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KUWAIT OIL COMPANY (K.S.C.)

Engineering Group

Specification Number

Pipeline Construction

Engihedng Grwp

Specification Number

Rev

Date

Sheet

015-IH-1001

1

9-7-94

2 of 28

CONTENTS

1.0

SCOPE

3

2.0

STANDARD SPECIFICATIONS

 

3

3.0

SERVICE CONDITIONS

6

4.0

TECHNICALREQUIREMENTS

6

5.0

RIGHT-OF-WAY (ROW)

6

6.0

GRADING

OF

CONSTRUCTION

ROW

AND

CARE

OF

EXISTING

FEATURES

6

7.0

UNLOADING.

STOCKPILING.

HAULING

AND

STRINGING

OF

MATERIALS

 

8

8.0

DITCHING INCLUDING ROCK EXCAVATION

 

9

9.0

CROSSINGS

 

11

10.0

FIELDBENDS

12

11.0

LINING-UP AND WELDING

 

14

12.0

PROTECTIVE COATING OF FITTINGS. LlNE PlPE AND FIELD JOINTS

15

13.0

LOWERING-IN

 

15

14.0

TIE-INS

16

15.0

FITTINGS

17

16.0

WASHOUTS AND DRAINAGE

 

18

17.0

PADDING AND BACKFILLING OF THE TRENCH

 

18

18.0

CATHODIC PROTECTION TEST POINTS AND LINE MARKERS

 

19

19.0

IMPRESSED CURRENT GROUNDBEDS

 

19

20.0

FINAL CLEAN-UP OF THE CONSTRUCTION ROW

19

21.0

AS-BUILT DRAWINGS AND PIPE BOOK

20

21.1 General

 

20

21.2 As-Built Drawings

 

20

21.3 Pipe Book

 

22

21.4 Identification

23

@KoC

EngMng Grwp

SpecJfication

Specification Number

015-IH-1001

Rev

1

Date

9-7-94

Sheet

3 of 28

1.0

SCOPE

1.I

This document covers the minimum requirements the Contractor shall consider in supply of materials and the construction of the pipelines and ancillary facilities for installation at the Facility in Kuwait.

1.2

The construction of the pipelines shall fully comply with all relevant contractual requirements specified in the Scope of Work and the Technical Specification of the Contract.

2.0

STANDARD SPECIFICATIONS

2.1 The construction of pipelines and ancillary shall conform, except where specified otherwise, with the current issue and amendments of the following prevailing on the effective date of the Contract:

2. I.IInternational Standards

ASME Section IX

ASME Section Vlll

Qualification Standard for Welding and Brazing Procedures, Welders, Brazers and Welding and Brazing Operators

Boiler and Pressure Vessel Code

ASME 81.20.1

Pipe Threads

 

ASME B16.5

Pipe Flanges and Flanged Fittings

ASME B16.9

Factory-made

Wrought

Steel

Buttwelding Fittings

 

Buttwelding Ends

Gas

Transmission

and

Distribution

Piping Systems

Liquid Petroleum Piping Systems

 

Welded and Seamless Wrought Steel Pipe

ASME B46.1

Surface Texture

 

API 5L

Specification for Line Pipe

 

API

6D

Specification for Pipeline Valves (Gate, Plug, Ball and Check Valves)

API

6FA

Fire Testing of Valves

 

API 594

 

Wafer Type Check Valves

 

API

598

Valve Inspection and Testing

API 600

 

Steel Gate Valves-Flanged Welding Ends

and Butt

API

602

Compact Steel Gate Valves

API 609

 

Lug-and Wafer-type Butterfly Valves

API RP 1110

Pressure Testing of Liquid Petroleum Pipelines

API RP 1102

Pipeline Road Crossing

 

API RP

1 104

Welding

of

Pipelines

and

Related

 

Facilities

ASTM Specifications for Ferrous Piping Materials

MSS-SP-25

Standard Marking System for Valves, Fittings, Flanges and Unions

MSS-SP-44

Steel Pipeline Flanges

MSS-SP-75

High Test Fittings

NACE MR0175

Sulphide Stress Cracking Resistant- Metallic Materials for Oilfield Equipment

NACE RP01-77-83

Mitigation of Alternating Current and Lighting Effects on Metallic Structures and Corrosion Control Systems

2.1.2 British Standards

BS 5146

BS 5351

Specification for Inspection and Test of Steel Valves for the Petroleum, Petro- Chemical and Allied lndustries

Steel Ball Valves for the Petroleum, Petro-Chemical and Allied lndustries

EnglnfHIring Group Specification

EnglnfHIring Group

Specification

EnglnfHIring Group Specification Rev Date Sheet

Rev

Date

Sheet

015·fH-l00l

9·7·94

5

of 28

Rev Date Sheet 015·fH-l00l 9·7·94 5 of 28 Structural of 1.3   0 1 1 Criteria
Rev Date Sheet 015·fH-l00l 9·7·94 5 of 28 Structural of 1.3   0 1 1 Criteria
Rev Date Sheet 015·fH-l00l 9·7·94 5 of 28 Structural of 1.3   0 1 1 Criteria
Rev Date Sheet 015·fH-l00l 9·7·94 5 of 28 Structural of 1.3   0 1 1 Criteria
Structural of

Structural

of

Structural of

1.3

1.3
 

01

1

0 1 1 Criteria  

Criteria

 

