydrotesting activities on the pipeline.
F.2.8.9.3 For GRE lines, a layer of elastomeric material 6 – 10 mm thick shall be wrapped
around sections of pipes or fittings before concrete is applied. Concrete shall not be poured
directly on to unprotected GRE surfaces.
F.2.8.9.4 No more than half the circumference of the pipe or fitting shall be cast into the
concrete thrust block. Thrust block casting around entire fittings or joints shall be avoided.
Where GRE pipelines are required to cross under roads and highways, the pipe shall be
protected by installation within a steel or HDPE casing pipe with a minimum cover of 1500
mm to the top of the casing pipe.
Detailed installation methods of cased pipe shall be in accordance with the Manufacturer’s
recommendations for the particular pipeline material and shall be agreed with the Company.
The following requirements shall apply for GRE pipe:
• Cased pipes shall be fitted with spacers (minimum 4 per pipe length at a
maximum spacing of 3000 mm) to ensure the pipe is centred and to prevent
damage during installation.
• The ends of the casing shall be sealed with flexible bellows of approved design to
be fitted over the casing ends and the pipe to prevent influx of backfill material
into the annulus. Filling the entire annular space with polyurethane foam is also
acceptable.
• Steel casing pipe shall be externally coated to prevent corrosion, with a Company
approved coating material.
• Prior to backfilling, suitable devices may be attached to both carrier pipe and
casing pipe on each side of the crossing to enable monitoring of differential
movement between the casing and the carrier pipeline.
F.2.9.3 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.
Continuous buoyancy compensation and impact protection may be provided by means
properly designed concrete coating of the casing pipe along the full length of the Wadi
crossing. Casings shall be externally protected against corrosion using an appropriate
coating system.
Requirement for installation of the GRE pipe into the casing is covered in 2.9.2, above.
Concrete coating of the casing pipe is required in accordance with Section 2.10 of the
main text.
F.2.15.1.1 On completion of installation, the GRE pipeline system shall be flushed, hydro tested
and certified in accordance with DEP 31.40.10.19, ISO-14692-4 and this specification.
F.2.15.1.2 The testing of each test section shall commence as soon as possible and, so far as is
practicable within the programme, shall be undertaken progressively throughout the
construction of the line. The first 500 meter of jointed pipe shall be tested within two weeks
of completion in order to provide confidence that the workmanship and installation
procedures are fit for purpose. If the 500 meter section hydrotest is satisfactory, then the
lengths of each subsequent test section shall be decided by the Contractor. If the test on
the first 500 meter fails, then the next 500 meter section shall also be tested separately.
The pipeline shall be tested in 500 meter sections until such time that the Contractor
demonstrates his ability to install a 500 meter section without hydrotest failures.
F.2.15.1.3 Only soft foam pigs shall be used for cleaning, filling and dewatering of GRE
pipelines.
F.2.15.1.4 No gauging of GRE pipelines is required as online pigging is not envisaged for GRE
pipelines.
The minimum requirements of hydrostatic testing operations relating to safety, materials and
equipment used, cleaning, filling, temperature stabilisation, pressurisation, air content
verification, testing, depressurising, dewatering and hydrotest documentation applicable for
metallic pipelines (SP-1212) shall also be reviewed and taken into account when preparing
the hydrotest procedures for GRE pipelines.
Any ambiguities or lack of clarity between these requirements specified and the
requirements of DEP 31.40.10.19 shall be identified to the Company for the purposes of
specification improvement. However, in the case of clearly contradictory requirements (e.g.
tightness test calculations), the additional requirements of this specification shall prevail
over other specifications.
The pipeline shall be subjected to one(1) hour strength test to a pressure equal to 1.5 times
the design pressure. The pressure shall be maintained at the test pressure + 100 kPa by
bleeding or adding water as required.
If a leak is suspected the pressure shall be reduced to the pipeline design pressure before
carrying out a visual examination. No personnel shall come closer than 5 meters from the
pipeline before the pressure has been reduced to design pressure. Subsequently, a “step
test” shall be performed. In this test the test section shall be 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. The quantity of water required to bring the section back to
the test pressure shall be recorded. This shall continue for a period of 24hours. If the
quantity of water added shows a decreasing trend then it may be considered that the
pipeline is tight. If the quantity of water added remains constant then it must be assumed
that the pipeline is not leak tight. No work shall be carried out to repair leaks until the
pressure has been reduced to a safe pressure i.e. static head plus 100 kPa.
During the test, deadweight tester readings shall be recorded every 30 minutes and pipe,
soil and air temperature recorded every 1.5 hours.
The pipeline shall be subjected to a 24 hour tightness test, immediately following the
strength test, at the pressure indicated on the drawings. (This should be 110% of design
pressure). No water shall be added or removed during the test.
The test shall demonstrate, to Company’s satisfaction that there are no leaks in the
pipeline. This shall be achieved by visual inspection of each joint every 4 hours during the
hydrotest period. A tightness test check calculation shall be made to verify that no large
leaks have been missed. Allowance shall be made for instrument inaccuracies and also the
pressure changes as a result of average temperature changes, calculated from the formula
given in DEP 31.40.10.19 (assuming a fully restrained line section). The average
temperature of the pipe may be used for this calculation. The temperature measurements
taken on the exposed pipe may be included in determining the average pipe temperature.
In the event of there being any doubt about the tightness of the line, as determined from the
visual inspections, the test shall be extended or repeated to Company’s satisfaction at no
additional cost to Company. The tightness test calculation shall be provided to the
Company for information.
During the test, the pressure shall be recorded continuously, deadweight tester readings
shall be recorded every 30 minutes and pipe, soil and air temperatures recorded at
maximum 3 hour intervals. The temperature recording interval shall be reduced to 30
minute duration for the first and last 2 hours of the 24 hours to assist with the
pressure/temperature variation check calculation.
Name:
Ref ID Date:
UIP5(UEL1)