Petroleum Development Oman L.L.C.
Pipeline Construction Specification
(SP-1208)
Document ID
SP-1208
Document Type
Standard
Security
Unrestricted
Discipline
Pipeline Engineering
Owner
Issue Date
Revision
UEL – Pipelines Corporate Functional Discipline Head
01/03/2011
3.0
This document is the property of Petroleum Development Oman, LLC. Neither the whole nor
any part of this document may be disclosed to others or reproduced, stored in a retrieval
system, or transmitted in any form by any means (electronic, mechanical, reprographic
recording or otherwise) without prior written consent of the owner.
Pipeline Construction Specification
Version 3.0
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SP-1208
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Feb 2011
Pipeline Construction Specification
Version 3.0
ii Revision History
The following is a brief summary of the 3 most recent revisions to this document. Details of all
revisions prior to these are held on file by the issuing department.
Revision No.
Version 3.0
Date
Author
Scope / Remarks
Feb 2011
UEL/1
Reviewed, updated and revised.
Major updates includes the followings:
•
Update of all applicable
standards throughout the
document
•
Removed FBE coating
application.
•
Modified recommended
minimum cover for onshore
pipelines (Inline with SP-1211).
•
Replacement of Pearson
survey with DCVG.
•
Modified Appendix D (List of
Handover And As-Built
Documentation
Version 2.0
September
2005
Jan Belt, UIP/5
Specification
reviewed
Requirements
for
GRE
construction included.
Version 1.0
April 2001
R
J
OIP/31
Text of Specification PCS-01 adapted
and re-formatted. References updated
and text edited.
No significant
technical changes made.
SP-1208
Harris,
Page 2
updated.
pipeline
Feb 2011
Pipeline Construction Specification
Version 3.0
TABLE OF CONTENTS
i
Document Authorisation .......................................................................................................... 1
ii Revision History ........................................................................................................................ 2
TABLE OF CONTENTS................................................................................................................... 3
1 Introduction ............................................................................................................................... 7
1.1
Purpose ....................................................................................................................... 7
1.2
Changes to the Specification....................................................................................... 7
1.3
Conflicting Requirements ............................................................................................ 7
1.4
Exceptions ................................................................................................................... 7
2 Specification Requirements ..................................................................................................... 8
2.1
Health, Safety and Environment (HSE) ....................................................................... 8
2.1.1
Scope ......................................................................................................................... 8
2.1.2
General....................................................................................................................... 8
2.1.3
HSE Advisor ............................................................................................................... 8
2.1.4
Specific Pipeline Activities .......................................................................................... 9
2.2
Quality Assurance ....................................................................................................... 9
2.2.1
Scope ......................................................................................................................... 9
2.2.2
General....................................................................................................................... 9
2.2.3
Quality Assurance Team ............................................................................................ 9
2.2.4
Company Inspection................................................................................................. 11
2.3
Materials Handling and Control ................................................................................. 12
2.3.1
Scope ....................................................................................................................... 12
2.3.2
General..................................................................................................................... 12
2.3.3
Pipe Inspection ......................................................................................................... 12
2.3.4
Pipe Handling ........................................................................................................... 13
2.3.5
Pipe Stacking ........................................................................................................... 13
2.3.6
Linepipe Specifications ............................................................................................. 13
2.3.7
Inspection of Materials other than Pipe .................................................................... 14
2.3.8
Handling of Materials other than Pipe ...................................................................... 14
2.3.9
Reconciliation ........................................................................................................... 14
2.4
R.O.W. and Trenching ............................................................................................... 15
2.4.1
Pipeline Right-of-Way and Working Strip ................................................................. 15
2.4.2
Staking, Clearing and Grading ................................................................................. 16
2.4.3
Trenching ................................................................................................................. 19
2.5
Stringing and Bending ............................................................................................... 22
2.5.1
Scope ....................................................................................................................... 22
2.5.2
Stringing ................................................................................................................... 23
2.5.3
Pipe Bending ............................................................................................................ 23
2.6
Welding and NDT ...................................................................................................... 24
2.6.1
Scope ....................................................................................................................... 24
2.6.2
Off-Plot Pipelines ...................................................................................................... 24
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Pipeline Construction Specification
2.6.3
2.7
Version 3.0
On-Plot Pipework ..................................................................................................... 25
Anti-Corrosion Field Joint Coating............................................................................. 25
2.7.1
Scope ....................................................................................................................... 25
2.7.2
Materials ................................................................................................................... 25
2.7.3
Surface Preparation ................................................................................................. 26
2.7.4
Shrink Sleeve Application ......................................................................................... 26
2.7.5
Coating Repairs........................................................................................................ 27
2.7.6
Testing, Inspection and Acceptance......................................................................... 27
2.8
Lowering-In, Backfilling and Reinstatement .............................................................. 29
2.8.1
Scope ....................................................................................................................... 29
2.8.2
Pre-Padding ............................................................................................................. 29
2.8.3
Lowering-in and Post-Padding ................................................................................. 29
2.8.4
Tie-ins....................................................................................................................... 30
2.8.5
Backfilling ................................................................................................................. 30
2.8.6
Stabilising Sand Areas ............................................................................................. 31
2.8.7
Livestock Passageways ........................................................................................... 31
2.8.8
Reinstatement .......................................................................................................... 31
2.9
Road and Wadi Crossings ......................................................................................... 32
2.9.1
Scope ....................................................................................................................... 32
2.9.2
Road Crossings ........................................................................................................ 32
2.9.3
Wadi-Crossings ........................................................................................................ 33
2.10
Concrete Coating for Wadi Crossings ....................................................................... 34
2.10.1
Scope ....................................................................................................................... 34
2.10.2
General..................................................................................................................... 34
2.10.3
Concrete Materials ................................................................................................... 35
2.10.4
Application ................................................................................................................ 35
2.10.5
Curing ....................................................................................................................... 37
2.10.6
Inspection and Testing ............................................................................................. 37
2.10.7
Concrete Coating Repairs ........................................................................................ 38
2.11
Permanent Markers and Barriers .............................................................................. 38
2.11.1
Scope ....................................................................................................................... 38
2.11.2
General..................................................................................................................... 39
2.11.3
Chainage Markers .................................................................................................... 39
2.11.4
Block Valve Station Markers..................................................................................... 39
2.11.5
Road Crossing Markers ............................................................................................ 39
2.11.6
Wadi Crossing Markers ............................................................................................ 39
2.11.7
Pipeline Crossing Markers........................................................................................ 39
2.11.8
Cable Crossing Markers ........................................................................................... 39
2.11.9
Markers at Horizontal Bends .................................................................................... 39
2.11.10
Cathodic Protection Markers .................................................................................... 39
2.11.11
R.O.W. `STOP` Signs............................................................................................... 40
2.11.12
Corrosion Monitoring Pit Marker ............................................................................... 40
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Pipeline Construction Specification
2.11.13
2.12
Version 3.0
Access Barriers ........................................................................................................ 40
Station Works ............................................................................................................ 40
2.12.1
Scope ....................................................................................................................... 40
2.12.2
Earthworks ............................................................................................................... 41
2.12.3
Civil and Mechanical Works ..................................................................................... 41
2.12.4
Painting .................................................................................................................... 42
2.12.5
Instrumentation......................................................................................................... 43
2.12.6
Electrical Works........................................................................................................ 43
2.12.7
Fencing..................................................................................................................... 43
2.13
Cathodic Protection ................................................................................................... 43
2.13.1
Impressed Current Cathodic Protection ................................................................... 43
2.13.2
Materials ................................................................................................................... 43
2.13.3
Installation ................................................................................................................ 44
2.13.4
Temporary Cathodic Protection ................................................................................ 44
2.13.5
DCVG Survey ........................................................................................................... 45
2.13.6
Commissioning ......................................................................................................... 45
2.14
Quality and Treatment of Hydrotesting Water ........................................................... 45
2.15
Hydrostatic Testing .................................................................................................... 45
2.16
Precommissioning Of Pipelines ................................................................................. 45
2.16.1
Scope ....................................................................................................................... 45
2.16.2
General..................................................................................................................... 45
2.17
Work on Live Pipe Systems ...................................................................................... 46
2.17.1
Scope ....................................................................................................................... 46
2.17.2
General..................................................................................................................... 46
2.18
As-Built Records and Hand-Over Documentation ..................................................... 46
2.18.1
Scope ....................................................................................................................... 46
2.18.2
Storage Format ........................................................................................................ 47
2.18.3
Storage Location ...................................................................................................... 47
2.18.4
Pipeline As-Built Documentation .............................................................................. 47
2.18.5
Documents ............................................................................................................... 47
2.18.6
Test, Calibration and Inspection Reports.................................................................. 48
2.18.7
Material Certificates .................................................................................................. 48
2.18.8
As-built Drawings and Pipeline Data Sheets ............................................................ 48
2.19
Effective Period ......................................................................................................... 49
2.20
Review and Improvement .......................................................................................... 49
Appendix A
Glossary of Definitions, Terms and Abbreviations ....................................... 50
Appendix B
Reference Documents .................................................................................. 51
Appendix C: Facilities For Company Personnel ..................................................................... 55
Appendix D:
List of Handover and As-built Documentation .............................................. 58
Appendix E
List of Typical Drawings for Pipeline Construction ....................................... 65
Appendix F
CONSTRUCTION REQUIREMENTS FOR GRE PIPELINES ..................... 83
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User Comment Form .............................................................................................................. 92
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Pipeline Construction Specification
1
Introduction
1.1
Purpose
Version 3.0
This document shall be used as the base specification for construction of all new carbon steel
and GRE pipelines required in PDO operations. Hydrostatic testing and Pre-commissioning of
new pipelines are covered separately in SP-1212 and DEP 31.40.50.30 respectively.
Appendix – F of this specification specifies requirements for construction of GRE pipelines.
1.2
Changes to the Specification
This specification shall not be changed without approval from the Custodian (UIP, CFDH
Pipelines), who owns this specification. If you think any part of this specification is not correct,
write your comments on a copy of the User Comments Form. The form is included as the last
page of this specification.
1.3
Conflicting Requirements
In case of conflicting requirements between documents relating to an inquiry or order, the
following priority of documents shall apply:
1.4
-
Contractual Scope of Work, Purchase Orders and Variations thereto.
-
Project Specification and Requisition Sheets.
-
This document and PDO/Group standards referred to in this document.
-
International Standards and Specifications referred to in this document.
Exceptions
The user shall obtain written approval prior to construction from the appropriate Technical
Authority within PDO for any deviation from or exception to the requirements of this Standard.
The appropriate technical authorities are set out in SP-2061.
Any work completed with unauthorised modifications may be rejected by the Company. Any
subsequent re-work shall be in accordance with this specification and shall be to the
Contractor’s expense.
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2
Version 3.0
Specification Requirements
2.1
Health, Safety and Environment (HSE)
2.1.1
Scope
This Section of the Specification covers the minimum HSE requirements required during
installation work.
2.1.2
General
The Contractor shall comply in all respects with all HSE Specifications listed in C-6 and C-9
documents of the Contract, paying particular attention to: The requirements for construction
and lifting equipment in CP-189, SP-1251, PR-1708 and PR-1709; the specification for
Aqueous Effluents SP-1006; SP-2000 “Road Transport” and GU-140.
As part of Contractor’s mobilisation, Contractor shall submit and obtain Company’s approval
for the HSE Plans and Procedures for the Work, prior to any Work commencing.
2.1.3
HSE Advisor
Contractor shall appoint one or more HSE Advisors, to be approved by the Company,
reporting directly to the Contractor’s Project Manager.
The HSE Advisor shall be fully conversant with the Work and shall have previous experience
and qualifications as specified in the HSE Regulations. Details of qualifications and
experience of the HSE Advisor(s) proposed by the Contractor shall be submitted to the
Company for approval before mobilisation of the HSE Advisor(s).
The responsibility of the HSE Advisor(s) is to ensure that all Contractor’s work and conditions
are in accordance with the Company’s HSE Regulations.
The Contractor’s HSE Advisor(s) shall make daily reports about all accidents, unsafe acts,
unsafe situations etc. noticed by himself or brought to his attention. The daily report shall be
transmitted to Contractor’s Project Manager on each morning following the reported day. A
copy shall be handed to the Company’s Site Engineer. The daily report is in addition to those
required by the Safety Regulations. Contractor’s Project Manager shall advise the Company’s
Site Engineer in writing within 24 hrs of the report being issued, what action has been taken to
prevent re-occurrence of any incidents reported.
The HSE Advisor(s) shall carry out his work from the moment the Contractor starts
mobilisation and until the date of completion.
Contractor shall provide a dedicated vehicle with VHF radio, for the sole use of the HSE
Advisor(s), for communications with Contractor’s Construction camp/head office.
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Pipeline Construction Specification
2.1.4
Version 3.0
Specific Pipeline Activities
Contractor shall specifically instruct all personnel of the dangers relating to the internal
inspection of pipelines. Only under special circumstances shall anyone be allowed to enter a
pipeline, and only after a specific procedure has been agreed and approved by the Company.
During construction of pipelines, the working strip shall be marked with road traffic signs and
specific warning signs relating to the construction activities. This applies particularly to road
crossings.
Generic pipeline construction hazards are identified in the Company’s Pipeline Construction
HSE Case. The Contractor shall make use of the information contained in the Pipeline
Construction HSE Case to identify and control HSE risks specific to the Work. Any additional
hazards identified through the HEMP process shall be advised to the Company for
incorporation in future issues of the Pipeline Construction HSE Case.
2.2
Quality Assurance
2.2.1
Scope
This Section of the Specification and SP-1171 “Specification for Quality Assurance of Design,
Construction and Engineering Works” covers the minimum requirements of Quality Assurance
required for the Work.
2.2.2
General
Before starting the Work, Contractor shall submit his proposed quality assurance procedures
and organisation to the Company for Company’s approval. Contractor’s proposed plan shall
include the internal procedures to report non conformances, how corrective action requests
are to be generated and how it will be demonstrated that such actions have been carried out
and are effective.
2.2.3
Quality Assurance Team
It is the duty of the Quality Assurance Team to ensure that the Work is carried out in
accordance with this Specification and other Contract Specifications. The Contractor shall
have a full time Quality Assurance Team and all necessary equipment at the Work Site. The
Team shall have no other work or responsibilities apart from Quality Assurance.
The Quality Assurance Team should as a minimum consist of:
One Contractor’s Quality Assurance Engineer responsible for procedure preparation and
implementation, drawing and document control and supervision.
Required number of Contractor’s Inspectors (depending on contract size and geographical
spread of the work sites) to cover welding/jointing, NDT, joint coating/painting, sand padding,
lowering, backfilling, tie-ins, hydro testing and pre commissioning activities.
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Pipeline Construction Specification
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Quality Inspector’s duties include but not limited to the following activities:
2.2.3.1
-
incoming materials inspection and acceptance
-
materials certification
-
traceability of materials
-
check pot life of adhesives (GRE pipelines)
-
welding / jointing procedures as the case may be
-
field welding / jointing
-
NDT procedures (CS pipelines)
-
identification numbering systems
-
shrink sleeve application (CS pipelines)
-
trench depth
-
sand padding
-
lowering in
-
post padding / plugging
-
backfilling
-
painting/coating (CS pipework)
-
as-built drawings
-
reports and general documentation
-
document control
Personnel
The Head of Quality Assurance shall have a detailed knowledge of welding and NDT and
other activities of pipeline construction. He shall have experience in quality assurance matters
and be suitably qualified.
All Contractor’s inspectors shall be fully conversant with and experienced in the aspects of the
Work for which they will be employed. They shall have previously worked on similar projects
in similar capacities. All Contractor inspectors shall be suitably qualified and a copy of all
qualification certificates relevant to the inspection function for which they are proposed by the
Contractor and shall be submitted for Company approval before mobilisation of the
Inspectors. All Contractor’s inspectors shall have a dedicated vehicle.
Following Company’s approval and the arrival of the Inspectors on site, Company has the
right to request all Inspectors to an examination to ensure their suitability for the work they are
required to do, and reject any Inspector who is found unsuitable, at the Company’s sole
discretion.
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Pipeline Construction Specification
2.2.3.2
Version 3.0
Organisation
The Head of Quality Assurance shall report directly to the Contractor’s Project Manager. His
duties shall be to liaise with the Company, organise the Contractor’s Inspectors so that they
carry out their duties in an efficient manner, and prepare all necessary reports. The Head of
Quality Assurance shall not carry out inspection work himself other than in supervision of the
Contractor’s Inspectors.
Contractor’s NDT supervisors and shrink sleeves manufacturers representative shall report
directly to the Head of Quality Assurance on quality assurance matters.
The Quality Assurance organisation shall be similar to that shown in Figure 1.
2.2.4
Company Inspection
Company will employ a team of Inspectors throughout the contract period, to monitor all work
activities including safety aspects. These Company Inspectors are hereafter referred to as the
Inspectors.
The Inspectors will have authority to stop the work in the case of unsafe situations and noncompliance with the HSE Specifications, as well as documented non compliance with agreed
installation or quality procedures which could impact on the future safety of the pipeline during
hydro testing or in service.
Interpretation of weld radiographs shall be performed by Contractor’s Specialist sub
Contractor and the Inspectors independently, in accordance with the NDT flowchart included
in the Procedures. Non-compliance certificates and other forms are also to be included in the
Procedures.
The inspectors will report non-compliances with this specification and other contract
standards to the CSR, who will advise the Contractor formally of any required corrective
action.
COASTAL BASED
PROJECT MANAGER
SITE CONSTRUCTION
MANAGER
FIELD JOINT COATING
REPRESENTATIVE
HEAD QUALITY
ASSURANCE
CONTRACTOR’S
INSPECTOR
NDT SUB-CONTRACTOR
Figure 1 Quality Assurance Organisation
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Pipeline Construction Specification
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2.3
Materials Handling and Control
2.3.1
Scope
This Section of the Specification covers the minimum requirements for handling, storage and
administration of all materials, either Company or Contractor supplied, to be incorporated in
the Work.
2.3.2
General
2.3.2.1
Handling, including but not necessarily limited to receipt, checking, lifting, loading, transport,
unloading, stacking, and storage of materials shall be carried out by the Contractor in such a
manner as to avoid harm to personnel and any damage and loss of materials. Method and
means of transport and handling (including documentation) shall be subject to approval by the
Company.
2.3.2.2
Contractor’s material control and storage procedure shall be submitted to the Company within
two weeks of the start of mobilisation on site, for approval.
2.3.2.3
Contractor shall give the Company at least 24 hours notice in writing on each occasion when
he intends to start transporting Company supplied materials. A lapse greater than 24 hours
shall require re-notification. Pipe can be removed from Company’s yard 7 days per week
during daylight hours, unless otherwise specified by the Company. Contractor shall provide
the Company with a written confirmation of receipt of all materials (identified by type and
quantity) and a written reconciliation of all materials (identified by type and quality)
transported by them from Company’s storage yard on a weekly basis.
2.3.2.4
Contractor is required to supply lifting equipment for lifting materials at all locations. Lifting
equipment and operations shall be in accordance with CP-189.
2.3.2.5
Contractor shall appoint a dedicated site-based materials Controller whose sole function shall
be to control and report on the receipt, issue, and stock status of the Contractor and
Company supplied materials.
2.3.2.6
Contractor shall not be held responsible for manufacturing defects in Company supplied
materials, but shall be held responsible for any delays to the Work caused by Contractors
failure to report defects discovered during inspection by the Contractor within 24 hours of
such inspection.
2.3.2.7
Contractor’s procedures for material receipt and return of surplus materials shall conform to
Company’s materials procurement/administration procedures.
2.3.3
Pipe Inspection
2.3.3.1
The Contractor shall visually inspect at the Company storage yards, all pipes internally and
externally for damages, surface defects and defective bevels. The Contractor shall satisfy
himself at this stage of the suitability of each pipe for welding and shall accept all
responsibility thereafter for all damages however caused.
2.3.3.2
Prior to haulage of pipe from Company’s storage yard, Company and Contractor shall carry
out a joint survey of pipe coating damage and bevel damages. On the basis of this survey,
Company will pay the Contractor a lump sum for repair of all bevel and coating damage,
based on the submitted unit rates in the Schedule of Rates, in accordance with this
specification. For bevel damages between 1 and 3 mm deep, the repair shall be by grinding.
For bevel damage depth greater than 3 mm, the repair shall be by re-bevelling.
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2.3.4
Version 3.0
Pipe Handling
2.3.4.1
Pipe shall not be allowed to drop or strike objects which may damage the pipe and/or coating
but shall be lifted, moved and lowered from one position to another by suitable equipment.
When lifting pipe, non-abrasive wide nylon pipe slings or special lifting hooks equipped with a
non-metallic bevel protectors curved to fit the curvature of the inside of the pipe shall be used.
Temporary attachments for handling or lifting shall not be welded to any pipe. A spreader bar
shall be used for all bulk pipe lifting/handling (excluding welding operations).
