B4 U&O HDPE - 2nd Constructability 1

2ND CONSTRUCTABILITY WORKSHOP - U&O
CRITICAL AREAS
102.380
99.750
97.903
Interconnecting Piperack CWA 128293

Bottom of foundations: 99.750m
CRITICAL AREAS
102.300
97.400 97.966
96.400
Interconnecting Piperack CWA

128295
CRITICAL AREAS
102.300
99.718
97.400 97.966
96.400

128295 & 128297
CRITICAL AREAS
102.500
99.400
97.400 97.966
96.400

128295
HDPE INSTALLATION METHOD
The installation sequences intended to be adopted for the cooling water and
sea water HDPE UG lines networks are based on the following concepts:
1. Supply of HDPE bars in length of 24 meters.

2. Assembly and welding outside the trench of spools up to 96 meters (4 x
24) when possible.
3. Backfilling of the lines simultaneously along its installation except for the
4. Simultaneous work fronts from both sides.

5. Cleanliness installation approach. Specific procedure/ITP and dedicated
supervision to ensure Cleanliness and its inspection records.
6. Hydrotest philosophy in harmony with commissioning and startup.
RESULTING NETWORK BREAKDOWN

1. General layout divided in 13 groups.
2. 32 lines.
3. 24 test packages/circuits.
HDPE INSTALLATION METHOD 1
Assembly and welding outside the trench of spools up to 96 meters (4 x 24) when possible
HDPE pipe installation requires a certain sequence of installation due to the welding methodology.
As a main approach, pipe lengths will be assembled in a working station (cutting, joining and
welding) creating pipe strings up to 96 m length.
Assembly working stations will be located outside trench as much as possible, especially where
line are single or double in order to keep the trench width as narrow as possible.
HDPE INSTALLATION METHOD 1 - sequences
Once ready, the strings will be positioned inside the trenches by means of multiple cranes.
Use of spreader bar might be required according (to be checked)
HDPE INSTALLATION METHOD 1- sequences
Once the string is positioned inside the trench, backfill will be performed in order to maintain the
line fixed, to protect the line from UV ray and to reduce the dewatering wherever foreseen.
HDPE INSTALLATION METHOD 1- sequences
Then strings will be joined inside the trench up to the required length.
Whenever the trenches are too narrow to access for perform the welding between strings, an
enlarged portion shall be foreseen inside the trench.
HDPE INSTALLATION METHOD 1 - Backfilling
HDPE INSTALLATION METHOD 1 (Summary) - Sequences
HDPE INSTALLATION METHOD 2 - Sequences
Fixed Welding
Station
Piping pulling
Piping enter
welding station
INSTALLATION METHOD
Simultaneous work fronts from both sides
Different work fronts can be considered on the same line where there is a change in direction.
This is feasible without inserting any joint in between.
These points will be called SPLIT POINTS
WORK FRONT SPLIT POINT

INSTALLATION METHOD
Simultaneous work fronts from both sides
SPLIT
POINT
Line backfill
Backfill can be completely done
except for the portion near by
the split joint in order to
position and operate the
welding machines.
Line will be fixed during the
entire welding operation
Line backfill
Backfill can be completely
done except the last portion
of approx. 20 m to allow the
line movement while welding
machines is working.
Line movement will be
supported by means of sliding
points/cranes.
INSTALLATION METHOD
Clean installation approach
A Clean installation method shall be adopted during the HDPE line erection in
order to avoid any dirt or foreign objects inside the line.
Every single pipe length or component will be inspected by all parties prior the
installation and signed records will be implemented during all phases of
installation.
Clean installation method will
foresee:
Dedicated procedure to be approved by
company and endorsed by HDPE subcontractor
Training to subcontractor personnel
Dedicated hold point on the ITP which will
involve subcontractor, Tecnimont and
Company
Blinding device to ensure that no dirt can get
inside while the lines are not attended
Full time contractor inspector to ensure Clean
methodology is applied and maintained
INSTALLATION METHOD
Hydrotest philosophy
Line hydrotest will be mainly performed once the line is totally completed end to end
point. At that moment, the line will be entirely backfilled to guarantee also stability
while filling and pressurizing.
Test will be performed essentially in 4 steps:
- Step 1 Filling and venting