01

1002

01 1002 Codes  

Codes

01 1002 Codes  
 

015-1

1001

Pipeline

Pipeline
 

015-IH-1002

Pipeline

n

015-IH-1004

Pipeline

ing and Hyd

ing and Hyd T e s t

Test

 

015-1

1

Pipeline

Pipeline

and Drying

015-IH-1006

g Lau

g Lau Ivers

Ivers

 

015-IH-1008

peline

peline

Welding

Welding
 

Service

 

015-IH-1010

External

External 9 of Line Pipe with Coal

9 of Line Pipe with Coal

 

r Enamel

015-IH-1011

Induction Be

s

015-IH-1012

Joint

J o i n t
 

015-IH-1014

Line Pipe Materials (Spiral Pipe), Submerged-Arc Welding (SAW)

 

015-XH-1005

and

a n d
 

01

01 1

1

Cathodic

Protection

Design

 

uirements

 

2.2

Compliance with this specification

2.2 Compliance with this specification

responsibility to supply and

responsibility to supply and pment

pment

N43·0160

Eng/Mng Group

SpeMIwbn

Specification Number

015-IH-1001

Rev

1

Date

9-7-94

Sheet

6 of 28

2.5 Where conflicts exist between this specification and other Drawings, standards, codes or specifications, the most stringent shall be applied.

3.0 SERVICE CONDITIONS

3.1 The construction of the pipelines and ancillary shall be suitable for continuous operations at the desert location under high ambient temperatures and humidity. The atmosphere at the Facility is generally dusty and corrosive and may contain traces of hydrogen sulphide.

3.2 The installed pipelines shall in all respects be suitable for continuous operation in service conditions stated in the Engineering Group Specification entitled "Basic Design Criteria" (Number 015-AH-1001).

4.0 TECHNICAL REQUIREMENTS

The Contractor shall establish a chainage marking survey for the Crude Oil Transit System, low-pressure (LP) gas lines, high-pressure (HP) gas lines and Fuel Gas System.

The survey control shall be staked at a maximum of 50-m intervals on the tangents and 10-m intervals on curves. The numbering system shall be continuous. Staking shall be on the ditch centre line with reference stakes established for each centre line stake, but offset by 20 m from the ditch centre line.

The survey shall locate all buried services, which shall then be shown on the alignment sheets. This survey shall also establish the depth of the services.

5.0

RIGHT-OF-WAY (ROW)

5.1 The Contractor shall not start any construction work on the ROW until control staking has been approved by the Company.

5.2 The Contractor shall clear and level the construction ROW to the degree required to support all work scope activities.

6.0

GRADING OF CONSTRUCTION ROW AND CARE OF EXISTING FEATURES

6.1 The Contractor shall perform such grading of the ROW as is required to properly perform the pipeline construction, and to provide access to the pipeline during the construction period.

Specification Number

015-IH-1001

Rev

1

Date

9-7-94

Sheet 7 of 28

except in those locations where easements for ROW or permits restrict the same to a lesser width or the particular circumstances at specific locations necessitate a lesser width. When such lesser widths of ROW are necessary, such lesser widths shall be controlling and binding on Contractor.

The ROW width shall be limited to 20 m. Where the construction ROW passes over, through or along roads, the Contractor shall grade only the width of the ROW necessary for digging the pipeline trench and constructing the pipeline. In areas which require a greater width for construction activities, prior approval of the Company shall be obtained.

The Contractor shall perform all necessary grading at road crossings and at any other location required to permit the passage of construction equipment.

The Contractor shall take every precaution in providing temporary fencing, supports, and other protective devices as necessary to avoid damaging existing pipelines, electrical lines and cables, fences, roads, drainage, irrigation systems and any other existing above- or belowground structures, or property, adjacent to or crossing the pipeline being constructed.

The Contractor shall perform any clearing necessary to accommodate the installation of the pipeline and related facilities. Above the ground pipelines crossing, the ROW shall be lowered to a procedure submitted by the Contractor and approved by the Company.

Great care shall be taken of any cultivated ground. For these areas the topsoil shall be carefully removed and protected against erosion and contamination by blown sand and kept for reinstatement by the Contractor after the pipeline is constructed.

Any archaeologicalmonuments and remains uncovered during trenching and ROW clearance shall be brought to the attention of the Company immediately on discovery.

The Contractor shall stop operations in the area of an archaeologicalfind until the significance and extent of the find is determined and the Company gives approval to resume with the work and any special actions to be taken.

During any work on pipelines influenced by high-voltage lines, specific safety measures shall be taken for the protection of personnel. These protective measures shall be detailed in the Contractor's Pipeline Safety Manual. This shall include protection to cranes, sidebooms and all other construction equipment.

6.1 1 The Contractor shall comply with Company hot working, permit and safety systems.

6.12

When any existing line is located and/or when the berm is removed from any existing line, the Contractor shall clearly indicate its buried route by pegs and warning signs.

6.13

The Contractor shall protect the existing line from vehicle wheel loads

by suitable barriers or the placement of protective slabs.

Berms of

existing lines so removed shall be replaced or left at the discretion of the Company.

7.0 UNLOADING, STOCKPILING, HAULING AND STRINGING OF MATERIALS

The Contractor shall unload, stockpile, load, haul and string all materials and shall make all the necessary arrangements and agreements.

The Contractor shall be responsible to maintain pipe in good condition. All end caps removed for inspection shall be replaced.