2.3.4.2
Trucks used to transport coated or bare pipes shall be free of any materials that might
damage or contribute to movement of the pipe during transport. Pipes shall be protected
against truck beds and side metallic posts by means of non-metallic soft materials. Pipes shall
be loaded and stacked on trucks in such a manner that flexing and shifting of the pipe during
transport is avoided. After loading, suitable non-metallic slings shall be used to tie the pipes
securely to the truck. During transport the tension of these slings shall be regularly checked.
Pipe ends shall be protected from contact with other metallic materials. Contractor shall
ensure that no bevel protectors are lost during transport. Pipes shall only be transported on
trucks (lifting equipment shall not be used to transport pipe).
2.3.4.3
Trucks used for loading of pipes will be checked by the Company prior to lifting the pipes to
ensure that the trucks and loading/load securing arrangements comply with the requirements
of PDO’s Transport Manual TOM/04/001, SP-2000 ‘Road Transport’ and government
regulations.
2.3.5
Pipe Stacking
2.3.5.1
Ground surfaces to be used for stacking of pipe shall be reasonably flat. Stacked pipes shall
be raised above ground surfaces and prevented from movement by berms of screened sand
covered by polyethylene sheeting or by using timber covered with non-metallic soft materials.
When stacked, the bottom layer of pipes shall be wedged or clipped. Pipes of different
diameter, wall thickness, grade or manufacturer shall be stacked separately. Each stack shall
be properly marked to the satisfaction of the Company. It is advisable to stack CS pipes in
the East-West direction to avoid natural magnitization due to North-South magnentic polarity.
2.3.5.2
Epoxy-coated pipes shall be stacked during transport and storage using rubber or other
suitable separator strips.
2.3.5.3
Pipes shall not be stacked higher than 3.5 metres. Pipes shall be stacked in such a way that
no water is retained inside the pipe during storage.
2.3.6
Linepipe Specifications
2.3.6.1
Line-pipe shall be manufactured in accordance to DEP 31.40.20.35 and DEP 31.40.20.37 for
non critical and critical services respectively. These specify amendments/supplements to ISO
3183 Specification.
2.3.6.2
Minimum average pipe length shall be 11.50m as per above DEP. The minimum and
maximum length of pipe shall be between 9m and 18m long.
2.3.6.3
Linepipes if required, shall be provided with a factory-applied polyethylene / polypropylene
coating. Each polyethylene / polypropylene coated pipe shall be left bare for a distance of 150
± 20 mm from each end. 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.
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Pipeline Construction Specification
2.3.7
Version 3.0
Inspection of Materials other than Pipe
2.3.7.1
Upon receipt of any materials, the Contractor shall ensure that they conform to the required
specification and are suitable for their intended application. Any damage/defects shall be
reported to the Company within 24 hours of receipt of these materials and prior to
transportation to the Contractor’s own storage yard. Visual inspection shall be adequate for
this purpose.
2.3.7.2
In the case of materials delivered in their original sealed crates, Contractor shall only open the
crates to examine the materials upon arrival at his own storage yard, except in the case of
damaged crates which shall be noted and the contents examined when Contractor takes
receipt at Company’s storage yard.
2.3.7.3
If no report is issued for damaged materials 24 hours after receipt (or in the case of 2.3.7.2
above, 24 hours after arrival of materials at the Contractors storage yard), then the materials
shall be considered free from damage and the Contractor shall be considered liable for any
damage reported or found at a later date.
2.3.8
2.3.8.1
Handling of Materials other than Pipe
Materials other than pipe materials such as, but not limited to, valves, fittings, scraper traps
etc., shall be lifted by suitable equipment provided by the Contractor at Company’s storage
yard and at all other locations. When lifting lugs are provided on materials, suitable lifting
hooks shall be used for lifting the materials. It is prohibited to use delicate parts such as hand
wheels, nozzles, etc. for lifting of the materials.
Temporary attachments for handling or lifting shall not be welded to any materials. Fittings
shall only be handled by suitable non-abrasive slings.
2.3.8.2
Materials other than pipe materials will be issued to the Contractor whenever possible in their
original sealed shipping cases/crates. Blinded openings of materials shall be kept closed until
installation. The blinds shall be replaced by the Contractor in case of damage during transport
or storage.
2.3.8.3
During transport, materials shall be secured by suitable non-metallic non-abrasive slings.
2.3.8.4
For materials which shall be stored cool and/or dry as required by the manufacturer or the
Specifications, Contractor shall provide suitable storage, transport and handling facilities in
accordance with the requirements of the manufacturer and/or the Specifications.
2.3.8.5
Contractor shall provide a separate fenced storage area for Company supplied materials.
Stored materials shall be protected from ground surfaces by using timber covered with nonmetallic soft materials. Ground surfaces in storage areas shall be clean and flat. It is
prohibited to store and transport fragile materials in more than one layer.
2.3.8.6
Distribution and supply of materials from Contractor’s storage yard to the worksites shall be
limited to quantities required for approximately one day’s production. Timing of the issue of
materials shall be as per the Company approved work schedule.
2.3.9
Reconciliation
2.3.9.1
At the end of the project, Contractor shall give reconciliation for all Company supplied
materials issued, detailing materials installed, materials wasted and scrapped, and surplus
materials. Contractor shall compile a list of the surplus materials, indicating quantity,
description and MESC / SAP number when available.
2.3.9.2
On approval of the surplus list by the Company, Contractor shall return all surplus materials to
Company’s storage yard.
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Pipeline Construction Specification
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2.4
R.O.W. and Trenching
2.4.1
Pipeline Right-of-Way and Working Strip
2.4.1.1
Scope
This Section of the Specification covers the minimum requirements for the Pipeline Right-ofWay (ROW) and the Working Strip.
2.4.1.2
Survey
The Company shall survey the route for the pipeline and prepare route maps from which the
centreline of the pipeline shall be staked out.
The actual centreline of the pipeline can in some instances deviate from the line staked e.g. at
station approaches. This should be taken into account where the word `centreline` is used in
the remainder of this Section.
The construction survey shall adopt the same marks and benchmarks as used in the
Engineering design unless otherwise approved by the Company.
2.4.1.3
ROW Width
The Right-of-Way for the pipeline is a corridor of 50 metres overall width and comprises:
The “Restricted Area”, a strip of land 25 meters wide on either side of the pipeline measured
from the centre line of the pipeline.
Where two or more pipelines are laid in parallel in the same corridor, the Right Of Way
corridor shall be enlarged by the space between the pipelines. The space between two
pipelines shall not be less than 2 meters from the existing or new pipeline.
Contractor may make use of a Working Strip, having a width of 31 metres (including a
continuous 6 metre wide vehicle access strip) from one edge of the Restricted Area.
Variations, if any, in this width caused by local conditions will be indicated on the drawings or
instructed to Contractor by the Company.
2.4.1.4
Planning/Approvals
Contractor shall, before starting any clearing operations, familiarise himself with any
requirements by the Authorities for work along the pipeline route or in connection with the use
of other lands or roads for construction purposes.
Contractor shall notify the Company 7 days in advance before start of work at road, pipeline,
cable, stream, river and wadi crossings and crossings of other existing structures, if any.
Contractor shall not commence work on such crossings before having obtained approval from
the Authorities and landowners concerned.
The crossings shall be installed to meet all requirements and conditions of the permits, issued
by the Authorities concerned.
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In the absence of any specific requirements by the Authorities, Contractor shall comply with
the Company’s instructions.
Where the pipeline is laid close to any existing buried or above ground pipeline, flowline and
utility cables, the Contractor shall propose methods to safeguard the existing line (e.g. a
demarcation fence). No work is allowed in such an area without Company approval. Work
near live pipelines shall comply with the requirements of GU-501, ‘Guidelines for Excavating
and Working around Live Pipelines’ and paragraph 2.4.3.2–f) of this specification.
2.4.2
2.4.2.1
Staking, Clearing and Grading
Scope
This Section of the Specification covers the minimum requirements for staking, clearing and
grading along the pipeline route as required for the Work.
Company will have obtained ‘approval in principle’ for laying the pipelines along the routes.
Contractor however will have to obtain permission from the concerned Authorities to execute
the work.
2.4.2.2
2.4.2.3
Definitions
a)
‘Clearing’ shall mean but is not necessarily limited to the cutting and disposal of
trees, farm crops, bushes and undergrowth.
b)
‘Grading’ shall mean but is not necessarily limited to removal and disposal of
rock, sand dunes, tree stumps and roots.
c)
‘Point of Intersection’ shall mean a point in which the centreline of the straight
sections of the pipeline route changes direction in the horizontal plane. In
general such a point will be outside the actual pipeline centreline because of
the bending radius to be applied.
Staking
a)
b)
SP-1208
The centreline of the pipeline shall be staked by the Contractor with markers
inter visible by binoculars or theolodite.
i)
Markers are located at the centreline of the pipeline where straight.
Reference markers are established at the Points of Intersection,
perpendicular to the previous pipeline direction, at 25 metre steps from
the pipeline centreline.
ii)
The markers are angle-iron profiles or wooden posts with sequential
numbers, starting with no. 1 at start point of the pipeline. Reference
markers are marked with the letter ‘A’ or ‘B’. All markers extend
approximately 500 mm above grade. The ‘A’ and ‘B’ markers are located
at the same side of the centreline marker, ‘A’ being closest to the pipeline
centreline.
Prior to the clearing operations Contractor shall stake:
i)
Markers in the centreline of the pipeline at distances of maximum 100
metres for straight line sections and maximum 10 metres for horizontal
bends, but in any case not less than one at the centre of every bend.
ii)
Two construction markers shall be installed at every existing marker
location or at least every 500 metres except where these have already
been provided at Points of Intersection. Construction markers and
existing markers are to be in one line, perpendicular to the pipeline route.
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The distance from construction marker to pipeline centreline shall be 25
metres wherever possible. Construction markers shall be painted red with
numbers painted in white. These shall be identical to existing marker
numbers with letters A (left-side) and B (right-side) added, (looking in
direction of construction). All construction markers shall be angle iron
profiles (min. 60 x 60 mm). Each marker shall be erected sturdily enough
to perform its purpose during the construction of the Work.
2.4.2.4
c)
Contractor shall be responsible for the maintenance and replacement of the
construction reference markers until the permanent pipeline markers are
placed.
d)
The Contractor shall verify that the radius of curvature of the pipeline trench in
any plane is greater than the minimum allowable bending radius specified. Any
deviation from the routing as staked by the Company and/or indicated on the
route maps shall be approved by the Company prior to the clearing operations.
Below and Aboveground Services
SP-1208
a)
Existing cables, pipelines, tunnels, falaj, etc. if indicated on the drawings are for
information only. Company does not guarantee that the information shown on
the Drawings is either complete or correct. Contractor is entirely responsible for
detecting and locating all underground obstacles whether shown on the
drawings or not, using metal detectors, cable/pipe detectors and other suitable
equipment for detecting buried non-metallic infrastructure like GRE pipelines,
FO cables etc.
b)
Contractor shall take utmost care to mark all exposed obstacles to avoid any
possible damage throughout the performance of the Work and restore them to
their previous state if damage occurs.
c)
Trenching or other excavation near any underground services shall be by hand
only (refer to GU-501 for detail requirements).
d)
Contractor is entirely responsible for protecting all foreign services throughout
the Work. Contractor shall propose methods of temporary and, if necessary,
permanent support and backfilling for all foreign services encountered, to the
Company and the relevant Authority for their approval.
e)
Contractor shall furnish all angle iron and other support material required at
crossings of underground obstacles. Contractor shall furnish and install all tiles
and tile supports to replace existing damaged ones encountered in the course
of the Work. Telephone, telegraph or electric power cables or foreign piping
encountered in the pipeline trench shall be supported prior to sand padding and
backfilling by a Company approved method.
f)
Contractor shall contact the local Electricity Authority to determine the minimum
safe clearances allowed underneath overhead power lines at each point where
these cross the Working Strip or access roads. Contractor shall then erect goal
posts at the agreed height on each side of any overhead lines which cross the
Working Strip or any access roads to it which will be used by the Contractor.
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2.4.2.5
2.4.2.6
Version 3.0
g)
Contractor shall liaise closely with relevant Authorities and give adequate
notice to them of trench excavation, and subsequently backfilling, in the vicinity
of all underground services to allow such Authorities to inspect and witness
such excavation and backfilling should they required to do so.
h)
Contractor shall repair without delay any ‘falaj’ (gravity water transport system)
damaged during the performance of the Work and restore it to the same state
as before the damage occurred.
i)
Line and cable marking posts, tiles, etc. shall be replaced by the Contractor in
the correct position.
j)
Where it is necessary for the Contractor to construct a temporary ROW
crossing over an existing service, Contractor shall hand-dig to expose the
service and verify cover. Contractor shall submit proposals for Company
approval of all ROW crossings. Surface flow line crossings shall be made by
ramping over in accordance with the Standard Drawing TYP 3 0005-001 in
Appendix E.
k)
Crossings of major pipelines may require special precautions against damage
by equipments and vehicles. As a minimum, the cover to the existing pipeline
shall be 1.5m, achieved if necessary by temporary ramping or installation of
slabs. Stresses imposed on the pipeline shall be evaluated in accordance with
API 1102 standard. The windrow and any marker posts shall be reinstated after
construction.
Clearing the Working Strip
a)
The Working Strip shall be cleared over its entire width, unless restricted by the
terrain or other features shown on the drawings. Contractor shall carry out all
operations within the limits of the Working Strip and shall not operate within 25
meters from existing pipe lines without Company approval.
b)
Holes remaining, after stumps have been pulled from the ground, shall be filled
with suitable fill material and compacted.
c)
Contractor shall protect all shrines and monuments, including border stones. If
it is necessary to remove a number of these items for safekeeping, the
Contractor shall contact the responsible persons concerned and conform to
their requirements.
d)
Where blasting is considered necessary, the Contractor is to comply with the
Sections of the General and Special Conditions and this Specification (ref.
2.4.3.3 Blasting).
Explosives (not used for blasting as part of the construction work)
In the event, the Contractor finds explosives in or along the Working Strip the Contractor shall
notify the Company and the appropriate Authority without delay. Contractor shall be
responsible for making all necessary arrangements to have the explosives removed by a
specialist approved by the controlling Authorities.
SP-1208
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Pipeline Construction Specification
2.4.2.7
2.4.3
2.4.3.1
2.4.3.2
Version 3.0
Grading the Working Strip
a)
Contractor shall grade off high points and fill low points to allow the pipe to be
bent and laid within the limits set forth herein with due regard to the minimum
radius of bends allowed and shall drill, blast, and excavate rock or other
material which cannot be graded off with ordinary grading equipment in order to
provide an adequate working space along the pipeline route. Contractor shall in
general be required to grade the whole of the Working Strip, but a narrower
width may be allowed by the Company, depending on ground conditions.
b)
Contractor shall perform all necessary grading at road or wadi crossings and at
any other location, required to permit the passage of construction equipment.
Contractor shall bridge over or ford through ditches, wadis and small streams
so as not to interfere with or cause pollution of the water flow and to avoid
damage to stream banks. Contractor shall be responsible for moving all
personnel, equipment and materials across or around all crossings, which may
require the construction of temporary bridges. No ditches, wadis or drains shall
be filled, bridged or otherwise obstructed without written approval of the
Company and/or the Authorities having effective control over such
watercourses.
c)
In rough or steep terrain, Contractor may wish to grade access roads into the
Working strip to facilitate moving in materials, personnel and construction
equipment. Where such roads are required by the Contractor he shall obtain
the necessary permission in writing from the Authorities concerned and shall
furnish the Company with a copy of such permission, prior to commencing any
work on roads. Contractor shall be responsible for and make good, all damage
caused by the construction and use of such roads.
d)
Contractor shall only obtain access to the Working Strip from existing road
where such roads cross the Working Strip, or via access roads constructed by
the Contractor between existing roads and the Working Strip at all other
locations. Such access roads shall be agreed with the Company prior to
commencement of Right-of-Way preparation, and shall be sign posted. Existing
pipeline ROW shall not be used for access to the Working Strip.
Trenching
Scope
a)
This Section of the Specification covers the minimum requirements for
trenching as required for the work.
b)
A banks man shall attend the operation of each unit of excavation equipment to
prevent personnel entering the field of work of such equipment.
Excavation
SP-1208
a)
Contractor shall excavate the pipeline trench on the staked centreline of the
pipeline.
b)
Contractor shall keep trenching operations ahead of bending and stringing
operations, but at a maximum distance of 15000 metres ahead of backfilling
operations at each spread.
c)
The trench shall be excavated so as to provide a minimum depth of cover as
specified in the table below, unless specified otherwise in the Contract scope of
work or drawings.
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Pipeline Construction Specification
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MINIMUM COVER (M)
LOCATION CLASS (as defined in ASME
B 31.8)
Location Class 1
SP-1208
IN NORMAL
GROUND
0.80
IN ROCK, REQUIRING
BLASTING OR ROCK
CUTTING
0.50
Location Class 2
0.90
0.60
Location Class 3 and 4
1.20
0.90
Roads, Wadi, and live stock passageways
1.50
1.50
I.
For pipelines transporting category A and B fluids, the minimum cover
to the pipeline shall meet the requirements of Location Class 1 above.
II.
Minimum depth of cover shall be measured from the top of the pipe to
the top of the undisturbed surface of the soil or top of graded Working
Strip which ever is smallest. Fill material in Working Strip shall not be
considered to add to the depth of cover. However, surface of fill
material placed to fill low points to accommodate pipe bending
limitations may be used to determine depth of cover subject to approval
by the Company of detailed location-specific design drawings including
soil stabilisation measures such as rip-rap or gabions.
III.
ii) The minimum depth of cover at crossing of wadis, drainage ditches,
tarmac and graded roads, tracks and live stock crossings, whether or
not indicated on the route maps, shall be measured from the bottom of
wadis, ditches or from the top of roads and tracks as the case may be.
This depth shall be extended 5m outside the edge of the road, track,
wadi, ditch, etc. measured perpendicular to its axis.
d)
Contractor shall excavate and grade the trench sufficiently deep and wide to
provide space for 150 mm of padding material after compaction all around the
pipe and for the continuous length of the pipeline.
e)
The trench bottom and sides shall be kept free of all brush, skids, pipe
protectors, rocks, large clods, sticks, projecting rocks and other hard objects at
all times. Any such items encountered shall be removed prior to pre-padding
operations so that the pipe is not damaged, punctured or abraded.
f)
Where the pipeline crossed other pipelines, sewers, water lines, cables,
conduits or other underground structures of any kind, Contractor shall excavate
and grade the trench to a depth in such a manner that the top of the pipeline
will be at a minimum of 500 mm below the bottom of the underground structure
crossed, subject to compliance with the minimum specified bending radius of
the pipe. If clearance of more than 500 mm is required by the Authorities
having jurisdiction, Contractor shall provide such increased clearance. The
construction over or under all existing structures such as roads, water lines,
telephone lines, and other pipelines shall be the responsibility of Contractor. In
the event that the pipeline crosses over existing structures, the same clearance
as described above shall be maintained and depth of cover as per paragraph
(c) above. For crossings of buried live pipelines, the requirements of GU-501
shall apply.
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Pipeline Construction Specification
2.4.3.3
Version 3.0
g)
In locations where the trench is cut across roads, tracks, paths, walkways, etc.
Contractor shall provide temporary bridges or diversion road of adequate
strength and properly constructed to allow the passage of normal traffic with a
minimum of inconvenience and interruption. Whenever it is permissible to open
cut a road, Contractor shall remove and restore the surface in accordance with
the requirements of the Authorities having jurisdiction thereof or as directed by
the Company. Wherever possible, Contractor shall arrange to complete the
trenching, laying and backfilling of such crossings and to remove the temporary
bridging before the end of the regular work day in order to minimise hazard to
night traffic. Proper warning signals shall be placed and maintained while such
crossings are open. If the crossings are open at night, Contractor shall provide
and use warning lights or lanterns, all as required and approved by the
Authorities having jurisdiction and/or the Company.
h)
Contractor shall provide and use sheet piles, struts, walling, jacks, pumps etc.,
as required to maintain the trench in good condition until the pipe is laid in
place and backfilled.
i)
Contractor shall do hand work in the trench as is necessary to free the bottom
of the trench of loose rock and stones, and all other irregularities so as to leave
the trench bottom in a clean and suitable condition to receive the pipe.
j)
If Contractor elects to carry out a rip survey, then the results of this survey shall
be made available to Company. The extent of rock encountered during
trenching shall be recorded on the as-built Alignment Sheets by the Contractor,
whether or not a rip survey is carried out.
Blasting
All activities including but not limited to storage, transportation of explosives and blasting shall
be carried out in accordance with the N.F.P.A. No. 495, BS 5607 and the instructions of the
Authorities and/or the requirements in this section, whichever are the most stringent.