- Step 2 Pressurization up to operational pressure
- Step 3 Pressurization up to test pressure
- Step 4 De-pressurization up to operational pressure (test result evidence)
X
1.3
INSTALLATION METHOD
Hydrotest philosophy
Wherever possible (line conformation), water can be maintained inside the

line after hydrotest, ready for the following flushing activities.
This approach will increase benefit for precommissiong during the flushing
activities reducing time and having also positive ecological impact avoiding
disposal of thousands of water cubic meters
INSTALLATION METHOD
Use of couplings
The concept of the analysis focuses on ZERO breaking points.

Nevertheless, couplings or flanges might be considered the volume of water is
too important for performing the hydrotest.
Coupling or flanges will allow testing of already installed line up to the

selected break up point.
Anyhow, we identified that possible coupling might be used only for lines lower
than Ø1200mm.
Coupling or flanges might be direct buried after installation provided that

service test is completed to ensure no leakages are present
From Sea Water
2ND CONSTRUCTABILITY WORKSHOP - U&O Intake
CWA 600181
UG LINES GROUPING
From
SWI
CWA
600081
From Sea Water
2ND CONSTRUCTABILITY WORKSHOP - U&O Intake
CWA 600181
UG LINES GROUPING
Sea Water Intake
CWA 600081
To cooling towers
CWA 610280-610281-
610282
CIRCUIT DEFINITION
discharge
CIRCUIT LINES total length total volume water Proposed test media
required
1 Line 1 group 3 791 621 No Potable water
2 Line 2 group 3 663 341 Yes Potable water
4 Line 1 group 8 (portion) 35 89 Yes Potable water
6 Line 1 group 2A 574 1305 Yes Potable water
8 Line 2 group 2A 572 1455 Yes Potable water
10 Line 1 group 2B 731 1126 Yes Potable water
16 Line 1 group 1C 332 668 Yes Potable water
19 Line 2 group 1A +Line 2 Group 4 1099 1015 Yes sea water
20 Line 2 group 5A+ Line 2 group 5B 2222 1745 Yes sea water
21 Line 2 group 6A+ Line 2 group 6B 2860 2246 Yes sea water
Line 1 group 1A + Line1 group 4 + Line 1
22 3983 4467 Yes sea water
group 6A + Line 1 group 6B
Line 3 group 1A + Line 3 group 4 + Line 3
23 3311 3723 Yes sea water
group 5A+ Line 3 group 5B
CIRCUIT DEFINITION
2ND CONSTRUCTABILITY WORKSHOP - U&O Flanged Ends
CIRCUIT 1
Line 1 Group 3
Flanged End Split point

Split point
Line 2 group 1A
WF Work front available
Assembled string limits
Consideration for HYT:

1000 mm Main line diameter Line tested alone, flanges are present in both side.
Not require drainage after test.
791 m Line length Line ready for flushing.
621 m³ Water volume for HYT

CIRCUIT 2
Line 2 Group 3
Flanged End
Split point Split point

Line 1 group 1A
Flanged End
Line 1 group 1A
Flanged
End
WF Work front available Flanged
End
710 mm Main line diameter

663m Line length - Line tested alone: whole line is flanged, north part
required valves, therefore line shall be discharged.
341m³ Water volume for HYT
No flange
CIRCUIT 3
Line 1 Group 7
Split point
Flanged End Flanged End
Split
point

1200 mm Main line diameter Line tested alone, flanges are present in one side
only.
855 m Line length Line end point in basin has no flanges. Temporary cap
shall be foreseen.
After test line shall be discharged.
CIRCUIT 4 & 5 Flanged End Consideration for HYT (top):
Line tested alone: line is flanged in
Line 1 Group 8 both side. Line shall be discharged
after test
Line 1 group 2A
Flanged End

