sp-1208_sep 2005 pipeline_construction_specification_(pcs-01)_sp-1208

Petroleum Development Oman L.L.C.

UNRESTRICTED September 2005

Document ID: SP-1208 Filing key: xxxx

Pipeline Construction Specification

Keywords: This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any part of this document may be disclosed to others or reproduced, stored in a retrieval system, or transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise) without prior written consent of the owner.


Version 2.0

Authorised For Issue

Signed : Maqbool Al Zadjali, UIP CFDH Pipelines

The following is a brief summary of the 4 most recent revisions to this document. Details of all revisions prior to these are held on file by the issuing department.

Version No. Version 2.0

Date September 2005

Author Jan Belt, UIP/5 R J Harris, OIP/31

Scope / Remarks Specification reviewed updated. Requirements for GRE pipeline construction included. Text of Specification PCS-01 adapted and re-formatted. References updated and text edited. No significant technical changes made.

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TABLE OF CONTENTS1.1 Purpose............................................................................................................................1 1.2 Changes to the Specification............................................................................................1 1.3 Conflicting Requirements.................................................................................................1 1.4 Exceptions........................................................................................................................1 1.5 Health, Safety and Environment (HSE)............................................................................2 1.6 Quality Assurance............................................................................................................3 1.7 Materials Handling and Control........................................................................................6 1.8 R.O.W. and Trenching....................................................................................................11 1.9 Stringing and Bending....................................................................................................18 1.10 Welding and NDT.........................................................................................................20 1.11 Anti-Corrosion Field Joint Coating................................................................................21 1.12 Lowering-In, Backfilling and Reinstatement .................................................................29 1.13 Road and Wadi Crossings............................................................................................34 1.14 Concrete Coating for Wadi Crossings..........................................................................37 1.15 Permanent Markers and Barriers.................................................................................44 1.16 Station Works...............................................................................................................46 1.17 Cathodic Protection......................................................................................................49 1.18 Quality and Treatment of Hydrotesting Water..............................................................51 1.19 Hydrostatic Testing.......................................................................................................51 1.20 Precommissioning Of Pipelines....................................................................................52 1.21 Work on Live Pipe Systems.........................................................................................53 1.22 As-Built Records and Hand-Over Documentation........................................................53 1.23 Effective Period............................................................................................................55 1.24 Review and Improvement.............................................................................................55 Appendix A Glossary of Definitions, Terms and Abbreviations...........................................56 Appendix B Reference Documents.....................................................................................57 Appendix C: Facilities For Company Personnel..................................................................61 Appendix D: List of Handover and As-built Documentation.................................................64 Appendix E List of Typical Drawings for Pipeline Construction...........................................69 Appendix F CONSTRUCTION REQUIREMENTS FOR GRE PIPELINES.........................95 User Comment Form.........................................................................................................105

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

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1.5.1 Scope 2 1.5.2 General...................................................................................................................................2 1.5.3 HSE Advisor............................................................................................................................2 1.5.4 Specific Pipeline Activities.......................................................................................................3

1.6 Quality Assurance............................................................................................................31.6.1 Scope 3 1.6.2 General...................................................................................................................................3 1.6.3 Quality Assurance Team........................................................................................................3

1.6.3.1 Personnel....................................................................................................................4 1.6.3.2 Organisation...............................................................................................................51.6.4 Company Inspection...............................................................................................................5

1.7 Materials Handling and Control........................................................................................61.7.1 Scope 6 1.7.2 General...................................................................................................................................6

1.7.2.1 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 any damage and loss of materials. Method and means of transport and handling (including documentation) shall be subject to approval by the Company..........................................................................................6 1.7.2.2 Contractors material control and storage procedure shall be submitted to the Company within two weeks of the start of mobilisation on site, for approval.............6 1.7.2.3 Contractor shall give the Company at least 2 Company working days notice in writing on each occasion when he intends to start transporting Company supplied materials. A lapse greater than 2 working days shall require re-notification. Pipe can be removed from Companys 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 Companys storage yard on a weekly basis..............................................6 1.7.2.4 Contractor is required to supply lifting equipment for lifting materials at all locations. Lifting equipment and operations shall be in accordance with SP-1239....................6 1.7.2.5 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.............................................................6 1.7.2.6 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...........................................................6 1.7.2.7 Contractors procedures for material receipt and return of surplus materials shall conform to Companys materials procurement/administration procedures................61.7.3 Pipe Inspection.......................................................................................................................6