Blasting shall be performed only by a specialist blasting contractor approved and registered
with the Company. A blasting procedure shall be submitted to the Company for review and
approval. The procedure shall detail the restrictions and special requirements for controlled
blasting to be applied when operating in the proximity of existing pipelines and structures, as
defined in clause b), following.
a)
A qualified blasting inspector may be appointed by the Company. If an
inspector is appointed, he will be present at all blasting operations to monitor
compliance with the approved blasting procedures.
b)
Areas to be blasted are categorised as follows:
i)
SP-1208
Where blasting is to be carried out at or more than 50 metres away from
any existing pipelines or structures (either above or below ground), the
Contractor shall submit his proposed blasting procedure and perform a
trial blast for Company approval.
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Pipeline Construction Specification
2.4.3.4
Version 3.0
ii)
Where blasting is to be carried out between 50 and 20 metres from any
existing pipeline or structure (either above or below ground), the
Contractor shall submit a procedure for controlled blasting, which shall
also detail safety precautions to safeguard existing pipelines or structures
(e.g. break holes, slit trenches, etc.). No trial blasting shall be performed
until the procedures are approved by the Company.
iii)
No blasting is allowed within 20 metres of any existing pipeline or
structure (either above or below ground).
c)
Blasting shall be carried out prior to stringing the pipes.
d)
Ground vibrations due to blasting within 50 m of existing structures shall be
continuously monitored with certified instruments to be provided by the
Contractor and approved by the Company. Peak particle velocities near
existing structures (e.g. pipelines running parallel) shall be kept to a minimum
and must be approved by the Company as part of the Contractors proposed
blasting procedure. In no case shall the peak particle velocity exceed 10
mm/sec.
e)
Blasting shall not be permitted in any location where possible danger exists to
the general public, property, existing utilities or other structures. In such
locations other methods of extracting rock shall be proposed by the Contractor
for approval by the Company.
Definition of Rock
For depth of cover purposes, rock in trench is defined as the rocky part of the specified trench
which cannot be removed by ditching machines, rock plough, back hoe or ripper, to be
decided after two passes of a D9 Caterpiller tractor (or one pass of a tandem D9) or equal,
equipped with proper ripping equipment.
2.4.3.5
Sloping Trenches
Trenches having a longitudinal slope of more than 10% shall be provided with structures or
retaining barrier(s) as specified on the drawing TYP 3 0015 001 provided in Appendix E of
this specification. No retaining barriers are required in areas of sand dunes.
2.4.3.6
Trench Width
In the case of a single pipeline to be laid in the trench, the trench width shall normally be
outside diameter of the pipe plus 300 mm (i.e. 150 mm on each side of the pipe) unless
otherwise approved by the Company (refer drawing TYP 3 0002 001). In the case of more
than one pipeline to be laid in common trench, the trench width shall normally be the sum of
the diameters of the pipes plus 300 mm (i.e. 150 mm on each side of the pipe) plus 500 mm
clearance between the outside edges of adjacent pipes unless otherwise approved by the
Company.
2.5
Stringing and Bending
2.5.1
Scope
This Section of the Specification covers the minimum requirements for stringing the line pipe
along the trench side and for cold bending of metallic pipe as required for the work.
SP-1208
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2.5.2
Version 3.0
Stringing
2.5.2.1
No pipe shall be strung before the trench is excavated to full depth and accepted by the
Company to meet the requirements of this Specification. Pipe shall not be placed directly on
the ground but on wooden skids with proper protective padding or sand bags as deemed
acceptable by Company. The skids and protective padding material shall be subject to
Company (CSR) approval. Dragging, skidding or dropping of the pipe is not permitted.
Wooden wedges shall be used to prevent movement of each strung pipe.
2.5.2.2
Where possible the skid elevations shall be planned such that minor differences between
grade profile and bottom of trench profile (e.g. at locations where an increased trench depth is
required) can be accommodated without requiring an additional tie-in. The distance between
the trench edge and the pipe string shall be planned such that safe working space is
provided.
2.5.2.3
Contractor shall be responsible for proper stringing and locating of the pipe by size, wall
thickness, specification and manufacturer. Company may supply line pipe from different
manufacturers. Contractor shall string all line pipe of one manufacturer before commencing
the stringing of line pipe supplied by the second manufacturer. Pipes of different
manufacturers shall not be mixed per line section without prior approval of the Company.
2.5.2.4
Contractor shall string the pipe in such a manner so as to cause no interference with public
roads, footpaths, tracks, etc. Suitable gaps shall be left at intervals as necessary to permit the
passage of live stock and/or equipment across the Right-of-Way and as directed by the
Company.
2.5.2.5
Contractor shall layout and measure the pipes such that, the number of pieces cut-off with
less than one metre length is kept to a minimum.
2.5.2.6
The length of pipe string shall be planned with due consideration of thermal expansion and
other expected or accidental movement of the pipe string. Special attention shall be paid to
strings with one or more bends, in view of the inherent increased risk of failure of skids due to
movements of the pipe. Length of individual pipe strings shall be subject to Company
approval and shall generally not exceed 1 km.
2.5.2.7
Pipe shall be strung with the use of a spreader bar and two guide lines. (See Section 2.3 for
requirements for slings and hooks).
2.5.3
Pipe Bending
2.5.3.1
Contractor shall make all necessary bends required for proper construction of the pipeline,
following a trigonometric survey to establish the number and degree of bends required, to
ensure that the installed pipe shall conform to the contours of the pre-padded trench.
2.5.3.2
Contractor shall, before the start of the Work, submit and demonstrate to the Company a
bending procedure, which shall conform to the recommendations of the manufacturer of the
bending machine. This procedure shall be subject to Company’s approval. The procedure
shall include amongst others, step length, degrees per pull and method and accuracy of
measurement during pulling of the bend.
2.5.3.3
Elastic bends with radius of curvature less than 500 x D, D being the pipeline diameter are not
allowed unless approved by the Company.
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Pipeline Construction Specification
2.5.3.4
Version 3.0
The radius of cold bends shall be not less than:
-
20 D for pipe OD of less than 200mm
-
30 D for pipe OD of 200mm to 400mm
-
40 D for pipe OD of over 400mm
The radius of hot bends shall not be less than:
-
Pipeline below DN150:
7D-10D
-
Pipeline DN150 to DN 250: 5D
-
Pipeline DN 300 and above: 3D
2.5.3.5
The cold bends shall be made by a smooth stretch bending machine. Bends with ripples with
a depth exceeding 0.5 mm, wrinkles and kinks are not acceptable. Contractor shall provide a
procedure for measuring ripples which shall be approved by the Company.
2.5.3.6
The pads, dies and rolls of the bending equipment shall have soft surfaces to avoid damage
to the pipe coating. Where applicable, fully retaining bending shoes shall be used. Roller type
bending machines are preferred. Bends in pipe of diameter 8" or greater shall be made by
using an internal (hydraulic or pneumatic) mandrel.
2.5.3.7
All bends shall be tested in the presence of the Company with a gauging plate of 97.5% of the
nominal internal diameter of the pipe prior to installation.
The longitudinal weld of the cold bend shall be located approximately within 10° from the
pipe’s neutral axis. The position of the longitudinal weld for successive pipe joints shall be
chosen such that the longitudinal welds are staggered and always occur in the top half of the
pipe (as specified in the welding specification).
2.5.3.8
The procedure for bending shall be such that the extremities of each joint remain straight over
a minimum distance of 2 m or twice the pipe diameter, whichever is greater. Contractor shall
lay out and measure the pipe for bending such that the length of off-cuts is kept to a
minimum.
2.6
Welding and NDT
2.6.1
Scope
This Section of the Specification covers the minimum requirements for the fabrication,
welding, and non-destructive testing of ‘on-plot’ piping and ‘off-plot’ pipelines for oil and gas
service, as required for the Work.
2.6.2
Off-Plot Pipelines
‘Off-Plot’ Pipelines are defined as all pipelines and pipe work covered by Codes ASME B31.4
or ASME B31.8 as specified in the drawings. This includes all pipeline work, block valve
stations and most parts of the pig trap stations.
The minimum requirements for welding are contained in Specification SP-1177 (for Class 1
Pipelines), SP-1174 (for Class 2 & 3 Pipelines) and SP-1097 (for Duplex Stainless Steel
Pipelines).
SP-1208
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Pipeline Construction Specification
2.6.3
Version 3.0
On-Plot Pipework
‘On-Plot’ Pipework is defined as all pipework and pipe runs covered by the code ASME B31.3
as specified in the drawings.
The minimum requirements are contained in Specification SP-1173.
2.7
Anti-Corrosion Field Joint Coating
2.7.1
Scope
This Section of the Specification covers the minimum requirements for the external field
coating of pipeline weld joints and repair of damaged coating. Painting of station pipework,
valves, fittings etc. is specified in Section 2.12, Station Works.
Line-pipe is supplied with mill applied anti-corrosion coating unless specifically stated to the
contrary in the contract Scope of Work. The type of field joint coating that can be applied shall
be compatible with and have good adhesion to the mill applied coating:
--
For Polyethylene (PE) / Polypropylene (PP) coated line pipe, the field joint
coating shall be by heat shrink sleeves.
Contractor shall supply all equipment including spares and skilled manpower required for pipe
cleaning, application of coating, coating repair in the field, and inspection and testing of the
same in accordance with this Specification and DEP 31.40.30.37-Gen.
2.7.2
Materials
2.7.2.1
Only materials supplied by Company approved manufacturers shall be used in the Work.
2.7.2.2
Contractor shall as a minimum follow manufacturer’s 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.
2.7.2.3
The materials, at time of application by the Contractor, shall not be older than the shelf life
stated by the manufacturers.
2.7.2.4
The coating materials shall be properly packed and clearly marked with:
2.7.2.5
-
The manufacturer’s name
-
Material qualification and identification
-
Batch number
-
Date of manufacture
-
Test certificates and test data
-
Storage temperatures
-
Material Safety Data Sheet
Coating materials shall be kept dry and stored as long as possible in the manufacturer’s
original packaging, not exposed to direct sunlight, and in accordance with manufacturer’s
instructions.
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Pipeline Construction Specification
2.7.2.6
2.7.3
2.7.3.1
Version 3.0
The list of Company approved wrap-around shrink sleeves is given in the Approved Vendors,
Manufacturers and Equipments (AVME) list of the company.
Surface Preparation
Prior to coating, the field joint area shall be blast cleaned. Surface preparation, including blast
cleaning, shall be carried out in accordance with SP-1246 and this specification.
Any weld spatter or sharp edges of the mill coating shall be removed by filing or light grinding
prior to blast cleaning. If the mill coating is disbonded along the edges, or if there is an
evidence of corrosion under the coating, the coating shall be cut-back until sound coating has
been obtained. Polyethylene coating shall be chamfered by torch and knife and F.B.E. coating
shall be feathered over a distance of 10-15 mm during grit blasting.
Abrasives for blast cleaning shall be certified in accordance with the relevant parts of ISO
11124 or ISO 11126. Certificates shall be maintained by the Contractor. The blasting nozzle
shall be fitted with a dead man’s handle so that the equipment will not operate unless the
handle is held.
2.7.3.2
The blast surface visual appearance shall conform to ISO 8501 grade Sa 2 1/2. Any field joint
not coated within 4 hours of grit blasting shall be reblasted prior to the application of the
coating.
2.7.3.3
The surface profile attained by the grit blasting shall conform to ISO 8503-2 and shall be 4075 microns peak to trough or as specified by field joint coating manufacturer.
2.7.3.4
The surface cleanliness shall conform to ISO 8502-1 to 4 and shall be such that the chloride
2
contamination is less than 20 mg/m .
2.7.3.5
Coating of the field joint shall not take place until the weld has been non-destructively tested
and approved by the Company.
2.7.4
Shrink Sleeve Application
2.7.4.1
Contractor shall propose the application procedure for Company approval. The application
procedure shall be in accordance with manufacturer’s instructions and the minimum
requirements specified below, whichever are the most stringent, and shall be demonstrated to
the Company prior to field application by means of a procedure qualification test joint.
2.7.4.2
The joint shall be heated to a temperature required by the procedure. Induction heaters, ring
burners or propane torches of a suitable type may be used for pipe diameters smaller than
16". Induction heaters shall be used for pipe diameters of 16" and larger where the pre-heat
temperature exceeds 100° C. In all other cases burners or torches may be used. Torches
may be used for tie-in welds at Company’s discretion. To check that the required preheat
temperatures have been achieved, a digital contact thermometer shall be used.
2.7.4.3
The sleeve shall be wrapped entirely around the joint. The closure patch shall be positioned
off to one side of the pipe. There shall be a minimum overlap of 50 mm onto the factory
applied coating.
2.7.4.4
The procedure for shrinking the sleeve shall ensure that all entrapped air is forced out at
either end using gloved hands and concave hand rollers. Special attention must be given to
the closure patch and overlapping areas.
2.7.4.5
The installed sleeve shall be left undisturbed for 4 hours or until the adhesive has been
solidified, whichever is the longer.
2.7.4.6
The sleeves shall be visually inspected for the following points:
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a) Adhesive extruded from the ends of the sleeve indicates proper application. The ends
of the sleeve shall be firmly bonded to the surface of the coated pipe.
b) There shall be no sign of punctures or pinholes. The external appearance of the
sleeves shall be smooth and without dimples.
2.7.5
Coating Repairs
2.7.5.1
Coating repairs shall be executed on all coating damage and imperfections detected visually
or by holiday testing.
2.7.5.2
The coating repair procedure and the required materials for this, including the installation of
repair sleeves when applicable, shall be in accordance with a procedure submitted by the
Contractor and approved by the Company.
2.7.5.3
The repair procedure for mill applied polyethylene / polypropylene coatings shall be selected
based on the criterion of magnitude of the damaged area, i.e.:
a)
for pinholes and damages with a diameter or width of 10 mm maximum, a
thermoplastic repair stick shall be used.
b)
for damages from 10 mm width to 100 mm diameter, a patch of thermoplastic
heat shrink materials shall be used.
c)
for damages with a greater diameter than 100 mm, a thermoplastic wraparound shrink sleeve shall be used.
d)
minor flaws of polyethylene / polypropylene coating may be smoothed down
using a torch and a hot iron.
Polyethylene / polypropylene coating repair materials shall as a minimum be in accordance
with DEP 31.40.30.31.
2.7.6
Testing, Inspection and Acceptance
2.7.6.1
The testing and inspection for acceptance of the coating system shall be carried out and
recorded by the Contractor as instructed and witnessed by Company’s representative. The
frequency of testing as specified herein may be altered by the Company at Company’s sole
discretion.
2.7.6.2
The cleanliness of the blast cleaned surfaces for every field joint shall be inspected and shall
be in accordance with ISO 8501 grade Sa 2 1/2. After the surface has been blast cleaned and
dusted off, a strip of transparent cellotape shall be applied to the surface, and subsequently
removed and examined for particle contamination. This shall be done on the first joint cleaned
each day, plus two more times during the day and when a new batch of grit is used. If in the
opinion of the Company the test has failed, Contractor shall undertake to perform additional
cleaning to the specified standard.
2.7.6.3
The profile of the blast cleaned surfaces shall be tested by means of Testex Replica Tape
(type X-course), produced at least twice a day and additionally the first few joints and at each
change or replenishment of grit. Before applying the coating, the surface shall be free of rust
or residual grit. The surface profile shall be evaluated from the replicas in accordance with
manufacturer’s instructions, using a recently calibrated micrometer. As an alternative to the
above, the Company may allow the surface profile to be tested on site by a suitable profile
gauge in accordance with SP-1246.
2.7.6.4
Additionally, general checks at random shall be carried out such as monitoring of particle size
of copper slag, grit/shot used for blast cleaning, cleanliness of materials used for blast
cleaning and coating, and temperature control of the pipe surface.
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2.7.6.5
Contractor shall supply all equipment required for inspection and testing including dry film
thickness gauges and holiday detectors. All equipment shall be approved by the Company
prior to use.
2.7.6.6
Shrink Sleeves Testing
a)
All shrink sleeves shall be visually inspected in accordance with Section 2.7.4
above.
b)
Destructive testing on shrink sleeves shall be executed as follows:
-
Sleeves for testing will be chosen by the Company.
-
From each test sleeve one or more strips of 2.5 cm wide and 20 cm long
shall be cut perpendicular to the pipe axis and slowly peeled off, using an
approved peel strength gauge.
-
The temperature of sleeve and pipe during such a peel test shall be as
per manufacturer’s recommendation, i.e. the time of day of the testing
shall be taken into account.
-
The required peel strength for the above strip shall be in accordance with
the manufacturer’s temperature/strength correlation data. Repair shall be
carried out as per Section 2. 7.6.
c)
Following the peel test, the Company may request the Contractor to remove
the entire sleeve to check the overall degree of adhesion and absence of bare
metal voids achieved. After removal of the shrink sleeve, the bulk of the
adhesive layer which remains on the pipe surface shall be essentially free from
voids. For acceptance criteria, reference shall be made to DEP 31.40.30.37.
Voids exposing bare metal shall not be acceptable and shall be reason to fail
the shrink sleeve application. In the event that the test fails, it shall be repeated
on the two sleeves adjacent to the tested sleeve. Tests shall continue until the
sleeves which are inspected are acceptable.
d)
Company shall have the right to test one out of every hundred shrink sleeves
applied or one sleeve out of every days production if less than one hundred
sleeves are applied in any day.
2.7.6.7
Holiday detection of 100% of the surface area of all coated pipeline shall be carried out
immediately prior to lowering in the ditch. The holiday detection equipment which shall be
Company approved shall be set at 22000 Volts DC for PE coated pipes based on 5V per
micron of coating thickness. However, the voltage setting for holiday detection may be
lowered slightly at Company’s discretion if coating gets damaged. The electrode shall be a
conductive rubber or a spiral metal ring. Brush type electrodes shall not be used. The voltage
applied by the holiday detection equipment shall be measured by means of a voltage read
out. Alternatively a means of calibration of the applied voltage of holiday detection equipment
shall be provided to enable daily calibration of each piece of equipment. All holidays,
imperfections and damaged areas shall be identified with a waterproof marker at sufficient
distance from the defect to allow surface preparation and patching to take place without
detriment to the adhesion of the coating.
2.7.6.8
Company will carry out a ‘DCVG Survey’ to check the integrity of the buried coating. If coating
defects are found on any portion of the coating, Contractor shall excavate, repair and backfill
at Contractor’s expense.
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2.8
Lowering-In, Backfilling and Reinstatement
2.8.1
Scope
This Section of the Specification covers the minimum requirements for pre and post padding,
lowering the pipe and backfilling, compacting and stabilising the trench as required for the
work.
2.8.2
Pre-Padding
2.8.2.1
All trenches shall be padded before lowering in of pipe string. No padding shall be placed until
the Company has inspected and approved the trench bottom.
2.8.2.2
To ensure that fine and clean padding material is used, the Contractor shall use mobile
screening plants that enable a continuous direct application of padding from the plant to the
trench. The type of screening plant is to be approved by Company prior to mobilisation to site
(minimum sieve size shall be 5 x 5 mm). Mobile screening plants are defined as screening
plants which move along the trench whilst they are in operation. Only in those areas where
mobile screening plants cannot be used due to access problems, pre-screened material may
be used after approval of the source by the Company. Pre-screened material shall be stored
in areas which have been cleared of rocks and stones and protected with plastic sheets to
prevent contamination with unacceptable padding materials.
2.8.2.3
The installed padding material shall be free of sharp rocks, stones, metal parts, roots, clods,
etc. and without sharp edges which could damage the pipeline. Base materials from which
pre and post padding material will be produced shall consist mainly of sandy material. More
than 75% by weight of the screened material should have grain size between 0.06 and 3.0
mm and no more than 25% by weight shall have a grain size between 3.0 and 5.0 mm. To
ensure compliance with the above requirements, the Contractor shall produce a grading curve
with typical screened material from the proposed source of sand or a representative section of
the working strip. If the base material is not sourced from the working strip, sources of
padding material shall first be approved by the Company. Suitable base material from the
working strip may not always be available or acceptable, in which case it shall be Contractor’s
responsibility to obtain suitable padding material from a source approved by the local
government authorities. Near residential areas and roads, padding material shall be dust free
(e.g. 'coarse sand' with a minimum grain size of 0.6 mm) in order to avoid inconvenience or
danger to the public.
2.8.2.4
The bottom of the trench shall be padded with sand throughout its length, whether in normal
ground or rock, so as to provide a minimum compacted padding thickness of 150 mm below
the invert of the pipe. Contractor shall keep the pre-padding operation within 1 km of the
lowering-in operation.
2.8.3
Lowering-in and Post-Padding
2.8.3.1
Welded pipe strings shall be lowered-in within 96 hours of completion of joint coating.