The method of stacking pipes, bare and coated, shall be subject to review by the Company. It is the Contractor's responsibility to ensure that no distortion of pipe shape or any other damage to pipe or coating occurs during storage and pipelay operations.

The Contractor shall be responsible for providing suitable trucks and equipment in sufficient quantity to transport materials to construction sites in accordance with agreed-to schedules.

The Contractor shall set up adequate methods of inventory and material transfer so as to provide accurate accountability of all material at all times during the Contract.

The Contractor shall use a Pipe Traceability System that shall enable control and tracing of all pipe from source through to its as-built position.

The Contractor shall handle pipe with equipment of a suitable capacity using approved slings, spreader bars, and protected hooks. The slings, spreader bars and hooks shall be made available to the Company for inspection and approval before loading or unloading is commenced. Pipes shall not be rolled onto or from conveyances, nor handled in any manner which distorts the round form of the ends, or scratches, gouges or dents the pipe. Pipes shall not be dragged along the ground.

Any damage to the bare pipe or coating

stockpiling, subsequent handling or any other cause shall be repaired or the pipe and coating replaced by the Contractor at the Contractor's

hauling,

resulting from

expense.

The Company shall be notified prior to any repairs taking

place.

Pipes strung on the construction ROW shall be protected by setting the pipe in a manner that shall cause no damage to the pipe coating.

Pipe stringing in rock ditch areas shall not be permitted until ditching is complete. Pipe ends may be placed on wooden skids to prevent ground contact during stringing.

Pipe shall be strung in such a manner as to result in the least amount of interference to the normal use of the land crossed, and gaps shall be left at approximately 500-m intervals or at existing tracks to permit the use of the land and the passage of equipment, or other normal traffic across the construction ROW.

Materials shall be stored, as required, hauled to the work Site and assembled on the Site in such a manner as to prevent damage, theft, or other loss. Materials shall be covered whenever possible, materials shall not be stored near sites of operations such as blast cleaning or painting, and all materials shall be stored in locations separated from surplus and scrap materials.

The Contractor shall be fully responsible for providing and paying for all storage areas, except as may be made available by the Company.

The Contractor shall be responsiblefor construction and maintenance of any necessary temporary roads for the construction of the pipeline.

repairs to and reinstatement

of existing roads or any property damaged by the hauling and stringing operations.

The

Contractor shall be responsible for any

8.0 DITCHING INCLUDING ROCK EXCAVATION

8.1 The Contractor shall stake the centre line of the pipeline and flag the limits of the working area of the ROW in accordance with Construction Drawings approved by the Company. The Contractor shall dig the pipeline trench on the staked centre line of the pipeline.

8.2 The Contractor shall employ equipment and methods to keep the ditch to the line established regardless of the type of soil and rock encountered and regardless of the depth of excavation necessary.

QKK- Englm~Gnwp

Specification Number

015-IH-1001

Rev

1

Date

9-7-94

Sheet 10 of 28

The Contractor shall, wherever practicable, maintain depth of cover and stability by minimising bending and by operating the trenching machine

at various depths andlor grading the ROW.

The Contractor shall carefully preserve any stakes andlor benchmarks set by the Company. The Contractor shall be liable for any extra expense due to its failure to maintain such stakeslbenchmarks.

The Contractor shall dig the pipeline trenches in accordance with the approved Construction Drawings.

The use of explosives is not permitted in the trenching operations.

The minimum width of the trench as measured at the horizontal centre line of the pipe when in place in the trench shall be 0.4 m greater than the outside diameter of the pipe. Where two pipes are in a single trench, the spacing and clearances shall be as shown on the approved Construction Drawings.

The minimum depth of cover shall be as shown on the approved Construction Drawings. Where not shown, the minimum depth of cover shall be 1.0 m.

Minimum depth of cover shall be measured from the top of the pipe to the level of the graded surface of the soil.

In any locations where, in the opinion of the Company, the use of ditching equipment may result in damage to existing pipelines, property,

or facilities crossed by the ROW, the Company may require the ditch to

be excavated by hand.

The Contractor shall use detectors or other devices to locate foreign installations that may be crossed or encroached upon.

The Contractor shall do such hand work in the trench as is necessary to free the bottom of the trench of loose rock and hard lumps and to trim other foreign matter from the bottom and sides of the trench.

The Contractor shall excavate as necessary for the installation of valves, foundations, supports, anchors and other equipment shown on the Project Drawings.

If jack hammers andlor rock breakers are required to be used within 2

m of any buried pipelines and between any pipelines running in the same

easement, all-around pipe protection shall be provided by the Contractor

before commencing.

8.16 Existing pipelines shall be excavated using hand tools and be adequately supported. Mechanical equipment shall not be operated within 5 m of the existing pipelines.

8.17 Precautions shall be taken at these exposed pipelberm areas to ensure

place during trenching

that

operations.

no erosion of the soft sandfill takes

8.18 Prior to exposure of any existing pipelines, the Contractor shall erect a suitable, substantial barrier to prevent any damage to those pipelines, particularly where removal of the berm for trenching operations opens up a gap which could be used by vehicles as an unauthorised crossing.

8.19 Trenches shall be approximately 4.5 m from the agreed-to edge of the ROW.

9.0

CROSSINGS

Where the pipeline crosses roads, other pipelines, sewers, water lines, cables, conduits or other underground structures of any kind, the Contractor shall dig and grade the trench to a depth and in the manner specified on the Project Drawings.

