Inspection & Testing for Pipeline Works. 3 owas pa Parone ij apr | BIT ‘A [ONC Beste + getage | rc apr [708 Rev | Prepared By ‘hek/oritee By |NpprovedBy| DateTab of Contents 4. PROCEDURE No. 2. SCOPE AND PURPOSE 3. APPLICABILITY 4. RESPONSIBILITY GENERAL 6. DEFINITIONS 7. PROCEDURE 7A, Process Conti! for Pipeline Works 7.44. Matera 4.2. Wotiing Procedure Qualification 3. Weller Qualifications 4. Survey and Staking 5. R.O. Way Preparation ‘8. Ditch Preparation 7. Padding 8. Haul and String 9. Bending 40. Filting and Welding OF Line Pipe ‘1. Internal Cleaning and Gauging 12, Lowerand Lay 7.4.48. Temperature Tie-Ins TA114, Backfiing 7.416. Cable, Pipe and Road Crossings TA16, Pressure Testing Requirements TAIT. Pressure Tesling Safety 7.1.18, Paintirg, Coating and Insulation 7.4.18. Concrete 7.1.20. Roadsand Paving 7.41.24. Structural Stee! Work 7.1.22. Fencing 7.128. Cathodie Protection 7.4.24. Electrical and Instrumentation 8. RECORDS 9. REFERENCES4, PROCEDURE NO. 16a 2. SCOPE AND PURPOSE ‘The scope of this procedure is te define the construction phases for the process Control of the pipelines works and o ensure that these processes ate carried out under controlled corditions. Similarly this procedure shall define the manner of installation in accordance with client and applicable specifications and standarde, The purpose of this procedure is to detail the techniques fo be applied on the sitferent activities relevant to the proper execution and installation of pipelines, Glient specifications SATIP's and drawings shall supersede the techniques \elailed in this procedure when they dif. 3, APPLICABILITY All Aspects of Pipeline works (Supported by Specific Activity Documents) 4. RESPONSIBILITY Project Manager * Distipine Engineers © Discipine Foremen ° (QA Manager QC Personne! Material Controller 5. GENERAL | This procedure covers field Process control of Pipeline Works. | ‘The construction phases for the pipeline will start with the mobilization of personnel, equipment and camp facilities (when applicable) and shall continue {throughout the pianned schedule up to the mechanical completion documentation requirements and the county laws and regulations. Unless otherwise indcated in the specifications, SATIP's or detalls shown on the drawings the following detailed process shall apply Equipment to be vsed shal be with vals documents in accordance with Chnt | & — eHNTIONS None7. PROCEDURE 7.4, Inspection and Testing for Pipeline Works TAA. Materia Mateial shall be in accordance with Client specifications and requirements. Material shall be oblained from Client approved suppliers list. Purchasing procedure shall apply for material procurement 7.12. Welding Procedure Qualification ‘As per SATIP-W-012.01, SAES-W.012 Sect 7 and Code 7.1.8, Welder Qualifications ‘As por SATIP-W-012-01, SAES-W-012 Sect 8 and Code 7.44. Survey and Staking ‘The surveyor shall estabish the final RO.W. route taking into Consideration the soil conkitions, existing faites and installations. ‘And as per SATIP-L-450-01, SAES-A-100, SAES-L-450 ‘The Surveyor shall take in evidence all particular points: roads ‘rossings, sol conditions, existing facilities ele. in such a manner, to ‘enable the Project Team to havo a better view of the overall Project and its difficulties and consequently will be able to develop an effective work plan 7.15. Right OfWay Preparation Preparation and construction of the Right Of Way for the pipeline will start taking into consideration the construction programme requitements SATIP-L-450-01,5.0.W, and SAES-L-450, C.A.7. wil construct and maintain through Project completion the ecossary access ronds. Blasting shall be executed as_per Client requirements, specications and Country Laws and Regulations Wher blasting is necessary proper safely measures will be ‘adopted to prevent accidents and damages to people, animals, existing pipelines, facies and other properties. 7.4.6, Ditch Preparation ‘The trench routing shall be marked accurately as per the approved plan and profile drawings, and the trench shall be excavated to theproper dimensions, SATIPL-450.02, SAES1-450 and SAES-M- 100. “The trenching activiy shal be in accordance with the procedure for Civil and Earth Works, SATIP1-450-02, SAES-M-100, And SAES-L- 450. The tenching actviies shall be executed by utilizing dliferent excavation techniques according to the type of terrain encountered, Prior to start any excavation a front-end crew will perform the ripping survey for the tock identification. Backhoes wil then perform the initial enching. The hard rock exposed by the backhoes may be blasted with explosive or removed by rock breakers Backhoes are used forthe final excavation of the trench, In areas of loose soil the ditch wil be excavated by backhoes and the sol shall be deposited on the spoil side of the ditch in a suitable ‘manner for subsequent iting, screening for padding, if required, and for backing 7A. Paddirg The trench will be pre-paded with approved paddling materials in compliance with SAES-M-100 and SAES--450, the padding rmatefals will