2.8.3.2
Immediately before commencing the lowering-in operation, the coating shall be checked for
holiday and if necessary, repaired to the satisfaction of the Company, as specified in Section
2.7.6. Only side booms shall be used for the lowering operation.
2.8.3.3
Wide non-abrasive slings or belts shall be used in all lowering-in operations and care shall be
taken when removing the slings from around the coated pipe after it has been lowered into
the trench. Any damage caused to the pipe and coating during lowering operations shall be
repaired before backfill commences.
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2.8.3.4
The trench shall be maintained in a dry condition during lowering-in and backfill operations.
2.8.3.5
A minimum of 3 sidebooms shall be used for lowering in. Contractor shall submit to Company
a calculation to demonstrate that side booms used are sufficient to withstand the pipeline
section load. During lowering in operations the pipe shall not be subject to bending in excess
of the minimum allowable bending radius. A detailed procedure specifying the means of
demonstrating compliance with the minimum bending radius requirement shall be submitted
as part of the Contractor’s installation procedures, for Company approval, at least 3 weeks
prior to the planned commencement of any lowering in operations.
2.8.3.6
Contractor shall take measures to restrain the pipe in the trench by means of ‘plugging’, i.e.
placing sand on top and around the pipe at regular intervals (one 2m ‘plug’ on every welded
joint) or Company approved equivalent method. Contractor shall plan the work such that the
lowering in and ‘plugging’ operations take place during the hottest part of the day. Company
may, at its sole discretion, waive the requirement for ‘plugging’ and allow the post-padding
operation to be executed as one continuous operation, dependant on completion time and
ambient temperature considerations.
2.8.3.7
Sand padding shall be placed around and above the pipe, so as to fill the trench to a depth of
300 mm above the crown of the pipe, with the sand padding shaped to its natural angle of
repose and with a minimum of 150 mm at any point around the pipe. No pipe shall be left
overnight in the trench without sand padding around and above the pipe.
2.8.3.8
Where the trench has been excavated through or along drive-ways, walk ways, roads, etc.
and at live stock passage ways and other locations indicated on the drawings, the sand
padding shall be thoroughly compacted by watering and Company approved hand tools, to
achieve a compacted sand fill around the pipe and up to 300 mm above the crown of the pipe.
2.8.4
Tie-ins
Unless otherwise agreed by the Company, tie-ins shall take place in the trench. For tie-ins
outside the trench, holding and lowering operations shall be undertaken in such a manner as
to minimise stresses in the pipe and therefore avoid movement of the pipe from the skids, for
safety reasons. Due consideration shall be given to ambient temperature changes throughout
the day and the resultant pipe length changes/stresses.
2.8.5
Backfilling
2.8.5.1
The trench shall not be backfilled until the Company has approved the sand padding around
and above the pipe and has approved starting the backfilling operation. Any settlement that
occurs after installation or when loaded with hystrostatic test water shall not impose stress on
the pipe because of differential settlement. The properties of the backfill materials shall
permit the CP system to work effectively. The permeability of the replaced material shall be
similar to that of the unexcavated material to prevent tunnel erosion in the case of heavy
rains. Backfilling shall be performed as soon as possible after padding has been approved.
2.8.5.2
In areas containing buried cables, backfilling shall not be performed until all tiles have been
replaced and protected and/or all cables have been supported to Company’s satisfaction. The
backfill around all underground services shall be thoroughly compacted by hand.
2.8.5.3
The material used for initial backfill shall be from the screening plant or other loose material
not greater than 100 mm in diameter, all subject to Company approval. The fill material shall
be placed in such a manner as to avoid disturbing the sand padding and excessive
penetration (more than 150 mm) of rocks into the sand layer. Contractor shall demonstrate
that his proposed method of backfilling achieves this requirement. The initial backfill shall be
placed in the trench to a level slightly above surrounding ground.
2.8.5.4
After the initial backfill, the remaining excavated material shall be neatly crowned over the
trench (the windrow), except in wadi areas. Where rock is excessively large, in Company’s
opinion, shall be removed from site and not used as windrow material. On either side of road
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crossings, the windrow shall be tapered from full height to ground level to improve the visibility
of drivers on the ROW.
2.8.5.5
Trenches crossing ditches shall be backfilled with the material excavated from the trench at
the location. If the excavated material, in Company’s opinion is not suitable for backfilling,
Contractor shall provide and use suitable material from another source. Ditches with lined or
otherwise improved surfaces shall be resurfaced in a manner satisfactory to and approved by
the Company and the Authorities. Backfill in or on banks of ditches, wadis shall be compacted
as necessary to prevent soil erosion or other damage which might be caused by the
construction of the pipeline.
2.8.5.6
Where the trench has been excavated through or along drive-ways, walks, roads, etc., and at
live stock passage ways and other locations indicated on the drawings, the initial backfill shall
be thoroughly compacted by mechanically tamping the material into place. The surface of
such areas shall be stabilised and/or restored to its original condition to the satisfaction of the
Company and the Authorities.
Where wadis or roads are graded, trenched or otherwise disturbed, the Contractor shall
restore the property to its original contour and condition even to the extent of hauling in and
placing new fill materials, gravel and stabilising materials or compounds, or by using special
compaction methods, as necessary to obtain the approval of the Company and the
Authorities.
2.8.5.7
2.8.6
‘Sloping trenches’ (see Section 2.4.3.5) shall be backfilled as shown on Standard Drawing
TYP 3 0015 001.
Stabilising Sand Areas
To ensure the retention of sand cover in active sand areas (i.e. where the windrow consists of
sand only), the backfill shall be stabilised, preferably with a 150 mm layer of marl or other
stable material. The width of stabilisation shall be 3 metres on each side of the pipeline (plus
0.6 metres for every 3 metres of dune height if the line passes through a sand dune).
2.8.7
Livestock Passageways
Unless otherwise indicated on the drawings, livestock passageways shall be installed at
intervals of approximately 2 km and may be combined with graded road and track crossings.
The livestock passageways shall be constructed with a minimum of 1.5 m cover over the total
pipeline length of 6.5m. The width of the live stock passage shall be 2.5 m. Compaction of the
livestock passageways shall be such that the passing of light vehicles will not have any
detrimental effect on the passageway. Access barriers shall be installed on the ends of the
crossing to indicate the safe crossing width of the livestock passageway for light vehicles.
2.8.8
Reinstatement
2.8.8.1
Contractor shall clean-up the Working Strip and all working areas used by the Contractor
regularly during the course of the work, and shall restore the lands traversed, to the
satisfaction of the Company. Areas of soft sand in the continuous 6 m wide vehicle access
strip shall be removed and replaced by approved infill material so as to leave the vehicle
access strip in a safe condition for driving. The vehicle access strip shall be deviated at road
crossings in order to give a visual indication to drivers of the presence of the road.
2.8.8.2
The excess soil in the working strip shall be levelled in a manner satisfactory to the Company.
All loose rock exposed by the construction operations which is scattered over the working
strip or adjacent property shall be removed and placed over the windrow. However, rocks
larger than 750mm in diameter shall not be placed directly on the backfill material, but may be
placed next to the windrow.
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2.8.8.3
All creeks, water courses, wells, syphons, drains, streams, wadis, ditches and irrigation
channels shall be reinstated by the Contractor to their former condition and their banks shall,
if deemed necessary by the Company, be pitched with stone and/or faced with special
protection to prevent washing out or erosion.
2.8.8.4
All enclosures, walls, gates, etc. shall be restored by the Contractor to at least as good a
condition as they were prior to the commencement of the Contractor’s operations to approval
of the Company.
2.8.8.5
All private roads, bridges and other private structures used by the Contractor for access or
haulage shall be restored by the Contractor to a condition equal to or better than that which
existed prior to the commencement of the Contractor’s operations.
2.8.8.6
Construction roads, used at escarpments, may be required by the Company to be left as they
are.
2.8.8.7
Construction markers shall not be removed, unless requested by the Company.
2.8.8.8
All rubbish/debris left over after removal of camp facilities shall be removed to designated
scrap dumps. The sites shall be levelled and cleared in accordance with the Regulations for
Pipeline Contractor Camps in the Interior and to Company’s satisfaction.
2.9
Road and Wadi Crossings
2.9.1
Scope
This Section of the Specification covers the minimum requirements for road and wadi
crossings as required for the work.
2.9.2
Road Crossings
2.9.2.1
The carbon steel pipeline shall cross all roads and highways, without the installation of
casings. All road crossings shall be made by the open cut method. Trench less methods such
as horizontal drilling, pipe jacking may be considered for major road crossing to avoid
disruption of traffic. If directional drilling is used, tests are to be conducted to confirm the
integrity of the coating, the method for which is to be agreed prior to the installation of the
pipe.
2.9.2.2
The construction of road crossings shall meet the requirements of API RP 1102 latest issue
and shall be installed as shown on the drawings. The crossings shall be installed to meet at
all times the requirements and conditions set forth by the Authorities having jurisdiction.
2.9.2.3
Contractor shall install an off-set diversion road, when specifically permitted or required to do
so by the Company and/or responsible Authorities and provide adequate maintenance to
ensure safe passage of vehicles. The diversion shall not cross the pipeline where it has
already been installed.
2.9.2.4
Contractor shall at all times and at every unfinished road crossing provide adequate and
proper traffic aids, such as warning signs, and other safeguards to the satisfaction of the
Company and the Authorities to ensure safety of the public. All warning signs shall be in both
Arabic and English language.
2.9.2.5
Contractor shall comply with the following minimum requirements of the Directorate General
of Roads for major road crossings:
a) Contractor shall submit details of all proposed diversions, methods of crossings,
reinstatement and standards of construction to the Directorate General of Roads for
approval before commencing work on site.
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b) Reinstatement of roads must be to the same standard as existing roads. Diversion
roads must be constructed with compacted non-plastic materials, which must not
degenerate into dust during use.
c) Approvals must be obtained from all Utility Authorities and the Ministry of Land Affairs
and Municipalities prior to seeking permission from the Directorate General of Roads.
d) Final approval of any proposed road works must be obtained from the Royal Oman
Police.
e) Contractor shall be required to give to the Directorate General of Roads, a Bank
Guarantee. This requirement applies to each individual crossing point.
2.9.3
2.9.3.1
Wadi-Crossings
‘Wadi’ shall mean dry river bed which could be temporarily filled with water following rain. The
wadis will be identified on the Alignment Sheets as ‘Flood plains’, ‘Wadi type ‘A’’, ‘Wadi type
‘B’’, or ‘Wadi type ‘C’’. Pipe installed in ‘Flood plains’ does not require casing protection, but
shall be stabilised at 3 meter intervals by means of bags of dry cement/sand mix placed on
top of the pipeline. The Contractor shall demonstrate by calculations that the weight of the
cement bags and soil overburden (excluding the windrow and post padding) is sufficient to
counteract the buoyancy force of the pipeline in empty condition. Wadis may be classified
based on judgement and careful evaluation of the crossing location with due consideration to
wadi’s width, bed slope, past discharge history and erosion potential at the crossing location.
The wadi types are described below.
a)
Type ‘A’ wadis are those where low velocity flow is expected after heavy rains.
At these wadi crossings, line pipe without concrete protection shall be installed
(TYP 3 0008 001) with a minimum cover of 1500 mm.
b)
Type ‘B” wadis are those where erosion due to high velocity flow is expected
after heavy rains At these wadi crossings, line pipe with continuous concrete
protection shall be installed (TYP 3 0009 001) with a minimum cover of 1500
mm.
c)
Type ‘C” wadis are those where heavy erosion due to high velocity flow is
expected after heavy rains combined with the existence of large stones and
boulders. At these wadi crossings, line pipe with continuous concrete protection
shall be installed (TYP 3 0010 001) with a minimum cover of 1500 mm.
Additionally, the pipeline trench shall be protected with gabions placed at the
surface.
2.9.3.2
Wadi crossings shall be installed to meet at all times the requirements and conditions issued
by the Authorities having jurisdiction in the area.
2.9.3.3
All concrete coated pipes shall be electrically tested on site prior to installation in order to
demonstrate that there is no contact between the reinforcing steel and the pipe steel. The
concrete shall be applied in accordance with Section 2.10, following.
2.9.3.4
At locations where concrete protection has been applied, the trench shall be backfilled with
coarse gravel and rock with a minimum dimension of 50 mm up to a level 500 mm below
grade level.
2.9.3.5
For type `C` wadi-crossing, gabions consisting of packages of boulders with dimensions
between 100 and 200 mm contained in galvanised, coated steel wire mesh, shall be placed
on top, up to grade level over the full width of the trench. The type of wire mesh shall be
approved by the Company prior to use. Additional requirement of gapions on both sides of
the pipeline and 150mm thick concrete slap, inclusive of wire mesh, top and 4-6 meters both
sides of the pipeline shall be considered for pipelines with high H2S levels and MOL/SOGL (in
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view of the recent cyclones), reference for these additional requirements are to be made to
drawing no. RBB-3-0118-002-1A-1-A.
2.9.3.6
Normally the windrow shall not be installed over the pipeline through the wadi section.
However for wide wadi crossings, greater than 100m, the windrow shall be installed
intermittently in order to mark the location of the pipeline (Windrow lengths shall be
approximately 25m at 75m intervals).
2.10
Concrete Coating for Wadi Crossings
2.10.1
Scope
This Section of the Specification covers the minimum requirements for concrete coating of the
pipeline at Wadi crossings type B and C as required for the work.
2.10.2
General
2.10.2.1
Contractor shall be responsible for the supply and installation of all concrete coatings,
including all associated handling and transport of linepipe etc. Contractor shall furnish all
materials, equipment, labour, supervision, worksite and services incidental to and necessary
for the application of concrete in accordance with this specification and all subject to
Company approval.
2.10.2.2
The concrete shall have a minimum dry density of 2400 kg/m 3 after 28 days. The minimum
thickness shall depend on the pipe outside diameter as specified below:
Up to 6.625"
:
40 mm
6.625" to 12.75"
:
50 mm
over 12.75"
:
60 mm
The concrete shall be Grade 30 to BS 8110 with a characteristic crushing strength of 21
N/mm2 at 7 days and 30 N/mm2 at 28 days.
2.10.2.3
The mill identity of each pipe length shall be preserved and records kept during and after the
coating process. A certified permanent record shall be supplied to the Company showing the
serial number, average outside diameter, length and all weights.
2.10.2.4
The concrete coating of line pipe shall be applied either in an approved coating plant or in the
field before welding of linepipes, at Contractor’s option. Field application shall be by dry mix
gunite technique or Company approved equivalent. The plant application procedure and the
coating plant may involve methods other than guniting and shall be Company approved.
Reference is made to Company Specification SP-1282 for concrete production.
The Contractor shall prepare, and submit to the Company for approval, a minimum of 1 month
before commencement of the work, a detailed coating procedure specification containing, but
not limited to, the following.
SP-1208
-
Contractor-supplied materials: specifications, type, supplier, methods of control,
etc.;
-
concrete coating procedures covering the concrete mix, placement of steel
reinforcement, concrete application, curing, repair procedures, coating equipment
and facilities and identifying the ranges of parameters to be used;
-
inspection and testing (including procedures and pro-forma)
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2.10.3
Version 3.0
Concrete Materials
2.10.3.1
The cement shall be ordinary Portland cement conforming to BS EN197 or ASTM C150.
Cement which is held in stock for longer than three months, or any cement which shows signs
of deterioration, partial setting or other defects or which fails when tested, shall be rejected.
2.10.3.2
Aggregates shall be naturally occurring washed sand and shall be hard, dense, durable,
clean, sharp and graded evenly from fine to coarse, as per the grading limits specified below,
and be in compliance with BS 882. If in the opinion of the Company, the aggregate contains
an undesirable proportion of chemicals, dust, clay, organic matter or other undesirable
constituents, the consignment shall be rejected. The grading of aggregate when plotted
against sieve size shall be within the limits tabulated below:
BS 410 Sieve Size
Percent by Weight
passing a 3/8 inch
100
passing a no. 4
95 - 100
passing a no. 8
65 - 90
passing a no. 16
45 - 75
passing a no. 30
30 - 50
passing a no. 50
10 - 22
passing a no. 100
2-8
Stockpiles of aggregates shall be covered by tarpaulins.
2.10.3.3
Water for use in concrete shall be clean and free from all substances which may be injurious
to concrete or steel. It shall satisfy the requirements of BS 3148 and contain no staining or
colouring.
2.10.3.4
Reinforcement of concrete coating shall be by one layer of electrically welded galvanised
steel mesh fabric reinforcement to BS 4483. Maximum mesh dimensions shall be 38mm x
38mm x 2 mm wire diameter. The minimum overlap between two consecutive rolls of mesh
shall be 50 mm except at field joints where no overlap is required. The reinforcement shall be
placed at the centre of the concrete coating layer by using P.V.C. spacer blocks or a
Company approved equivalent. The reinforcement shall be clean, free from scale, mud,
grease, hardened rebound or anything likely to destroy adhesion or promote corrosion.
2.10.4
2.10.4.1
Application
Prior to concrete coating, Contractor shall apply a protective layer or ‘barrier coat’ to epoxy
coated pipe. The type of barrier coat to be used shall be a two component fibre reinforced
cementetious coating such as FBE Brushcrete, Fosroc H.I.M, Epoxytar, Rezex water based
epoxy coating ES2 or equivalent. Contractor shall demonstrate to the satisfaction of the
Company that the proposed barrier coat prevents the occurrence of holidays in the epoxy
coating due to the concrete application process, and promotes a good bond between the
epoxy and concrete coating.
To this end one or more sections of a test joint shall each be coated with a proposed barrier
coat, in accordance with manufacturer’s recommendations. The number of applications, film
thickness and curing time shall be representative for the application in the production process.
The test joint shall be concrete coated, whereupon the concrete is immediately washed off
and each test section subjected to a holiday test and an adhesion test both in accordance
with Section 2. 7.
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2.10.4.2
Batching, proportioning and mixing of the materials shall be such that a concrete coating is
provided with the minimum specified strength and density. No batch of cement and aggregate
shall be used in the work if it has stood for more than half an hour after mixing. No rebound
material shall be mixed into any batch.
2.10.4.3
Contractor shall pay attention to the moisture content of the sand used for guniting. If the
sand is too wet, the hose will block and a mortar layer will build up inside the gun. If the sand
is too dry the cement will not adhere to the sand grains on mixing and excessive separation
will occur in the hose. In case the moisture content falls outside the critical range of 5 to 8%,
Contractor shall make the sand suitably damp either by spraying the dry sand with water or
mixing wet sand with specially supplied dry sand.
2.10.4.4
The mixing equipment shall be capable of providing a uniform mix. The dry mix used for
guniting shall be screened to prevent inclusion of stone, flakes from the mixer drum, pieces of
cement bag, etc. Mix temperature shall not exceed 32°C.
2.10.4.5
Concrete shall not be placed until:
a)
The line pipe corrosion coating has been holiday detected and approved by the
Company.
b)
The barrier coat (if required) has been applied and cured.
c)
Reinforcement has been adequately secured in the correct position with use of
spacer blocks, to prevent displacement during concrete application.
d)
Shading has been installed to prevent the line pipe temperature exceeding
35°C.
2.10.4.6
Since the technique of guniting relies significantly on the skill of the nozzle man, he shall have
at least 3 years experience in work of a similar nature. Other operators of the guniting crew
shall have a minimum of one year’s experience. Written evidence of such experience shall be
furnished to the Company. Contractor shall have a minimum of five years experience in
guniting or alternatively shall subcontract the guniting work to a specialist Sub Contractor with
similar minimum experience level. The guniting crew shall demonstrate their ability to
consistently coat pipe to this specification by guniting at least three separate quarter length
pipe samples prior to start of production.
2.10.4.7
Before directing the guniting nozzle onto the pipe surface the nozzle man shall ensure that
the proportioning of water and dry mix is correct. Further regulating of the water supply should
be kept to a minimum to ensure uniform concrete quality. The nozzle shall be held in the
optimum position for placement at all times i.e. 0.6 to 1.2 m from and at right angles to, the
surface of the pipe.
2.10.4.8
The outer surface of the concrete coating shall be smooth, without corrugations and
concentric with the steel pipe. At both ends of each pipe, a distance of approx. 0.30 m from
the end shall be completely left free of concrete to facilitate field joints. The concrete shall
taper back from these points at a two-to-one slope until the required thickness of coating is
reached.
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2.10.5
Version 3.0
Curing
2.10.5.1
The finished concrete coating shall be completely protected from wind, draught, rain, spray,
etc. for a minimum period of 7 days by wrapping with suitable hessian or polyethylene
sheeting. Also during this period the pipe shall not be exposed to direct sunlight and/or
temperature below freezing point. After a period of 4 hours from placement and for the 7 days
curing period, the concrete surface shall be kept wet.
2.10.5.2
The concrete coated pipe shall not be lifted or transported from the curing area during the 7
day curing period. The Contractor shall take precautions to prevent detrimental movement of
line pipe after concrete coating to minimise handling stresses whilst concrete is hardening
and curing.
