Nigerian Gas Company Limited: Tender Document FOR Engineering, Procurement and

NIGERIAN GAS COMPANY LIMITED
(A SUBSIDIARY OF NIGERIAN NATIONAL PETROLEUM CORPORATION)
TENDER DOCUMENT
FOR
ENGINEERING, PROCUREMENT AND
CONSTRUCTION
OF
GAS SUPPLY FROM IBAFO TO SAGAMU

INTERCHANGE CUSTOMERS
VOLUME IV
NOVEMBER, 2013
GAS SUPPLY FROM IBAFO TO SAGAMU INTERCHANGE CUSTOMERS
SPECIFICATIONS
VOLUME IV Page 2 of 210

CONTENTS
PART 1A MECHANlCAL AND PROCESS EQUlPMENT
SECTION 1 General
2 Boiler Packages & Heat Exhangers
3 Pressure Vessels
4 Horizontal, Cylindrical Welded Steel Tank
5 Gas Scrubbers
6 Cold Vent. /Burn Pit
PART 1B MECHANICAL INSTALLATION SPECIFICATION
SECTION 1 General
2 Setting out the works
3 Fabrication standard
4 Installation of Piping
5 Joints
6 Construction Tolerance for Fabricated Piping
7 Thermal insulation & Cladding
8 Valve Installation
9 Testing
PART 2A PIPELINES AND PIPEWORK MATERIALS SPECIFICATION
SECTION 1 Line pipe

2 Station Piping
3 Deleted
4 Welding fittings
5 Forged Steel Butt-Welding Fittings
6 Flanges
7 Gaskets
8 Stud Bolts and Nuts
9 Pipeline Anchor flanges
10 Insulating Pipe Couplings
11 Scraper Launchers and Receivers
12 Sphere Tees
13 Valves –General
14 Steel Gate, Plug, BaII and Check. Valves
15 Needle Valves
16 Cast Iron Globe Valves Angle Pattern
17 Fire Valves

2B PIPELINES AND PIPEWORK INSTALLATION SPECIFICATION
SECTION 1 General and Miscellaneous

2 Pipeline construction
3 Welding of Pipeline
4 Coating
5 Protective Coating of above ground Paperwork
6 Cathodic Protection
7 Hot Tapping

PART 1A MECHANICAL AND PROCESS EQUIPMENT
SECTION 1 GENERAL AND MISCELLANEOUS
CONTENTS
1A.1.1 General
1A.1.2 Installation and Supervision
1A.1.3 Workmanship and GeneraI Design
1A.1.4 Drawings and Information to be provided
1A.1.5 Sub-Orders
1A.1.6 Works Testing and Inspection
1A.1.7 Initial Charges of Oils etc
1A.1.8 Spare Parts and Tools
1A.1.9 Release of Equipment for Delivery
1A.1.1 Packing for Shipment
1A.1.1 Guarantee
1A.1.12 Site Storage
1A.1.13 Plant Identification
1A.1.14 Lock, Padlocks and Key Cabinets
1A.1.15 Maintenance Equipment

SECTION 1 GENERAL AND MISCELLANEOUS
1A.1.1 General
The Specifications for those items of equipment and materials that the Contractor shall
supply, install and incorporate to the works other than for those specified separately, are listed
and specified in the foIIowing clauses of this section. The Contractor shall ensure that all
equipment and, materials are supplied to their correct specifications complete with aII
necessary spares, tools, lubricants (oils, grease etc), and instruction manuals for operation and
maintenance aIl to ensure the safe and correct handling, instaIIation, maintenance and
operation of the equipment and materials.
The Contractor shall be responsible and liable for all cost related to failure or damage to his
workmanship, materials or equipment and shall replace any such failed or damaged
workmanship, materials or equipment at his own cost to the satisfaction of the Engineer, and
in sufficient time to ensure that no delay occurs to the completion of the works as a result
thereof.
It shall be the Contractor's responsibility to obtain approval from the Engineer for the full and
correct specification of any materials or equipment that he has to replace. Spares shall be
readily inter-changeable with the parts they replace.
The Contractor shall carry out the Engineer's instruction to update the specifications if in the
opinion of the Engineer the Specs proposed by the Contractor Iacks sufficiency.
Data Sheets - it is the responsibility of the Contractor, to provide the data sheets referred to in
the specifications which follow in this document and it is also his responsibility to ensure that
they are fully completed. Such data sheets shall be approved by the Engineer who placed the
purchase order.
Alternative standards shall be considered by the Engineer for approval if such standard can be
demonstrated to be equal or more stringent than the contract standard.
All materials that are to be supplied by the Contractor and which are not to be incorporated
into the permanent works as fixed items, but are nevertheless part of this contract (e .g spare
parts), are to be safely stored by the Contractor until ordered to hand them over to the
Employer by the Engineer, which wiII in general be on or about the date of issue of the
Certificate of Completion.
1A.1.2 INSTALLATION AND SUPERVISION
The Contractor shall be responsible for the provision on site of speciaIized personnel to
supervise the installation, checking for accuracy, testing, commissioning of all materials, plant
and equipment being supplied under this contract, and shall include in his Tender Price for so
doing including all costs and expenses associated with such personnel.
The Contractor shall where necessary, without undue delay, and to ensure programme is met,
supply Vendor's specialists for installation, checking and commissioning and such services
shall be included in the Tender Price.
1A.1.3 WORKMANSHIP AND GENERAL DESIGN
The plant shall be new, of sound workmanship and of good engineering design. The generaI
design of the plant and particularly that of the bearings, contacts and all other wearing parts
shall be governed, by the need for Iong periods of service without frequent maintenance and
attention being necessary.
Unless otherwise specified, all items of plant shall be rated for continuous service at the
specified duties under the prevailing climatic and operating conditions on Site.
All component parts of the plant shall be, manufactured to strict tolerance Iimits and compIete
interchangeability of similar parts if required.
All items of plant shall be provided with an engraved 18/8 stainless steel or monel nameplate,
securely fixed at some convenient and accessible point, giving basic information, including,
but not limited to the following:
i) Manufacturer's Name and Manogram

ii) Purchaser's Order Number
iii) Type, size and serial number of items
iv) Ratings
v) Bearing manufacturer(s) identity numbers (if applicable)
vi) Lubricant Oil (if required)
vii) Year of manufacture
Provision shall be made for taking up wear in all bearings and other wearing parts or for easy
replacement if adjustment is not practicable.
Ball and roller bearings shall be interchangeable with simiIar items from alternative
manufacturers. Parts lists shall include alternative reference numbers and maker. Adequate
and, as far as practicabIe, automatic means of lubrication shall be provided for aII moving
parts. The positions of all greasing and oiling points shall be arranged so as to be readily
accessible for maintenance servicing. Where necessary to achieve this, suitable extension
pipes shall be fitted.
Suitable packers and/or shims shall be fitted for ease of adjustment and re-alignment of all
machinery units; where fitted bolts, spigots or other means for precise location are not
employed in the assembly of the plant, Iocation doweIs shall be fitted on compIetion of
erection to the satisfaction of the Engineer.
Jacking boIts to the approvaI of the Engineer shall be provided for aIl skid mounted
equipment.

The complete erection, checking and testing of all mechanical works will be carried out by the
Contractor strictly following the procedure, and wholly in accordance with the standard
specified by the suppliers of the installed equipment.
It is the sole responsibility of the Contractor to ensure that he obtains compIete and
comprehensive instructions from such suppliers and ensures that the works are carried out to
these instructions, and to the satisfaction of the Engineer.
Where possible all equipment will be located at the correct elevation relative to plant datum
level and not to heights above the foundations. Equipment may only be lifted using lifting
lugs provided, or sling positions indicated.
No erection works will proceed over or above any equipment in so far as it is practicable.
Where this is unavoidable, the Contractor will exercise all due care and attention, including
provision at his own expense of temporary staging to protect the equipment and men working
on it from falling debris from the works above.
Any damage to equipment shall be made good at Contractor's expense.
1A.1.4 DRAWINGS AND INFORMATION TO BE PROVIDED
A) By the Bidder with his Tender
In addition to the requirements specified elsewhere, six copies of the following shall be
provided:
i) Preliminary arrangement drawings of paint and sectional elevation of the paint to be

supplied.
ii) Outline and sectional drawings together with .parts lists to indicate the leading features
of the main items.
iii) A detailed specification of the various main items of equipment.
iv) The Schedules of Technical Information fully completed.
v) The name and address of any sub-supplier the Bidder intends to employ for the works.
vi) Estimated performance curves and type test certificates.
B) By the Contractor when the Contract is Let
i) On acceptance of his Tender, two additional copies of all technical information and
data relating to equipment.
ii) Within one month of the acceptance of his Tender, detailed drawings of the general
arrangements of equipment and the paint, including the definition of hazardous areas,
in duplicate for approval by the Engineer.
iii) Additional drawings in duplicate of particular items, if called for by the Engineer, for
approval by the Engineer.
iv) GeneraI arrangement drawings of pipework and also isometric drawings.
The manufacture of items of main parts shall not be commenced until the approval of all
relevant specification and drawings by the Engineer in writing has been obtained. Such
approval shall not be unreasonably delayed. Any costs resulting from failure to comply with
this requirement shall be borne by the Contractor.
If the specifications and drawings are not approved, one copy shall be returned to the
Contractor marked to indicate where modifications are desired.
Upon final approval, one copy shall be marked ‘Approved' by the Engineer and returned to
the Contractor.
C) By the Contractor Prior to Taking-Over by the Employer
Prior to the Employer Taking-Over, the Contractor shall provide for the use of the Employer
and the Engineer
Five (5) copies plus 1 elecronic copy of the following documents:
i) Operating Manual
ii) Maintenance Manual (including consumables)
iii) Plant Register
iv) Spare Parts Lists
The Works shall not be considered to be completed for the purpose of Taking Over under the
terms of the GeneraI Conditions of Contract until the above information has been supplied
and approved.
D) By the Contractor during the Maintenance Period
After erection has been completed, the Contractor shall submit to the Engineer three (3)
copies of the following ‘as fitted' drawings for approval:
i) Drawings showing the internal construction of The major items, with parts listed and
reference numbers for ordering spares.
ii) Complete assembly drawings of machinery and ancillary plant showing all pipework
connections and fittings etc.
iii) General arrangement drawings.