be transported to the ste by dump trucks, if necessary, and placed in the trench, Final Padding operations wil continue until the pipe is totally covered to the requited depth. The retaining trench wil then be backfilled with spoil materials fram the ‘trench, ulizing equipment such as loaders and dozers and as per ‘SATIP-L-450-02, SAES-M-100 and SAES-(-450, ‘The Ledding/padiding material wll be placed under and around the pipe te cover the pipe to the depth specified in SAES-L-450 Particular care will be taken then during the subsequent backfiling ‘operation in order to place the material in a manner that will not ‘damage the sand pad, ‘Sand padding wil begin as ealy after lowering-n as practical. ‘The crown cover is at the pipeline centerline. The backfil material shall meet the requirements of SAES-M-109, 74.8. Haul and String ‘The acivity shall be carried out in accordance with SAES- ‘SAES-_-450 Checklist SAIC-L-2132 shall be filled out.74.10, TAA Pipes wil be off loaded from trailers using appropriate size sido booms or cranes. Aluminum, Brass or other type padded hooks will be used to eliminate damage to the pipe and bends. ‘The pipe shall be off loaded and strung on padded skids, sandbags (F rubber tires for coated pipes. No padding is required for non- ‘coatec pipes. Bending From a study of the terrain or applicable contract drawings, a qualified land surveyor prepares a bending schedule on a pipe bendlrg dala sheet taking inlo consideration such factors as limitation on bending radius, horizontal or vertical bending, bending ‘machine specs, ete Cold eld bends will be made to conform to the profle of the excavaied trench. GAT. shall utlize a conventional bending ‘machine with bending sets to ensure smooth bending and maintain the sizing ofthe pipe. The bending sets are lined for coated pipes as per SAES-H.200 Sec’5, Nylon slings will be used fer pipe handling {to avoit damaging of pipe coating. Bite stacing and bend per bite will be as SAES-L.450, Fitting and Welding OF Line Pipe Fiting of fine pipes for welding is made by experienced fitter spacers under the supervision of the welding foreman according to WPS, SAES-W-012, SATIP.W.012-01 and API 1104, Proper line Up clamps is used for the diameter ofthe pipe to be welded, Line welding proceeds as per WPS, SAES-W.012, SATIP-W.012- Of and API 1104 ‘Acceptance criteria for al fit up and completed welds are those by applicable standards, Project revision. N.D.E. and acceptance criteria will be as required by SAES-W.012 ‘ond relovant SATIP's ‘A ground clamp or insulated strip of pipe with an exposed contact point of same material as pipe is securely gripped on the previous uncoated joint of the pipeline to provide the proper grounding action Inlemal Cleaning and Gauging _ ‘Wher standard’ requires, a gauging plate approves by Client (Diameter as per SAES-L°450) shall be attached to the inside disc ‘of scraper and pushed by compressed air.TAA2, 7448. rata Lowerand Lay Proper belts and cradles shail be used to lit and lower the section. The rales of the cradles are lined with PVC to prevent damage to coated pipes as per SAES-H-200, No lowering in wil be performed in rary periods until the trench is dewatered / drained from any accumulated water. ‘The trench bottom shall be properly padded to comply with SATIP-L- 450-04, SAES-L-450 & SAES-M-100, During lower in a holiday detector previously checked against a calibrated voltmeter is used set to the voltage called for in the scope of work and SAES-H-200 Sect 7. The holiday testing will be conducted once the pipe isin the ditch or just as itis being lowered:in, ‘When holidays are detected, repairs are carried out. The type of repair depends on size. For small repairs less than 2.254nch melt sticks is used. For larger size holidays patching compounds are Used. iFor reporting purposes use the attached FBE coating jeeping record Both types of materials wil be as per Client standards, Methods for repair of material other than F.B.E. wil be as recommended by manufacturer Temperature Tie-Ins Temperature tie-ins occur at end of weld stings and al road crossings and some pipe crossings. Temperature tie-ins will be done during the hottest temperature of the day and in compliance with SATIP-L-450:04, SAES-W.012 / SAES-450. The tie-in temperature shall be above the minimum or within the range stated in the Project Specification. Racking Pipe back fil shall be in accordance with SATIP-L-450-02, SAES-M- 100 & SAES-L-450. Berm wil be placed in accordance with SAES1-450 and in @ ‘manner to avoid disturbing sand paddling ofthe pipelines. No coarse matarial shail be placed on top of sand pad or allow it to ralldown-- ad In sandy area, stabilization of the berm, if and when required, is by having either weathered crude oil spread over the berm, with a ‘minimum penetration given in the specifications or by spreading ma(on top of backfil. CAT shall cary out the temperature te-ins as per the paragraph 16 of SAES--460, 7.4.46, Cable, Pipeline and Read Crossings ‘All Road/ Rail crossings actives shall be executed as per