2.10.5.3
For factory applied coating, any other curing methods apart from that mentioned in 2.10.5.1
may be adopted subject to approval of the Company.
2.10.6
Inspection and Testing
2.10.6.1
Every length of coated pipe shall be inspected visually and by spiral ring holiday detector and
repaired, in accordance with Section 2.7, Anti-Corrosion Coatings, prior to concrete
application.
2.10.6.2
The concrete shall be visually inspected immediately after the application and after
approximately 3 days. If concrete is faulty, Contractor shall remove cores from the suspected
pipe. If the compressive strength tests of the cores fail to meet the specified strengths,
Contractor shall remove the defective coatings by Company approved method, inspect and
where necessary repair the corrosion coating or reapply the concrete coating. Contractor may
optt not to wait for the test results and immediately initiate the stripping and subsequent
coating repair work.
2.10.6.3
Test panels, made from mild steel, shall be made every day, one at the start of work, and one
during the day as instructed by the Company. These test panels shall be positioned alongside
the work and in a position similar to the work (horizontal, vertical or overhead) and gunited.
On a regular basis, to be decided by the Company, cores shall be taken from each test panel
after it has cured in a similar manner as the coated pipe.
2.10.6.4
Core samples shall be obtained using a diamond core cutter set to ensure that the cut is
perpendicular to the surface and fitted with a positive depth of cut limit to ensure that the core
barrel shall not penetrate closer than 6 mm to the corrosion coat of the line pipe, where
applicable.
The minimum diameter of the core shall be at least three times the nominal maximum
aggregate size. The length to diameter ratio of the core when trimmed for testing shall not be
less than one-to-one. Sampling, storing, testing and calculation shall be in accordance with
the provisions of BS 1881. Cores shall be cut four days after concreting and stored in a curing
tank until tested.
Samples shall be tested as specified in BS 1881. The compressive strength of each specimen
shall be calculated using the computed cross-sectional area based on the average diameter
of the specimen. For acceptance, each core shall have the minimum density and compressive
strength as specified in Section 2.10.2.2.
Company may accept any other method of testing that Contractor can demonstrate to give a
consistently reliable measure of strength attained by the concrete coating. Cube tests will be
accepted for crushing strength instead of core samples, but the required compressive
strengths will be 20% greater than specified for core tests. The Contractor shall arrange for an
independent agency acceptable to the Company to test these cubes.
2.10.6.5
The thickness of applied concrete coating shall be measured on every joint at three or more
points to check compliance with the minimum requirements as per Section 2.10.2.2. The
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three points shall be spaced at approximately equal intervals with distance between the end
points at least eighty (80) percent of the coated length. Concrete coatings not in accordance
with the dimensional requirements shall be repaired or stripped and recoated at the discretion
of the Company.
2.10.6.6
Factory applied coated pipes shall be weighed and weight of each coated pipe shall have a
tolerance of +10% on any one joint and a tolerance of –4% on the total length as calculated
from the specified density and thickness. Weighing devices used to determine the weights of
the coated joints shall be certified in writing to provide an accuracy of one half on one percent
(0.5%).
2.10.6.7
Effective electrical separation between reinforcing steel and pipe shall be determined for each
pipe joint by electrical tests.
2.10.7
Concrete Coating Repairs
2.10.7.1
Concrete coating that is found to be defective at the time of coating shall be immediately
stripped from the pipe and the pipe recoated. All other defects shall only be repaired once the
concrete has hardened.
2.10.7.2
Defective concrete coating areas affected by spalling due to compression or shearing caused
by impact against other objects which have caused a loss of not more than twenty five
percent (25%) of the total thickness of the coating shall be repaired. An area of less than 0.1
m2 per joint where the concrete remaining on the joint is sound shall be accepted without
repairs. Should the area affected be more than 0.1 m 2 and less than 0.33 m2 per joint, the
concrete remaining in place over that area shall be undercut so as to provide a key lock for
the same basic material as the coating. Should the damaged area be more than 0.33 m 2 per
joint, the coating shall be removed around the entire periphery of the line pipe throughout the
entire damaged area and repaired.
Repairs shall be made by satisfactorily restoring the reinforcing, removing all cracked or
broken concrete at the point of coating damage, wetting the fresh surface of the broken
coating (unless the coating is still too ‘green’ to require it), and troweling a stiff mixture of
cement, water and aggregate, of the same materials and proportions as the coating, into and
through the reinforcing. This mixture shall be built up until the surface is level with the coating
around the repair. The pipe shall then be allowed to moist cure for a minimum of four days.
The resulting coating shall be equal in weight, density, uniformity, strength and characteristics
to the originally applied coating.
2.10.7.3
Concrete cracks that are in excess of 1.5 mm in width and extend over 180° circumferentially
around the pipe, or where cracks are over 330 mm in length longitudinally along the pipe
irrespective of width, shall be repaired. Repairs shall be made by chiselling the crack out to
width of not less than 25 mm throughout the length of the crack. The crack shall be repaired
with materials similar to that from which the coating is made and in a manner similar to that
outlined above.
2.10.7.4
Core sample holes shall be repaired with materials similar to that from which the coating is
made and in a manner similar to that outlined above. The repairs shall be kept moist and
allowed to remain undisturbed for a period of not less than 36 hours. Further curing shall be in
accordance with the Specification.
2.11
Permanent Markers and Barriers
2.11.1
Scope
This Section of the Specification covers the minimum requirement for the supply and
installation of permanent pipeline markers and access barriers, as required for the Work.
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2.11.2
Version 3.0
General
The Contractor shall supply and install permanent pipeline markers along the pipeline route
as close as possible to the windrow. Construction details of all types of markers are shown on
the drawings. Each marker consists of a post sealed with a cap end, mounted with two
marker plates as per the drawings. Marker plate no. 1 shows general information about the
pipeline involved, whereas marker plate no.2 shows relevant information for each location.
The different types of pipeline markers are listed below. As-built chainage shall be indicated
on the marker plates with an accuracy of one meter. (The start point of the pipeline, KP 0,
shall be the pipeline isolation valve in the scraper trap station).
Colour coding of the background of the pipeline markers shall be as follows:
Crude :
red
Gas
:
blue
Water :
green
The marker plates shall be parallel with the pipeline i.e. they shall face the R.O.W. access
road. Separate markers are required on parallel lines.
2.11.3
Chainage Markers
Chainage markers shall be installed along the pipeline at each one (1) kilometre chainage
station. A chainage marker is not required if the distance between its location and any other
type of pipeline marker, as mentioned hereafter in this section is less than 200 metres.
2.11.4
Block Valve Station Markers
Block valve station markers shall be installed along the pipeline at each block valve station. A
schematic diagram of the block valve station pipe work layout shall be installed on the block
valve station fencing.
2.11.5
Road Crossing Markers
Road crossing markers shall be installed at both sides of each paved or graded road
crossing. Location shall be 5metres from the borders of the road.
2.11.6
Wadi Crossing Markers
Wadi crossing markers shall be installed at both sides of each wadi crossing.
2.11.7
Pipeline Crossing Markers
Pipeline crossing markers shall be installed at each crossing with an existing underground or
above ground pipeline. (This does not apply to flowlines).
2.11.8
Cable Crossing Markers
Cable crossing markers shall be installed at each crossing with an existing underground
cable.
2.11.9
Markers at Horizontal Bends
Markers shall be installed at the tangent points of each horizontal bend, with an indication of
the actual bend angle of the pipeline at that location.
2.11.10
Cathodic Protection Markers
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At all C.P. test stations, bonding stations and negative connection stations, a pipeline marker
shall be installed. Locations shall preferably be combined with chainage markers. At pig trap
stations, the insulating joint test station post/marker shall be installed outside the station fence
but no further than 25 m from the insulating joint.
2.11.11
R.O.W. `STOP` Signs
At each road crossing, permanent `STOP` signs shall be installed on the R.O.W. access strip,
at both sides of the road for the attention of drivers of maintenance vehicles on the R.O.W.
2.11.12
Corrosion Monitoring Pit Marker
A marker shall be installed adjacent to each of the corrosion monitoring pit, in the case where
the pit is not located inside a station. The marker shall be inside the pit with fencing.
2.11.13
Access Barriers
2.11.13.1
When specified on the drawings, access barriers shall be constructed in accordance with
Standard Drawing GEN-2-1633-01.
2.11.13.2
Breaks in the barriers shall be provided at each road/track/livestock crossing and at least
once every two kilometres to coincide with livestock crossings. At these crossings, removable
barriers shall be installed to prevent normal access from the crossing to the Right-of-Way, but
allowing inspection vehicles to pass when required. Final configuration shall be approved by
the Company Site Representative.
2.11.13.3
Painting of access barriers shall be in black and yellow bands of 0.3 m length. Paintings shall
be carried out in accordance with Section 2.12, Station Works.
2.12
Station Works
2.12.1
Scope
This Section of the Specification covers the minimum requirements for all above and below
ground station works, including pig trap and block valve stations. The sections below make
reference to relevant PDO Specifications and detail any additional requirements. The
following works are included in this Section:
-
Earthworks
-
Civil and Mechanical Work
-
Painting
-
Instrumentation
-
Electrical Works
-
Fencing
Requirements for the following related activities are included in other sections of this
document or other Specification.
SP-1208
-
Materials
-
Cathodic Protection
-
Supply of hydrotest water
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-
Hydrotesting
-
Work on `live` systems
-
Use of explosives
-
Access barriers
Contractor shall supply all materials and equipment unless stated otherwise in the Schedules.
2.12.2
2.12.3
2.12.3.1
2.12.3.2
Earthworks
a)
Pig trap station plots will be prepared, by others, to final elevations unless
specifically stated otherwise in the Scope of Work/Drawings.
b)
All earthworks, specifically those relating to supports, drain pits and corrosion
monitoring pits, shall be in accordance with SP1279-C.
Civil and Mechanical Works
General
a)
All station works shall be fabricated and installed in accordance with the
Drawings and this Specification, including standard Civil and Mechanical
drawings from GU-628 and SP-2039, respectively.
b)
Precautions shall be made to prevent entry of sand or debris etc. into pipework
and fittings during construction.
c)
Contractor shall maintain the elevations shown on the drawings and carry out
any pipework adjustment necessary to achieve this.
d)
Valves with flow arrows shall be installed in the normal flow direction of the
product.
Concrete/ Block work
a)
All concrete works shall be in accordance with SP1279-D. Reference is also
made to SP-1282.
b)
The block work of corrosion monitoring pits shall be in accordance with SP1279-E.
c)
Anchor bolts, pipe sleeves, anchor rails, insert and sliding plates shall be built
in as formwork proceeds. They shall be positioned accurately and be firmly
fixed such that no movement shall occur during the concrete pour. If provision
is to be made to allow for slight adjustment in position of anchor (holding-down)
bolts, this shall be clearly indicated on the detail foundation drawings with the
method(s) to be applied.
Anchor bolts, etc. shall be properly protected against damage and corrosion.
Threaded parts shall be greased and securely protected from damage before
pouring of concrete. Anchor bolts shall be as shown on the drawings. All
embedded parts shall be free from oil, loose scale, rust, paint, grease or other
harmful matter.
2.12.3.3
Structural Steel
All structural steelworks shall be in accordance with SP1279-G.
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2.12.3.4
Version 3.0
Process Pipework
a)
Fabrication and welding of process pipework and fittings shall be in accordance
with SP-1173 Specification for Welding of On-Plot Pipework.
The on-plot Specification states that all welding shall be by the uphill technique.
In certain circumstances, downhill welding may be considered for filling and
capping runs, any proposals for which shall be reviewed on a case by case
basis by the Company welding TA-2 and endorsed by the CFDH Welding.
2.12.4
c)
Corrosion probe fittings shall be welded and drilled prior to hydrostatic testing.
Flame cutting of holes is not permitted.
d)
The bases and valves of pig indicators shall be installed prior to hydrostatic
testing and the complete assembly fitted after test.
e)
If temporary vents are required by Contractor for hydrostatic testing, in stations
or on the pipeline, these shall be provided with prior approval of the Company.
The size of such vents shall be 1 inch. All welds shall be subject to MPI and the
final cap to nipple weld shall be radiographed. Thereafter the cap, nipple and
weldolet shall be painted as specified in Section 12.4 below. The proposed
location for temporary vents shall be U.T. checked for laminations and to
confirm adequate wall thickness. A MPI check shall also be made to confirm
the absence of surface breaking defects, prior to welding or cutting.
f)
In the event that anchors are required, these shall be installed at the locations
shown in the drawings. The anchor flange with a pipe joint welded at both ends
shall be completely installed prior to start of civil work. The anchor flange to be
embedded in the concrete shall be coated in accordance with Section 2.12.4
below. Pipe coating shall be tested with the holiday detector prior to embedding
in concrete. The concrete work shall be backfilled and left to cure a minimum of
three weeks before further joints are allowed to be welded to the anchor flange
assembly.
Painting
a)
All above and below ground steel surfaces (with the exception of polyethylene
or epoxy coated pipework and items supplied in a manufacturer’s finish) shall
be prepared and painted in accordance with this Specification.
b)
Valves and insulating joints shall be supplied with a single coat primer only, in
accordance with SP-1246.
c)
Underground steelwork, pipework, fittings and valves, including those inside
corrosion monitoring pits, shall be coated in accordance with SP-1246.
d)
Above-ground steelwork, pipework, fitting and valves shall be painted in
accordance with SP-1246. All items shall be colour white, except for the
following:
Actuators and insulating couplings
red
Covers of corrosion monitoring pits
black
Access barriers markers
black/yellow
Handrails
black
(In special instances Camouflaged paint may be required).
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e)
2.12.5
Version 3.0
Surface preparation and painting shall be in accordance with SP-1246.
Instrumentation
Contractor shall carry out instrumentation works in accordance with PR-1094 and DEP
62.10.08.11 GEN.
2.12.6
Electrical Works
2.12.7
a)
This section refers to permanent electrical works as specified in the Drawings
(normally earthing and bonding only), including standard drawings from SP1105, Electrical Standard Drawings.
b)
All work shall be carried out in accordance with the following Specifications:
SP-1099
Electrical Installation Practice
PR-1947
Electrical Safety Rules
SP-1109
Specification for Earthing and Bonding
Fencing
a)
The fencing required for the Work shall be of the medium security type, and be
supplied and constructed in accordance with SP1279-P. The exact
requirements for each location are shown in the drawings.
b)
If Contractor requires an opening in an existing fence for construction
purposes, he shall obtain prior approval of the Company and restore the
relevant part to its original condition upon instruction of the Company.
2.13
Cathodic Protection
2.13.1
Impressed Current Cathodic Protection
2.13.1.1
The cathodic protection design shall be in accordance with SP-1128 Specification for
Cathodic Protection Design’. Details of various design aspects are indicated in the standard
drawings specified in SP-1136 ‘Specification for Cathodic Protection Standard Drawings’.
2.13.1.2
When a complete new C.P test points connects to an existing system, then the Contractor
shall employ a qualified C.P supervisor who shall have the prior approval of the Company.
When solar panels are required, Contractor shall sub-contract the supply/installation to a
Company approved supplier/contractor.
2.13.1.3
Contractor shall give the Company 5 days notice prior to installation of special C.P items i.e.
solar stations, T/R units and ground bed anode systems, in order to mobilise a Company CP
Inspector.
2.13.2
Materials
Contractor shall procure all materials required for the Work, unless stated otherwise in the
Schedules. Specifications for materials shall be as shown on the drawings. The following
Company Specifications are applicable:
SP-1208
•
SP-1129 (Construction, Installation and Commissioning)
•
SP-1130 (Materials and Equipment)
•
SP-1136 (Standard Drawings)
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•
2.13.3
Version 3.0
PR-1234 (Safe Working Procedures)
Installation
2.13.3.1
Installation of the C.P. System shall be carried out concurrently with the main pipeline laying
work.
2.13.3.2
At approximately 2 km intervals, as shown on the drawings, a C.P. Standard Test Post shall
be installed (Ref. STD-7-3001). Welding of the attachments to the pipeline, including
procedure and welder qualification shall be in accordance with Section 2.6, Welding and NDT.
2.13.3.3
Cable connections to the pipeline (Ref. STD-7-2001) shall also be required, as shown on the
Drawings, at the following locations:
-
pipeline crossings
-
current measuring stations
-
buried or overhead high voltage powerline
-
negative connections
-
earthing electrodes
-
permanent reference cells
-
insulating joints
Where the required connections at pipeline crossings, current measurement stations, etc. are
within 200m of the planned location of a C.P. test station/pup piece point, the latter may be
relocated to coincide with the connection, subject to prior Company approval.
2.13.3.4
All C.P. testing facilities shall be installed in accordance with SP-1129.
2.13.3.5
Where Foreign Service Bonding Facilities are required on foreign services, for cross bonding,
the connection pad may be attached by welding a pad on the foreign services (Ref. STD-73005).
2.13.3.6
Current Measuring Stations shall be installed on the pipeline every 10 km, unless shown
otherwise on the drawings (Ref. STD-7-3004).
2.13.3.7
A Grounding Facility shall be installed at power line crossings and where the pipeline runs
parallel to, and within 50m of a power line (Ref. STD-7-3006).
2.13.3.8
Drain Point Facilities shall be installed as shown on the Drawings (Ref. STD-7-3003).
2.13.3.9
Insulating joints/flanges shall be installed in accordance with Drawings (Ref. STD-7-3007).
2.13.3.10
All C.P. cables shall be installed in accordance with SP-1129. Cable to pipeline connections
shall be made prior to hydrostatic testing. Cable markers shall be installed in accordance with
drawing STD-7-7001.
2.13.3.11
Ground beds, when required and shown on the Drawings, shall be installed in accordance
with SP-1129(Ref. STD-7-6001, STD-7-6002, STD-7-6003, and STD-7-6004).
2.13.4
Temporary Cathodic Protection
In the case that the pipeline is to be buried in a highly corrosive soil and when the installation
of the permanent cathodic protection system cannot be finalized before the pipeline is buried
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(pipelines with long construction periods) a temporary cathodic protection system shall be
installed. Such a system shall be designed in the same way as a permanent cathodic
protection system with the exception that material quantities and quality shall be adequate to
cover a lifetime equal to the time of the pipeline construction until the expected
commissioning of the permanent cathodic protection system. Anode connections shall be
constructed such that they can easily be connected / disconnected during and/or after
commissioning of the permanent system.
2.13.5
DCVG Survey
2.13.5.1
Company will carry out a ‘DCVG Survey’, after installation of the pipeline, to check the
integrity of the buried pipeline coating.. If coating defects are found on any portion of the
coating, Contractor shall excavate, repair and backfill at Contractor’s expense.
2.13.6
Commissioning
Contractor is required to provide a PDO approved C.P. Contractor to commission the C.P.
system after installation in accordance with documents SP-1129 and PR-1169. The
Contractor should inform the name of sub-contractor they intend to use to execute the
commissioning not less than 28 days prior to commencement of commissioning.
2.14
Quality and Treatment of Hydrotesting Water
The minimum requirements for the quality and treatment of flushing and hydrostatic testing
water as required for the Work is stipulated in SP-1212: Hydrostatic Testing of New Pipelines.
2.15
Hydrostatic Testing
The minimum requirements for hydrostatic testing operations, i.e. cleaning, gauging, filling,
hydrostatic testing and dewatering of pipeline and station works as required for the Work are
covered under a separate specification SP-1212: Hydrostatic Testing of New Pipelines.
2.16
Precommissioning Of Pipelines
2.16.1
Scope
The minimum requirements for precommissioning of oil and gas pipelines including but not
limited to bulk dewatering, final dewatering, cleaning, drying and preservation of oil and gas
pipelines as required for the Work are covered under a separate DEP 31.40.50.30.
2.16.2
General
The Contractor shall carry out the pre-commissioning activities of pipelines in accordance with
the requirements of the Scope of Work, this specification and DEP 31.40.50.30. Precommissioning records shall be in accordance with chapters 6 and 8 of DEP 31.40.50.30.
Hydrotest water shall be disposed of in accordance with SP-1006.
Contractor shall supply all materials, consumables, equipment, spares, labour, supervision
and other services incidental to and necessary for the successful performance of the precommissioning work in a manner satisfactory to the Company.
2.16.2.1
Contractor shall make detailed proposals, for Company approval, for the precommissioning
work including but not limited to detailed procedures, programme and schedule for Work.
Contractor’s proposals shall include complete information regarding the following aspects:
SP-1208
-
precise definition of the sections to be precommisioned
-
the method or combination of methods to be employed
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complete summary and lay out of the temporary pipework, equipment and facilities
including spares for each section to be pre-commissioned.
-
the method(s) to be employed to preserve the dryness and cleanliness of the line.
-
any tie-in work to be carried out after pre-commissioning.
-
precommissioning of valves, branch off takes, etc.
-
tests to verify the success of the operation.