iv) Three copies of detailed revised Specification and Schedules of the plant as actuaIIy
installed.
v) Relocation drawings
When items (i) to (v) inclusive have been approved by the Engineer, the Contractor shall
provide two (2) black and white prints of each for the use of the Employer and two (2)
negatives of each for the use of the Engineer for all installations.
1A.1.5 SUB-ORDERS
The Contractor shall Supply to the Engineer two (2) unpriced copies of all sub-orders. The
sub-orders shall indicate the words for which the item is required, state in detail the
specification and list requirements, give sufficient information for ready identification and
shall state which items shall be subject to witness tests and inspection.
1A.1.6 WORKS TESTING AND INSPECTION
The Contractor shall offer all items of plant for inspection, examination and witness testing
and shall inform the Engineer, 21 days in advance of the date when the plant will be ready for
inspection and witness testing. If the tests are beyond the resources of the Contractor, he shall
make arrangements for these to be carried out elsewhere.
The Contractor shall carry out tests, performance tests and such other tests as are necessary, in
the opinion of the Engineer to determine that the plant complies with the specification, either
under test conditions in the manufacturer's works, on site or elsewhere or in the ordinary
working. Where tests and inspection have been completed to the Engineer's satisfaction and
when the test certificates, curves, etc have been checked, the Engineer shall confirm
acceptance in writing and the plant shall, not be delivered until this acceptance has been
received.
Six copies of all test certificates and characteristic curves shall be supplied to the Engineer
within two weeks of completion of any witnessed tests. Such characteristic curves shall form
part of the Operating Procedures.
On each test certificate, sufficient information to enable the Engineer to issue a release of
certificates, including specification, Purchase Order number and details, shall be given for
ready identification of the materials or equipment to which the certificate refers. No
inspection or passing by the Engineer of the plant or materials or work covered by this
specification, whether carried out or supplied by the Contractor or his supplier shall release
him from any of his obligations under the GeneraI Conditions of Contract.
The Employer reserves the right to require the Contractor to meet any extra costs which are
occasioned by failure of the Contractor to comply with the above testing and inspection
requirements, including the provision of test certificates, curves, sub-orders etc, or which in
the opinion of the Engineer, are due to insufficient care having been taken by the Contractor
or his unauthorised delivery has taken place, the Contractor may be required to arrange for the
plant to be returned to the manufacturer for inspection and/or witness testing at the
Contractor's expense.
Any equipment used in the testing of the plant shall in all respects comply with the
appropriate safety regulations and/or requirements regarding electrical apparatus for the safety
of the plant and the men working thereon.
All vessels designed to ASME VIII code shall be inspected and stamped by an approved
agency competent to do so. Contractor shall propose such agency for approval.
The Employer may appoint a Third Party Inspectorate or Agency to perform the necessary
inspection services on his behalf. Inspection shall take into account any Nigerian Law or
prevailing directive.
1A.1.7 INITIAL CHARGES OF OILS ETC.
The initial charges of oil, grease, and similar materials necessary for the correct testing,
commissioning and first 12 months operation of the plant shall be included in the Contractor’s
price.
1A.1.8 SPARE PARTS AND TOOLS
A priced schedule of spare parts shall be submitted with the tender recommended by the
Contractor for 36 months operation. All spare parts shall comply with the same specifications
and tests as the original equipment and shall be fully interchangeable with original parts
without any modifications at site, They shall be correctly marked with reference numbers and
the manufacturer's part numbers and shall be properly protected to prevent deterioration
during shipment and storage in humid tropical climates, All spare parts are to be separately
boxed in order that they may be taken into the Contractor's store immediately on delivery,
checked by the Contractor and repacked. Those spare parts shall be taken into the Employer’s
stores by the Contractor when ordered to do so by the Engineer, suitably categorized and
documented to enable the Employer to take over thereafter. The availability of spare parts
shall be guaranteed for twenty (20) years.
Spares shall be adequately protected and packed for storage. The protection shall be such as to
afford avoidance of corrosion and spoilage for a minimum of 36 months after delivery to the
Employer.
Electrical equipment in particular shall be packed in sealed polythene or similar bags with a
liberal supply of desiccant and secured with tongued and grooved boarded cased. To all spares
shall be attached untarnishable metal plates giving full information for ready identification
incIuding maker's name, serial number and purpose.
All boxes etc. shall be marked with Purchase Order number, Employer’s name and Site
Address. A List of contents in detail shall be provided within all packages. All spares will be
inspected before delivery. The Engineer reserves the right to correct or vary the list submitted
and adjust the total price in accordance with the rates quoted provided that all such spares are
included with the main consignment.
A complete list of any specialized tools needed for the efficient servicing of all equipment to
the approval of the Engineer, shall be provided at station.
The spare parts and tools shall not be used for the purpose of the erection and commissioning
of the paint.
The above tools are to be supplied, as described above, for every item of plant and equipment
and shall clearly be identified as such.
1A.1.9 RELEASE OF EOUIPMENT FOR DELIVERY
Major items of equipment shall not be delivered to Site until released by the Engineer.
1A.1.10 PACKING FOR SHIPMENT
a) Certain items which have to be skid mounted as part of an equipment package shall be
sent to the skid packager for inclusion with the rest of that skid mounted equipment.
b) The following preparations shall be Made prior to any shipment.
i) All foreign matter, Such as metal cuttings, mill scale, cutting oil, weld slag and other
loose debris shall be removed.
ii) Steel surfaces shall be blast cleaned, or cleaned in such a manner to meet with
Swedish Standard SA 2 1/2.
iii) Immediately after cleaning, equipment shall be coated with two coats of zinc
phosphate primer. Each coat shall have a minimum dry film thickness of 2 mils .Refer
to –Paint Specification. Remainder of painting in accordance with this Specification
shall be carried out on site by the Contractor.
iv) Upon completion of all tests and inspection, machined surfaces shall be coated with a
protective coating easily removed by a commercial solvent which shall not damage the
paint system,
v) Internal surfaces which shall be kept dry are to be dried and sealed and where possible
provided with a suitable desiccant.
vi) Internal wetted surfaces shalI be coated with a suitable preservative which can be
removed if necessary.
vii) Flanges shall be covered with steel covers. Wood is prohibited.
viii) Threaded openings shall be plugged.
ix) Finned tubes, where provided, shall be coated with a heat transfer epoxy.
1A.1.1 GUARANTEE

The Manufacturers of all items of equipment shall guarantee that articles, materials and work
shall conform to the specifications supplied and shall be new, fit and sufficient for the purpose
for which they are intended .The material design and workmanship shall be of the highest
quality and free from defects. In addition, at the request of the Engineer, the manufacturer
shall repair or replace at the site of installation, free of aIl costs to the Employer, any
equipment or parts that shall, in normal use and service and under proper operation, fail
because of faulty design or workmanship or defective material for the period of guarantee
which shall be the Maintenance Period.
1A.1.12 SITE STORAGE
a) The Contractor shall be responsible for all charges pertaining to material and equipment
arrival on site. These shall incIude interracial, carriage, insurance, freight offloading,
onloading, demurrage if applicable, port duties and customs clearance. He shall also arrange
for onIoading and transportation to site. The Contractor shall be responsible that no delay
occur in the overall programme due to dispatch and delivery of material and equipment.
b) The Contractor shall be responsible for the unloading, handling and storage of all plant
equipment prior to it being installed.
Each item of plant and equipment shall be handled, stored, installed and made ready for start-
up in accordance with the manufacturer's instructions, drawings and recommendations, ruling
standards and good engineering practice.
For machinery Units, an installation specialist employed by the Machinery or plant

manufacturer shall be called Upon to supervise the complete installation of the unit, as well as
pre-operational checks and commissioning tests. The presence of the Manufacturer’s
specialist shalI not relieve the Contractor from any of his responsibilities and obligations
under the conditions of contract.
The Contractor shall provide access and assistance to the Engineer for inspecting and
checking the installation work.
The plant storage work shall be carried out strictly with the approved programme for the
whole contract work.
c) Equipment Handling
For all loading/unloading operations and the movement and replacement of mechanical plant
and equipment, the Contractor shall employ suitable approved cranes and lifting equipment.
All Lifting appliances, incIuding chain blocks, beams, spreader bars, ropes, slings and
shackles must be regularly inspected by a competent responsible person employed by the
Contractor and full records of all such inspections and tests shall be made available to the
Engineer immediately upon demand.
The Lifting and handling of all plant and equipment shall be carried out in such a manner as
to avoid distorting, jarring or damaging the equipment from any cause whatsoever. Properly
designed Lifting beams and approved spreader bars shall be used for Lifting skid-mounted
equipment and large packing cases. All printed/stenciled Lifting instructions on packing cases
must be strictly adhered to and under no circumstances shalI be safe working load or working
radius of any Lifting be exceeded.
d) Storage of materials and Equipment
The Contractor shall be responsible for the proper storage, protection and security of all plant
materials and equipment. A properly organized system of stores and Materials control must be
instituted to the approval of the Engineer and maintained throughout the equipment
installation contract.
The Contractor shall provide temporary buildings, sheds and covers to prevent the
deterioration of plant and equipment through all weather conditions. The side walls of storage
buildings shall prevent entry of wind borne rain and maintain permanent security against
pilferage. Properly constructed orderly systems offsheIving and bins shall be installed for the
storage of all items of equipment (other than heavy items requiring cranage) and all
construction materiaIs, to the approval of the Engineer.
A permanent inventory of all items plus documented control of all goods inward and outward
shall be maintained by full time experienced storekeeping personneI.
To prevent deterioration, accidental loss or pilferage prior to installation, all plant and
materials shall be unpacked, inspected and treated with a spray type preservative, such as
"Codrtec” or equal. After this treatment the equipment shall be stored under proper controlled
dry storage conditions.
No shipping cases of equipment shall be unpacked or uncrated without authorization and

witness by the Engineer. Where packaging appears to be damaged in transit, the Engineer
shall require the equipment material to be unpacked, inspected and a damage report compiled
and then put into dry storage as above. It is particularly important that sealed plastic/polythene
enclosures enveloping components protected by siIica-geI type air drying agents are not
unsealed, perforated or otherwise damaged. After, inspection and upon its completion, these
units will be resealed as required by above specifications.
Bulk materials such as piping components, gasket materials, instrumentation fittings bolting
etc must be segregated in the store by size and material type such that withdrawal and use on
site is in accordance with design requirements.
Materials found lying loose and Unidentified on site or material deteriorating due to incorrect
storage and control shall be ordered to be immediately removed and scrapped by the Engineer
at the consequential cost of the Contractor.
Temporary (low power) electrical supplies of correct voltage must be provided for in-built
anti-condensation heaters in motors, switchboards/control panels, where operation of such
heaters during storage of the paint and equipment is recommended by the manufacturers.
Rotating machinery must be stored in accordance with the manufacturer’s instructions.

Any extra Support required between bearing centers as may be expected in a rotor of large
bearing span, shall be supplied to prevent shaft deformities.
Barring over facilities either by manual or electrical means shall be provided when requested
by the vendor so as to avoid a permanent set occurring in shafts.
When spare rotors are specified, they shall be prepared for indoor storage for at least a 3-year
period.
Rotors shall be coated with a rust preventive, housed in a vapor barrier envelope with a vapor
phase inhibitor and crated for overseas shipment. TFE sheeting of 3.2 mm minimum thickness
shall be used between the rotor and the cradle at the support areas (not the journal areas).
Where anti-friction bearings are employed, the necessary instructions must be followed to
prevent brinelling. Any item of equipment having anti-friction bearings which has been idle
for any length of time without barring over must have the bearings changed prior to
commissioning.
Mechanical seals must have their faces backed off to prevent face to face contact. After
commissioning, it may well be necessary to change the seal faces.
The Contractor must also supply a separate workshop for his own tools etc and their
maintenance and this must be completely self contained.
In order that inclement weather shall not adversely affect the programme execution, the
Contractor shall provide a temporary fabricating shop where welding can be carried out
throughout the construction period.
This shop must be kept dry at all times and water must not be allowed to accumulate on the
floor or anywhere else within the building.
Storage must be made available specifically for welding electrodes. It is most important that
once any electrode container is opened, it is maintained in a dry warm atmosphere and
subjected to proper electrode control and baking prior to use in accordance with Contract
Welding Code.
At the end of each working shift, all electrodes in open containers shall be discarded if not
maintained in heating ovens or ready-for-use heated quivers.
Shielding gases shall be kept in the container in which they are supplied and shall be stored
against temperature extremes.
For all equipment and materials received on site, the Contractor shall complete and submit
within 5 days of the receipt, a Material Report to the Engineer.
Provision shall be made by the Contractor to process radiographs accurately and immediately
and a dark room shall be provided for this purpose. Provision shall also be made for the
storage of isotopes. The above facilities shall be made available to the Engineer 24 hours per
day.
Ultrasonic equipment and an operator qualified to C.S.W.I.P Level 3 or acceptable equivalent

to the Engineer shall be provided.
1A.1.13 PLANT IDENTIFICATION
The Contractor shall prepare comprehensive Plant identification schedule showing the name
and number of each item of plant and its respective arrangement drawing number and add any
additional items necessary to fully identify the plant. These schedules shall be subject to the
Engineer's approval.
The Contractor shall supply all labels, nameplates, instruction and warning plates necessary
for the identification and safe operation of the plant and all inscriptions shall be in the English
language.
Nameplates for plant identification and record purposes shall be manufactured from stainless
steel with a matt or satin finish and engraved with black lettering of a size which shall be
legible from an operational level. Warning plates shall be manufactured from stainless steel
with a matt or satin finish, engraved with red lettering and sited in a position which shall
afford maximum personnel safety.
All equipment within panels and desks shall be individually identified by satin or matt finish
stainless steel labels or laminated plastic labels where approved.
Each valve shall be fitted with a nameplate indicating the valve service and reference number
in accordance with the valve schedules as approved by the Engineer. The colour of the valve
nameplate engraving shall correspond to the service of the pipework in accordance with the
requirement of the schedule.
Where possible, valve nameplates shall be circular and fitted under the hard wheel captive
nut, on check valve and small valves. The Contractor may provide rectangular nameplates to
flange or cover bolts.
1A.1.14 LOCKS, PADLOCKS AND KEY CABINETS
Locks shall be corrosion resistant and preferably of the barrel type. Padlocks shall be of
nonferrous material. Three keys shall be supplied for each lock, each being suitably labeled.
All locks and keys shall be non-interchangeable.
Where a set of locks is provided under any particular section of plant, or apparatus, a set of
master key is to be supplied in addition, except where specified to the contrary, for example,
switch gear.
Sufficient approved labelled metal cased key cabinets shall be supplied and each cabinet shall
be capable of containing all the keys relating to one specific item or group of related items of
plant segregated to facilitate safe operation and maintenance.