The Contractor shall install combined cathodic protection test stationslline markers at road crossings and crossings of existing pipelines. The markers shall be in accordance with Project Drawings.

The Contractor shall provide adequate supports for all existing services during the construction operations including concrete slabslbeams as required by the Company.

Although Project Drawings may indicate certain existing aboveground and underground utilities such as water lines, telephone lines and other pipelines, such location and crossing information is only provided as guide to the Contractor. The Company does not warrant or guarantee the accuracy or completeness of the said information, and the identification of all existing services is the responsibility of the Contractor. The Contractor shall perform a survey of the route prior to ditching to find all buried and aboveground services. All these services shall be shown on the alignment sheets. The survey shall also establish the depth of the service.

In locations where the trench is cut across roads, paths, wadis, walkways, and other access routes, the Contractor shall provide temporary bridges of adequate strength and proper construction. The Contractor shall submit its proposals for temporary bridges to the Company for review prior to construction.

Specification Number

015-IH-1001

Rev

1

Date

9-7-94

Sheet

12 of 28

The Contractor shall construct bypass roads as required by the Company and in accordance with any statutory requirements in order to allow the passage of normal traffic with a minimum of inconvenience and interruption.

Whenever it is permissible to open cut a paved road crossing, the Contractor shall remove and replace the paving in accordance with the restrictions and requirements of the Company.

The Contractor shall submit a method statement of its proposals to effect paved road crossings with a view to complete the trenching, laying and backfilling of such crossings and to remove the temporary bridging or bypass before the end of the regular workday.

Proper warning signs and barricades shall be placed and maintained while paved road crossings are open. If such crossings are open at night, the Contractor shall provide and use electrically operated warning lights or lanterns in accordance with the requirements of the responsible authorities, and, if necessary, provide watchmen.

The Contractor shall place danger signs visible during dry light and red lanterns of flame visible during night 100 m from excavated road crossing in both direction of traffic. Danger signs are to be in English and Arabic and must be recognisable at 50 m.

Breaks in the berm for a vehicle crossing at every kilometre post shall be constructed as a track crossing. This provision does not apply to pipelines in existing corridors where no corresponding crossing is provided over the existing pipelines. In existing corridors, the Company shall instruct the Contractor as to the correct location for such crossings.

The sections of pipeline route crossing overhead power line way leaves shall be buried without bunds and constructed as a track crossing.

The Contractor shall provide trench crossings at other locations as necessary to permit operators and/or other contractors to perform their work with a minimum of inconvenience and

10.0 FIELD BENDS

10.1

The Contractor shall make all necessary pipe bends req juired in the

construction of the pipeline. The Contractor shall provide for change in

vertical and horizontal alignment by making cold field bend, except where otherwise stated in the specifications or Project Drawings or as authorised by the Company.

.

E@&ng

Spe&whn

Grwp

Specification Number

Rev

Date

Sheet

015-IH-1001

1

9-7-94

130f 28

The Contractor shall furnish competent engineers and assistants necessary for determining location and size of all bends. Such bends shall be reviewed by the Company.

The Contractor shall bend the pipe to conform to the grade and horizontal alignment of the trench. Field bends shall be required at all points where the change in grade or horizontal alignment is such that the pipe will not conform to such changes by elastic bending.

The Contractor shall develop a procedurefor field bending for approval.

Company

In no case shall the radius of a field bend be less than 40 times the outside diameter (OD) of the pipe being bent.

Bending machines shall be of a type approved by the Company and shall be suitable for bending coated pipe without damage to the coating.

The Contractor shall employ and use an experienced Bending Engineer, who shall be furnished with such equipment and assistance as is required to ensure that all field bends are made in such a manner that the pipe fits the trench with uniform bearing, maintains the required depth of cover indicated on Construction Drawings and, when in place in the trench, is neither in tension nor compression.

All bends shall be of a uniform radius and the curvature shall be distributed over as great a length of pipe as is reasonably possible.

The configuration of field bends shall be in accordance with the following:

10.9.1 Bending shall not be made within 2 m of the end of a joint of pipe or girth weld.

10.9.2 For bending the longitudinal weld of the pipe shall be on the neutral axis of the pipe. Bending of spirally welded pipe shall not be made.

10.9.3 No bend shall be acceptable if the difference between the largest diameter of the pipe and the smallest diameter, at any point in the bend, is more than 2.5% of the inside diameter (ID).

10.9.4 Before any bend is incorporated in the pipeline, it shall be tested for ovality with a gauging plate of diameter not less than 95% of the pipeline ID.

EngJmng Gnwp

mn

Specification Number

015-IH-1001

Rev

1

Date

9-7-94

Sheet 14 of 28

10.1 1

No mitre bends shall be

permitted for installation of the pipelines.

10.12

The Contractor shall cut out and remove any bends which do not meet the specification and replace them at its own cost.

10.13

Pipeline induction bends shall be as per the Engineering Group Specification entitled "Induction Bends" (Number 015-IH-1001).

11.0 LINING-UP AND WELDING

The Contractor shall align and weld together the joints of pipe into a continuous pipeline, and all welds in the pipeline made by the Contractor shall be of strength equal to that of the pipe and of the quality set forth in this specification. Permitted weld hardness and other parameters shall be in accordance with the applicable weld qualification procedure. All welding procedures shall conform to the Engineering Group Specification entitled "Field Welding" (Number 015-IH-1008) and API 1104 (latest edition).