Flanged End
Consideration for HYT (bottom):
190 m Line length - Both sides are flanged.
Line tested alone: both side flanged. Line
shall be discharged after test
CIRCUIT 6
Line 1 Group 2A
Split point
Flanged End
Flanged
End

Line 1 group 8 Consideration for HYT (top):
1800 mm Main line diameter - Line tested alone: line is flanged in
both side and all branches.
574 m Line length Line shall be discharged after test

CIRCUIT 7 Flanged End
Line 2 Group 8
Line 2 group 2A

Split
point
Flanged End
166 m Line length Consideration for HYT
Line tested alone: line is flanged in both
side. Line shall be discharged after test
CIRCUIT 8
Line 2 Group 2A
Split point
Flanged
End
Flanged
End
Line 2 group
1800 mm Main line diameter Consideration for HYT (top):
8
- Line tested alone: line is flanged in
571.6 m Line length both side and all branches.
Line shall be discharged after test

Flanged End
CIRCUIT 9
Line 3 Group 8
Line 1 group 2B

Split point

Flanged End
Consideration for HYT
166 m Line length - Line tested alone: line is flanged in both
side.
CIRCUIT 10
Line 1 Group 2B
Split
Flanged point
End
Flanged
End

Flanged End Consideration for HYT (top):
731 m Line length - Line tested alone: line is flanged in
Line 3 group 8 Line shall be discharged after test
CIRCUIT 11
Line 4 Group 8 Flanged End
Line 2 group
2B

Split
point
Flanged End
211 m Line length
Consideration for HYT
- Line tested alone: line is flanged in both
424 m³ Water volume for HYT side.
CIRCUIT 12
Line 2 Group 2B
Split
point
Flanged End
Flanged End

Flanged End Consideration for HYT (top):
720.4 m Line length - Line tested alone: line is flanged in
Line 4 group 8 Line shall be discharged after test
CIRCUIT 13
Line 1 Group 1B Split
point
Flanged
End
Split
point

Flanged
Assembled string limits End
490 m Line length Consideration for HYT:

Line tested alone: line is flanged in both side and
985 m³ Water volume for HYT all branches.
CIRCUIT 14
Line 2 Group 1B Flanged Split point
End
Split point
Assembled string limits Flanged

End

CIRCUIT 15
Line 3 Group 1B
Flanged Split point
End
Split point
Flanged
End

CIRCUIT 16
Line 1 Group 1C
Flanged
End Split
Split point
point
Flanged
End

CIRCUIT 17
Line 2 Group 1C
Flanged
End
Split point
Split point
Flanged
End

CIRCUIT 18
Line 3 Group 1C
Flanged
End Split
point
Split
point
WF Work front available Flanged

End

CIRCUIT 19 Split
Line 2 Group 1A point
Line 2 group 4
No flange
Split point
Flanged
End
Line 1 group 3
439 m Line length Since line has one flanged connection south and no
flanged connection north part it has to be tested with
the next part of the pipe until next flanged end
496 m³ Water volume for HYT available. Therefore test shall consider line 2 group 4
+ Line 2 Group 1A.
CIRCUIT 19 Line 2 group 5A
Line 2 Group 4
Line 2 group 6A
Flanged
Ends

Assembled string limits Since line has two flanged connection on
the north and no flanged connection
Line 2 group
south it has to be tested with the next
1200 mm Main line diameter 1A
part of the pipe until next flanged end
available. Therefore test shall consider
676 m Line length No flange line 2 group 4 + Line 2 Group 1A.