1.7.3.1 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.......................................................................................................................6 1.7.3.2 Prior to haulage of pipe from Companys 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

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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......................................................................61.7.4 Pipe Handling..........................................................................................................................8

1.7.4.1 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).......................................8 1.7.4.2 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)...............................................8 1.7.4.3 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 PDOs Transport Manual TOM/04/001, SP-2000 Road Transport and government regulations.....................................................................81.7.5 Pipe Stacking..........................................................................................................................8

1.7.5.1 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................................................................................8 1.7.5.2 Epoxy-coated pipes shall be stacked during transport and storage using rubber or other suitable separator strips....................................................................................8 1.7.5.3 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.....................................81.7.6 Linepipe Specifications...........................................................................................................8

1.7.6.1 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...............................................8 1.7.6.2 Minimum average pipe length shall be 11.50m as per above DEP. The minimum and maximum length of pipe shall be between 9m and 13.7m long.................................8 1.7.6.3 Linepipes if required, shall be provided with a factory-applied polyethylene / polypropylene coating or a factory applied fusion bonded epoxy powder coating. Each polyethylene / polypropylene coated pipe shall be left bare for a distance of 150 20 mm from each end. Each fusion-bonded epoxy powder coated pipe shall be left bare for a distance of 80 15mm. Where concrete coating of linepipe is envisaged, the concrete coating cut back shall be increased by 100mm over and above the cut back left in the mill coated pipe...........................................................81.7.7 Inspection of Materials other than Pipe................................................................................10

1.7.7.1 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

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these materials and prior to transportation to the Contractors own storage yard. Visual inspection shall be adequate for this purpose...............................................10 1.7.7.2 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 Companys storage yard.....................10 1.7.7.3 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....................101.7.8 Handling of Materials other than Pipe..................................................................................10

1.7.8.1 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 Companys 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..................................................................................................................10 1.7.8.2 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........................................................10 1.7.8.3 During transport, materials shall be secured by suitable non-metallic non-abrasive slings........................................................................................................................10 1.7.8.4 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.....................................................................................................10 1.7.8.5 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..................................................................................................................10 1.7.8.6 Distribution and supply of materials from Contractors storage yard to the worksites shall be limited to quantities required for approximately one days production. Timing of the issue of materials shall be as per the Company approved work schedule.....101.7.9 Reconciliation........................................................................................................................10

1.7.9.1 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. .................................................................................................................................11 1.7.9.2 On approval of the surplus list by the Company, Contractor shall return all surplus materials to Companys storage yard......................................................................11 1.8 R.O.W. and Trenching....................................................................................................111.8.1 Pipeline Right-of-Way and Working Strip.............................................................................11

1.8.1.1 Scope........................................................................................................................11 1.8.1.2 Survey......................................................................................................................11 1.8.1.3 ROW Width ..............................................................................................................11 1.8.1.4 Planning/Approvals...................................................................................................111.8.2 Staking, Clearing and Grading..............................................................................................12

1.8.2.1 Scope........................................................................................................................12

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1.8.2.2 Definitions.................................................................................................................12 1.8.2.3 Staking......................................................................................................................12 1.8.2.4 Below and Aboveground Services............................................................................13 1.8.2.5 Clearing the Working Strip........................................................................................14 1.8.2.6 Explosives (not used for blasting as part of the construction work)..........................14 1.8.2.7 Grading the Working Strip........................................................................................151.8.3 Trenching..............................................................................................................................15