Coated pipe shall be suitably supported on padded supports giving a ground clearance not less than 0.3 m.

Each pipe joint shall be thoroughly swabbed to remove all dirt and foreign matter from the inside of the pipe before the joints are lined up and welded. The swabbing operation shall not be carried out on more than six pipe joints ahead of the stringer bead welders.

Where the pipeline is welded in long sections for crossings or other obstructions, the ends of the long sections shall be capped in a manner approved by the Company until the long sections are tied-in. During the laying operations, close attention shall be given to open ends to ensure an open, clean line free of any obstructions. All precautions shall be taken to prevent water from entering the pipeline.

The open end of the line shall be securely closed at the end of each day's work to prevent entrance of small animals or the introduction of foreign matter of any nature and shall not be reopened until work is resumed. The Contractor shall remove all obstructions in the line after the completion thereof.

Tack welding of end caps to the line pipe is not permitted.

The Contractor shall use approved line-upclamps and shall ensure during the line-up operation that longitudinal or spiral welds are offset at 90° or 10 in., whichever is larger. Internal line-up clamps shall be used for 16-in. and larger size pipes.

11.8 All welding procedures, welder and NDT personnel shall be qualified as specified in the EngineeringGroup Specification entitled "Field Welding" (Number 015-IH-1008).

11.9 Pipelines constructed within the area of high-voltage lines may be electrically influenced by these high-voltage lines. The induced voltage caused by the influence may at times be high enough as to pose a danger to personnel working on the pipeline. The Contractor shall specify detail safety aspects of this construction in the Contractor's Safety Manual.

12.0 PROTECTIVE COATING OF FITTINGS, LINE PIPE AND FIELD JOINTS

12.1 The pipeline shall be protected by an external coating of glass fibre, reinforced coal tar enamel or polyken system as detailed in the Engineering Group Specification entitled "External Coating of Line Pipe Using Coal Tar Enamel" (Number 015-IH-1010).

12.2 The Contractor shall furnish all materials, equipment, labour and supervision and shall be responsible for cleaning, priming and coating the line pipe, field joints, valves, fittings, connections and appurtenances,

recleaning, repriming and recoating to meet the

together

with

specification.

12.3 The coating of pipeline field joints, tie-ins and fittings shall be made in accordance with the Engineering Group Specification entitled "Pipeline Field Joint Coating" (Number 015-IH-1012).

12.4 Repairs to coatings shall be made in accordance with the Engineering Group Specification entitled "External Coating of Line Pipe with Coal Tar Enamel" (Number 015-IH-l Ol O), and to procedures submitted by the Contractor and approved by the Company for the coating materials to be used.

12.5 The Contractor shall make a detailed inspection of the coating for

immediately

preceding the lowering in of the pipe. The Contractor shall furnish high voltage electric holiday detectors set to the Approved Manufacturer's recommendations.

holidays and imperfections,

with

a

holiday detector,

12.6 All holidays and damaged places in the coating shall be repaired by the Contractor until the detector is passed over the entire joint without disclosing any holiday or imperfections in the coating.

12.7 The coating condition shall be inspected by the Company prior to backfilling.

13.0 LOWERING-IN

Specification Number

015-IH-1001

Rev

1

Date

9-7-94

Sheet

16 of 28

The Contractor shall provide sufficient sidebooms, cradles, slings and equipment to adequately support the pipe during lowering in. All equipment must be tested and certified by an Approved Authority prior to any work.

The Contractor shall lower in the pipe into the trench after the coating and wrapping of field joints.

Pipe shall not be lowered into the trench until the bottom of the trench has been cleared of all debris and the bedding has been graded so that the pipe has a uniform bearing. The Contractor shall request and receive approval from the Company prior to lowering in any pipe.

The Contractor shall be required to provide padded slings for handling coated pipe. The use of belting reinforced with wire cable is not permitted. Any method of lowering-in that prevents damage to the coating shall be acceptable; however, the use of pneumatic-tyred cradles is preferred. A holiday detection survey shall be run continuously behind the cradle, and any repairs necessary shall be made prior to bedding the pipe.

The handling of the pipe shall be done in such a manner that the pipe in its final position in the trench shall be free from abraded spots or holidays.

Where water is present, no lowering-in shall be permitted until the ditch has been dewatered to the extent and for the time necessary to make visual inspection by the Company of the bedding material on which the pipe is to be laid. Following such inspection, the presence of water shall be permitted provided that it is not so high as to cause cave-in of the walls of the trench or floating of the pipeline before padding and backfilling, when weighting of the pipe is not provided.

When lowered in, the pipeline shall have a clearance of 0.1 5 m on either side of the trench wall.

When lowering in parallel pipelines in the same trench, the minimum distances between the pipelines indicated in the approved Drawings shall be maintained and shall be minimum 0.5 m.

The lowering operation shall be carried out by the Contractor when pipe temperatures are within the limits and in accordance with the lowering- in temperatures.

Eng/dng Grwp

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Specification Number

Rev

Date

Sheet

015-IH-1001

1

9-7-94

170f 28

13.11 All equipment used for lifting and handling the pipelines and components shall be tested, inspected and certified by an Approved Authority. The test certificates showing safe working loads, safety systems, etc. shall be submitted to the Company for approval.