The key cabinets shall be provided with labelled hooks, each identifiable with its appropriate
key and each cabinet shall be provided with a nameplate identifying the cabinet with its
respective item or items of plant.
1A.1.15 MAINTENANCE EQUIPMENT
The Contractor shall install all runway beams, trolleys, lifting blocks and tackle tools etc,
necessary for the safe and efficient handling and maintenance of the plant.
All lifting equipment shall be tested in accordance with relevant B.S Code before they are
erected and before used for erection purpose.
All lifting equipment shall be clearly marked with the safe working load to B.S PD 643. and
certified. All wire rope slings shalI be provided in accordance with B.S 1290, B.S 3481 and
B.S 5281 as appropriate.
The Contractor shall compile and maintain a Lifting and hoisting register to include all
permanent and temporary fixed and mobile lifting or hoisting equipment including
construction equipment. this register shall be available for inspection by Engineer from
mobilization onwards.
The Contractor shall provide all special tools such as pullers, extractors, torque wrenches, bolt
heating equipment and alignment jigs, etc., necessary to enable him to erect and to maintain
the compIete works in an efficient manner. A schedule indicating number of, type and
function of equipment provided shall be submitted to the Engineer for approval. The lifting
tackle and special tools to be provided shall be hoisted in the Workshop and Stores building in
a new and unused condition suitably protected against corrosion. Any item of special Lifting
tackle which the Contractor uses during the erection of the plant shall be restored to its
original condition and referred to the Engineer for approval prior to the issue of the Taking
Over Certificate.

SECTION 2 BOILER & HEAT EXCHANGERS
CONTENTS
1A.2.1 General
1A.2.2 Scope
1A.2.3 Process Design
1A.2.4 Mechanical Design
1A.2.5 Welding
1A.2.6 Control and Instrumentation
1A.2.7 Miscellaneous
1A.2.8 Services Available
1A.2.9 Preparation for Shipment
1A.2.10 Inspection and Tests
1A.2.11 Guarantees

SECTION 2 BOILER & HEAT EXCHANGERS
1A.2.1 General
This specification relates to the design, manufacture and supply of boiler and heat exchangers
in accordance with the following specification.
1A.2.2 Scope
The supplier shall provide the packaged containerized skid mounted Boilers and Heat
Exchangers including, but not limited to the following:
i) Water colled bi-metalic burner assembly
ii) Pre-mix fan
iii) Self supporting Stack
iv) Instrument Gauges , Controls and Safety Devices
v) Fuel Gas Pipework including control valves, Strainer, Shut-off Cock.
vi) Skid assembly suitable for mounting inside a container.
Each Boiler and Heat Exchangers shall be provided with an identification tag bearing the
manufacturer's name, the highest design temperature and pressure , the Boiler duty, the Boiler
service and the Boiler number.
1A.2.3 PROCESS DESIGN
The heating plant comprises ,6 off 20% heating load stokvis R307 type ultra-low , premix
high frequency boilers with full modulating control. The boilers incorporate stainless steel
exchangers with mild steel headers and is suitable for a maximum working pressure of up to
6.0 Bar.The boiler plant is to provide primary heat source to duplex shell and tube heat
exchangers for heating the supply gas prior to pressure reduction in order to offset the Joule-
Thomson effect associated with pressure reduction of gaseous substances.
Process design conditions shall be given to the vendor by the Contractor.

Contractor shall provide temperature and pressure profiles of gas in tubes for the heat
exchanger design case and shall also state protective devices proposed which shall include but
not limited to:
i) Water level supervision
ii) Flame monitoring
iii) Water Temperature/Pressure monitoring
DESCRIPTION OF AUTOMATIC CONTROL SYSTEM - CONTROLS OVER-VIEW
A single compartment, wall mounted Motor Control Centre will be provided

incorporating all necessary control,monitoring and alarm functions.
The control system will monitor the outlet gas temperature after pressure reduction via
the hard wired temperature sensor (provided by others). This sensor is intrinsically safe
via the Galvanic Barrier within the MCC. The modulating controller within the control
panel will sequence the boilers to provide control of the downstream gas temperature.
The Gas Main Temperature is measured by a sensor provided by others giving 4-20ma
signal to the PLC Controller, mounted within the packaged Boiler House Control Panel.
When the temperature of the Gas Main falls to within 1 deg.C., the following sequence of
events will occur automatically:
- The duty selected heating pumps will start.
- The lead boiler will fire and modulate to high fire, if the gas main temperature sensor is
not satisfied;
- The first standby boiler will fire and modulate to high fire.
If for any reason either of the above boilers does not operate then the second standby boiler
will automatically start and modulate accordingly.
As the gas main sensor become satisfied the boilers are modulated for high fire in sequence
until the boiler or boilers output matches the load, then the boilers will modulate to maintain a
constant gas main temperature of 20 deg.C.
When the temperature rises above 22 deg.C. the boilers are modulated off and after a pre set
time period (to dissapate heat) the heating pump is switched off.
The boilers are interlocked with the pressurisation unit such that if a high or low alarm is
raised the boilers can not fire.
The boilers are also interlocked with the heating pumps such that if water flow is not
established as monitored by the appropriate pump differential pressure switch then the boilers
can not fire.
The incoming gas pipe to packaged boiler house can be automatically isolated by an
electrically operated gas solenoid valve which will shut if any of the four thermal links
(mounted over boilers) operate or the wall mounted emergency stop button is used.
The sequence of the boilers is selected by the control panel facia mounted switch, as follows:
Position 1 – Boiler 1, 2, 3 4 5
Position 4 – Boiler 4, 5 6 1, 2
The selection of the duty heating pump is made by the control panel facia mounted switch as
follows:
Pump No. 1/ Pump No. 2
The standby pump will automatically start if the duty pump fails as monitored by the
differential pressure switch.
Hand/Off/Auto switches are also provided for each boiler and the pumps, this allows for
service engineer over-ride.
A standby gas main temperature sensor is provided by a separate sensor, which operates via a
Galvanic Cell safety barrier and will automatically take over control of the boilers in the gas
main temperature falls to 10 deg.C. for more than 15 minutes, this indicates that the master 4-
20 ma temperature signal has failed.
An alarm will also be raised if the above occurs

.
A volt free pair of contracts are provided at the control panel for monitoring by others as
follows:
Pressurisation Unit LowPressure
(Auto Fill Set) Low Pressure

LowTank Level
Boiler No. 1, 2,3,4,5 & 6 Fault
Heating Pumps No. 1 or No. 2 Fault
Master Gas Main Temperature Sensor Fault
General Control Panel Functions
Main door interlocked isolator.
MCB’s for Control Panel Circuit and Powers Supplies to Pressure Unit, Pumps, Boilers and
Gas Valve.
Indicator Lamps are provided on the Control Panel Facia for the following functions:
Panel Alive Indicates electrical supply available to panel.
Gas Fired Boiler Indicates boiler failure due to burner lock-out or high
On/Fault temperature limit trip.
System Pressurisation Indicates water content fault due to low water level Fault in make-up
tank, low pressure or high pressure in system.
Circulating Pump Indicates no water flow (as monitored by differential pressure
switches) caused by either pump starter trip or MCB trip.
1A.2.4 MECHANICAL DESIGN

Mechanical details shall be designed, fabricated and tested in accordance with the applicable
standards listed below.
a) Code and Standards
Mechanical Standards
Pipe threads for tubes and fittings BS 21
Capillary and Compression fittings for copper tubes BS 864
Draw-off taps and stop valves for water services BS1010
Tubes and tubular steels suitable for welding or screwing BS 1387
Circular flanges for pipes, valves and fittings BS 1560
Identification of pipelines and services BS 1710
Wrought steel pipe fittings BS 1740
Bourdon tube pressure and vacuum gauges BS 1780
Butt-welded pipe fittings for pressure purposes BS 1965
Copper and copper alloy tubes BS 2871
Draining taps (screw down pattern) BS2879
Class II arc welding of carbon steel pipework BS 2971
Seamless steel pipes and tubes for pressure purposes BS 3600
Carbon steel pipes and tubes with specified room temperature properties BS 3601
for pressure purposes
Pipe supports, pipe hangers, slider and roller type supports BS 3974
Un-sintered PTFE taper for thread sealing BS 4375
Circular flanges for pipes, valves and fittings (FN designated) BS 4504
Ductile iron pipes and fittings BS 4772
Dimensions of gaskets for pipe flanges BS 4865
Arc welding of tube BS 4870

Approval testing of welders working to approved welding procedures BS 4871
Approval testing of welders when welding procedure approval is not BS 4872

required
Cast iron gate valves for general purposes BS5150
Cast iron globe and globe stop and check valves for general purposes BS 5152
Cast iron check valves for general purposes BS 5153
Copper alloy globe, globe stop and check, check and valve gate BS 5154
Butterfly valves BS 5155
Diaphragm valves BS 5156
Steel gate (parallel slide) valves BS 5157
Cast iron plug valve BS 5158
Cast iron and carbon steel ball valves BS 5159
Steel globe valve, globe stop and check valves and lift type check valves BS 5160
Code of Practice for Painting of Building BS 6150
Dial type expansion thermometers BS 5235
Design, installation, testing and maintenance of services supplying water BS 6700

for domestic use within buildings and their curtilages
Raw, refined and boiled linseed oils for paints and varnishes BS 6900
Jointing materials and compounds BS 6956
Gas Installation Standards
Gas Industry Standards IGE/SR/15
Installations of Low Pressure Gas Pipework up to 28mm In Domestic Premises BS 6891
The Institute of Gas Engineers Utilisation Procedures IGE/UP/1,2& 4
a) Soundness Testing Procedures for Non-Domestic Gas Installations IM/5
b) Purging Procedures for Non-Domestic Gas Installations IM/2

Specification for screwed and socketed steel tubes BS 1387
Wrought steel pipe fittings BS 1552
Copper and copper alloy tubes BS 2871
Electrical safety and performance of gas fired space heating appliances with BS 5986
Inputs 60 KW and 2 MW
Thermal Insulation Standards
Thermal insulation for building application BS EN 822, 823, 824 & 825
Pre-insulated bonded pipe systems for underground hot water BSEN 253,448, 488 & 489
Fire tests on building materials and structures BS 476
Thermal insulation properties and definition of terms BS 874
Test for inorganic thermal insulating materials BS 2972
Glossary of thermal insulation terms BS 3533
Rigid phenolic foam (PF) for thermal insulation, slabs and profiled sections BS 3927
Thermal insulating materials BS 3958
Thermal insulating materials on pipes, ducts and equipment BS 5422
Preformed rigid polyurethane (PIR) foam BS 5608
Fire precautions in the design construction and use of buildings BS 5588
Code of Practice for accommodation of building services in ducts BS 8313
Rigid expanded polyvinyl chloride for thermal insulation and building BS 3869
application
Code of Practice for thermal insulation of pipework and equipment BS 5970
Electrical, Control and Instrumentation Standards
Conduits for Electrical Installations BS 6099
Cable Trunking BS 4678

Non-metallic Conduits and Fittings BS 4607
Selection Installations and Maintenance of Electrical Apparatus for use

In Potentially Explosive Atmosphere BS 5345
Steel Conduit and Fittings BS 31
Steel Conduit and Fittings with Metric Threads of 150 Form BS 4568
Clamps for Earthing and Bonding BS 951
Non-metallic Conduits and Fittings BS 4607
Flexible Steel Conduit BS 731
Conduit Systems for Electrical Installations (1994) BS EN 50086
b) Materials
Materials for tubes and Shell shall be as shown on the individual data sheets. Other materials
of construction shall be in accordance with the following ASTM spec approved equivalent.
Columns, beams and other

structural shapes Carbon Steel ASTM-A-7
Steel Plates enclosures Carbon steel ASTM-A-283
Bolts Alloy steel ASTM-A-193
(for high temp. services)
Nuts Carbon Steel ASTM-A-194
Tube Supports Chrome Nickel Alloy
ASTM-A-447
Type II
c) Tube Design
Tube wall thickness shall be calculated in accordance with B.S or A.P.I .Recommended
Practice for calculation for Heater Tube Thickness in Petroleum Refineries.
Design pressure for calculating the tube wall thickness shall be at least equal to the minimum
recommended thickness.
Design temperature for calculating the tube wail thickness shall be 27.8 °C(50 °F) above the
maximum calculated tube wall temperature. The maximum calculated tube wall temperature
shall be based on the maximum local heat flux.
Corrosion allowance shown on the individual data sheet shall be added to the calculated tube
wall thickness.
All tubes and pipes shall meet the dimensional standards given in API-630. Tube and Shell
Dimensions for Boiler in Gas pressure regulating stations
1A.2.5 WELDING
Heat Excangers tubing welds shall be fully penetrated butt joints in accordance with ANSI
B.31.3, latest edition..
Inspection requirements for tubing welds shall be in accordance with the following table:
Inspection Requirements for Heater Tubing
Material Design Max.Tube VisuaI Random 100%