1.8.3.1 Scope........................................................................................................................15 1.8.3.2 Excavation................................................................................................................15 1.8.3.3 Blasting.....................................................................................................................17 1.8.3.4 Definition of Rock......................................................................................................18 1.8.3.5 Sloping Trenches......................................................................................................18 1.8.3.6 Trench Width............................................................................................................18 1.9 Stringing and Bending....................................................................................................181.9.1 Scope 18 1.9.2 Stringing................................................................................................................................19

1.9.2.1 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. 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............................19 1.9.2.2 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...................................................19 1.9.2.3 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.........................................................................................19 1.9.2.4 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-ofWay and as directed by the Company.....................................................................19 1.9.2.5 Contractor shall layout and measure the pipes such that, the number of pieces cutoff with less than one metre length is kept to a minimum........................................19 1.9.2.6 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............................................................................................................................19 1.9.2.7 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)...............................................................191.9.3 Pipe Bending.........................................................................................................................19

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1.9.3.1 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....................................................................................................19 1.9.3.2 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 Companys approval. The procedure shall include amongst others, step length, degrees per pull and method and accuracy of measurement during pulling of the bend.........................................................................................................................19 1.9.3.3 Elastic bends with radius of curvature less than 500 x D, D being the pipeline diameter are not allowed unless approved by the Company...................................19 1.9.3.4 The radius of cold bends shall be not less than: ......................................................20 1.9.3.5 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.......................................................................................................20 1.9.3.6 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.....20 1.9.3.7 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....................20 1.9.3.8 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....................................................................20 1.10 Welding and NDT.........................................................................................................201.10.1 Scope 20 1.10.2 Off-Plot Pipelines................................................................................................................20 1.10.3 On-Plot Pipework................................................................................................................21

1.11 Anti-Corrosion Field Joint Coating................................................................................211.11.1 Scope 21 1.11.2 Materials..............................................................................................................................21

1.11.2.1 Only materials supplied by Company approved manufacturers shall be used in the Work........................................................................................................................21 1.11.2.2 Contractor shall as a minimum follow manufacturers recommendations regarding material storage, application methods, equipment, spares and tools. Contractor shall submit for Company approval and demonstrate to the Company, the proposed work methods for coating application and coating repair, two weeks prior to application................................................................................................................21 1.11.2.3 The materials, at time of application by the Contractor, shall not be older than the shelf life stated by the manufacturers......................................................................21 1.11.2.4 The coating materials shall be properly packed and clearly marked with:..............21 1.11.2.5 Coating materials shall be kept dry and stored as long as possible in the manufacturers original packaging, not exposed to direct sunlight, and in accordance with manufacturers instructions...............................................................................22 1.11.2.6 The list of Company approved wrap-around shrink sleeves is given in the Approved Vendors, Manufacturers and Equipments (AVME) list of the company...................221.11.3 Surface Preparation............................................................................................................22

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1.11.3.1 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.............................................................................................................22 1.11.3.2 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.........................................................................................22 1.11.3.3 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............................................................................................................22 1.11.3.4 The surface cleanliness shall conform to ISO 8502-1 to 4 and shall be such that the chloride contamination is less than 20 mg/m2...................................................22 1.11.3.5 Coating of the field joint shall not take place until the weld has been nondestructively tested and approved by the Company................................................221.11.4 Shrink Sleeve Application...................................................................................................22

1.11.4.1 Contractor shall propose the application procedure for Company approval. The application procedure shall be in accordance with manufacturers 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...............................................................................22 1.11.4.2 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 Companys discretion. To check that the required preheat temperatures have been achieved, a digital contact thermometer shall be used............................................22 1.11.4.3 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...............................................................................22 1.11.4.4 The procedure for shrinking the sleeve shall ensure that all entrapped air is forced out at either end using gloved hands and hand rollers. Special attention must be given to the closure patch and overlapping areas....................................................23 1.11.4.5 The installed sleeve shall be left undisturbed for 4 hours or until the adhesive has been solidified, whichever is the longer...................................................................23 1.11.4.6 The sleeves shall be visually inspected for the following points:............................231.11.5 F.B.E. Application...............................................................................................................23