CIRCUIT 20
Line 2 Group 5A
Line 2 group 5B
No flange
Flanged
Split End
point
Line 2 group 4
Assembled string limits Consideration for HYT:

Since line has one flanged connection south
and no flanged connection north part it has
1000 mm Main line diameter to be tested with the next part of the pipe
until next flanged end available. Therefore
1097 m* test shall consider Line 2 group 5A + Line 2
Line length
group 5B.
862 m³* Water volume for HYT

*For overall circuit length and water volume for
HYT refer to circuit definition table
Flanged End
CIRCUIT 20
Line 2 Group 5B
Split point Consideration for HYT (top):
- Both sides are flanged.
Flanged Line tested alone. Line shall be
discharged after test
Ends
Split point

Split point
Consideration for HYT (bottom):
1000 mm Main line diameter Line 2 group 5A Since line has one flanged connection
north and no flanged connection south, it
has to be tested with the next part of the
1125 m * Line length pipe until next flanged end available.
No flange Therefore test shall consider Line 2 group
5A + Line 2 group 5B.
883 m³ * Water volume for HYT
CIRCUIT 21
Line 2 Group 6A
Line 2 group 6B No flange
Split point
Flanged End
Line 2 group 4

1000 mm Main line diameter Since line has one flanged connection
south and no flanged connection north it
has to be tested with the next part of the
937 m * Line length pipe until next flanged end available.
Therefore test shall consider Line 2 group
736 m³ * Water volume for HYT 6A + Line 2 group 6B.

CIRCUIT 21
Line 2 Group 6B
Split point
No flange
Flanged End
Line 2 group
6A
1000 mm Main line diameter Consideration for HYT (bottom):

Since line has one flanged connection
north and no flanged connection south it
1923 m * Line length has to be tested with the next part of the
pipe until next flanged end available.
1510 m³ * Water volume for HYT Therefore test shall consider Line 2 group
6A + Line 2 group 6B.
CIRCUIT 22
Line 1 Group 1A Split point
Line 1 group 4
Split No flange
point
Flanged
End
1200 mm Main line diameter Line 2 group 3
413 m * Line length Consideration for HYT:

Since line has one flanged connection south and no flanged connection north
467 m³ * Water volume for HYT it has to be tested with the next part of the pipe until next flanged end
available. Therefore test shall consider Line 1 group 1A + Line1 group 4 +
*For overall circuit length and water volume for Line 1 group 6A + Line 1 group 6B
CIRCUIT 22 Line 1 group 6A
Line 1 Group 4
Split point
No flange
Split point

WF Work front available Since line has no flanged connection has
to be tested with the next part of the
Therefore, test shall consider Line 1
group 1A + Line1 group 4 + Line 1 group
1200 mm Main line diameter Line 1 group 1A 6A + Line 1 group 6B
710 m * Line length

No flange
Split
point
CIRCUIT 22 No flange
Line 1 Group 6A Line 1 group 6B
Split point
No
flange
Line 1 group 4
Assembled string limits Consideration for HYT:

Since line has no flanged connection has
to be tested with the next part of the
Therefore, test shall consider Line 1
937 m * Line length group 1A + Line1 group 4 + Line 1 group
6A + Line 1 group 6B
CIRCUIT 22
Line 1 Group 6B
Split point
No flange
Flanged End
Line 1 group 6A

Since line has a flanged end on the
1200 mm Main line diameter north part, has to be tested with the
next part of the pipe until next
1923 m Line length flanged end available. Therefore test
shall consider Line 1 group 1A + Line1
group 4 + Line 1 group 6A + Line 1
2175 m³ Water volume for HYT group 6B
CIRCUIT 23
Line 3 Group 1A
Split point
Line 3 group 4
No flange
Split point

Flanged
Assembled string limits End + valve
Line 2 group
1200 mm Main line diameter 3

Since line has a flanged connection on the south part, has to be tested with
467 m³ the next part of the pipe until next flanged end available. Therefore test
Water volume for HYT
shall consider Line 3 group 1A + Line 3 group 4 + line 3 group 5A + Line 3
*For overall circuit length and water volume for group 5B
CIRCUIT 23 Split
Line 3 Group 4 point
Line 3 group
6A
Split
point
No flange