Pressure Metal Temp.
Radiograph
Carbon steel Not exceed-. or 343 deg.C x x

ing 34.47 bar
Carbon steel Above or above x x

34, 47.bar
Alloy (all sizes) x x

__________________________________________________________________
One (1) out of every ten (10) completed welds shall be 100%. radiographically examined.
Acceptance criteria for heat exchangers tubing welds shall be in accordance with ANSI
B.31.3. latest edition.
1A.2.6 CONTROL AND INSTRUMENTATION
Electrical and instrumentation requirements shall be in accordance with the relevant codes.
Instrument and controls shall be gas-operated with electronic transducers fitted for remote
monitoring or supervisory control functions.
Flame detection equipment shall be provided. Excessive metal temperature, fuel gas
temperature, gauge glass level, level alarms and trips shall also be provided.
1A.2.7 MISCELLANEOUS
Terminal flanges shall be raised, face drilled to conform to American Standard ANSI B.16.5,
latest edition, except where specified otherwise. A detailed welding procedure for aIl
pressure-containing parts shall be submitted to the Engineer for approval prior to commencing
fabrication. On approval, this procedure shall be strictly adhered to. Refer to piping welding
specification and also to Inspection Specification.
1A.2.8 SERVICE AVAILABLE

The Vendor shall ensure that all services he needs are available via the Contractor.
1A.2.9 PREPARATION FOR SHIPMENT
As in Packing for Shipment Under GeneraI and Miscellaneous Section.
1A.2.10 INSPECTION AND TESTS
All pressure-containing parts shall be hydrostatically tested to 1.5 times the maximum
possible working pressure.
All protective and safety devices shall be tested according to procedure approved by the
Engineer.
Refer to Works Testing and inspection under General and Miscellaneous Section.
1A.2.11 GUARANTEES
In addition to the guarantee specified in this specification, the Boiler and Heat Exchangers
manufacturer shall guarantee the following:
i) Turndown
ii ) Operation over range of flow/pressure./temperature duties
iii ) Also over range of gas analysis specified in the Data Sheet(s).

SECT ION 3. PRESSURE VESSELS
CONTENTS
1A.3.1 Scope
1A.3.2 Design Codes
1A.3.3 Design Requirements for Particular vessels
1A.3.4 Design Requirements -General
1A.3.5 Fabrication Requirements -GeneraI
1A.3.6 Inspection and Testing
1A.3.7 Preparation for Shipment
1A.3.8 Approval of Drawings
1A.3.9 Name Plate
1A.3.10 Guarantee

SECTION 7. PRESSURE VESSELS (CARBON AND ALLOY STEEL)
1A.3.1 SCOPE
This Specification covers the requirements for the design, materials, fabrication, testing and
inspection of fusion welded pressure vessels of carbon alloy steels and these materials when
protected with an alloy lining or cladding.
1A.3.2 DESIGN CODES
Design, materials, fabrication, inspection, testing and marking of the vessels (including
openings in the vessels and nozzles and other pipework welded to the vessels) shall conform
to latest edition of ASME Boiler and Pressure Vessel Code, Section VIII “Unfired Pressure
Vessels and to ANSI B.16.5, "Steel Pipe Flanges and Flanged Fittings" unless overruled by
this Specification. Vessels must Comply with any statutory Nigerian Code or Requirement
which might be imposed.
1A.3.3 DESIGN REQUIREMENTS FOR PARTICULAR VESSELS
The design conditions and the principal required mechanical features for particular vessels
shall be determined by the Contractor who shall provide data sheets.
1A.3.4 DESIGN REQUIREMENTS -GENERAL
The requirements listed below Supplement the requirements of the codes referred to in the
above section.
a) The corrosion allowance, as referred to in the ASME code section VIII shall be 3mm
unless otherwise specified for a particular vessel
b) All surfaces of pressure parts and non-pressure parts directly welded to the pressure
shell or otherwise non-removable and exposed to contained media shall have either the
specified corrosion allowance added, or be of resistant material. No corrosion
allowance need be added to replaceable non-pressure parts unless specified on the
vessel data sheets or drawing
c) The minimum thickness of any vessel including any corrosion allowance that may be
necessary shall not be less than 6 mm. For additional protection where corrosive
liquids may be in contact with the surface of the vessel for a finite length of time, an
internal coating of a suitable epoxy-based paint may be applied to the total internal
surface of the vessel
d) Openings in shells and head shall be reinforced in accordance with the applicable
code. Vessel corroded thickness in excess of the required design or minimum code
thickness shall not be considered in the design of opening reinforcement under
operating conditions.

e) Reinforcing peg shall be provided with two tapped tell-tale holes located 180° apart at
right angles to the longitudinal center line of the vessel. One of these holes shall be
used for an air connection and the other for use of a pressure gauge when testing the
welding in the pad.
f) Vessel seams shall be located in such a way so as to avoid openings or important

intervals (trays, etc.). No joint shall be located coincidental with or across saddle
supports. Attachment welds shall be Located to clear seam welds by at Least one plate
thickness.
g) Adjacent Longitudinal seams shall be staggered so as to give, *wherever permitted by

the clause on Design Requirement -GeneraI (f) above, a minimum of 60 deg.
orientation between seams.
h) In addition to the design requirements for maximum operating conditions, each beam
or segment of pan, baffle, tray, etc., shall be designed before corrosion allowance to
support a 100 (One hundred) kg concentrated load at the midpoint of the beam, etc for
erection or clean out conditions.
i) Removable internals shall be designed in units as large as may be withdrawable from

through the nearest manhole or opening specified for that purpose.
j) Manholes shall be furnished with handgrips inside the vessel located conveniently
above the manhole. If the bottom manhole in a vertical vessel is more than 1.5 m from
the bottom head, internal ladder rings shall be provided. All manhole covers shall be
fitted with davits.
k) All manholes, nozzles and couplings shall be accurately located longitudinally from a
common base plane and radially from the axis of the vessel. The maximum tolerances
on openings shall be as follows:
i) longitudinally ±6 mm
ii) projection ±3 mm
iii) radially ±1 degree
l) Where two or more openings are provided for installation of equipment, such as gauge
glasses, float controls etc., they shall be set with a jig to prevent tolerances from being
additive.
m) Nozzle necks smaller than 40 mm shall have a minimum thickness equal to schedule
160 pipe. Nozzle necks 40mm through 150mm size shall have a minimum wall
thickness equal to Schedule 80 pipe. Nozzle necks 200 mm size and larger shall have
not less than 11.5 mm wall thickness.
n) Boreholes in nozzles, man ways, and handholds shall straddle the normal centre-line.

o) Flanges shall have sufficient clearance from the body of the vessel to permit the
insertion and complete withdrawal from the back of any stud bolts used to couple
associated blinds, valves and pipework flanges.
p) When lugs or clips are required to support insulation, piping ladders, platforms, etc.,
they shall be welded to the vessel in the shop.
q) On stress-relieved vessels, a pad at least 6 mm thick shall be welded to the vessel

before stress relieving, at each location where a clip or lug is to be installed.
r) Wind speed shall be taken as 144 km/h and loadings comply with B.S Code of practice
No. 3 Chapter V.
1A.3.5 FABRICATION REQUIREMENTS – GENERAL
a) Plates shall be bent in the same direction as final roll given the steel in manufacture.
b) All welds shall be made by the shielded metal process using electrodes of a
composition and quality compatible with the vessel materials.
c) All Welders shall be qualified under Section IX of the ASME Code. Work involving
welding shall not be subject to any work codes without the prior approval of the
Engineer.
d) Welding by automatic or semi automatic equipment is permitted.
e) Gas, bare wire, carbon-arc or forged welding shall not be used.
f) All nozzles, manholes and small connections and their reinforcements shall be
attached to the vessel with full penetration welds.
g) All longitudinal and circumferential seams in shells and all seams in heads shall be
full penetration. Butt welds, lap welds shall not be used.
h) All internal equipment which is specified to be welded in place shall be installed

before stress relieving. All internal equipment which is to be bolted, screwed or
clamped in place shall be installed by the manufacturer before shipment, unless
otherwise specified.
i) All clips that are to support insulation, ladders, platform, pipe etc., shall be furnished
by the manufacturer. They shall be welded to vessel in the shop, and clips on stress
relieved vessels shall be installed before stress relieving is done. External clips on
stress-relieved vessels shall not project more than 200 mm from the vessel.
j) Pre and post-weld heat treatment shall be as called for in the ASME Code Section
VIII. Before manufacture, the vendor shall inform the Engineer of the heat treatment
operations to be performed. All flanged facings and threaded connections must be
adequately protected against oxidation during the heat treatment.
1A.3.6 INSPECTION AND TESTING
a) All pressure vessels shall be fabricated to ASME VIII code and inspected and
certified by an independent inspection agency with ASME stamp.
b) All longitudinal welds and circumferential welds shall receive 100% X-ray
examination.
c) Pressure containing parts shall be hydrostatically tested at 1.5 times the design
pressure shown on the appropriate data sheets.
d) Bolts and gaskets furnished by the supplier for field erection of bolted attachments
shall not be those used in testing vessels.
e) All alloy linings for the inside of vessels that are attached by electric resistance spot
welds or seal weld shall be given a pneumatic or hydrostatic test of sufficient intensity
to prove the tightness of the lining and the strength of the welds.
f) All welded attachments provided with tell-tale holes shall be tested by pneumatic or
hydrostatic pressure prior to the thermal stress relief and final hydrostatic test.
g) Vessels, or parts thereof, or materials entering therein, which show indications of

irremediable or injurious defects, improper fabrication, excessive repair or that they
are not in accordance with the requirements of this specification and the applicable
code shall be subject to rejection. Vessels shall also be subject to rejection if such
conditions are discovered after acceptance of the items at the fabricator's Works. All
costs of repairs, replacement, transportation shall be borne by the Contractor.
h) After completion of all tests, the supplier shall submit six (6) volumes containing
material test report, X-ray reports, stress relieving temperature recorder charts,
hydrostatic test pressure reports and reports of test conducted on thermal parts, if any.
As in Packing for Shipment under GeneraI and Miscellaneous.
1A.3.8 APPROVAL OF DRAWINGS
The Contractor shall forward three (3) prints of each vessel Manufacturing Drawing and
necessary certificates for review by an approved Third Party Plan Approval and Inspection
Agency. This Third Party will ascertain that vessels are designed to satisfy ASME Section
VIII. Any deviations from Code that do not meet with Third Party or Purchaser’s approval,
shall be corrected to meet Section VIII design and re-submitted for Third Party and
Purchaser’s approval.
Approval by Third Party in no way relieves that Contractor of his responsibility.