-
a summary of the amount of material and consumables and the number and
qualifications of personnel, to be used for the precommissioning work.
-
test/calibration procedures for all main equipment and instrumentation.
-
calculations and any other evidence necessary to demonstrate that the work will be
executed in accordance with the requirements of the Contract. The sizing of drying
equipment and calculations of the time required for drying shall be based on a film
thickness of residual water of not less than 0.1 mm. Lower values may be assumed
if the Contractor can demonstrate, to the Company's satisfaction, their validity from
previous experience.
2.17
Work on Live Pipe Systems
2.17.1
Scope
This Section of the Specification covers the minimum requirement for work on live pipe
systems as required for the Work.
2.17.2
General
2.17.2.1
The work permit system shall apply to all work on live pipe systems. Contractor shall do all
that is necessary to obtain work permits and to execute the Work in adherence to the work
permit.
2.17.2.2
Specialised tools and equipment as required for the performance of work on live pipe systems
shall only be acquired form the Company approved vendors. A vendor’s representative shall
be present at all times during the use of such tools and equipment.
2.17.2.3
Hot tapping on live pipe systems shall be carried out in accordance with DEP 31.38.60.10.
Welding on pressurised pipes shall be carried out in accordance with SP-1167.
2.18
As-Built Records and Hand-Over Documentation
2.18.1
Scope
This Section of the Specification covers the minimum requirements for keeping and
maintaining records, drawings and documents of all aspects of the pipeline project. These
requirements supplement those contained in SP-1131, to which reference should be made for
the definitions and general requirements. The scope includes new pipeline construction and
modifications to existing lines and related facilities.
The primary purpose is to provide a comprehensive list of Handover and As-Built
documentation that should form the handover package at the completion of a pipeline project.
The scope also covers responsibility for document preparation and custody, the minimum
recommended retention period for each type of document and the appropriate form in which
storage should take place.
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Where any conflict occurs with the requirements of SP-1131, this specification shall take
precedence.
The types of documents/drawings required for handover of a pipeline are detailed in
subsequent sections. These requirements are developed as a comprehensive list of
documentation specific to pipeline projects and listed in Appendix D of this specification. This
Appendix also include, the recommended storage period before disposal, storage format and
the storage location.
2.18.2
Storage Format
Retention of information as hard copy shall be minimised and wherever possible master
copies of documentation shall be acquired and stored in a suitable electronic format. Route
survey data shall be presented in accordance with XTO documents TS18v1-0: Pipeline Data
Specification and TS19v1-0: Flowline Data Specification. All master documents should be
classified, coded and compiled on to a minimum number of fully indexed compact discs or
other media that may be specified by the Company. Controlled and separately stored back-up
copies of key items shall be maintained. All NDT data shall be presented to Company in
electronic format.
Documentation available only as hard copy shall be scanned for archiving. In the cases where
the required storage life is short (e.g. less than 2 years), or the document is not suitable for
scanning, exceptions to this requirement should be agreed by the responsible Project
Engineer in consultation with the relevant CFDH or nominated discipline engineer.
Hard copies of whichever master documents are required for day to day operation and
maintenance, or for permanent reference to support future engineering activities during the
operational life, may be made as required provided documents maintained ‘As-Built’ are
formally issued as controlled copies.
2.18.3
Storage Location
Master copies of all textual documentation after handover shall be held by the pipeline owner
(Asset Manager) in a properly managed archive. This shall include storage of pipeline
radiographs for the prescribed retention period before disposal. Autocad drawings shall be
stored and referenced in CCMS in accordance with Company practice.
Controlled hard copies of documents required for pipeline operation and maintenance
(Operating Manuals, Design Reference Manual, PEFS etc. as per Appendix D) should be
provided to Operations as part of the handover package. Issue of further documents should
be authorised and controlled by the Asset Manager.
A detailed listing shall be filed within CCMS Business Records of the storage location of all
master documents for each pipeline. This list, along with copies of all key drawings within
CCMS and the basic pipeline design and operating data held in SAP, shall be linked to the
relevant pipeline location in GIS to enable the data to be readily identified and/or retrieved.
2.18.4
Pipeline As-Built Documentation
Original pipeline drawings and other documents required to be maintained ‘As-Built’ (see
Appendix D) shall be updated during the construction and commissioning phase in line with
SP-1131, Section 4. Subsequent revisions of the master documents shall be authorised and
all As-Built copies issued on a properly controlled basis in accordance with CP-102.
2.18.5
Documents
The Contractor shall prepare summary sheets (3 copies) containing a full list of the
documentation sets provided to the Company Site Representative prior to demobilising.
Contractor shall record the name of the Company Site Representative who received the
documentation on the sheet and retain one copy for Contractor’s own records and pass one
SP-1208
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copy of the sheet to the Company Site Representative and one copy to the Company coastal
based Project Engineer.
The required documents to be provided by the Contractor are:
-
Test, Calibration and Inspection Reports
-
Material Certificates for Contractor Supplied materials
-
As-built Drawings and Pipeline Data Sheets
Unless otherwise stated, Contractor shall provide originals of documents plus two copies.
2.18.6
Test, Calibration and Inspection Reports
Contractor shall make available inspection, calibration and testing reports, (including welding
procedures, NDT procedures, radiographs, ultrasonic test reports, hydrostatic testing and
drying reports), as specified in applicable Sections of the Specification.
2.18.7
Material Certificates
Contractor shall make available Mill and Test Certificates, where applicable, for all materials
supplied by Contractor and incorporated in the permanent facilities.
2.18.8
As-built Drawings and Pipeline Data Sheets
Contractor shall return to the Company one copy of each drawing (provided by the Company)
corrected with as-built information for those drawings in the Drawing List which are indicated
to be revised as as-built. These as-built drawings shall be submitted for approval to the
Company within 2 weeks of the Completion Date and shall be approved by the Company
before Acceptance of Work.
The as-built information shall include but not be limited to:
SP-1208
-
Measured trench depth at each 12 meter intervals, with chainage
-
Measured top of pipe level at each installed joint location, with chainage
-
Cover and grade elevations at 12 meter intervals, with chainage
-
Type of rock/soil encountered in trench preparation, and depth at which it was
encountered.
-
The location and degree of all points of intersection.
-
The locations of all temporary vents.
-
The chainage, elevation, size, type, shape of all roads, wadis, pipes, cables and
other objects crossing and/or obstructing the pipeline.
-
The identification and the location of circumferential welds and pipe lengths with the
manufacturer’s number, heat number, sequence number and length installed.
-
The position of all permanent markers.
-
Other relevant data including the chainage of block-valves, anchors, changes in
pipe grade, wall thickness, diameter, cathodic protection appliances,
instrumentation, etc.
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Contractor shall provide a site-based experienced, full-time ‘As-Built’ surveyor, with valid
driving licence and vehicle, throughout the duration of the Contract. He shall maintain the
Pipeline Data Sheets (originals provided by the Company) and shall collect and maintain all
data required for the ‘As-Built’ drawings. Refer to Pipeline Data Base requirements in
Appendix D.
‘As-Built’ drawings shall be prepared during the progress of the Construction Work and
Contractor shall provide a drawing office, personnel, and all necessary equipment and
facilities, to the approval of the Company, for the purpose of producing as-built drawings.
Preliminary ‘As-Built’ drawings shall be submitted to the Company for approval on a weekly
basis within 2 weeks of the completion of backfilling of the trench on that part of the pipeline
route contained on the drawing concerned.
2.19
Effective Period
The requirements of this specification shall remain in force indefinitely unless superseded by
an authorised revision.
2.20
Review and Improvement
It is intended that the present version (3.0) of this specification will be reviewed and updated
once in every three years. The review authority will be UIP (CFDH Pipelines).
SP-1208
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Pipeline Construction Specification
APPENDIX A
A1.1
A1.2
Version 3.0
GLOSSARY OF DEFINITIONS, TERMS AND
ABBREVIATIONS
Terms and Definitions
Company
Petroleum Development Oman LLC. The Company may
also include an agent or consultant authorised to act for,
and on behalf of, the Company.
Contractor
The party which carries out all or part of the design,
engineering, procurement, construction, commissioning or
management of a project, or operation or maintenance of a
facility. The Company may undertake all or part of the
duties of the Contractor.
Corporate Functional
Discipline Head
The person within the Company responsible for the
discipline to which the standard belongs.
Manufacturer/Supplier
The party which manufactures or supplies equipment and
services to perform the duties specified by the Company.
User
The Company, Consultant or Contractor that uses this
document.
shall
Indicates a requirement.
should
Indicates a recommendation.
may
Indicates a possible course of action.
Abbreviations
SP-1208
BCD
Business Control Document
CFDH
Corporate Functional Discipline Head
CP
Cathodic Protection
CSR
Company Site Reprensative
EPC
Engineering, Procurement, Construction
GRE
Glass Reinforced Epoxy
GRP
Glass Reinforced Plastic
GRVE
Glass Reinforced Vinyl Ester
HDPE
High Density Polyethylene
HEMP
Hazard and Effects Management Process
MPI
Magnetic Particle Inspection
NDT
Non-Destructive Testing
N.F.P.A
National Fire Protection Association
PE
Polyethylene
PP
Polypropylene
ROW
Right of Way
RTP
Reinforced Thermoplastic
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Pipeline Construction Specification
APPENDIX B
Version 3.0
REFERENCE DOCUMENTS
In this SP, reference is made to the following publications. Unless specifically designated by
date, the latest edition of each publication shall be used, together with any
amendments/supplements/revisions thereto.
REFERENCE
REF #
PDO STANDARDS
Code of Practice
Corporate Document Management
CP-102
Health Safety and Environment Management System
CP-122
Lifting And Hoisting
CP-189
Specification
SP-1208
Specification for Aqueous Effluents
SP-1006
Specification for Waste Management
SP-1009
Specification for Site Preparation, Abandonment and
Restoration
SP-1012
Specification for welding of Duplex Stainless Steel Pipelines
SP-1097
Electrical Installation Practice
SP-1099
Electrical Standard Drawings
SP-1105
Specification for Earthing and Bonding
SP-1109
Specification for Cathodic Protection Design
SP-1128
Specification for Construction, Installation and
Commissioning of Cathodic Protection System
SP-1129
Specification for Cathodic Protection Materials and
Equipment
SP-1130
Specification for Handover and As-built Documentation
SP-1131
Specification for Cathodic Protection Standard Drawings
SP-1136
Specification for Earthmoving and Construction Equipment
SP-1143
Specification for welding of martensitic Stainless Steel
Pipelines
SP-1147
Specification for welding on pressurised pipes
SP-1167
Specification for Quality Assurance of Design, Construction
and Engineering works
SP-1171
Specification for welding of on-plot Pipework
SP-1173
Specification for welding of Class 2 Pipelines (Flowlines)
SP-1174
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Pipeline Construction Specification
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REFERENCE
REF #
PDO STANDARDS
Specification for Welding of Class 1 Pipelines
SP-1177
Specification for Application and selection of Standard Pipe
Supports
SP-1187
Pipeline Operations and Maintenance
SP-1210
Onshore Pipeline Engineering
SP-1211
Hydrostatic Pressure Testing of New Pipelines
SP-1212
Specification for painting and coating of oil and gas
production facilities (Part 1 – 5)
SP-1246
Training requirements for lifting operations personnel
SP-1251
HSE Specification, Camps, Offices, Laboratories,
Workshops and Industrial Safety Specification
SP-1256
HSE Specification, Safety, Training Observation Programme
(STOP)
SP-1259
Specification for Civil and Building Construction
SP-1279
Specification for Reinforced Concrete – Production &
Construction Guidelines
SP-1282
HSE Specification, Road Transport
SP-2000
Mechanical Standard Drawings
SP-2039
Technical Authority System
SP-2061
GRP Specification (Qualification and Manufacturing)
SP-2092
Specification for Polyethylene Liners in Carbon Steel
Flowlines & Pipelines
SP-2094
Procedure
Instrumented Protective Functions Test Procedure
PR-1094
Initial Start up Procedure
PR-1169
Safe working Procedures for Cathodic Protection Systems
PR-1234
Procedures for Lifting Operations
PR-1508
Procedure for Analysis of Pipeline Road Crossings
PR-1522
Lifting and Hoisting Procedure Inspection Testing and
Certification
PR-1708
Lifting and Hoisting Procedure Lift Planning Execution
PR-1709
Electrical Safety Rules
PR-1947
Guideline
SP-1208
C-09 HSE Requirements and Guidance for use
GU-140
Environmental Assessment Guideline
GU-195
Guidelines for the protection of buried sections of surface
laid Pipelines/Flowlines
GU-368
Guidelines for Project Certification and Completion
Management System (CCMS) Users
GU-623
Civil & Building Standard Drawings Index
GU-628
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Pipeline Construction Specification
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REFERENCE
REF #
SHELL STANDARDS
SP-1208
Index to DEP publications
DEP 00.00.05.05-Gen.
Piping – General requirements
DEP 31.38.01.11-Gen
Piping classes – exploration and production
DEP 31.38.01.15-Gen.
Hot tapping on pipelines, piping and equipment
DEP 31.38.60.10-Gen
Design of pipeline pig trap systems
DEP 31.40.10.13-Gen.
Pipeline overpressure protection
DEP 31.40.10.14-Gen
Upheaval buckling of pipelines
DEP 31.40.10.16-Gen
GRP Pipelines and piping systems (amendments /
supplements to ISO 14692)
DEP 31.40.10.19-Gen.
Line pipe induction bends (amendments / supplements
to ISO 15590 – 1)
DEP 31.40.20.33-Gen
Linepipe for non-critical service
(Amendments/supplements to ISO 3183-1)
DEP 31.40.20.35-Gen
Linepipe for critical service
(Amendments/supplements to ISO 3183-3)
DEP 31.40.20.37-Gen
Pipeline Fittings (amendments / supplements to MSS SP
– 75)
DEP 31.40.21.30-Gen
Pig signallers: Intrusive type
DEP 31.40.21.33-Gen
Carbon and low alloy steel pipeline flanges for use in oil
and gas operations (amendments / supplements to MSS
SP – 44)
DEP 31.40.21.34-Gen
Concrete coating of linepipe
DEP 31.40.30.30-Gen.
External polyethylene and polypropylene coating for line
pipe
DEP 31.40.30.31-Gen
Thermoplastic lined pipelines
External Field Joint And Rehabilitation Coating Systems
For Line Pipe
DEP 31.40.30.34-Gen
DEP 31.40.30.37-Gen
Pre-commissioning of pipelines
DEP 31.40.50.30-Gen
Pipeline Repairs (supplements to ASME B31.4 / B31.8)
DEP 31.40.60.12-Gen
Inspection and Functional testing of instruments
DEP 62.10.08.11-Gen
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AMERICAN STANDARDS
Process Piping
Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids
Gas Transmission and Distribution Piping Systems
ASME B31.3
ASME B31.4
ASME B31.8
Issued by:
American Society of Mechanical Engineers
Publications and Distribution Section
1220 L Street Northwest
Washington DC 20005, USA
Specification for Linepipe
API Std 5L
API Std 1104
Standard for welding pipelines and related facilities
Recommended practice for liquid petroleum pipelines crossing railroads and API RP 1102
highways
Issued by:
American Petroleum Institute
Publications and Distribution Section
1220 L Street Northwest
Washington DC 20005, USA
Steel Pipeline Flanges
Specification for high test wrought butt welding fittings
MSS SP-44
MSS SP-75
Issued by:
Manufacturers Standardization Society of the Valve and Fittings Industry,
Inc.127 Park street, Northeast Vienna,
VA 22180, USA
BRITISH STANDARDS
Code of Practice for the Safe Use of Explosives in the Construction Industry
BS 5607
Issued by:
British Standards Institution
389 Chiswick High Road
London, W4 4AL, UK
INTERNATIONAL STANDARDS
Preparation of Steel Substrates before Application of Paints and Related
Products – Visual Assessment of Surface Cleanliness
Preparation of Steel Substrates before Application of Paints and Related
Products – Tests for the Assessment of Surface Cleanliness
Preparation of Steel Substrates before Application of Paints and Related
Products - Surface Roughness Characteristics of Blast-Cleaned Steel
Substrates
Preparation of Steel Substrates before Application of Paints and Related
Products - Specification for Metallic Blast-Cleaning Abrasives
Preparation of Steel Substrates before Application of Paints and Related
Products - Specification for Non-Metallic Blast-Cleaning Abrasives
Petroleum and Natural Gas Industries – Glass Reinforced Plastics (GRP) Piping
Petroleum and Natural Gas Industries – Induction bends, fittings and flanges for
pipeline transportation systems – Part 1: Induction Bends
ISO 8501-1
ISO 8502-1 to 4
ISO 8503-1 to 4
ISO 11124
ISO 11126
ISO 14692
ISO 15590-1
Issued by:
International Organization for Standardization
1,Rue de Varembé
CH-1211 Geneva 20, Switzerland
SP-1208
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Pipeline Construction Specification
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APPENDIX C: FACILITIES FOR COMPANY PERSONNEL
C.1
Scope
This Section of the Specification covers the minimum requirements for facilities for Company
personnel at Contractor’s Construction Camp and is supplementary to the Regulations for
Pipeline Contractor Camps in the Interior.
C.2
Accommodation
C.2.1
Where the Contractor is required in the Contract Scope of Work to provide his own camp,
Contractor shall provide and maintain in its camp, good quality accommodation for the
number of Company’s senior personnel stated in the Scope of Work. Company may choose
to use this accommodation for personnel other than Company personnel.
C.2.2
Where the Contractor is required in the Contract Scope of Work to provide accommodation
for the Company’s personnel, the minimum accommodation requirements for each of
Company’s aforementioned senior personnel shall be:
a)
Bed-sitting room of 14.0 square metres floor area. This shall be furnished with:
one standard bed and mattress, of minimum width 1.2 metres
one full length wardrobe.
one writing desk with drawers and with a matching chair.
one refrigerator.
one 24” portable colour TV connected to a sattalite dish, sattalite reciver,
and DVD Player
one bedside rug, 1.5 metres long and 1 metre wide.
one bedside table.
one chest of drawers.
two coffee tables, each 0.75 metres square.
one bedside light.
two easy chairs, adequate heating and air-conditioning, sewerage,
electricity, general lighting, electrical power points, fly screens, ashtrays,
glasses, cups and saucers.
one waste paper basket.
one electric kettle.
b)
Private toilet/shower of minimum 3.5 square metres floor area (minimum width
1.5 m) containing:
one western type flush toilet
one shower with shower curtain
one wash basin
hot and cold running water of potable quality
one shaving cabinet with mirror
towel rails
SP-1208
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Pipeline Construction Specification
c)
Version 3.0
All necessary bed and bathroom linen.
C.2.3
Contractor shall replace all linen twice per week, clean all accommodation daily, and keep all
accommodation in good repair.
C.2.4
All accommodation provided for the Company’s use shall be subject to Company’s approval.
C.3
Messing
C.3.1
Where the Contractor is required in the Contract Scope of Work to provide messing,
Contractor shall provide and maintain complete and clean messing facilities for the Company
personnel and shall provide adequate good quality meals with soft drinks at such meals. The
menu should have at least one alternative main course.
C.3.2
Contractor shall provide an adequate laundry service for the personal clothing of the
Company personnel.
C.3.3
Contractor shall keep the Company personnel refrigerators stocked with a selection of soft
drinks.
C.4
Offices and Office Services
C.4.1
Contractor shall furnish, clean and maintain good quality office equipment and
accommodation at each spread camp for 5 members of the Company’s personnel.
C.4.2
Unless otherwise agreed by the Company, office space for these persons shall have a
minimum floor area of 16 square metres for each office and each office shall be supplied with
the following for sole use by the Company’s personnel:
One desk with plain drawers and filling drawers
One swivel chair
Two plain chairs
one drawing rack
one drawing table
one side board/bookcase
shelves
two filling cabinets
adequate heating and air conditioning, general lighting, electricity,
electrical power points, in trays, waste paper baskets, and ashtrays.
one Pentium (latest edition) PC with MS Office 2007 software including a
CDRW drive
one laser printer
one facsimile machine type RICHO 3300 or similar one photocopier type
XEROX 1035 or equivalent.
five handheld radios
office telephones
internet / email facilities
two digital camera
one refrigerator
SP-1208
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Pipeline Construction Specification
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C.4.3
The offices shall be interconnected. At each spread camp, the Contractor shall provide and
maintain for Company’s sole use such materials and equipment (computer, stationary, etc.)
as may be required for the Company’s clerical work at the camp.
C.4.4
As and when required, Contractor shall make available for Company’s use at the main spread
camp site, a furnished conference room of minimum floor area 24 square metres and with
seating for a minimum of 15 persons.
C.4.5
All offices and office services, provided for Company’s use shall be subject to Company’s
approval.