14.1

The Contractor shall do all work necessary to tie-in separate welded sections of the pipeline into a continuous system.

14.2

All bevelling, aligning and welding shall be done in accordance with the Engineering Group Specifica,tion entitled "Pipeline Field Welding Non- Sour Service" (Number 015-IH-1008).

14.3

Welding after the pipe has been lowered into the ditch (bell-hole welding) shall be done only where sufficient clearance has been provided to enable the welder to exercise normal welding skill and ability and to ensure against trench collapse.

14.4

The protective coating of tie-in welds shall be done in accordance with the Engineering Group Specification entitled "Pipeline Field Joint Coating" (Number 015-IH-1012).

14.5

All pipe 2 m or more in length cut off at tie-in points shall not be allowed to accumulate but shall be moved ahead daily as the Work progresses and welded into the line as directed by the Company.

14.6

The Contractor shall observe the maximum and minimum tie-in temperature to be used based on the prevailing temperature conditions and the calculations developed during detail design.

14.7

The Contractor shall perform tie-ins as soon as practicable after lower-in

of the strings.

Extended periods between lower-in and tie-in shall only

be allowed when specified tie-in temperatures cannot be reached.

14.8

The maximum length of exposed unsupported pipeline must not exceed 7 m. When it exceeds five 5 m, a central substantial wooden support shall be installed with a minimum 10-mm-thick rubber "shoe" or equivalent contacting the pipe.

15.1

Pipeline fittings shall include but not be limited to insulating joints, temporary scraper traps, valves and fittings and branch connections, cathodic protection test stations, anchor flanges, line markers and miscellaneous supports and concrete foundations for the above and for the specified related facilities as needed.

GTOUD

I Specification Number

I

Rev

I

Date

1

Sheet

15.2 The Contractor shall install all such fittings as specified herein and as shown on the approved construction Drawings. Welding shall be in accordance with the Engineering Group Specification entitled "Field Welding Non-Sour Service" (Number 015-IH-1008).

15.3 All scale, dirt and debris shall be removed from the inside of the piping fittings before installation.

16.0 WASHOUTS AND DRAINAGE

Wherever the possibility exists of soil erosion due to surface water runoff as in wadis, underground water or wind, the Contractor shall provide protection for the pipeline and install drainage, barrier wind breaks or other installations, as required.

17.0 PADDING AND BACKFILLING OF THE TRENCH

The Contractor shall pad and backfill the trench after the pipe is in place as set forth in the approved construction Drawings.

Padding material shall be finely graded material with a maximum particle

Padding material may be graded desert fill, graded

size of 3 mm.

excavated material or dune sand but shall be free of organic material.

When the depth of the trench is 1.5 m or more, proper shoring arrangements shall be implemented. Shoring shall be monitored on a daily basis.

The Contractor shall avoid passing by or crossing of heavy machinery across the trench. Shoring shall be carried out by competent workmen. Excavated trench shall not be left open for a long time to avoid any inward cavement at the toe of the trench.

The Contractor shall grade the trench bedding material to give the maximum amount of support to the pipeline when it is lowered into place. The material shall be compacted to the degree specified by the approved detail design calculations.

The Contractor shall place padding material in such a manner as to cause no damage to the pipe coating and compact it to the degree specified in the approved detail design calculations.

The depth of padding shall be such as to give the pipe in place the specified clearance from the hard material.

The Contractor shall not commence the padding operation until the Company has inspected and approved the lowered-in pipe. If any backfilling is done without Company approval, the Company shall have the right to require removal of the backfill for examination, and the cost

Eng/1)001jngGrwp

mn

Specification Number

Rev

Date

Sheet

015-IH-1001

1

9-7-94

19 of 28

of such uncovering shall be borne by the Contractor.

shall survey and record as-built measurements, including location and record pipe joint numbers and welds before padding material is placed.

The Contractor

17.9 The padding material to shade the pipe shall be applied immediately after the trench is approved for backfilling.

17.10 All lowered-in pipe shall be shaded with padding material at the end of each working day or otherwise restrained by spot backfilling.

17.1

1

After the padding operation is complete and compaction requirements achieved, the Contractor shall commence the backfill and berm installation as specified on the approved construction Drawings.

17.1

2

Backfill material, as specified on the approved construction Drawings, shall be piled over ditch to at least 1 m high above original ground and covered with the Company-approved material as soon as possible for stabilisation.

17.13

Berm material shall be selected from desert fill or excavated material in rock areas. Berm material shall be free from organic material and course graded. Fines shall be placed at the bottom of the berm with greater particle sizes on the top. The berm angle shall be less than the normal angle or repose of the berm material. Crude oil for berm stabilisation will be made available to the Contractor by the Company.

18.0 CATHODIC PROTECTION TEST POINTS AND LINE MARKERS

Shall be executed by others.

19.0

IMPRESSED CURRENT GROUNDBEDS

Shall be executed by others.

20.0

FINAL CLEAN-UP OF THE CONSTRUCTION ROW

20.1 After approval of berm placement above the backfilled trenches in accordance with construction Drawings, the Contractor shall restore the construction ROW to its original contour and condition, or as otherwise agreed upon, with the approval of the Company

20.2 All surplus and defective materials supplied by the Contractor for the construction of the pipelines and all trash, refuse and unusable spoil materials shall be collected and disposed of by the Contractor to the satisfaction of the Company.