It is the Contractors responsibility to arrange for payment of approved Third Party who must
have Purchaser’s prior approval.
1A.3.9 NAME PLATE
Each complete vessel shall be provided with a corrosion-resistant nameplate securely attached
by welding to the vessel shell, in a Location that is easily accessible after installation. The
nameplate shall contain the following data:
1) Code symbol and type of construction

ii) Manufacturer’s name
iii) Manufacturer’s serial number
iv) Maximum test pressure
v) Date tested
vi) Minimum thickness of shell
vii) Minimum thickness of each head
viii) Maximum allowable working pressure
ix) Corrosion allowance
1A.3.10 GUARANTEE
As in Guarantee under General and Miscellaneous
SECTION 4 HORIZONTAL CYLINDRICAL WELDED STEEL TANKS

CONTENTS
1A.4.1 GENERAL
1A.4.2 MANUFACTURING CODES AND STANDARDS
1A.4.3 DESIGN AND FABRICATION
1A.4.4 MOUNTING
1A.4.5 PAINTING
1A.4.6 REPORTS AND RECORDS
1A.4.7 INSPECTION
1A.4.9 GUARANTEE

SECTION 4 HORIZONTAL, CYLINDRICAL WELDED STEEL TANKS
1A.4.1 GENERAL
This specification, together with data sheets and drawings, covers the requirements for the
design, materials, fabrication and inspection of welded steel storage tanks.
A conflict between requirements of this specification, standards, codes, purchase order or

drawings shall be clarified with the Engineer/Purchaser, before proceeding with the
fabrication of the affected part.
1A.4.2 MANUFACTURING CODES, STANDARDS AND SPECIFICATIONS
All equipment shall be manufactured in accordance with the applicable features of the
following Codes, Standards and Specifications unless otherwise indicated or stated in this
specification.
i) B.S 2594 Carbon Steel Welded Horizontal Cylindrical Storage Tanks or agreed
equivalent
ii) B.S 5135 Metal-Arc Welding of Carbon and Carbon-Manganese Steels.
iii) B.S 1387 Steel Tubes and Tubulars suitable for screwing to BS 21 Pipe
Threads,
iv) B.S.2708 Unified Black Square and Hexagon Bolts, Screws and Nuts (UNC
and UNF Threads).
v) ANSI B.16.5 Steel Pipe Flanges and Flanged Fittings.
ASME equivalents are acceptable unless B.S. is more stringent.
1A.4.3 DESIGN AND FABRICATION
This design and construction of the tanks shall be in accordance with British Standard 2594
for Carbon Steel Welded Storage Tanks, or equivalent standards.
Welding Procedure shall be carried out in accordance with British Standard 5135 or
equivalent standard.
1A.4.4 MOUNTINGS
All piping Used shall be supplied to B.S. 1387 Grade "B" (extra strong weight) or equivalent.
The diameter and position of the manhole shall be as indicated on the attached drawing and
data sheet.

The type of bolts required e.g. for manhole lid or mountings attachment shall be to B.S. 2709
or equivalent.
1A.4.5 PAINTING
The tank shall be shot blasted to SA 2 1/2 for the removal of mill scale and rust etc on both
inside and outside surfaces prior to painting.
Refer to Specification on Painting. The inside and outside of the tank shall be given the full
paint system less the final coat which shall be applied on site.
1A.4.6 REPORTS AND RECORDS
The fabricator shall maintain a file of material records. These records shall be checked by the
Fabricator and inspector, and so certified on the manufacturer’s vessel data report. Evidence
shall be kept to the effect that the materials of construction comply with the appropriate
standards and specifications.
1A.4.7 INSPECTION
Inspection shall be carried out by the Engineer/Purchaser at the works in accordance with
standard B.S. 2594, (latest edition) or equivalent standard.
In addition to any inspection required under a code, all fabrication and materials shall be
subject to inspection by the Engineer.
All manhole cover hinges and hinge bolts shall be in place before the tank is tested. The hinge
bolts shall fit so that they can be turned freely by hand. Covers shall be swung open to ensure
that no binding takes place.
As in General and Miscellaneous Specification above.
1A.4.9 GUARANTEE
As above.

SECTION 5 GAS SCRUBBERS
CONTENTS
1A.5.1 GENERAL
1A.5.2 PERFORMANCE
1A.5.4 MANUFACTURE TESTING AND INSPECTION
1A.5.6 GUARANTEE

GAS SCRUBBERS
1A.5.1 GENERAL
This specification provides for the manufacture, testing at works, packing for shipment and
delivery to site of the gas scrubbers described herein.
The scrubbers are to be skid mounted for installation within a natural gas transmission
pipeline system.
Each scrubber shall be sized to carry that proportion of the total design flow conditions given
for the metering station.
1A.5.2 PERFORMANCE
The Supplier shall furnish with his Tender, a curve showing the actual efficiency of his
equipment presented as a percentage of particles removed whether wet and/or dry by weight
against particle size in microns for the range of flows specified.
The Supplier’s design shall include appropriate provision for the removal of any liquid which
may be carried in the gas. The Supplier shall state the efficiency of liquid removal from the
gas as stipulated in the above paragraph.
The allowable pressure drop between the inlet and outlet nozzles under maximum flow and
minimum pressure conditions shall be stipulated by the Vendor on data sheets provided by the
Contractor.
The Supplier shall furnish specifications of all materials used in the construction of all
scrubbers. All flanged connections shall be ANSI raised face flanges, with the class suited to
the conditions given in the data sheets.
The scrubbers shall be fitted with manholes not Less than 18" nominal size which shall
provide access for cleaning and maintenance of internal elements.
A davit shall be attached to each scrubber to facilitate removal of the manhole covers. The
scrubbers shall be furnished skid mounted suitable for locating on a flat concrete base.
If a filter/scrubber is offered, the equipment should include a quick release closure for rapid
filter- element changes. Each scrubber shall have a liquid capacity adequate for the conditions
given by the gas analysis.
The scrubbers shall be supplied compIete with all necessary local instrumentation controls
and piping, including but not limited to, differential pressure gauges, level gauges, level
controllers, relief valves, etc.
1A.5.4 MANUFACTURE, TESTING AND INSPECTION

The vessels shall be manufactured in accordance with the requirements of ASME Code
Section VIII, except where otherwise noted herein. All longitudinal welds and circumferential
welds shall receive 100% X-ray examination.
The vessels shall be stress-relieved for periods and at holding temperatures and heating rates
appropriate to the materials and thickness chosen, as referred to in, sub-section C of ASME
VIII. Pressure-containing parts shall be hydrostatically tested at 1.5 times the design pressure
shown on the appropriate data sheets.
After completion of all tests, the Contractor shall submit six (6) volumes containing materials
test reports, X-ray reports, stress relieving temperature recorder charts, hydrostatic test
pressure reports, and reports of tests conducted on internal parts, in accordance with the
Schedule of Documents required from the Supplier.
As in General and Miscellaneous Specification.
1A.5.6 GUARANTEE
As above.

SECTION 6 COLD VENT/BURN PIT
CONTENTS
1A.6.1 GENERAL
1A.6.2 GAS ANALYSIS
1A 6.3 CLIMATE
1A.6.4 SPECIFIC REQUIREMENTS
1A.6.5 EMERGENCY BURN PIT

SECTION 6 COLD VENTS /BURN PIT
1A.6.1 General
A cold vent shall be required at the metering station for venting gas during emergency
Shutdown.
1A.6.2 Gas Analysis
The compositions of gases which may be vented shall be in this range specified in Attachment
6 of Volume 1B of the Tender Documents.
1A.6.3 CIimate
The climate is tropical and the meteorological information is set out for generaI guidance in
Part 3, Volume 1B of the Tender Documents.
1A.6.4 Specific Requirements
The height of the vent stack shall be sufficient to enable personnel to work at the base of the
stack. Account should be taken of the fact that at the metering station, the stack shall be
located well away from the offices and process area. It is proposed to site the stack at least
100 metres from any buiIding but the Contractor is to forward detaiIed proposaIs for the vent.
The design basis for the vent shall be subject to approval by the Engineer.
1A.6.5 Emergency Burn Pit -Metering Station
The metering station site shall have an emergency burn pit fitted with ignition system which
shall be sized and positioned by the Contractor. This shall be subject to the approval of the
Engineer.
PART 1A
PART 1B MECHANICAL INSTALLATlON, SPECIFICATION PIPEWORK -

FABRICATION, ASSEMBLY AND ERECTION
SECTION 1 GENERAL
CONTENTS
1B.1.1 SCOPE
1B.1.2 STANDARDS.
1B.1.3 PERMITS
1B.1.4 DETAILED DESIGN OF MANIFOLD PIPING

PART 1B MECHANICAL INSTALLATION SPECIFICATION PIPEWORK

FABRICATION, ASSEMBLY AND ERECTION
SECTION 1 GENERAL
1B.1.1 Scope
This specification describes the construction of station pipework for gas and services which
shall be designed and installed in accordance with Nigerian Safety Regulations and the
requirements as detailed.
The Contractor shall famiIiarise himself with the use of the various Iines which are to be
installed under this Specification, and his particuIar attention is called to the various operating
pressures and temperatures involved in each Line.
Specifications for protective coating and pickIing are provided separately.
1B.1.2 Standards
The latest editions of the following engineering standards and specifications shall be adhered
to unless otherwise defined, amended or specifically excluded by this specification.
ASTM applicable materials specifications.
ANSI B31.3 Petroleum Refinery Piping (for design).
ASME Section VIII Pressure Vessels, Division 1
ASME Section IX Welding and Brazing Qualifications
API 1104 Standard for Welding PipeIines and Related Facilities (for Construction).
1. B.1.3 Permits
In manifolds and installations owned or operated by others, it shall be the Contractor’s

responsibility to ensure that he has the necessary permits to enter or work in any area, whether
it be gas-free of live. The Contractor shall at aII times comply with the permit restrictions
imposed by the operators.
1B.1.4 Detailed Design of Manifold Piping
a) General
i) Piping and equipment shall be adequately supported so as to prevent excessive

vibration and with sufficient flexibility to prevent undue loads on the equipment
served.

Flexible joints or similar fittings to allow for any expansion or settlement can only be
used on lines with the specific prior approval of the Engineer.
ii) When differential settlement between items of equipment or support may be expected,
sufficient flexibility shall be provided in the connecting pipework.
iii) All hangers and supports shall be as detailed and shall be made of non-combustible
material capable of sustaining the load to which subjected. Wood or wire may not be
used for permanent installations. Material shall be supplied by the Contractor and
approved by the Engineer.
iv) Hangers and Supports shall be so installed as not to interfere with the free expansion
and contraction of the piping between anchors, and strictly in accordance with
locations assumed in the flexibility analysis.
v) Sleeves shall be provided for all pipe penetrating waIIs whether detailed on the
Drawings or not unless details provide for pipe to be cast in pIace. Sleeves shall be
cast in concrete waIIs or installed during erection of masonry.
vi) In all cases where service pipes pass through floors, walls, ceilings or partitions of
buildings, a sleeve shall be provided with edges cut clean and packed with neoprene or
equivalent to prevent metal to metal contact between pipe and sleeve.
vii) Escutcheons shall be installed around all exposed pipe passing through a finished
floor, waII or ceiling other than concrete. Escutcheons shall be of sufficient outside
diameter to cover the sleeve opening, and shall fit snugly around the pipe.
viii) Spades or other means of positive isolation (e.g. flanged fittings or line blinds) shall be
provided to isolate any item of equipment or group of items for testing, gas freeing,
making safe, to prevent contamination, or other reasons.
ix) Suitable access to spades shall be provided. Blanks used to separate two sections of
pipeline shall be of adequate rating and have conspicuous or projecting tabs.
b) Over-head Piping
i) All overhead piping shall be installed to provide at least two metres (6’ 6”) minimum
headroom in aIl passageways, unless detailed otherwise. Valves shall be accessible for
operation and maintenance. Platforms may be used to provide such access
ii) Overground lines shall be grouped together to form pipe-tracks and shall be run on
supports to give the lines the same bottom elevation.
iii) The piping shall be run true to vertical, horizontal and the axis of the buildings in such
a way that it is pleasant to the eye unless the type of installation demands a slope on
the pipe in which case the slope shall remain even along the length of the pipe.

iv) All piping shall be designed in a neat workman like manner properly insulated, guided
and supported and pitched to provide suitable venting and draining of lines. In all
cases, care shall be taken, wherever possible, to avoid formation of air or liquid
pockets throughout the system. High point vent shall be provided.
v) Pipes for corrosive fluids shall not, as far as possible, be run overhead across
walkways or areas where persons may pass.
c) Pipe on Sleepers
Pipes on sleepers shall be high enough to clear all flanges, valve bodies, etc from
grade. A clearance of 230mm (9 inches) from grade to underside of pipes shall be
provided unless otherwise specified.
d) Clearances
Where pipework is laid on gantries, in tracks or in permanent trenches, the

arrangement and clearances shall permit removal of any pipe, fitting or valve without
the necessity to disturb adjacent pipework.
Where underground lines run side by side, there shall be a minimum clearance of
50mm (2 inches) between a pipe and an adjacent flange or pipe after allowing for
insuIation.
e) Bending and Setting
Changes in direction of pipe shall be made by means of factory made fittings in all
cases. Elbows shall normally be 1 1/2"D in radius, except in pigging Iines where 7D
radius or greater bends shall be used.
f) Liquid Lines
Liquid pipework shall be sloped appropriately to permit proper drainage.
Hose and hydrant connections for fire service lines shall conform to the standards of
the Iocal fire brigade, or in the event of this not being possible, suitable adaptors shall
be provided.
g) Line Identification
Lines shall bear colour marking or other identification to indicate the product or
service for which the line is intended. The colour scheme to identify the contents of
pipelines shall comply with Employer's requirements, to be specified. Direction of
flow shall be indicated by arrows.
SECTION 2 SETTING OUT THE WORKS