1.11.5.1 The mill applied epoxy coating of the linepipe shall be applied in accordance with DEP 31.40.30.32. The epoxy material for the field joints shall be compatible with the linepipe coating and shall conform to the material requirements of DEP 31.40.30.32. .................................................................................................................................23 1.11.5.2 Contractor shall propose the application procedure for Company approval. The application procedure shall be in accordance with manufacturers 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. Contractor shall also submit test data to demonstrate that the applied coating satisfies the requirements DEP 31.40.30.32, with respect to:.........................................................................................................23 1.11.5.3 The resin powder shall be stored in waterproof containers which are insulated and cooled by refrigeration or air conditioning to a temperature not exceeding 27C. Temperature recorders shall be used to monitor the storage temperature inside each container. During the daily powder coating operations, the powder in the fluid bed can be kept at ambient temperatures up to 85C, but must be returned to the normal storage temperature below 27C at the end of the day. For any powder that has temporarily experienced temperatures in excess of 27C, gel time tests as per

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manufacturers recommendation must be carried out on each box of powder before use...........................................................................................................................23 1.11.5.4 The area of the pipe to be coated shall be preheated by induction heating coil to a maximum temperature of approximately 250C. The actual temperature range shall be in accordance with the powder manufacturers recommendations. If the ambient temperature falls, it may be necessary to increase the preheating temperature slightly to provide adequate curing energy. Powder application shall start as soon as the metal temperature is within the qualified temperature range, such that the metal temperature does not drop below the specified lower temperature limit during coating application. Metal temperatures shall be checked by means of digital contact thermometers..............................................................................................23 1.11.5.5 For pipeline sizes equal to or greater than 12", Contractor shall use automatic coating machines, capable of applying the powder at a uniform rate over the entire width of the area to be coated. For smaller pipeline sizes, Company may accept powder application by a hand held device used by a skilled operator, using a technique which achieves an even coating thickness. There shall be a minimum overlap of 50 mm onto the factory coating...............................................................25 1.11.5.6 The applied coating shall have a minimum dry film thickness of 400 75 micron. Dirt or deleterious materials shall not contaminate the powder coated area during the application and curing stages. In the event of contamination, the coating shall be rejected, stripped and recoated to the original procedure. The cured coating shall be free of blisters, pinholes, scratches or any other irregularities and shall be of uniform gloss and thickness..................................................................................................25 1.11.5.7 All operators shall wear Company approved safety equipment to prevent inhalation of powder dust and contact with eyes. Smoking shall not be allowed in the vicinity of the coating operation...............................................................................................25 1.11.5.8 The powder container, hoses, etc. on the application unit shall be cleaned after each days work.......................................................................................................251.11.6 Coating Repairs..................................................................................................................25

1.11.6.1 Coating repairs shall be executed on all coating damage and imperfections detected visually or by holiday testing......................................................................25 1.11.6.2 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..................25 1.11.6.3 The repair procedure for mill applied polyethylene / polypropylene coatings shall be selected based on the criterion of magnitude of the damaged area, i.e.:................25 1.11.6.4 The repair procedure for both mill and field applied fusion bonded epoxy powder coatings shall be selected based on the criterion of magnitude of the damaged area, i.e.:...........................................................................................................................261.11.7 Testing, Inspection and Acceptance...................................................................................26

1.11.7.1 The testing and inspection for acceptance of the coating system shall be carried out and recorded by the Contractor as instructed and witnessed by Companys representative. The frequency of testing as specified herein may be altered by the Company at Companys sole discretion...................................................................26 1.11.7.2 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....................................................................................................26 1.11.7.3 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

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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 manufacturers 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........................................................................................26 1.11.7.4 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.. .26 1.11.7.5 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.........................................................................................26 1.11.7.6 Shrink Sleeves Testing...........................................................................................27 1.11.7.7 Fusion Bonded Epoxy Testing................................................................................27 1.11.7.8 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 2000 Volts DC for Fusion Bonded epoxy and 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 Companys 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...............................................................................................................28 1.11.7.9 Company will carry out a Pearson 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 Contractors expense..............................................28 1.12 Lowering-In, Backfilling and Reinstatement .................................................................291.12.1 Scope 29 1.12.2 Pre-Padding........................................................................................................................29