Since line has no flanged connection, it
WF Work front available has to be tested with the next part of the
Assembled string limits Therefore test shall consider Line 3 group
1A + Line 3 group 4 + line 3 group 5A +
Line 3 group 5B
1200 mm Main line diameter Line 3 group
1A
676 m Line length
Split
point
CIRCUIT 23
Line 3 Group 5A
Line 3 group 5B
Split point
No flange
No flange
Split point
Line 3 group 4

Since line has no flanged connection, it
1200 mm Main line diameter has to be tested with the next part of the
1067 m * Line length Therefore test shall consider Line 3 group
1A + Line 3 group 4 + line 3 group 5A +
Line 3 group 5B
Flanged End
CIRCUIT 23
Line 3 Group 5B
Split
point Consideration for HYT (top):
Flanged - Both sides are flanged.
Line tested alone
Ends
Split
point
WF Work front available Split

point
Since line has a flanged connection
1200 mm Main line diameter on the north part, it has to be
Line 3 group tested with the next part of the
5A pipe until next flanged end
1125 m * Line length
available. Therefore test shall
consider Line 3 group 1A + Line 3
1272 m³ * Water volume for HYT group 4 + line 3 group 5A + Line 3
group 5B
CIRCUIT 24
Line 4 Group 4
Flanged End Flanged

Ends
Line 3 group 4
Line 1 group 4
900 mm Main line diameter Consideration for HYT:

Line tested alone, flanges are present in both sides.
Required drainage after test.
58 m Line length Line tested together with line 1 group 4 and line 3 group
4
37 m³ Water volume for HYT Required drainage after test.
HDPE LINES ERECTION IMPROVEMENT
U&O plant is set on different elevation (+105.000 / +102.000)
HDPE lines across this elevation change in several points (13 lines)
Cooling Water + HDPE:
FOCUS ON HDPE ERECTION EXECUTION STRATEGY
2
3
2 3
43
7
5
6 6 6
KEYPLAN
11) CRITICAL POINT SEA WATER BASIN B2 (CWA 600081)
A) SEA WATER MAKEUP B) NEW PIT

A
PUMPS 60-PC-2842
A/B/C
C) EXISTING SEA WATER BASIN D) 600081-RP003A

PIT FOR DEWATERING AND
B PIPING SUPORTS
D
KEYPLAN
11) CRITICAL POINT SEA WATER BASIN B2 (CWA 600081)
D) 600081-RP003A
Depth: 5.00m
PIT FOR DEWATERING AND
PIPING SUPPORTS
KEYPLAN
22) CRITICAL POINT HDPE LINE ROAD CROSSING
Installation of pipe sleeve (by Pipe Jacking)

The crane will lower the welding machine into the trench and position
Generator will place nearer to the location
Load the pipe unto both side of welding machine with the end of the
pipe will be in the clamps of welding machine.
Attach the clamps & tight on the pipeline. Load pipe into the welding
machine in the trench and weld. After the required length for NDRC
achieved, remove the welding machine and generator and shift to
another place.
After welding completed, the welded pipeline will be tow by excavator
until nearest to the NDRC.
KEYPLAN
22) CRITICAL POINT HDPE LINE ROAD CROSSING
Place the wire rope that coming from other side of NDRC. And start pulling and full length of pipeline
will be inside the sleeve. The pipeline can be push also by excavator depends on requirement.
Pulling or pushing the pipeline can be execute by excavator assisted by crane.
Hydro testing will be done before the pipeline will pull or push into NDRC [pipe sleeve]
And continue the welding on either both sides until weld reach on elbow or change direction of pipeline.
After completed the welding on the whole straight pipeline, shift the equipment on the other side.
KEYPLAN
32) CRITICAL POINT HDPE LINE UNDER PIPELINE
PLACING SLEEVE PIPE BELOW EXISTING PIPELINE (BY PIPING JACK)
A stablished thrust wall (concrete)

for jacking equipment will lean.
Steel rail will also place for guide of
pipe steel.
The hydraulic jack and the steel