CONTENTS
1B.2.1 SETTING OUT
1B.2.2 STORAGE OF MATERIALS
PART 1B MECHANICAL SPECIFICATION
SECTION 2 SETTING OUT THE WORKS

1B.2.1 Setting Out

The Contractor shall duly set out, align, install and connect the various items of piping and
associated equipment in accordance with the design drawings which have been supplied by
the Contractor and approved by the Engineer.
Reference points, ordinates and datum levels for setting out the piping and associated
equipment within and around the station confines shall be those established and maintained by
the mechanical equipment and piping installation Contractor. Elsewhere (where there are no
reference joints and datum levels) these shall be established by the Contractor and approved
by the Engineer.
The Contractor shall be entirely responsible for accurately fabricating piping and setting out
and aligning all parts of the works. The fabrication and setting out shall be to the compIete
satisfaction of the Engineer. The Contractor shalI give such notice to the Engineer as wiIl
enabIe the Engineer’s site staff to check the setting out and alignment of the Works. The
Contractor shall also provide such Iabour, tools, instruments or any other items necessary for
the Engineer or his Representatives to check any part of the Works.
No approval, either given or impIied by the Engineer’s Representative(s) shall relieve the
Contractor of his obIigations in connection with the fabrication, setting out, positioning and
alignment of any part of the Works.
1B.2.2 Storage of Materials

The Contractor shall be responsible for the proper storage, protection and security of all
piping, materials and equipment. A properly organised system of stores and materials control
must be instituted to the approval of the Engineer and maintained throughout the piping
installation contract.
All materials received shall be stored off the ground on timber skids or pallets and protected
from the weather. All machined faces, such as the contact faces of flanges, shall be greased if
not otherwise protected to prevent corrosion.
The Contractor shall provide temporary buildings, sheds and cover as necessary to prevent the
deterioration of materials and equipment through all weather conditions. The side walls of
storage buildings shall prevent entry of wind borne rain and maintain adequate security
against pilferage. A properly constructed orderly system of shelving and bins shall be
installed for the storage of smaller items of materials and equipment (particularly nut and
bolts, small valves, joint rings and welding rods, etc) to the approval of the Engineer’s
Representative.
Upon receipt of materials on site or local fabrication shop, the Contractor shall carefully
segregate items of differing piping class and ANSI rating and label them accordingly.
SECTION 3 FABRICATION STANDARDS

CONTENTS
1B.3.1 GENERAL
1B.3.2 TYPES OF WELD
1B.3.3 WELDING EQUIPMENT AND MATERIALS
1B.3.4 WELDING PROCEDURES
1B.3.5 WELDING PROCEDURE QUALIFICATION TESTS
1B.3.6 GAS TUNGSTEN ARC WELDING QUALIFICATION TEST
1B.3.7 NON-DESTRUCTIVE TESTING OF WELDS
1B.3.8 INSPECTION OF PIPING MATERIAL
1B.3.9 PIPE CUTTING AND WELDING PREPARATION
1B.3.10 FIT-UP OF FABRICATION ASSEMBLY
1B.3.11 WELDING OF FABRICATED ASSEMBLY
1B.3.12 CONSTRUCTION TOLERANCES
1B.3.13 STORAGE OF FABRICATED ASSSEMBLIES
SECTION 3 FABRICATION STANDARDS

1B.3.1 General
The Contractor shall propose, for the approvaI of the Engineer, a pipe fabrication and weId
quaIity control system for identifying and correlating the various parts of each fabricated
assembly incIuding material batch reference/serial numbers, weId and repair numbers,
weIding operators, radiograph tests and non-destructive tests, together with dates and
inspection/acceptance signature.
a) The material and schedule identification shaIl be checked and all reference numbers which are
painted on the body of the pipe or stamped onto the welding Ievel shaIl be recommended and
marked up on the fabrication drawings for inclusion on the As-Built drawings.
b) Welds shall be made by the ShieIded metal arc welding process (SMA) or the Gas Tungsten
Arc WeIding process (GTAW).
c) All welding shall be carried out in compliance with the latest editions of:
ANSI B.31.3 Chemical PIant and Petroleum Refinery Piping.
API 1104 Standard for welding pipelines and related facilities and as further described in
this specification.
d) No welding shall be carried out when the shade temperature is below five degrees (5º)
centigrade on a falling thermometer, or three degrees (3º) centigrade on a rising thermometer
without the prior approval of the Engineer.
e) Adequate precautions shall be taken to protect welding operations from wind, rain, sand, etc.
The Engineer’s decision on when welding shall be shut down is final.
1B.3.2 Types of Weld
a) Butt welds may be of the SingIe V, double V, or other suitable types of groove. Welding
groove details shall be fully in compliance with the requirements of qualified weIding
procedure.
b) Fillet welds may be concave to slightly convex.
c) Butt welds shall be made by the "Uphill" method
d) Mitre welds shall not be permitted.
1B.3.3 Welding Equipment and Materials

a) All welding machines, bevelling machines, cutting equipment, line-up clamps, tools and
supplies used in connection with the welding work shall be of good quality and be maintained
to the satisfaction of the Engineer.
b) Welding electrodes shall conform to the requirements of the latest edition of:
AWS-ASTM Specification for Mild Steel Arc Welding Electrodes, or:

AWS-ASTM Specifications for High Tensile and Low Alloy Steel Arc Welding Electrodes.
Electrodes containing more than 1% Nickel shall not be used unless approved in writing by
the Engineer.
c) Filler Metal or G.T.A.W. shall comply with the requirements of the ASME VIII Code for
Unfired Pressure Vessels.
1B.3.4 WeIding Procedures
a) All welding shall be carried out in accordance with the specific and qualified procedures
prepared by the Contractor and approved by the Engineer.
b) All gas high pressure pipework shall be welded using "Low Hydrogen Electrodes or Hydrogen
controlled Welding Processes" unless otherwise approved by the Engineer. EIectrode storage,
handling, drying and baking wiII be to the Manufacturer’s recommendations.
c) All low pressure service pipework may be welded with non-hydrogen controlled techniques
with the approval of the Engineer.
d) The detailed weIding procedure shall incIude details of aII pre-heat and /or post-heat
requirements. The minimum pre-heat temperature shall be 100ºC and shall be effective for aII
weIding passes. The maximum interpass temperature shall be 250ºC.
e) For all welding, the following conditions shalI apply:
i) The maximum time delay between the root and second pass shall be five minutes.
ii) Two welders shaIl be used on pipe 12 inches diameter and above.
iii) Internal line-up clamps shall be used if possible; otherwise external clamps shall be
used.
iv) In general, welding shall be a continuous operation. Welding shall never be stopped
until at least three runs are complete.
v) Before roll welding is started, three runs shall be completed in the fixed position.
vi) Back welding/any internal welding shall require approval from the Engineer and must
be pre-qualified on the welding procedure qualification test (10.3.6 (e)).
1B.3.5 WeIding Procedure Qualification Test

a) WeIding procedures and weld repair procedures for aIl weIding processes and materials to be
constructed in manifold areas shaIl be proposed by the Contractor, approved by the Engineer
and qualified generaIIy in accordance with the requirements of the specification for pipeIine
weIding.
No welder shall be employed on tacking or production welding of piping unless he is

qualified to weld the procedure established for the diameter and materiaIs comprising the
joint. AIl welders must carry identity card duly signed by the Engineer’s representative
indicating the procedure in which he has been qualified.
Welder qualification, weld inspection, standards of weld acceptability, repair and cut-out
limitations shall be as defined in specification for welding of pipeIine unless modified by
contents of Mechanical InstaIIation Specification.
b) A hardness survey shall be carried out on one section from each quadrant. Hardness shall be
measured by the Diamond Pyramid method (Vickel 10 kg). At no point shall the hardness
value exceed 248 VPN (10 KG)
c) Fracture toughness properties of the heat-affected zone of test welds , on gas pressure piping,
shall be determined:
i) Two sets of three Charpy 'V' notch specimens shall be tested for each procedure test
weId. One set shall test the weld metal and one set shall test the weld heat-affected
zone.
d) Each set of three Charpy V-notch specimens shall be impact tested at 10ºC and shall show a
maximum average energy value of 34 joules. No single value shall be less than 27 joules.
1B.3.6 Gas-Tungsten Arc Welding Qualification Test
Before a welder shall be permitted to perform gas-tungsten arc welding on station piping, he
shall demonstrate his qualification by means of test conducted by the Engineer's Welding
Inspector. The test shall be carried out in accordance with the requirements of the ASME
Boiler and Pressure Vessel Code, Section IX.
1B.3.7 Non-destructive Testing of WeIds
a) All welds in process and utility piping shall be subject to 100% radiographic inspection with
the exception of weIds in water and compressed air services and open drainIines which shall
be subject to spot radiography as defined in ASME Section VIII.
b) Supplementary non-destructive examination by ultrasonic and/or magnetic crack detection

methods shall be made by the Contractor where the type of geometry of the weIds do not
permit radiographic inspection, or where deemed necessary by the Engineer to assist
radiographic interpretation.
c) Routines and procedures for visual, radiographic, ultrasonic inspection and magnetic crack
detection shall be as defined in specification for welding of pipeline.
1B.3.8 Inspection of Piping MateriaIs
a) The pipe and fittings shall be visually inspected for any dents, flaws or end damage and shall
be cleaned out to remove any dirt, rubbish or other debris.
b) All cases of damaged or defective pipe materials and fittings shall be reported to the Engineer
for visual inspection before any repairs or rectification shall be subject to Engineer’s appoval.
c) Dented pipe shall only be acceptable within the Iimits of the manufacturing specification but
in any case, the maximum permissible dent depth shall not exceed 1% of the pipe diameter.
Pipe dented beyond this Iimit shall be cut out in a cylindrical section and discarded.
d) Pipe flaws such as laminations or cracking shall be reported to the Engineer for visual
inspection before cut out.
e) Pipe damaged by scouting or gouging may only be repaired in as much as the defects can be
removed by grinding without reducing the nominal wall thickness of the pipe section by more
than 20% and without impairing the weld preparation.
f) Where gouging has reduced the pipe wall thickness by an amount greater than 12.5% of the
minimal wall thickness at any point in the deformed area of a dent, the damaged part shall be
cut in a cylindrical section and discarded.
1B.3.9 Piping Cutting and Weld Preparation
a) The piping shall be constructed as economically as possible and to achieve this, the
Contractor shall review the actual lengths of each pipe diameter/wall thickness in store, in
conjunction with the various lengths of spooled pipe required from each pipe
diameter/thickness schedule and shall plan his cutting list so that pipe wastage and additional
pipe to pipe welds are kept to a minimum. No residual pups of length less than three pipe
diameters shall be welded up in composite lengths in pipe fabrications.
b) Cutting of pipe may be done either by mechanical means or by flame cutting. Flame cutting
and bevelling is acceptable for carbon steel and low alloy steel pipe only if the cut is
reasonably smooth and true and all oxides are subsequently removed from the cut surfaces (in
the case of alloy steel pipe, at least 2mm thickness of material must be removed from the
bevel surface by grinding). Stainless steel piping shall not be flame cut under any
circumstances .
c) Wherever possible the pipe shall be cut to the welding preparation bevel angle using a
proprietary cutting/bevelling machine. Where the pipe is cut by hand, the cut shall be dead
square and the welding preparation shall be formed by grinding back the body of the pipe wall
to the required angle.
d) In either case, the weIding beveI and root Iand shaIl be ground so that aII nicks and sIag
remaining from the cutting process are removed and the weIding preparation is in accordance
with the quaIified weIding procedure.
e) The rebevelled ends shall be smooth and uniform and dimensions shall be in accordance with
the approved welding procedure, All rebevelled ends shall be subject to the approval of the
Engineer and shall be subjected to an Ultrasonic lamination check to the material Purchase
Specification.
f) The cut pipe spools shall be marked with their respective spool numbers and lengths in
accordance with the marked up fabrication drawings, and the established quality control
system.
1B.3.10 Fit -up of Fabrication AssembIies
a) Prior to fitting Up components of fabricated assemblies, all weld preparations shall be power
wire brushed or lightly ground to remove all rust , scale or paint from the weld area and the
heat-affected zones. Any oil or grease shall be removed with solvent for a distance of at least
40 mm on each side of the weld area.
b) Where longitudinal seam welded piping is being assembled, care shall be taken to ensure that
the seam weld is in the top quadrant of the pipe and that seams in adjacent lengths of pipe
butted together are offset by a minimum angle of 90º or 250 mm, whichever is less. ParticuIar
attention must be given where weld offsets or branch fittings are to be attached to seam
welded pipe. The attachment welds shall not be located within 100 mm of the longitudinal or
circumferentiaI weld seams and the pipe shall be rotated if necessary to ensure adequate
clearance from the longitudinal seam weld.
c) Piping joints shall be offered up the fitting of the weId root lands, checked and corrected if
necessary. External cIamps and adjustabIe pipe supports shall be used to obtain the correct fit-
up required. Pipes and fittings shaIl be used to achieve fit-up alignment. Finger bars, strips,
braces across eIbows or other temporary fixing arrangements involving weIding may not be
used under any circumstance. Tack weIding shall be in accordance with the weIding
procedure and tack weIds shall not be worked to achieve correct gap line-up, concentricity
etc. All broken or cracked tack welds shall be completeIy removed by grinding.
d) Careful attention shall be given to the proper grinding of the tack weld stop-starts so that the
tack welds merge uniformly into the root pass of the weId. WeIding arc strikes shall only be
made on fusion faces in the weIding preparation only.
e) When fitting-up joints, where there is a mis-match due to ovality or disparity in wall thickness,
the mis-match shall be equalised around the circumference of the joint within the limits of the
welding specification.
f) The internal offset of adjoining surfaces due to dimensional variations or difference in wall
thickness shall not exceed 2.0mm. Particular attention shall be given where pipes and fittings
are of different schedule/wall thickness. The grinding of pipe or fittings to achieve fit up shall
be in accordance with the limitations of geometry and wall thickness imposed by ANSI B31.3