SATIP-L- 1480-04, SAES-1-460, Cable and pipeline crossings shall be executed as per Client specifications and as shown on the drawings and SATIP-P-107-01 & SATIP-T-811-01. Pipeline crossing from the Area Classification 3 & 4 should go for under 100% RT. ‘Authorzations/Permissions shall be obtained ffom the local ‘competent authorities prior to start of work Unless otherwise specified, the folowing shall appiy: Paved road shall be open cut oF thrust bored as required by the ‘specifisations, in the fist case a by-pass may be required to keep the traffic flowing, The pipe shall be positioned in accordance with the drawings, The road shall then be backfiled, compacted and then restored to its orginal condition. The traffic on the public road shall then be resumes. {road boring is required, the activity shall be subcontracted to a pro- ualfied sub-contractor. C.AT. Sub-contractors Coordinator shall fensute that works is executed as per the procedure, to the applicable and Cent requited specifications, Other crossings shal be executed by canrying-out the ditch excavation by using mechanical means or by hand digging wien necessary. The line pipe shall be instaled under the existing facilis and then the backfling shall be conducted in a manner nol ta distur the existing facts. Ratiography will be made as called for in the scope of work relevant SATIPS and SAES-W-0T2. ‘Sand pading will be applied as per Procedure for Ditch Preparation and Process Control procedure for Civil and Earth Works F106. Backfing will be in layers, unless specified otherwise, and compacted to a density matching the surrounding soll Cathodic Protection shall be carried out in accordance with Procecure for Cathodic Protection, SATIP-X-600-02 and SAESX- 40071.16. 74.47, 74.18 TAA9. ‘Sorapping and Flushing Flushing shall be done witen required as per SAES-L-150 8 SAES- A004, Pressure Testing Requirements AA pressure testing procedure will be completed and submitted for approval as per GL0002.102, SAES-A.004, SAES1-180 and folovant SATIP's, The procedure shall indude as a minimum the following:- ‘© The flushing and cleaning requirements + Layup procedures (i applicable) + Alt of reference standards ‘© A section on test equipment to be used for the test, stating the ‘albration requirements ‘A section on safety requtements forthe test entiation of water source Pressurization Description of the steps to be taken during the pressurization of the system Strength and tightness tests ‘A section containing the pressure test diagrams prepared by Discipine Engineer will show as a minimum, the following © Tost section breaks. Location for filing © Lising of test pressures and robiof valve setings Location of pump, manifold, and chemical tank Pressure Testing Safely ‘The pressure testing procedure as desciibed inthe previous section Will contain sufficient safety considerations to ensure thatthe testis ‘conducted safely. Paintirg, Coating and Insulation The application methods and procedures used in painting on the projects are as per scope of work, Client specications APCS s and QArPt43,7.4.20. 7.421, 74.22, 74.23, 7424, 7.428. 7.1.26, RECORDS Concrete Unless otherwise specified the Concrete Works shall be as per the Process Control Procedure for Concrete Works P133 and SAES-Q. 01 Roade and Paving Unless otherwise specified the Paving Works shall be as per the Process Control Procedure P47 for Roads and Paving Works and SAES-0.006, Structural Steet Work ‘As pe’ Process Control Procedure for Metal and Structural Stee! Work P149, Standards, Codes and SAES-M-100 Fencing ‘As per the Process Control Procedure for Fencing, P140 SAES-O- 100, & 105 Cathodic Protection {As per Process Control and Inspection and Testing Procedures for Cathedic Protection, P134 and SAES-X-400 Electrical and Instrumentation ‘As pet, Process Control Procedures for, atemalivaly, Electrical ‘Works and Instrumentation Works, P136, P142, SAES-P- 104, 171, 122. SAES-J-002, 004, 005, 200,400, 505, 600. & N.E.C. ‘As Built Survey and Marked-Up Drawings During construction, records will be maintained showing changes ‘and Iccations of underground installations that they may need recording on aa-bult drawings according to specications, The ‘alignment drawings will be prepared as sections ofthe pipeline are ‘completed with the final as-bult drawings submitted for approval ‘They will eflect final grade and alignment, All records relevant to above procedure shall be kept in the site office by the QN/QG Supervisor for the duration of the project and transferred tothe Area Head Office, atthe achieve nent of the Project, to be fled, archived and kept for a period of Three years9. REFERENCES Inspection and Testing Procedures Glient Specifications: SAES-L-460, 180, 450, 110 SAES-H-200, 204 SAES-J-002, 002, O64, 005, 200, 400, 605, 600 SAES-M-100, 5 ‘SAES-0-001, 006 ‘SAES.0-100, 105 SAESP-104, 111, 118-124, SAES.X-400 SAEP 1142 SATIP-H-002-10 SATIP-L450-04, SATIP-L-450-02 SATIP-L-450-04 SATIP-P-107-01 SATIP-T-911-01 SATIPW.012.01 International Codes: NEC. APL 1104 AWS D1 Attachments: None