pipe will be placed as sleeve,
jacking until the steel pipe
penetrates completely the soil.
KEYPLAN
32) CRITICAL POINT HDPE LINE UNDER PIPELINE
PIPE TO PIPE WELDING FOR NDRC [PIPE SLEEVE]
Procedure for HDPE line before and

after pipeline cross:
The crane lowers the welding
machine and the pipe into the
trench. The pipe will be in the
clamps into welding machine.
The clamps will be attached and
tighten on the pipeline. The pipe
will be loaded into the welding
machine in the trench and weld.
After the required length for
NDRC (sleeve) achieved, the
welding machine will be
removed.
After welding completed, the
welded pipeline will be tow or
push by excavator until will be
fully inserted into NDRC. If the
pipe will be pull, the wire rope
will be placed passing into NDRC
until it will be inside the sleeve.
KEYPLAN
CRITICAL AREAS: Microtunneling Jacking for HDD
KEYPLAN
4 FOCUS ON HDPE ERECTION EXECUTION STRATEGY
PIPERACK FOUNDATION UNDER HDPE

LINE FOR INTERCONNECTING
PIPERACKS CWA 128295-128297
HDPE Depth (bottom): 4.3m

Foundations Depth (bottom): 6.5m
KEYPLAN
COOLING WATER LINES PIT

BETWEEN U&O AND PO
CWA: 128U02
HDPE level is above Storm water lines

according to Company comments (to
facilitate maintenance in case of a
broken line).
To be checked and defined by
engineering.
KEYPLAN
PRIORITY ON HDPE LINE

UNDER INTERCONNECTING
PIPERACK 128291-IR003
Issues found on interface between

Piperack foundation and HDPE
line to EU4.
Is not possible to lower the
foundation of the Piperack due
the position of the HDPE lines/
To be studied by engineering.
KEYPLAN
COOLING WATER LINES PIT

BETWEEN U&O AND PO
CWA: 128U02
Pit dimensions: ENG ON HOLD

B4 U&amp;O HDPE - 2nd Constructability 1

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2ND CONSTRUCTABILITY WORKSHOP - U&O

Interconnecting Piperack CWA 128293

Interconnecting Piperack CWA

Interconnecting Piperack CWA

Interconnecting Piperack CWA

1. Supply of HDPE bars in length of 24 meters.

4. Simultaneous work fronts from both sides.

RESULTING NETWORK BREAKDOWN

WORK FRONT SPLIT POINT

- Step 1 Filling and venting

Wherever possible (line conformation), water can be maintained inside the

The concept of the analysis focuses on ZERO breaking points.

Coupling or flanges will allow testing of already installed line up to the

Coupling or flanges might be direct buried after installation provided that

Flanged End Split point

WF Work front available

Assembled string limits

Consideration for HYT:

621 m³ Water volume for HYT

Split point Split point

710 mm Main line diameter

Consideration for HYT:

WF Work front available

Assembled string limits

Consideration for HYT:

WF Work front available

Assembled string limits

WF Work front available

Assembled string limits

1305 m³ Water volume for HYT

WF Work front available

WF Work front available

Assembled string limits

1454 m³ Water volume for HYT

WF Work front available

1600 mm Main line diameter

WF Work front available

Assembled string limits

1600 mm Main line diameter

WF Work front available

WF Work front available

Assembled string limits

1600 mm Main line diameter

WF Work front available

1600 mm Main line diameter

490 m Line length Consideration for HYT:

WF Work front available

Assembled string limits Flanged

490 m Line length Consideration for HYT:

1600 mm Main line diameter

490 m Line length Consideration for HYT:

1600 mm Main line diameter

332 m Line length Consideration for HYT:

1600 mm Main line diameter

332 m Line length Consideration for HYT:

WF Work front available Flanged

1600 mm Main line diameter

332 m Line length Consideration for HYT:

Assembled string limits

WF Work front available

743 m³ Water volume for HYT

WF Work front available

Assembled string limits Consideration for HYT:

862 m³* Water volume for HYT

B4 U&O HDPE - 2nd Constructability 1

B4 U&O HDPE - 2nd Constructability 1