g) Where pipes of different material grades, or of different wall thicknesses (or both) are to be
joined, and where the mis-match of waII thickness cannot be rectified by grinding in
accordance with the tolerances of ANSI B31.3, then a transition piece shall be used.
h) The transition piece shall have a length of at least 2 pipe diameters and shall have a minimum
specified yield strength equivalent to the thinner of the two pipes to be joined. The ends of the
transition pieces shall be machined to suit the respective pipe wall thicknesses.
1B.3.11 Welding of Fabricated Assemblies
a) After dimensional checks on the piping assembly, the tackled joints between components
should be welded up without delay in accordance with the approved and qualified welding
procedure.
b) Careful attention shall be given to the proper grinding of the weld stop-starts so that the tack
welds merge uniformly into the root pass of the weld. Under no circumstances shall braces be
tacked across joints to be welded as a precaution against joint distortion during welding.
Welding arc strikes shall only be made on fusion faces in the welding bevel -NOT on other
adjacent areas of the pipe/fitting surface.
1B.3.12 Construction Tolerances
The tolerance for construction of fabricated piping is shown in Part 10.6 and the Contractor
shall exercise the care and workmanship necessary to achieve the tolerances stated.
Tolerances shall not be cumulative. Particular attention shall be given to the welding of joints
so that weld construction does not distort the piping.
1B.3.13 Storage of Fabricated Assemblies
Upon completion of a fabricated assembly and after radiographic and/or other non-destructive
testing (and hydrostatic testing if this is to be done before field erection), the assembly shall
be drained and dried out and stored off the ground on skids with all flanges or other openings
sealed.


SECTION 4 INSTALLATION OF PIPING ON SITE
CONTENTS
1B.4.1 GENERAL
1B.4.2 PIPING CONNECTIONS TO MECHANICAL EQUIPMENT
1B.4.3 FLANGED JOINTS AND CONNECTIONS
1B.4.4 UNDERGROUND PIPING
1B.4.5 TIE-IN-CONNECTIONS

SECTION 4 INSTALLATION OF PIPING ON SITE
1B.4.1 General
a) Adequate scaffolding and other temporary supports shall be provided for proper alignment of
pipes as well as for personneI safety; and they shall not be removed prior to inspection and
testing of the pipework.
b) Pre-fabricated piping received upon the installation site shall be carefully checked for damage
or distortion in transit, cIeaned of any debris, and swabbed or blown through with compressed
air.
c) The open ends of piping at the end of each day's work shall be securely closed with blanking
discs or plug.
d) The piping shall be erected to line and level on the pipe supports in a natural unstressed
condition. Piping shall not be strained into position by the use of levers, pull-lifts, chain-
blocks etc. If the piping does not fit, it shall be taken down, cut and adjusted to suit. Hot or
cold bending shall not be allowed. The welding of temporary braces or supports to the piping
is prohibited.
e) Oversize closing lengths of piping for field welding shall be offered up on measured cut back
and fitted up and welded. Piping erection shall be planned so that sufficient time is allowed
for the completion of welding of any field joints without interruption on the same day.
f) The tolerances for construction of fabricated piping are as described in Mechanical

Installation Specification – Construction Tolerances for fabricated piping. The Contractor
shall exercise the care and workmanship necessary to achieve the tolerance stated. Tolerances
shall not be cumulative. Particular attention shall be given to the weIding of joints so that
weld contraction does not distort the piping.
1B.4.2 Piping Connections to Mechanical Equipment
a) Where piping is to be jointed to the connection flanges of pumps, compressors or other

mechanical equipment, the loose (unwelded) pipe flange may be bolted to the equipment with
a spacer plate of correct thickness inserted in the joint. The piping shall be offered up and
adjusted to suit the pipe flange without springing or forcing into position and tack welded to
the flange.
NOTE :( Particular care shall be given to the attachment of the welding earth clamp to ensure
that the welding current does not run through the mechanical equipment. The earth clamp
must be fixed to the flange of the pipe being welded only).
b) After the joint has been tacked, the pipe flange shall be unbolted and the alignment of the two
flanges checked. If this is satisfactory, the pipe shall be removed and the flange fully welded.
Final alignment of the welded pipe assembIy to the equipment flange shall be
inspected/approved by the Resident Engineer before final bolting up of the joint.
c) Special care shall be exercised when erecting bellow pieces or expansion joints in piping, and
the manufacturer’s instructions shall be carefully followed. Any restraining mechanism fixed
to the bellows or joint shall not be removed until the approval of the Engineer has been
obtained.
d) The Engineer shall have the right to make the Contractor unbolt any piping flange or uncouple
any connection in order to check that there is no strain or mis-alignment in the installation.
The Contractor shall not be entitled to claim for any additional time, costs or expenses in
respect of such checks, whether or not the installation is found to be satisfactory.
1B.4.3 Flanged Joints and Connections
a) Mating flanges, flange bolt holes and flange concentricity shall be aligned in accordance with
the tolerances as aforementioned in this Specification.
b) Flange faces shall be cleaned of any rust, paint or grease and the gasket or joint ring shall be
carefully inserted and centralized. Stud bolts of the correct diameter and length shall be
selected in accordance with the relevant flange size and class. The nuts shall be run up by
hand so that the stud bolt protrusion through each nut is equalized and then nuts shall then be
tightened in a diametrically opposite sequence so as to compress the joint as evenly as
possible. The wrenches used for stud-bolt tightening shall correspond to the stud-bolt
diameter and for larger sizes, proper air-impact wrenches or flogging ring spanners shall be
utilized. If flogging ring spanners are used in hazardous areas, they shall be of non-sparking
materials.
1B.4.4 Underground Piping
Underground piping shall be carefully laid to grade specified on drawings and shall have the
minimum cover shown. Where possible, underground piping shall be laid so that it shall drain
to one end of the pipe without traps. Special attention shall be paid to road crossings as
regards protection of the pipe and drainage thereof.
A Corrossion Allowance of 1mm shall be added to the calculated Line pipe wall thickness
and 2mm for major river crossings and swamps.
All river crossings shall be Horizontal Directional Drilling (HDD) construction and not open
cut method.
All submerged piping shall be weight coated for negative buoyancy.
1B.4.5 Tie-in Connections

a) Connection in dry areas
Where manifold piping is to be tied in to pipelines, the tie-in shall be made in the ditch.
Lifting the pipeline and manifold piping for an over-the-ditch tie-in shall not be permitted.
The Contractor shall excavate a bell-hole at the tie-in weld location which should be sited so
that the soil around any pipe anchor position shall remain undisturbed.
b) Connections in Swamp Areas
The pipeline shall be aligned with the manifold piping marked, lifted and cut back with a
sufficient amount of slack pipe to allow re-installation in the ditch.
c) Transition Pieces
Transition pieces may be required at the transition from pipeline to manifold piping and care
shall be taken to ensure that they are lifted where required.

SECTION 5 JOINTS
CONTENTS
1B.5.1 FLANGED JOINTS
1B.5.2 SCREWED JOINTS
1B.5.1 Flanged Joints
a) All flanges, flanged joints and boltings shall comply with the appropriate section of
ANSl B.l6.5, latest issue, MMS SP 44 and particular contract specifications.
b) Flange faces shall be free from weld spatter, marks and scratches, and shall be
protected from corrosion or rust.
c) Flange bolt holes shall straddle vertical, horizontal or north-south center lines, unless
otherwise noted on the Drawings.
d) Flange bolts shall project a minimum of 3mm (1/8”) through the nuts when tightened
up.
e) Pipelines shall be sufficiently flexible to minimise load transmitted. Flexible joints or

similar fittings to allow for any expansion or settlement can only be used on lines with
the specific prior approval of the Engineer.
f) Insulating flanges shall be installed at the entry and exit to all stations, and shall
ensure electricaI discontinuity between pipeline and process equipment.
1B.5.2 Screwed Joints
a) Screwed pipe joints shall have API taper threads, and only seal welded where
specified.
b) When "seal-welding" of screwed pipe joint is specified, the joint shall be made up dry,
all threads shall be clean cut to full depth, and joints shall be made up wrench tight
without the use of thread compound .
c) Seal welding shall cover the exposed pipe threads at screwed fittings, but shall not
exceed 9mm (3/8 inch) fillet.
d) Minimum joint make-up shall be based on the following "Normal Engagement”.

Table N.E.
Nominal Pipe 8 8 10 15 20 25 32 40 50
Size (mm)
Pipe Size 1/8 ¼ 3/8 ½ ¾ 1 1¼

1½
(ins.)
N.E. (mm) 8 10 10 13 15 18 18 18 20
N.E. (ins.) ¼ 3/8 3/8 ½ 9/16 11/16 11/16 11/16

¾
e) PTFE (polytetrafluoroethylene) tape shall be used on joints which are not to be “seal-
welded”.
PART 1B MECHANICAL SPECIFlCATION

SECTON 6 CONSTRUCTION TOLERANCES FOR FABRICATED PIPING
The number references refer to the notes on figure 1.
(1) Positions of branches, bosses, flanged ends and instrument connections shall be within
a tolerance of ±3mm (1/8”). (Tolerances shall not be cumulative).
(2) The cumulative angular and concentric tolerances shown in Figure 1 shall not exceed
the following ;
Piping Nominal Size (mm) Maximum Misalignment

‘W’ (mm)
Up to and including 300 1.5

350 and above 2.5
(3) The off-square tolerance of flange faces as shown in Figure 1 shall not exceed the
following:
Piping nominal Size (mm) Off-square Tolerance ‘X’

Maximum (mm)
Up to and including 100 1.5

125 to 300 2.5
350 to 600 4
750 and above 5
(4) All angular dimensions of bends or branches shall be within ±0.5º (plus/minus half a
degree).
PART 1B MECHANICAL INSTALLATION SPECIFlCATION

SECTION 7 THERMAL INSULATION AND CLADDlNG
CONTENTS
1B.7.1 GENERAL
1B.7.2 MATERIALS
1B.7.3 INSTALLATION OF INSULATION AND CLADDING

SECTION 7 THERMAL INSULATION AND CLADDING
1B.7.1 General
Where insulation is for the Protection of Personnel, it shall Iimit the maximum surface
temperature to 600C (140ºF) on the basis of ambient Temperature of 30ºC (86ºF) .On chilled
or refrigerated lines, insulating will be used to reduce heat gain from ambient surroundings
into the pipe.
1B.7.2 Materials
Insulating materials shall be of mineral wool (such as ‘Rock;-wool’) and shall meet B.S 5970
and Regulations currently in force or national equivalent. Material shall not contain any
asbestos and shall be non-combustible, chemically inert and non-soluble, even when saturated
with water. All materials shall be new and of prime quality and shall be obtained specifically
for the work in hand from any approved manufacturer of high repute.
Insulating material for pipes shall be in compressed pre-formed round sections properly
matching the outside diameter of the pipe to be covered. High temperature pipes shall be
covered in two concentric Iayers, so arranged that the joints are staggered between the first
and second layers. Bends, elbows and tee-branches shall all be insulated with pre-formed split
sections of compressed material.
All insulation shall be encased in galvanised steel or anodised aluminum cladding of 20

S.W.G (0.914mm) thicknesses. For small bore insulated pipes (2 inch diameter or less), the
sheet metal thickness may be reduced to 22 S.W.G. (0.71mm).
1B.7.3 Installation of insulation and Cladding

All insulation shall be installed in accordance with the approved schedule of thickness agreed
to by the Engineer before hand.
It shall be understood that the insulation must not be applied to any components or parts of the
pIant before hydrostatic pressure and leakage tests have been successfully completed.
Insulation shall be properly installed so as to closely fit the contours of the hot surfaces
without voids or gaps. The material shall be securely fitted in position with non-corrodable
wire or galvanised steel bands, so as to resist vibration, sagging or bulging.
The insulation of pipes, valves and fittings shall be finished off adjacent to flanged joints so
that the joints can easily be dismantled without disturbing the main insulating material.
Insulation of valves and pipe joints and other connections shall be easily removable and made
from split boxes of cladding metal, lined on the inside with the correct thickness of insulating
materials, securely attached to the interior of each box.