1.12.2.1 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..............29 1.12.2.2 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................................................29 1.12.2.3 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

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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 Contractors 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.............................29 1.12.2.4 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...................................................291.12.3 Lowering-in and Post-Padding............................................................................................29

1.12.3.1 Welded pipe strings shall be lowered-in within 96 hours of completion of joint coating.....................................................................................................................29 1.12.3.2 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....................................................................................29 1.12.3.3 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................29 1.12.3.4 The trench shall be maintained in a dry condition during lowering-in and backfill operations................................................................................................................31 1.12.3.5 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..........................................................................................................31 1.12.3.6 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.........................................................................................................31 1.12.3.7 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.......................................................311.12.4 Tie-ins.................................................................................................................................31 1.12.5 Backfilling............................................................................................................................31

1.12.5.1 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. Backfilling shall be performed as soon as possible after padding has been approved.........................................................................................................31 1.12.5.2 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 Companys satisfaction. The backfill around all underground services shall be thoroughly compacted by hand................................................................................31 1.12.5.3 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

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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.......................................................................................31 1.12.5.4 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 Companys 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.....................31 1.12.5.5 Trenches crossing ditches shall be backfilled with the material excavated from the trench at the location. If the excavated material, in Companys 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......................................................................................32 1.12.5.6 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...........32 1.12.5.7 Sloping trenches (see Section 2.4.3.5) shall be backfilled as shown on Standard Drawing TYP 3 0015 001.........................................................................................321.12.6 Stabilising Sand Areas........................................................................................................32 1.12.7 Livestock Passageways......................................................................................................32 1.12.8 Reinstatement.....................................................................................................................32

1.12.8.1 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......................................................32 1.12.8.2 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..............................32 1.12.8.3 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...................34 1.12.8.4 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 Contractors operations to approval of the Company...................................................................34 1.12.8.5 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 Contractors operations................................................................................................................34 1.12.8.6 Construction roads, used at escarpments, may be required by the Company to be left as they are.........................................................................................................34 1.12.8.7 Construction markers shall not be removed, unless requested by the Company.. .34 1.12.8.8 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

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the Regulations for Pipeline Contractor Camps in the Interior and to Companys satisfaction...............................................................................................................34 1.13 Road and Wadi Crossings............................................................................................341.13.1 Scope 34 1.13.2 Road Crossings..................................................................................................................34

1.13.2.1 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.....................................................34 1.13.2.2 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...................................................................................34 1.13.2.3 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.............................................34 1.13.2.4 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...............................34 1.13.2.5 Contractor shall comply with the following minimum requirements of the Directorate General of Roads for major road crossings:............................................................341.13.3 Wadi-Crossings...................................................................................................................35

1.13.3.1 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 wadis width, bed slope, past discharge history and erosion potential at the crossing location. The wadi types are described below...................35 1.13.3.2 Wadi crossings shall be installed to meet at all times the requirements and conditions issued by the Authorities having jurisdiction in the area.........................35 1.13.3.3 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. .................................................................................................................................35 1.13.3.4 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...............................................................................35 1.13.3.5 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.........................36 1.13.3.6 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)..........................................................37 1.14 Concrete Coating for Wadi Crossings..........................................................................37

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1.14.1 Scope 37 1.14.2 General...............................................................................................................................37

1.14.2.1 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..................................................37 1.14.2.2 The concrete shall have a minimum dry density of 2400 kg/m3 after 28 days. The minimum thickness shall depend on the pipe outside diameter as specified below:37 1.14.2.3 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.....................................................................................................................37 1.14.2.4 The concrete coating of line pipe shall be applied either in an approved coating plant or in the field, at Contractors 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..................................................................................................371.14.3 Concrete Materials..............................................................................................................39