C.4.6
Contractor shall provide 2 administration clerks who is proficient in English, typing and
general office procedures, for Company use seven days per week at site and five days per
week at coast throughout the duration of the Contract
C.4.7
Contractor shall provide a suitable Digital camera with two 128 MB memory sticks and photo
editing software for the exclusive use of the Company Site Representative.
C.5
Vehicles and Maintenance
C.5.1
Throughout the construction period Contractor shall fuel, service, clean, maintain and repair
the vehicles which Company uses on the Work Site, up to the number given in the Scope of
Work.
C.5.2
Maintenance procedures shall be strictly in accordance with vehicle manufacturer’s local
representative’s recommendations for the specific terrain and climatic conditions involved. A
daily status check for all cars being used is required. Contractor shall maintain vehicles of the
Company with due diligence and utmost care to ensure safety of the vehicles. Contractor
shall keep a record of all checks and services for each Company vehicle.
C.5.3
Contractor shall provide an English speaking driver with the necessary experience to obtain a
PDO driving licence for Company use seven days per week for the duration of the Contract.
C.5.4
Where Contractor is required in the Scope of Work to provide vehicles for the use of
Company personnel, they shall at the start of the Contract be either new or have less than
10,000 Km mileage. The vehicles shall be 4 wheel Drive, preferably Mitsubishi Pajero V6
(LWB) or Company approved equivalent.
C.6
Recreational facilities
C.6.1
Contractor shall make available separate recreational facilities for the Company personnel,
with a floor area of minimum 24 square metres, and furnished with easy chairs.
C.6.2
In each camp a 29” colour TV connected to a sattalite dish, sattalite reciver, and DVD Player
shall be available for the sole use of Company personnel.
C.6.3
Magazines and daily newspapers shall be provided by the Contractor as per Company’s Site
Representative’s requirements.
C.6.4
At each Contractor Camp, facilities shall be provided for outdoor sports (football, tennis, etc.),
type to be agreed with Company Site Representative.
SP-1208
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Pipeline Construction Specification
APPENDIX D:
Version 3.0
LIST OF HANDOVER AND AS-BUILT DOCUMENTATION
The Contractor’s onsite representative shall ensure sufficient copies of the documents and data contained in this appendix are handed to the Company Site
Representative and Company Project Engineer to enable one copy to be given to the custodians listed for each item in this appendix. For example for
category 1.1 five copies are required (for custodians OXO1X, OXO4X, OXO61, UEC15, UIP4)
1.1
Drawing control register
DC
OXO1x, OXO4x,
OXO61, UEC15, UIP4
(See remarks)
N/A
N/A
Retained until drawings are as-built and stored in
CCMS.
1.2
Pipeline inspection reports
CC
OXO61, UEC15, UIP4
Service life
Electronic or Paper
CIRRAS-RBA
Archived items to be referenced in CCMS.
1.3
Equipment reports
Vendor
OXO1x,OXO4x, OXO61,
UEC15,UIP4
Service life
Electronic or Paper
3
Archive
Archived items to be referenced in CCMS.
1.4
Operating manual
DC
OXO1x, OXO4x,
OXO61, UEC15, UIP4
Service life
Electronic
3
CCMS
Essential data for each line held in CIRRAS-RBA,
accessed via GIS. All data specified in minimum
data requirements shall be entered into the
Company Asset Register (SAP)
Design reference manual
DC
OXO1x, OXO4x,
OXO61, UEC15, UIP4
Service life
Electronic
3
CCMS
Essential data for each line held in CIRRAS-RBA,
accessed via GIS
1.5
A) Pipeline Design basis – At minimum to
cover :
•
Design Code
•
Design Life
•
Design Factor
•
Pipeline Class
•
M.A.O.P
•
Design temperature (min / max)
•
Design Flowrate
•
Material grade
•
Outside Diameter
•
Length
•
MAOP
•
Nominal Wall Thickness
•
Internal Diameter Summary
•
Minimum bend radius
SP-1208
Page 58
Keep
Built
Storage
format
Feb 2011
Location
General Reports
Retention
time
1.0
**
Custodians
As-
Remarks
Originator *
Document Category
•
Wall thickness variations & locations
•
Internal & external coatings (types,
locations, thickness, inc field joints)
•
Liner thickness (applicable for PE lined
pipeline)
•
Number of vents (for PE lined pipeline)
•
Road and
(locations)
•
Summary of in line components &
dimensions (valves, pig traps, tees,
wyes)
wadi
crossings
Location
As-
Remarks
Keep
Built
Storage
format
Retention
time
Originator *
Document Category
**
Version 3.0
Custodians
Pipeline Construction Specification
details
B) Pipeline corrosion management plan at
minimum should contain the followings:
•
List of relevant Corrosion threats and
mitigation measures – corrosion risk
assessment
•
Pigging requirement and frequency
•
Corrosion mitigation e.g. corrosion
inhibition, biocide, O2 scavenger etc
•
Coupon and LPR location and its
frequency for retrieval
•
Design corrosion rate
•
Corrosion inhibition injection points
•
Cathodic protection system
Insulation joint
1.6
Soil investigation report
SC
OXO1x, OXO4x
2 years
Paper
Archive
Storage reference in CCMS.
1.7
Environmental data
SC
OXO1x, OXO4x
2 years
Paper
Archive
Storage reference in CCMS.
1.8
Studies - feasibility/conceptual/ front end
DC
OXO1x, OXO4x ,
OXO61, UEC15
Project
completion (see
remarks)
N/A
N/A
Conceptual data underlying chosen design
options to be retained with DRM (1.5 above)
1.9
Technical audit/HAZOP reports
DC
OXO1x, OXO4x
(See remarks)
Electronic
CCMS
Retained until close out of HAZOP actions.
1.10
Close-out reports
PE
OXO1x, OXO4x
2 years
Electronic
CCMS
2.0
General Drawings
2.1
Plot plans
DC
OXO1x, OXO4x,
OXO61, UEC15
Service life
Electronic/Paper
SP-1208
Page 59
Feb 2011
3
CCMS
Drawing reference in GIS.
Note, benchmark
locations included in plot plans.
Version 3.0
DC
OXO1x, OXO4x
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
2.3
Process flow schemes
DC
OXO1x, OXO4x,
OXO61, UEC15
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
2.4
Utility flow schemes
DC
OXO1x, OXO4x,
OXO61, UEC15
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
2.5
Process and engineering flow scheme
DC
OXO1x, OXO4x,
OXO61, UEC15, UIP4
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
2.6
Utility and engineering flow scheme
DC
OXO1x, OXO4x
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
2.7
Material identification diagram
DC
OXO1x, OXO4x
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
3.0
Civil Documents
3.1
Road and paving plan
DC
OXO1x, OXO4x
Service life
Electronic/Paper
3
CCMS
3.2
Foundation location plan
DC
OXO1x, OXO4x
Service life
Electronic/Paper
3
CCMS
3
Fencing and grading plan
DC
OXO1x, OXO4x
Service life
Electronic/Paper
3.4
Non-standard pipe supports, guides and
anchors
DC
OXO1x, OXO4x
Service life
Electronic/Paper
4.0
Mechanical Documents
4.1
Piping key plans
DC
OXO1x, OXO4x,
OXO61, UEC15, UIP4
Service life
Electronic/Paper
4.2
Piping plans
DC
OXO1x, OXO4x,
OXO61, UEC15, UIP4
Service life
Electronic/Paper
Equipment data sheets
Vendor
OXO1x, OXO4x,
OXO61, UEC15, UIP4
Service life
Vendor drawings for end closures, valves,
insulating couplings, barred tees, Pig signaller
Location
Keep
Built
Storage
format
Retention
time
3.3
4.3
Remarks
As-
Hazardous area classification drawing
**
2.2
Custodians
Document Category
Originator *
Pipeline Construction Specification
Drawing reference in GIS.
CCMS
Drawing reference in GIS.
CCMS
Drawing reference in GIS.
3
CCMS
Drawing reference in GIS.
3
CCMS
Drawing reference in GIS.
Electronic or Paper
Archive
Archived items to be referenced in CCMS.
4.4
Isometrics
DC
OXO1x, OXO4x,
OXO61, UEC15, UIP4
Project
completion
N/A
N/A
4.5
Material take off
DC
OXO1x, OXO4x,
OXO61, UEC15
Project
completion
N/A
N/A
4.6
Material/equipment requisitions
DC/PE
OXO1x, OXO4x
See remarks
Electronic
SAP
Retain for longer of guarantee period or 2 years.
Reference in CCMS
5.0
Pipeline Documents
5.1
Pipeline routing key plan
DC
OXO1x, OXO4x,
OXO61, UEC15, UIP4
Service life
Electronic
CCMS
Drawing reference in GIS.
SP-1208
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Feb 2011
3
Version 3.0
XTO/2
OXO1x, OXO4x,
OXO61, UEC15, UIP4
Service life
Electronic or Paper
3
GIS
Ref. TS18V1-0.doc & TS-19V1-0.doc
5.3
Alignment sheets
DC
OXO1x, OXO4x,
OXO61, UEC15, UIP4
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
5.4
Station approach drawings
DC
OXO1x, OXO4x,
OXO61, UEC15, UIP4
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
5.5
Tie-in schedule
DC
OXO1x, OXO4x,
OXO61, UEC15, UIP4
Project
completion
N/A
3
N/A
- Installation date
Remarks
Location
Keep
Built
Storage
format
Retention
time
As-
Route maps
**
5.2
Custodians
Document Category
Originator *
Pipeline Construction Specification
- SAP functional location
6.0
Electrical Documents
6.1
Single line diagram
DC
OXO1x, OXO4x, OXO62
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
6.2
Power cable layout layout drawing
DC
OXO1x, OXO4x, OXO62
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
6.3
Earthing layout drawing
DC
OXO1x, OXO4x, OXO62
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
6.4
Lighting layout drawing
DC
OXO1x, OXO4x, OXO62
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
6.5
Cable schedule
DC
OXO1x, OXO4x, OXO62
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
6.6
Trench layout
DC
OXO1x, OXO4x, OXO62
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
6.7
Electrical material requisitions
DC/PE
OXO1x, OXO4x, OXO62
See remarks
Electronic
SAP
As 4.6, above.
7.0
Instrument Documents
7.1
Instrument location plan
DC
OXO1x, OXO4x, OXO63
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
7.2
Instrument data sheets
DC
OXO1x, OXO4x,
OXO63
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
7.3
List of alarm and trip settings
DC
OXO1x, OXO4x,
OXO63
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
7.4
Shutdown matrices
DC
OXO1x, OXO4x, OXO63
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
7.5
Functional logic diagram
DC
OXO1x, OXO4x,
OXO63
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
7.6
Loop diagrams
DC
OXO1x, OXO4x, OXO63
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
SP-1208
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Feb 2011
Remarks
DC
OXO1x, OXO4x, OXO63
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
7.8
Control room layout
DC
OXO1x, OXO4x, OXO63
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
7.9
List of telemetry points
DC
OXO1x, OXO4x, OXO63
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
7.10
Control room instrument cable layout
DC
OXO1x, OXO4x, OXO63
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
7.11
Junction box layout
DC
OXO1x, OXO4x, OXO63
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
7.12
Instrument requisitions
DC/PE
OXO1x, OXO4x, OXO63
See remarks
Electronic
3
SAP
As 4.6, above
8.0
Cathodic Protection Documents
8.1
Ground bed layouts
DC
OXO1x, OXO4x,
OXO61, UEC15, UIP4
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
8.2
Wiring diagrams/cable sizes
DC
OXO1x, OXO4x
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
8.3
Cabling routing layout
DC
OXO1x, OXO4x
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
8.4
Transformer rectifier plot layout
DC
OXO1x, OXO4x,
OXO61, UEC15, UIP4
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
8.5
Layout of CP facilities
DC
OXO1x, OXO4x,
OXO61, UEC15, UIP4
Service life
Electronic/Paper
3
CCMS
Drawing reference in GIS.
8.6
CP survey report
SC
OXO1x, OXO4x,
OXO61, UEC15, UIP4
Service life
Electronic or Paper
Archive
Archived items to be referenced in CCMS.
8.7
CP material specification report
SC
OXO1x, OXO4x
Service life
Electronic or Paper
Archive
Archived items to be referenced in CCMS.
8.8
CP installation specification
SC
OXO1x, OXO4x
Service life
Electronic or Paper
Archive
Archived items to be referenced in CCMS.
8.9
CP requisitions
DC
OXO1x, OXO4x
Service life
Electronic
SAP
As 4.6, above.
9.0
Pipeline Construction Documents
9.1
Welding and NDT procedures
CC
OXO1x, OXO4x
Service life
Electronic or Paper
Archive
Archived items to be referenced in CCMS.
9.2
Welding/NDT progress chart
CC
OXO1x, OXO4x
2 years
Paper
Archive
Storage reference in CCMS.
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Keep
Built
Storage
format
Feb 2011
Location
Alarm annunciator system
Retention
time
Custodians
7.7
**
Originator *
Document Category
Version 3.0
As-
Pipeline Construction Specification
Location
As-
Remarks
Keep
Built
Storage
format
Retention
time
Originator *
Document Category
**
Version 3.0
Custodians
Pipeline Construction Specification
9.3
NDT reports/Test packs
CC
OXO1x, OXO4x
Service life
Electronic or Paper
Archive
Archived items to be referenced in CCMS.
Relevant data to be entered in PACER.
9.4
Radiographs
CC
OXO1x, OXO4x
2 years
Film
Archive
Storage reference in CCMS.
9.5
Commissioning documentation
OTL
OXO1x, OXO4x,
OXO61, UEC15, UIP4
2 years
Paper
Archive
Storage reference in CCMS.
9.6
Hydrotest certificates
CC
OXO1x, OXO4x,
OXO61, UEC15, UIP4
Service life
Electronic or Paper
Archive
Archived items to be referenced in CCMS.
Relevant data to be entered in PACER.
9.7
Insulating coupling test forms
CC
OXO1x, OXO4x
Service life
Electronic or Paper
Archive
Archived items to be referenced in CCMS.
Relevant data to be entered in PACER.
9.8
Instrument calibration certificates
CC
OXO1x, OXO4x
2 years
Paper
Archive
Storage reference in CCMS.
9.9
Launcher and receiver inspection form
CC
OXO1x, OXO4x,
OXO61, UEC15, UIP4
Service life
Electronic or Paper
Archive
Archived items to be referenced in CCMS.
9.10
Punch list
PE
OXO1x, OXO4x
(See remarks)
N/A
N/A
Retained until actions cleared.
9.11
CP Installation inspection report
CC
OXO1x, OXO4x
Service life
Paper
Archive
Storage reference in CCMS.
9.12
Construction drawings
CC
OXO1x, OXO4x
(See remarks)
N/A
N/A
Retained until master drawings are updated.
9.13
Misc. site correspondence, records, MOM etc.
CC
OXO1x, OXO4x
Project
completion
N/A
N/A
Selected documents of contractual significance
may be archived for 2 years.
10.0
Vendor Documents
10.1
Vendor drawings for end closures, valves,
insulating couplings, barred tees
Vendor
OXO1x, OXO4x,
OXO61, UEC15, UIP4
Service life
Electronic or Paper
Archive
Storage reference in CCMS.
10.2
Material certification, reports and test data for
linepipe and fittings.
Vendor/T OXO1x, OXO4x
PI
Service life
Electronic or Paper
Archive
Archived items to be referenced in CCMS.
Surplus material documentation held by TSP.
10.3
Material certification, reports and test data for
static and rotating equipment
Vendor/T OXO1x, OXO4x
PI
Service life
Electronic or Paper
Archive
Archived items to be referenced in CCMS.
10.4
Certification, reports and test data for surplus
materials
Vendor/T OXO1x, OXO4x
PI
Until required
Electronic or Paper
Archive
Archived items to be referenced in CCMS.
10.5
Operating instruction manuals
Vendor
Service life
Electronic or Paper
Archive
Archived items to be referenced in CCMS.
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OXO61, UEC15, UIP4
Feb 2011
10.6
Maintenance instruction manuals
List of maintenance activities reqd (type,
frequency)
•
Operating envelope (MAOP, flowrate,
temperature)
•
Pressure protection and relief valve
settings
•
List
of
SCE’s
and
performance standards
10.7
SPIR forms
**
Construction Contractor
DC
Design Contractor
PE
Project Engineer (Company)
SC
Specialist Contractor
TPI
Third Party Inspector
Location
As-
Service life
Electronic or Paper
Archive
Archived items to be referenced in CCMS.
Vendor
OXO1x, OXO4x,
OXO61, UIP4
Service life
Electronic or Paper
Archive
Archived items to be referenced in CCMS.
associated
The Project Engineer shall distribute the documents to the respective Custodians as per Company policy.
SP-1208
Keep
Built
Storage
format
OXO1x, OXO4x,
OXO61, UEC15 UEC13,
UIP4
Abbreviations
CC
Remarks
Vendor
At minimum the design data should contain:
•
Retention
time
Originator *
Document Category
**
Version 3.0
Custodians
Pipeline Construction Specification
Page 64
Feb 2011
Pipeline Construction Specification
APPENDIX E
Version 3.0
LIST OF TYPICAL DRAWINGS FOR PIPELINE
CONSTRUCTION
Sr.
No.
Sketch No.
Rev.
Drawing Title
1
TYP-3-0001-001
O
ROW and working strip details
2
TYP-3-0002-001
O
Trench Dimensions
3
TYP-3-0003-001
O
Cold field bending details
4
TYP-3-0004-001
O
Road crossing over existing above ground pipeline
5
TYP-3-0005-001
O
Road crossing over existing under ground pipeline
6
TYP-3-0006-001
O
Pipeline crossing tarmac road
7
TYP-3-0007-001
O
Live stock passageway crossing
8
TYP-3-0008-001
O
Pipeline crossing Wadi Type A
9
TYP-3-0009-001
O
Pipeline crossing Wadi Type B
10
TYP-3-0010-001
O
Pipeline crossing Wadi Type C
11
TYP-3-0011-001
O
Pipeline crossing existing above ground pipeline
12
TYP-3-0012-001
O
Pipeline crossing existing under ground pipeline
13
TYP-3-0013-001
O
Pipeline crossing existing under ground cables
14
TYP-3-0014-001
O
Pipeline in parallel
transmission line
15
TYP-3-0015-001
O
Retaining Barriers in sloping trenches
16
TYP-3-0016-001
O
Pipeline Markers & signs
17
TYP-3-0017-001
O
GRE pipeline crossing road
and
crossing
high
voltage
The drawings are for information only.
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Pipeline Construction Specification
Version 3.0
NOTES:
A
A
TYPICAL ROAD CROSSING OVER EXISTING UNDER GROUND PIPELINE
SECTION A-A
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Distance to be
confirmed by
Material and
Corrosion
Engineer TA2 Level
Distance to be
confirmed by
Material and
Corrosion
Engineer TA2 Level
Distance to be
confirmed by
Material and
Corrosion
Engineer TA2 Level
Note: R.O.W for Main Oil and Gas Lines, as per Royal Decree no. 2/99, shall have an inviolable area 25 meters wide on either side of their center line.
The above dimensions shall be in line with the referenced Royal Decree.
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Pipeline Construction Specification
APPENDIX F
Version 3.0
CONSTRUCTION REQUIREMENTS FOR GRE
PIPELINES
F.1. Introduction
F.1.1 Background and Scope
This Appendix specifies additional requirements for the construction of all new GRE pipeline
systems in PDO operations. Construction of LLRTP and GRE pipelines shall be carried out as
per requirements provided by the vendor and approved by the Company.
The numbering system in this Appendix is designed to allow for easy reference back to the
main text by using the same numbering system contained therein. Wherever applicable, only
additional requirements and modifications pertaining to construction of GRE pipelines are
given in this Appendix.
Activities that are largely common to both material groups, e.g. HSE, clearing, trenching etc.,
are included in the main text of this specification. Whilst these general topics may be applied
to the installation of any non-metallic linepipe material, including thermoplastic liners, specific
requirements and guidelines in the current version of this Appendix are primarily concerned
with GRE pipelines.
Apart from PE linings, GRE is the only non-metallic pipe material which has been used by
PDO for Class 1 pipelines in Hydrocarbon service. PE lining and RTP linepipe have been in
regular use for Class 2 pipelines (mostly flowlines) for a number of years. Current PDO
specifications DEP 31.40.30.34 / SP-2092 and SP-2094 apply for procurement and
installation of these materials. GRE pipelines shall be installed in accordance with this
specification and ISO 14692-4, taking due account of the limitations noted in the GRE linepipe
purchase requisition and associated stress analysis executed by the GRE linepipe vendor.
F.2.
Specification Requirements
F.2.2 Quality Assurance
F.2.2.3 Quality Assurance Team
F.2.2.3.1
Personnel
The Head of Quality Assurance shall have a detailed knowledge of installation and inspection
of GRE pipelines. He shall have general experience in quality assurance matters and be
suitably qualified.