20.3 The construction ROW shall be graded smooth, and surface soil shall be carefully replaced in a manner acceptable to the Company.

-

N43-0160

-

d-r flu. ar

I

Specification Number

1

Rev

1

Date

1

Sheet

The Contractor shall reinstate all fencing, temporarily removed or relocated by the Contractor during pipeline construction. All fences cut or damaged shall be repaired by installing new sections of fencing equal to or better than the sections cut or damaged. Temporary gates shall be removed and replaced by new fence sections as agreed upon with the Company.

The Contractor shall supply all the gravel or gatch required to cover areas as shown on approved Drawings. The Contractor shall dress-up areas disturbed during construction and shall rework surfaced areas as required for acceptable finish condition.

The Contractor shall reinstate all land drains disturbed by construction operations to the satisfaction of the Company.

The final ROW shall be graded smooth enough to provide for access to light four-wheel-driven units.

21.0 AS-BUILT DRAWINGS AND PIPE BOOK

21.1

General

21.1.1

The Contractor shall prepare as-built Drawings of all Company- issued Project Drawings and of all the Contractor's construction Drawings including vendor Drawings, such as but not limited to:

 

For pipeline section:

a. Piping and instrument diagrams.

b. Pipeline alignment sheets.

c. Route maps.

d. Profile maps.

e. Detail Drawings (road crossings, pipe crossings, etc).

f. General-arrangement Drawings of installation.

g. Isometric Drawings of special installations.

h. Pig launcher and receiver scraper areas arrangement Drawings and isometrics.

i. Cathodic protection.

 

21 .I.2

The Contractor shall prepare a Pipe and Weld Book.

EngJdng Grwp

SpeMiw&n

Specification Number

015-IH-1001

Rev

1

Date

9-7-94

Sheet

21 of 28

21.1.3 The Contractor shall submit to the Company for approval a procedure for all documentation gathering and compilation.

21.2 As-Built Drawinas

The Contractor shall prepare a complete set of as-built Drawings. From the start of construction, the Contractor shall process daily any changes into two sets of Drawings. Deleted parts shall be indicated in red, new parts in blue, remarks in green and unchanged parts in yellow. Said Drawings shall be kept onsite and be available to the Company at all times. The Contractor shall prepare as-built Drawings based on these data and as laid down hereafter. On completion of the work, the Contractor shall provide the Company with all as-built

Drawings.

The required measurements for as-built Drawings shall be

executed

by

the

Contractor's

experienced and qualified

surveyors.

21.2.3 The surveyors shall daily collect and compile all measurements required such as but not limited to:

a.

b.

c.

d.

e.

f.

g.

h.

i.

j.

Horizontal location of the pipeline with regard to deviations and permanent grid pillars.

Vertical levels with regard to mean sea level of pipeline and grade.

Location and type of bends, fittings, grades, points of intersections, tangent points, overbend, underbends, transition pieces.

Changes of wall thickness size, grade and materials.

Location and details of valves, insulating flanges, fencing, power lines, buildings within 30 m from pipelines, etc.

Location and details of buried services.

Location and details of crossings, existing pipelines and utilities.

Location and details of road and track crossings.

Location and type of coating, field joint material and location of changes.

Location and type of weighting and anchoring.

k.

Location and type of markers, warning signs, pig signals.

1.

Location of further appurtenances, i.e., cathodic protection connections, instruments.

m.

Location of ROW.

n.

Type of soil.

0.

Sand padding.

P.

Type of road pavement.

q.

Details of bank protection.

r.

Location of radiographical inspections welds.

S.

The Contractor shall locate the existing installations of whatsoever nature at its own expenses.

21.3

Pi~eBook

21.3.1 The Pipe and Welding Book shall contain, but not be limited to:

a.

Data relevant to the project and section thereof.

b.

Material certificates for each batch of pipe.

c.

Sequential number for each weld and pipe joint.

d.

Length brought forward (for pipes and other material).

e.

Length to bring forward (for pipes and other materials).

f.

Alignment sheet number.

g.

Diameter of pipeline.

h.

Length of each pipe.

i.

Length of pipe per page.

j.

Wall thickness.

k.

Location of wall thickness changes.

I.

Pipe letter and number.

Eng/WngGw

Specification Number

015-IH-1001

Rev

1

Date

9-7-94

Sheet

23 of 28

m. Location and angle of field bends, factory bends and in-line fittings.

n. Cut and renumbered pipe ends.

o. Coating.

p. Date of stringing.

q. Date of welding.

r. Direction of working.

s. Welder number.

t. Type of welding, electrode, diameter.

u. Weld treatment.

v. Equipment used for radiography.

w. Limits of valve stations, road, and pipeline crossings, buried services crossings.

x. Test pressure, date and test (hydrostatic).

21.3.2 In order to achieve this, the Contractor shall identify all pipe elements. The Contractor shall track and document all pipes 2 m and greater in length and all condemned pipe for material

21.4

accountability.

Identification

The Contractor shall provide all pipes, bends, valves and fittings greater than 2 in. with serial numbers as soon as possible and measure their length and state it on the pipes, valves and fittings. Pipes to be bent shall be measured prior to

bending. ldentification (i.e., letter, number and length) shall be

indelible.

All serial numbers shall be recorded in a list, which shall also state relevant pipe numbers.