1.14.3.1 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.................................................................................39 1.14.3.2 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: .......................................................................................39 1.14.3.3 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...............................................................................39 1.14.3.4 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........................................391.14.4 Application...........................................................................................................................39

1.14.4.1 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.....................................................................................................................39 1.14.4.2 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.....................40

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1.14.4.3 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.....................................................................................................40 1.14.4.4 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 32C....40 1.14.4.5 Concrete shall not be placed until:..........................................................................40 1.14.4.6 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 years 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....................................................................................................40 1.14.4.7 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........................................40 1.14.4.8 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..................................................................401.14.5 Curing42

1.14.5.1 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...........................................................................................................................42 1.14.5.2 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.....................................................42 1.14.5.3 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................................421.14.6 Inspection and Testing........................................................................................................42

1.14.6.1 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.....................................................................................42 1.14.6.2 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....................42

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1.14.6.3 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...........................................................................42 1.14.6.4 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.....................................................................42 1.14.6.5 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.......................43 1.14.6.6 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%)...........................................43 1.14.6.7 Effective electrical separation between reinforcing steel and pipe shall be determined for each pipe joint by electrical tests.....................................................431.14.7 Concrete Coating Repairs..................................................................................................43

1.14.7.1 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...................................................43 1.14.7.2 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 m2 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 m2 per joint, the coating shall be removed around the entire periphery of the line pipe throughout the entire damaged area and repaired...........................................................................43 1.14.7.3 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..............43 1.14.7.4 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...................................44 1.15 Permanent Markers and Barriers.................................................................................441.15.1 Scope 44 1.15.2 General...............................................................................................................................44 1.15.3 Chainage Markers...............................................................................................................44 1.15.4 Block Valve Station Markers...............................................................................................44 1.15.5 Road Crossing Markers......................................................................................................44 1.15.6 Wadi Crossing Markers......................................................................................................44

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1.15.7 Pipeline Crossing Markers..................................................................................................45 1.15.8 Cable Crossing Markers.....................................................................................................45 1.15.9 Markers at Horizontal Bends..............................................................................................45 1.15.10 Cathodic Protection Markers............................................................................................45 1.15.11 Pearson Survey Hole Marker...........................................................................................45 1.15.12 R.O.W. `STOP` Signs.......................................................................................................45 1.15.13 Corrosion Monitoring Pit Marker.......................................................................................45 1.15.14 Access Barriers.................................................................................................................45

1.15.14.1 When specified on the drawings, access barriers shall be constructed in accordance with Standard Drawing GEN-2-1633-01...............................................45 1.15.14.2 Breaks in the barriers shall be provided at each road/track/livestock crossing and at least once every two kilometres to coincide with livestock crossings. At these crossings, removable barriers shall be installed to prevent normal access from the crossing to the Right-of-Way, but allowing inspection vehicles to pass when required. Final configuration shall be approved by the Company Site Representative.........................................................................................................45 1.15.14.3 Painting of access barriers shall be in black and yellow bands of 0.3 m length. Paintings shall be carried out in accordance with Section 2.12, Station Works.......45 1.16 Station Works...............................................................................................................461.16.1 Scope 46 1.16.2 Earthworks..........................................................................................................................46 1.16.3 Civil and Mechanical Works................................................................................................47

1.16.3.1 General...................................................................................................................47 1.16.3.2 Concrete/ Block work..............................................................................................47 1.16.3.3 Structural Steel.......................................................................................................47 1.16.3.4 Process Pipework...................................................................................................471.16.4 Painting...............................................................................................................................48 1.16.5 Instrumentation...................................................................................................................48 1.16.6 Electrical Works..................................................................................................................49 1.16.7 Fencing...............................................................................................................................49

1.17 Cathodic Protection......................................................................................................491.17.1 Impresssed Current Cathodic Protection ..........................................................................49

1.17.1.2 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..................................................................................................49 1.17.1.3 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...............................49 1.17.1.4 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...........................................................................491.17.2 Materials..............................................................................................................................50 1.17.3 Installation...........................................................................................................................50