F.2.2.3.2
Organisation
Contractor’s supervisors and all manufacturer’s representatives of GRE pipe vendor, field
service engineers working for the Contractor under EPC contracts shall report directly to the
Head of Quality Assurance on quality assurance matters. (Under non-EPC contracts the pipe
vendor representatives and, if applicable, other manufacturer’s representatives for other
Company supplied materials, shall report to the Company CSR).
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F.2.3 Materials Handling and Control
F.2.3.2 General
Contractor shall confirm to the Company at an early stage in the project that the testing
methods of factory made GRE spools, piping and fittings are acceptable for installation. The
Company shall review and approve the test results prior to start of construction.
F.2.3.3 Pipe Inspection
F.2.3.3.1
The Contractor shall visually inspect and dimensionally check each pipe and fitting.
For Company supplied materials, the inspection shall be done before removal of the material
from the Company’s storage yards. Thereafter the Contractor shall accept responsibility for all
material losses and damage however caused. The inspection shall include a detailed check
for damage or dimensional non-conformances of bells and spigots. Any shortages,
dimensional non-conformance, missing end protectors or damage, including scratches,
gouges, crushing, cracking etc. shall be reported to the Company within 24 hours of receipt.
F.2.3.4 Pipe Handling
F.2.3.4.1
Pipe shall not be allowed to drop or strike objects which may damage the pipe but
shall be lifted, moved and lowered from one position to another by suitable equipment. Nonabrasive wide nylon or canvas pipe slings of minimum width 200mm shall be used for lifting
pipe. Chains, cables or clamps shall not be used.
F. 2.3.4.2
Trucks used to transport pipes shall be flat-bottomed and free of any projections or
loose materials that might damage or contribute to movement of the pipe during transport.
Pipes shall be protected against truck beds and side metallic protrusions by means of nonmetallic soft materials. Pipes shall be loaded and stacked on trucks in such a manner that
flexing and shifting of the pipe during transport is avoided. After loading, suitable non-metallic
slings shall be used to tie the load securely to the truck. During transport the tension of these
slings shall be regularly checked. The Contractor shall ensure that no pipe end protectors can
be lost during transport. Pipes shall only be transported on trucks (side booms and other
lifting equipment shall not be used to transport pipe on site for distances in excess of 50
meters).
F.2.3.5 Pipe Stacking
F.2.3.5.1
Ground surfaces to be used for stacking of pipe shall be reasonably flat. Pipe shall
not be laid directly on the ground, concrete floors or on to rails. Pipes shall be laid on suitable
supports, such as timber of 100mm x 50mm section. End protectors shall remain in place
during storage and care shall be taken to ensure adjacent socket and spigot ends are kept
out of contact. End protectors may be punctured with a 5mm drill to prevent them blowing off
the pipes.
F.2.3.5.2
Pipes may be stacked to a height of 1.5m provided suitable supports are provided
both at the sides of the stack and between layers. Typically, 100mm x 50mm timber (spacer
stripping) may be used for both purposes. Supports between layers should be in vertical
alignment, located no more than 3m apart and a minimum of 1m from the pipe ends. Where
strapping down of stacks is necessary, nylon straps should be used, and for long storage
periods a suitable cover should be fitted on each stack. Additionally, the Contractor shall
comply with GRE pipe manufacturer’s recommendations for pipe stacking. In the case of a
conflict or ambiguity, the Company will determine which requirements shall apply.
F.2.3.5.3
Pipes of different diameter, wall thickness, pressure class, material grade or
manufacturer shall be stacked separately. Each stack shall be properly marked to the
satisfaction of Company.
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F.2.3.6 Handling and Control of Consumable Products
F.2.3.6.1
Adhesives, resins and additives shall be stored in accordance with the manufacturer’s
written instructions in a cool air conditioned area, away from direct sunlight and excessive
humidity. Adhesives shall be kept in refrigerated conditions if the storage period is in excess
of one month, or as specified by the manufacturer, whichever is shorter. Contractor shall
demonstrate compliance with site storage procedures for all consumables in accordance with
detailed consumable handling procedures. A continuous record of temperatures of adhesive
storage conditions shall be maintained.
F.2.3.6.2
For reasons of safety, hardeners, catalysts and accelerators shall be stored
separately in accordance with manufacturer’s instructions. Solvents shall be similarly
segregated as required by the relevant Material Safety Data Sheets.
F.2.3.6.3
No consumables shall be stored or used beyond its stated shelf life.
F.2.3.6.4
GRE fittings shall be stored inside or in their original crates out of direct sunlight.
F.2.4 R.O.W. and Trenching
F.2.4.3 Trenching
F.2.4.3.2
Excavation
d) The Contractor shall excavate and grade the trench sufficiently deep and wide to provide
a minimum of 500 mm working space on both sides of the pipe (where jointing is done in
the trench) and space for 150 mm of padding material after compaction all around the
pipe and for the continuous length of the pipeline. The trench profile after excavation shall
be such that the radius of curvature in any plane is greater than the minimum allowable
bending radius specified by the linepipe vendor. Local high and low points in the trench
bottom shall be levelled off to provide a smooth continuous profile. The Contractor’s
surveyor shall survey the trench and submit a formal report with photographs, survey data
and a detailed profile drawing with invert levels at 12 m spacing, providing evidence that
this requirement is achieved.
i)
SP-1208
The Contractor shall do hand work in the trench as is necessary to free the bottom of the
trench of loose rock, stones and all other irregularities so as to leave the trench bottom in
a clean and suitable condition to receive the pipe. A fulltime dedicated crew shall be
employed by the contractor to maintain the trench in a rock-free condition before and after
pre-padding has been installed, at all times until the trench is completely backfilled.
Page 85
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Pipeline Construction Specification
Version 3.0
F.2.5 Pipe Stringing and Bending
F.2.5.3 Bends
F.2.5.3.1
Small changes in direction, in the vertical as well as the horizontal plane, may be
achieved by elastic bending, provided the bend radius is greater than the specified minimum
elastic bending radius specified by the pipe manufacturer for the supplied linepipe. Where this
is not possible, e.g. due to right-of-way restrictions, fabricated elbows shall be used, as
specified in the design drawings and approved by the linepipe manufacturer and the
Company. Special attention is required at transitions between above ground and buried
installation to avoid elastic bending. At locations where the pipeline comes above ground, the
bottom of the trench shall be flat for a minimum distance of 25 m. In this section, elastic bends
are not permitted. Any changes to the design layout of the pipeline, including moving of bend
locations shall be subject to written approval of the Company and the linepipe manufacturer.
This may require revised stress analyses to be executed for the pipeline.
F.2.5.3.2
To allow for large expansion at bends such as those caused by wide temperature
fluctuations or hydrotest conditions, expansion cushions shall be installed as per design
behind each bend and extending to approximately 5 m each side of the bend. However, it is
required to accommodate the expansion of bends through proper design and stress analysis.
F.2.6 Jointing
F.2.6.1 This section of the specification covers requirements for the jointing of GRE pipelines. The
requirements for qualification and production jointing of all types joints including laminated
joints are specified in ISO 14692-4.
F.2.6.2 The Contractor shall prepare a Method Statement covering the jointing work to be carried out
and a detailed procedure for each type and size of joint and fitting to be joined. These shall be
in accordance with the Manufacturer’s instructions, Company specification and standards.
Separate procedures shall be prepared for shop fabrication, site jointing work and repair work.
All joint types shall be qualified and approved by the Company before its use in production
joints.
F.2.6.3 In order to ensure piggability of the pipeline during hydrotest water filling, in service and for
future decommissioning work using foam pigs, particular attention shall be paid to the need
for effective internal cleaning of each completed GRE adhesive bonded joint after fit-up, and
prior to curing, in order to ensure that no significant amount of adhesive protrudes from the
inside seam of any glued joint. Reference is made ISO 14692-4 table 4.where it is specified
under possible defects – excess adhesive shall not be more than 5% of inner diameter or
10mm which ever is less. The Contractor shall propose a method for cleaning the internal
joints for Company review and approval in his detailed jointing procedure.
F.2.6.4 Each joint shall be inspected and certified by the QC Engineer to have been executed in
accordance with the approved jointing procedures. Inspection or witnessing of the make up of
any joints by the manufacturer’s field service engineer shall not absolve the Contractor of his
responsibilities to provide a fit for purpose joint. As a minimum, the Contractor shall keep
detailed records of make up and curing time, batch number of adhesive components as well
as jointer ID and date/time for each joint.
F.2.6.5 Jointed pipes shall not be moved or handled during curing.
F.2.6.6 No more than 3 km of pipe shall be jointed prior to successful completion of the hydrotest of
the first section of 50 joints of installed pipeline.
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F.2.6.7 All documents shall be submitted to the Company for approval. Procedures and operators
shall be qualified to the requirements of the controlling specifications before commencement
of any production jointing.
F.2.8 Lowering-in, Backfilling and Reinstatement
F.2.8.2 Pre-Padding
F.2.8.2.1
All trenches shall be fully pre-padded before lowering in or jointing in the trench. No
padding shall be placed until Company has inspected and approved the trench bottom and
the Contractor’s surveyor has confirmed that the trench bottom profile complies with the pipe
manufacturer’s minimum bending radius requirements.
F.2.8.3 Lowering-in and Post-Padding
F.2.8.3.1
All pipes shall be lowered in within 96 hours of completion of jointing. The Contractor
shall keep the lowering in operation within 1 km of the jointing operation.
F.2.8.3.3
A minimum of 3 sidebooms shall be used for lowering in strings of jointed pipe in
excess of 50 meter. Cranes shall not be used for lowering in operations of pipe strings longer
than 50 meters. The trench shall be maintained in a dry condition during lowering-in and
backfill operations. During lowering in operations the pipe shall not be subject to bending in
excess of the minimum allowable bending radius. A detailed procedure specifying the means
of demonstrating compliance with the minimum bending radius requirement shall be
submitted as part of the Contractor’s installation procedures, for Company approval, at least 3
weeks prior to the planned commencement of any lowering in operations.
F.2.8.3.4
The Contractor shall take measures to restrain the pipe in the trench by means of
‘plugging’, i.e. placing sand on top and around the pipe at regular intervals (one 6m ‘plug’ in
the middle of every pipe) or by a Company approved equivalent method. The Contractor shall
plan the work such that the lowering in and ‘plugging’ operations take place together during
the coolest part of the day, (i.e. in the morning). Strings longer than 100 meter shall not be
allowed to lie in the trench without sand plugging. This is to avoid ‘snaking’ and abrasion of
the pipe due to thermal movement.
F.2.8.3.5
Sand padding ‘plugs’ shall be placed around and above the pipe, so as to fill the
trench to a depth of 300 mm above the crown of the pipe, with the sand padding shaped to its
natural angle of repose and with a minimum of 150 mm at any point around the pipe. No pipe
shall be left overnight in the trench without sand padding around and above the pipe. (Joints
shall be left fully exposed around the joint circumference for inspection until completion and
acceptance of the hydrotest)
F.2.8.4 Tie-ins
F.2.8.4.1
Unless otherwise agreed by the Company, tie-ins of the pipeline sections shall take
place in the trench by means of the same type of connections as the pipeline or if the pipeline
connections are not of bonded type, by means of glued connections, using couplings if
necessary. For tie-ins outside or above the trench, holding and lowering operations shall be
undertaken in such a manner as to minimise stresses and bending in the pipe and avoid
movement of the pipe from the skids. Due consideration shall be given to ambient
temperature changes throughout the day and the resultant pipe length changes and induced
stresses.
F.2.8.4.2
To minimise excessive internal protrusion of adhesives in bonded tie-in connections,
care shall be taken not to place excess amounts of adhesive near the end of the bell, and to
use the tip of the spigot to locate no more than the minimum required amount of adhesive at
the internal joint seam location.
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F.2.8.4.3
All tie-in connections to metallic systems shall be by means of flanged connections.
Tie-ins to other GRE pipe systems may be made by flanged connections or by means of
bonded couplings.
F.2.8.5 Backfilling
F.2.8.5.1
The trench shall not be backfilled until the Company has approved the sand padding
around and above the pipe and has confirmed its approval for the backfilling operation to
commence. Backfilling shall be performed as soon as possible after padding has been
approved, but not prior to the successful completion of the hydrotest.
F.2.8.7 Livestock Passageways
Unless otherwise indicated on the drawings, livestock passageways shall be installed at
intervals of approximately 2 km and may be combined with graded road and track crossings.
The livestock passageways shall be constructed by means of a cased pipeline crossing in
accordance with drawing TYP-3-0017-001 buried at a minimum depth of 1500 mm to the top
of the casing pipe. The width of the crossing shall be 2.5 m and the total length shall be 6.5
m. Access barriers shall be installed on the ends of the crossing to indicate the safe crossing
width of the livestock passageway for light vehicles.
F.2.8.9 Anchor Blocks & Thrust blocks
F.2.8.9.1
The need for concrete anchor or thrust blocks in the pipeline system will be
determined during detailed design, depending on the expected operational pressure surges,
temperature changes, nature of the ground and the geometry of the pipeline layout. Approval
shall be obtained from the relevant linepipe and fittings manufacturers, if changes are
required.
F.2.8.9.2
Anchor blocks should normally be located in line with fittings, tie-ins to steel pipe and
to exposed runs of pipe. The concrete should be poured in situ on to undisturbed or
compacted soil. Where parts of the pipe or fitting joints are to be encapsulated by the block,
hydrostatic pre-testing of the joint assembly should be completed first. Alternatively blocks
may be cast before pipe laying and the pipes fastened with brackets inlaid with an elastomeric
strip. All anchor blocks shall be installed and cured prior to commencement of any
hydrotesting activities on the pipeline.
F.2.8.9.3
For GRE lines, a layer of elastomeric material 6 – 10 mm thick shall be wrapped
around sections of pipes or fittings before concrete is applied. Concrete shall not be poured
directly on to unprotected GRE surfaces.
F.2.8.9.4
No more than half the circumference of the pipe or fitting shall be cast into the
concrete thrust block. Thrust block casting around entire fittings or joints shall be avoided.
F.2.9 Road and Wadi Crossings
F.2.9.2 Road Crossing with Casing
Where GRE pipelines are required to cross under roads and highways, the pipe shall be
protected by installation within a steel or HDPE casing pipe with a minimum cover of 1500
mm to the top of the casing pipe.
Detailed installation methods of cased pipe shall be in accordance with the Manufacturer’s
recommendations for the particular pipeline material and shall be agreed with the Company.
The following requirements shall apply for GRE pipe:
•
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Specific construction requirements shall be in accordance with the project scope
of work and alignment drawings. The construction of cased crossings is covered
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by standard drawing TYP-3-0017-001. Signs indicating maximum axle loadings
shall be provided at each crossing.
F.2.9.3
•
The assembled pipeline section in crossing shall be subjected to an air leak
tightness test before its installation into the casing.
•
Cased pipes shall be fitted with spacers (minimum 4 per pipe length at a
maximum spacing of 3000 mm) to ensure the pipe is centred and to prevent
damage during installation.
•
The ends of the casing shall be sealed with flexible bellows of approved design to
be fitted over the casing ends and the pipe to prevent influx of backfill material
into the annulus. Filling the entire annular space with polyurethane foam is also
acceptable.
•
Steel casing pipe shall be externally coated to prevent corrosion, with a Company
approved coating material.
•
Prior to backfilling, suitable devices may be attached to both carrier pipe and
casing pipe on each side of the crossing to enable monitoring of differential
movement between the casing and the carrier pipeline.
Wadi-Crossings
All wadi crossings in GRE pipelines shall be through steel or HDPE casings with sufficient
negative buoyancy to prevent the casing and pipe from floating in empty condition.
Continuous buoyancy compensation and impact protection may be provided by means
properly designed concrete coating of the casing pipe along the full length of the Wadi
crossing. Casings shall be externally protected against corrosion using an appropriate
coating system.
Requirement for installation of the GRE pipe into the casing is covered in 2.9.2, above.
Concrete coating of the casing pipe is required in accordance with Section 2.10 of the
main text.
F.2.15
System Hydrotesting and Certification
F.2.15.1
Scope
F.2.15.1.1
On completion of installation, the GRE pipeline system shall be flushed, hydro tested
and certified in accordance with DEP 31.40.10.19, ISO-14692-4 and this specification.
F.2.15.1.2
The testing of each test section shall commence as soon as possible and, so far as is
practicable within the programme, shall be undertaken progressively throughout the
construction of the line. The first 500 meter of jointed pipe shall be tested within two weeks
of completion in order to provide confidence that the workmanship and installation
procedures are fit for purpose. If the 500 meter section hydrotest is satisfactory, then the
lengths of each subsequent test section shall be decided by the Contractor. If the test on
the first 500 meter fails, then the next 500 meter section shall also be tested separately.
The pipeline shall be tested in 500 meter sections until such time that the Contractor
demonstrates his ability to install a 500 meter section without hydrotest failures.
F.2.15.1.3
Only soft foam pigs shall be used for cleaning, filling and dewatering of GRE
pipelines.
F.2.15.1.4
No gauging of GRE pipelines is required as online pigging is not envisaged for GRE
pipelines.
F.2.15.2
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Hydrostatic Testing
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The minimum requirements of hydrostatic testing operations relating to safety, materials and
equipment used, cleaning, filling, temperature stabilisation, pressurisation, air content
verification, testing, depressurising, dewatering and hydrotest documentation applicable for
metallic pipelines (SP-1212) shall also be reviewed and taken into account when preparing
the hydrotest procedures for GRE pipelines.
Any ambiguities or lack of clarity between these requirements specified and the
requirements of DEP 31.40.10.19 shall be identified to the Company for the purposes of
specification improvement. However, in the case of clearly contradictory requirements (e.g.
tightness test calculations), the additional requirements of this specification shall prevail
over other specifications.
F.2.15.2.1
Short term Strength Test
The pipeline shall be subjected to one(1) hour strength test to a pressure equal to 1.5 times
the design pressure. The pressure shall be maintained at the test pressure + 100 kPa by
bleeding or adding water as required.
If a leak is suspected the pressure shall be reduced to the pipeline design pressure before
carrying out a visual examination. No personnel shall come closer than 5 meters from the
pipeline before the pressure has been reduced to design pressure. Subsequently, a “step
test” shall be performed. In this test the test section shall be re-pressurised to the leak
tightness test pressure and after each hour the pressure shall be recorded and the section
re-pressurised by adding water. The quantity of water required to bring the section back to
the test pressure shall be recorded. This shall continue for a period of 24hours. If the
quantity of water added shows a decreasing trend then it may be considered that the
pipeline is tight. If the quantity of water added remains constant then it must be assumed
that the pipeline is not leak tight. No work shall be carried out to repair leaks until the
pressure has been reduced to a safe pressure i.e. static head plus 100 kPa.
During the test, deadweight tester readings shall be recorded every 30 minutes and pipe,
soil and air temperature recorded every 1.5 hours.
F.2.15.2.2
Tightness Test
The pipeline shall be subjected to a 24 hour tightness test, immediately following the
strength test, at the pressure indicated on the drawings. (This should be 110% of design
pressure). No water shall be added or removed during the test.
The test shall demonstrate, to Company’s satisfaction that there are no leaks in the
pipeline. This shall be achieved by visual inspection of each joint every 4 hours during the
hydrotest period. A tightness test check calculation shall be made to verify that no large
leaks have been missed. Allowance shall be made for instrument inaccuracies and also the
pressure changes as a result of average temperature changes, calculated from the formula
given in DEP 31.40.10.19 (assuming a fully restrained line section). The average
temperature of the pipe may be used for this calculation. The temperature measurements
taken on the exposed pipe may be included in determining the average pipe temperature.
In the event of there being any doubt about the tightness of the line, as determined from the
visual inspections, the test shall be extended or repeated to Company’s satisfaction at no
additional cost to Company. The tightness test calculation shall be provided to the
Company for information.
During the test, the pressure shall be recorded continuously, deadweight tester readings
shall be recorded every 30 minutes and pipe, soil and air temperatures recorded at
maximum 3 hour intervals. The temperature recording interval shall be reduced to 30
minute duration for the first and last 2 hours of the 24 hours to assist with the
pressure/temperature variation check calculation.
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F.2.15.3 GRE and Steel Station Pipework
Station Pipework shall be subjected to a combined strength/tightness test of 4 hour
duration, at the test pressure shown on the Drawings. The first one hour of the test shall not
exceed a pressure 1.5 times the design pressure of any GRE component. The remainder of
the test shall not exceed 1.1 times the design pressure of any GRE component. The
pipework may be tied-in and retested as part of a pipeline section in order to avoid an
additional test head, an additional tie-in joint or bulk water loss etc.
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USER COMMENT FORM
SP-1208 – Pipeline Construction Specification User Feedback Page
Any user who identifies an inaccuracy, error or ambiguity is requested to notify
the custodian so that appropriate action can be taken. The user is requested
to return this page fully completed, indicating precisely the amendment(s)
recommended.
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