Besides recording the stamped-in pipe numbers, length of pipe and painted-on serial numbers, the stamped-in numbers of T- pieces, bends, valves and other fittings and the batch numbers of bends, T-pieces, valves and other fittings and the make of valves, shall also be recorded on said list.

Engtdng Grwp SpeMkWon

Specification Number

01 5-IH-1001

Rev

I

Date

9-7-94

Sheet 24 of 28

Before a pipe length, pipe end, etc. is cut, the painted serial number and stamped-in pipe number shall be transferred by the Contractor in the presence of the Company to either side of the joint which is to be made by cutting, and the changes shall be recorded in the above mentioned list stating the new length.

The result shall be such that all pipe pups of diameter greater than 2 in. bear clear marks painted on.

The Contractor shall explicitly instruct its staff that pipe which cannot be identified must be removed and condemned.

mn

Specification Number

015-IH-1001

Rev

1

Date

9-7-94

Sheet

25 of 28

APPENDIX 1: Pipeline Data Sheet Pipeline Length (Approx.) - For Information Only

Sheet 1 of 4

 

Length

KM

Crude Oil Transmission Line Network

One No. 20" spur line from GC-5 to manifold Burgan-1 (GI

4.5

One No. 12" spur line from new GC-12 to manifold Burgan-1 (GI

3.5

One 20" tie-in from GC-14 to existing line

1.5

Low Pressure Gas Transmission Network

One No. 18" gas line GC-5 to manifold "S7"

5.0

One No. 18" gas line from manifold "S7" to manifold "S6"

2.3

One 20" tie-in from existing line

GC-12 to

0.25

One 20" tie-in from

GC-5 to

2.5

existing 20" gas line

 

One 20" tie-in from existing line

GC-14 to

2.5

High Pressure Gas Transmission Network

One 12" tie-in from GC-5 to existing line

2.0

One 12" tie-in from GC-12 to existing line

0.25

One 12" tie-in from existing line

GC-14 to

0.10

Fuel Gas System

One 4" tie-in from existing line

GC-5 to

2.0

One 4" tie-in existing line

from

GC-12 to

0.25

One 4" tie-in from existing line

GC-14 to

1.5

EngiMng Gnwp

Category

Material

Nominal diameter

Wall thickness

Corrosion Coating

Operating and Design Pressure

Specification Number

015-IH-1001

Rev

1

Date

9-7-94

Sheet

26 of 28

APPENDIX 1

Requirement

API 5L Grade B

Sheet 2 of 4

120" NPS. 18" NPS. 12" NPS and 4" NPS

--

--

For all pipe size 9.5 mm

Polyolefin

MAOP

Design Pressure

20" NPS Spur Line

400

psi

500

psi

12" NPS Spur Line

400

psi

500

psi

20" NPS Crude Oil Tie-in

400

psi

500

psi

18" NPS Low Pressure Gas Line

60

psi

75

psi

20" NPS Low Pressure Gas Tie-ins

60

psi

75

psi

12" NPS High Pressure Tie-ins

300

psi

350

psi

4" NPS Fuel Gas Tie-ins

460

psi

500

psi

Flange Rating

Crude Lines

ASME Class 300

 

-

--

Fuel Gas

ASME Class 300

HP Gas Lines

ASME Class 300

LP Gas Lines

ASME Class 150

Hydrotest Pressure

ASME B.31.8 125% of MAOP or 90% SMYS

Minimum Cover

1.0 m (top of pipe)

Minimum Bending Radius Induction Bend

5D

Field Bend - Minimum Radius

40D

E~~ngGnwp

~~n

Specification Number

01 5-IH-1001

Rev

1

Date

9-7-94

Sheet

27 of 28

APPENDIX 1 GC-29 and 30

NetworklSystem

Crude Oil Transmission Line Network

Condensate Transmission Network

High Pressure Gas Transmission Network

Fuel Gas System

Length

Sheet 3 of 4

One 12" crude oil line from GC-30 to manifold

One 10" crude oil line from GC-29 to manifold

One 16" from manifold to existing line

One 6" condensate line GC-30 to manifold

One 4" condensate line from GC-29 to manifold

One 6" condensate line from manifold to existing line

One 10" from GC-30 to manifold

One 8" from GC-299 to manifold

One 10" from manifold to existing line

One 6" from existing line to manifold

One 6" from manifold to GC-30

One 6" from manifold to GC-29

APPENDIX 1

Category

Material

Nominal Diameter

Wall Thickness

Corrosion Coating

Operating and Design Pressure

lo", 12" 16" NPS Crude Oil Lines

8", 10" HP Gas

6", 4" Condensate

6" NPS Fuel Gas

Flange Rating

Requirement

Sheet 4 of 4

API 5L Grade B

16" NPS, 10" NPS, 8" NPS (spiral pipe) 6" NPS and 4" NPS (seamless)

For all pipe size 9.5 mm

1Polyolefin

I

I

MAOP

psi

930 psi

1230 psi

450

psi

I

I

1

I

Design Pressure

500 psi

950 psi

75 psi

400 psi

Crude Lines

ASME Class 300

Fuel Gas

ASME Class 300

HP Gas Lines

ASME Class 400

Condensate

ASME Class 600

Hydrotest Pressure

Minimum Cover

Minimum Bending Radius Induction Bend

Field Bend - Minimum Radius

ASME B.31.8 125% of MAOP or 90% SMYS

1.0 m (top of pipe)

5D

1400