1.17.3.1 Installation of the C.P. System shall be carried out concurrently with the main pipeline laying work..................................................................................................50

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1.17.3.2 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.................................................................................50 1.17.3.3 Cable connections to the pipeline (Ref. STD-7-2001) shall also be required, as shown on the Drawings, at the following locations:..................................................50 1.17.3.4 All C.P. testing facilities shall be installed in accordance with SP-1129.................50 1.17.3.5 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).....................................................................................50 1.17.3.6 Current Measuring Stations shall be installed on the pipeline every 10 km, unless shown otherwise on the drawings (Ref. STD-7-3004).............................................50 1.17.3.7 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)...........50 1.17.3.8 Drain Point Facilities shall be installed as shown on the Drawings (Ref. STD-73003)........................................................................................................................51 1.17.3.9 Insulating joints/flanges shall be installed in accordance with Drawings (Ref. STD7-3007)....................................................................................................................51 1.17.3.10 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...................................................51 1.17.3.11 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-76004)........................................................................................................................511.17.4 Temporary Cathodic Protection..........................................................................................51 1.17.5 Pearson Survey..................................................................................................................51

1.17.5.1 Company will carry out a Pearson Survey, after installation of the pipeline, to check the integrity of the buried pipeline coating. In order to achieve good earthing for this survey, Contractor shall install Pearson Survey Earthing Points adjacent to each 2 km C.P. Standard Test Post. If coating defects are found on any portion of the coating, Contractor shall excavate, repair and backfill at Contractors expense. .................................................................................................................................51 1.17.5.2 These earthing points shall be constructed during the main pipelay work, in accordance with drawing GEN-2-1633-01...............................................................511.17.6 Commissioning....................................................................................................................51

1.18 Quality and Treatment of Hydrotesting Water..............................................................51 1.19 Hydrostatic Testing.......................................................................................................51 1.20 Precommissioning Of Pipelines....................................................................................521.20.1 Scope 52 1.20.2 General...............................................................................................................................52

1.20.2.1 Contractor shall make detailed proposals, for Company approval, for the precommissioning work including but not limited to detailed procedures, programme and schedule for Work. Contractors proposals shall include complete information regarding the following aspects:...............................................................................52 1.21 Work on Live Pipe Systems.........................................................................................531.21.1 Scope 53 1.21.2 General...............................................................................................................................53

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1.21.2.1 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..................................................................................53 1.21.2.2 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 vendors representative shall be present at all times during the use of such tools and equipment.........................................................................................................53 1.21.2.3 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...................................................................................................................53 1.22 As-Built Records and Hand-Over Documentation........................................................531.22.1 Scope 53 1.22.2 Storage Format...................................................................................................................53 1.22.3 Storage Location.................................................................................................................54 1.22.4 Pipeline As-Built Documentation........................................................................................54 1.22.5 Documents..........................................................................................................................54 1.22.6 Test, Calibration and Inspection Reports...........................................................................54 1.22.7 Material Certificates............................................................................................................54 1.22.8 As-built Drawings and Pipeline Data Sheets......................................................................55

1.23 Effective Period............................................................................................................55 1.24 Review and Improvement.............................................................................................55 Appendix A Glossary of Definitions, Terms and Abbreviations...........................................56i. Terms and Definitions.................................................................................................................56 ii. Abbreviations..............................................................................................................................56

Appendix B Reference Documents.....................................................................................57 Appendix C: Facilities For Company Personnel..................................................................61 Appendix D: List of Handover and As-built Documentation.................................................64 Appendix E List of Typical Drawings for Pipeline Construction...........................................69 Appendix F CONSTRUCTION REQUIREMENTS FOR GRE PIPELINES.........................95 User Comment Form.........................................................................................................105

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11.1

IntroductionPurpose

This document shall be used as the base specification for construction of all new carbon steel 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 specifi

sp-1208_sep 2005 pipeline_construction_specification_(pcs-01)_sp-1208

Documents

gre pipeline construction

appendix c

appendix d

text of specification

document id

gre pipelines

appendix b reference

wadi crossings