SECTION 8 VALVE INSTALLATION
CONTENTS
1B.8.1 GENERAL

SECTION 8 VALVE INSTALLATION
1B.8.1 General
a) Valve flanges of screwed connections shall be protected by flange coverings or plugs prior to
installation.
b) Gate and Globe Valves shall be kept closed at all times before installation for protection of
seats. Ball and plug valves shall be kept fully open.
c) Undue stress shall be avoided during installation by proper alignment of joints.
d) Power actuated valves shall be installed without actuators. The actuators shall be properly
stored under cover until pipe installation is complete and preparations are being made for
functional testing of the installation. Exposed actuator sieves, mountings, etc. shall be
properly protected against damage or ingress of foreign matter.

SECTION 9 TESTING
CONTENTS
1B.9.1 PREPARATION
1B.9.2 PROCEDURE

SECTION 9 TESTING
1B.9.1 Preparation
a) Prior to start-up, all piping shall be carefully and thoroughly brushed clean, flushed or blown
clean and the necessary precautions taken to prevent damage to the equipment by dirt or
foreign objects. Precautions shall be taken to ensure that debris is not fIushed into associated
Vessels, equipment or "dead ends".
b) Pressure relieving devices shall be removed.
c) Expansion of joints of the sliding sleeve or bellows type shall be provided with temporary
means to limit lateral movement.
d) Pipe supports and anchors shall be fitted prior to pressure testing. AdditionaI temporary
supports where required due to weight of the testing medium shall be provided.
e) Welded, flanged or screwed connections shall not be painted or otherwise coated before
completion of pressure testing.
f) The procedure for preparing oil piping and accessories prior to testing by pickling is detailed
in a separate specification.
1B.9.2 Procedure
a) With the following exception, all lines shall be pressure tested in the presence of the Engineer.
At the Engineer's discretion, tests at closing weIds and re-tests at any "cut-in" to a line already
tested may be waived provided that:
i) Preparation and welding is carried out under the supervision and to the satisfaction of
the Engineer.
ii) Radiographic examination, if required by the Engineer, is satisfactorily completed in

accordance with the specifications.
b) The testing medium shall be inhibited water unless otherwise specified.
c) Each system shall be tested as agreed with the Engineer, and shall be in accordance with the
requirements of the Nigerian Safety Regulations and ANSI B 31.3.
d) Under no circumstance shall any tests be carried out unless approved and witnessed by the
Engineer's Representative.
e) A testing procedure and method of draining all Iines shall be submitted in writing to the
Engineer for approvaI.

f) Adequate provisions shall be made in advance of hydrostatic testing for the injection of water
into the system, including any venting and drains from the piping. Upon the completion of
these tests, openings installed for this purpose shall be designed, installed and finally closed in
strict accordance with the requirements of ANSI B31.3 covering the type of line concerned,
and the detailed piping specification.
g) Equipment or vessels manufactured according to ANSI or A.S.M.E. code and so stamped

shall be re-tested in the field.
h) When pipework is required to be heat treated, this treatment shall precede any hydrostatic
testing as specified by the standard.
i) In systems where residual moisture cannot be tolerated, the testing medium shall be subject to
approval by the Engineer. If water has to be used, the system shall afterwards be dried out
with hot air .Special attention shaIl be given to points where water may be trapped such as in
valve bodies or low points.
j) The hydrostatic test pressure for installed alloy steel pipework shall be approved by the
Engineer.
k) Where the pipework being tested contains flanges, the test pressure for piping as determined
above shall not exceed the hydrostatic body test pressure shown in the Pressure-Temperature
rating tables of the appropriate standards .
l) No piece of equipment shaIl be subjected to a pressure greater than manufacturer’s

recommendations.
m) Hydrostatic tests on above ground pipework shall be completed before insulation is installed.
If insulation is applied before testing, all welds and threads shall be left exposed until
completion of testing.
n) Where testing by compressed air is specified such as instrument-air piping, etc.
i) The pipework shall be tested in sections, as agreed with the Engineer, as soon as
erection of each section is complete and before any painting or external coating is
carried out.
ii) After making the necessary correction to air supply and seaIing off all open ends, a
preliminary check shall be made at not more than twenty-five (25) psig (1.7 bar).
iii) Subsequently, the pressure within the pipework under test shall be increased gradually
in steps, and maintained for a period of 4 hours. During this period, all joints,
couplings, valves and other fittings shall be leak-tested with a one percent (1%)
solution of soap and water. All Ieaks shall be rectified and the test repeated. The test
shaIl be considered successful when the pressure has been retained without visible
ions and without bubbles appearing in the solution for a period of one hour.
o) All instrument-air piping shall be tested with clean dry air.

p) If the piping is not to be tested as a whole, the Contractor shall identify the test sections and
ensure that they have sufficient vents and drains and are positively isolated by blind flanges
from other piping sections, particularly those of different ANSI rating. No reliance shall be
placed on closed valves for isolation during pressure testing.
q) After completion of tests and purging with gas, etc, spades and bIanks installed for testing
purposes shall be removed. The Contractor shall provide men as required to disconnect,
dismantle, and clean all equipment, pipe, valves, fittings, etc before re-assembling. On gas or
air lines where it is impossible to ensure complete elimination of moisture, the line shall be
filled with methanol, drained and purged with hot air until all methanol vapour is expelled.

SPECIFICATION FOR PIPELINES AND PIPEWORK MATERIALS
SECTION 1 LINE PIPE
2A.1.1 Introduction
2A.1.2 Process of Manufacture and Material
2A.1.3 Chemical Properties and Tests
2A.1.4 Physical Properties and Tests
2A.1.5 Hydrostatic Tests
2A.1.6 Dimensions, Weights and Lengths
2A.1.7 Non-Destructive Inspection
2A.1.8 Workmanship, Visual Inspection and Repair of Defects
2A.1.9 Marking and Coatings
2A.1.10 Appendix 'A'
2A.1.11 Appendix 'E'
SECTION 2 STATION PIPING
2A.2.1 Scope
2A.2.2 Dimensions
2A.2.3 Finish
SECTION 3. DELETED
SECTION 4 WELDING FITTINGS
2A.4.1 Scope
2A.4.2 Materials
2A.4.3 Tensile Properties
2A.4.4 Heat Treatment
2A.4.5 Fracture Toughness properties
2A.4.6 Process of Manufacture
2A.4.7 Dimensions
2A.4.8 Test and Inspection
2A.4.9 Certification
2A.4.10 Marking
SECTION 5 FORGED STEEL BUTT WELDING FITTINGS
2A.5.1 Scope
2A.5.2 Design
2A.5.3 Material and Manufacture
2A.5.4 Transition Pieces
2A.5 5 Inspections
2A.5.6 Marking
SECTION 6 FLANGES
2A.6.1 Scope
2A.6.2 General Requirement
2A.6.3 Temperature and Pressure Ratings
2A.6.4 Governing Specifications
2A.6.5 Flange Facing
2A.6.6 Material
2A.6.8 Weldability
2A.6.9 Mechanical Testing and Chemical Analyses
2A.6.10 Manufacture Toughness Properties
2A.6.12 Dimensions
2A.6.13 Inspection, Non-Destructive Testing, Repair of Defects
2A.6.14 Hydrostatic Pressure Test
2A.6.15 Marking
SECTION 7 GASKETS
2A.7.1 Scope
2A.7.2 General Requirements
2A.7.3 Pressure/Temperature Rating
2A.7.5 Dimension
2A.7.6 Materials
2A.7.7 Inspection
2A.7.8 Marking
2A.7.9 Packing
SECTION 8 STUDBOLTS AND NUTS
2A.8.1 Intended Service

2A.8.2 Sizes
2A.8.3 Type
2A.8.4 Dimensions
2A.8.5 Materials
2A.8.6 Threads
2A.8.7 Packing
2A.8.8 Inspection

SECTION 9 PIPELINE ANCHOR FLANGES
2A.9.1 Scope
2A.9.3 Pressure Ratings
2A.9.5 Materials
2A.9.6 Detailed Requirements
2A.9.8 Material for Transition Pieces
2A.9.9 Welding
2A.9.10 Non-Destructive Inspection
2A.9.11 Visual Inspection and Repair of Defects
2A.9.12 Information to be submitted with the Tender.
2A.9.13 Packing
2A.9.14 Guarantees
SECTION 10 INSULATING PIPE COUPLINGS
2A.10.1 Workmanship and General Design

2A.10.2 Function
2A.10.3 Clear Bore
2A.10.4 Electrical Connections
2A.10.5 Length of Insulating Coupling Assembly
2A.10.8 Coating
2A.10.9 Testing
2A.10.10 Factory Assembly
2A.10.11 Packing
SECTION 11 SCRAPER LAUNCHERS AND RECEIVERS
2A.11.1 General
2A.11.2 Size
2A.11.3 Design Pressure and Temperature
2A.11.4 Test Pressure
2A.11.5 Codes and Standards
2A.11.6 Description
2A.11.7 Operating Requirements
SECTION 12 SPHERE TEES
2A.12.1 Scope
2A.12.3 Mode of Construction
2A.12.4 Welding
2A.12.5 Non-Destructive Testing
SECTION 13 VALVES –GENERAL
SECTION 14 STEEL GATES, PLUG, BALL AND CHECK VALVES
2A.14.1 Scope
2A.14.2 General Service Conditions
2A.14.3 Materials
2A.14.4 Design and Construction
2A.14.5 Testing
2A.14.6 Inspection
2A.14.7 Data and Drawings
2A.14.8 Marking
SECTION 15 NEEDLE VALVES
SECTION 16 CAST IRON GLOBE VALVES ANGLE PATTERN
SECTION 17 FIRE VALVES

PART 2A SPECIFICATION FOR PIPELINES AND PIPEWORK-MATERIALS
PART 2A.1 LINEPIPE
SUPPLEMENTARY REQUIREMENTS
TO API SPEC 5L (LATEST EDITION)
2A.1.1 INTRODUCTION
This Specification covers requirements for API Std 5L line pipe of the grades and diameters
stated below, and shall supplement APl Spec 5L, latest edition.
Grad. Diameter
(Inches)
X52 6 5/8"
8 5/8"
10 3/4"
14"
16"
X60 24"
X65 – X80 48"
X70 – X80 56"
The numbering of the paragraphs shall correspond with API 5L. Paragraphs or parts of
paragraphs contained in API 5L and which remain unaffected by the requirements of this
Specification, shall remain fully applicable, insofar as these relate to electric-welded line pipe.
2A.l.2 PROCESS OF MANUFACTURE AND MATERIAL
Pipe furnished to this Specification shall conform to product specification level 2 and be
seamless or manufactured by the automatic submerged arc welding process, with at least two
welding passes, one of which shall be on the outside. Electric flash welded line pipe shall not
be used. All billets used for seamless pipe shall be free of surface defects.
Longitudinal welded pipe in diameters greater than 12.75 inches shall be furnished in the cold
expanded condition. Cold expansion shall not exceed 1.5% of the original pipe diameter.
Steel plates shall be made by the open-hearth, electric furnace or basic oxygen process, and
shall be fully kilned and made to fine grain practice.
Steel plates shall be of the low carbon controlled rolled type, unless otherwise agreed with the
Buyer. The quality of the welded seam shall be such as to produce a joint efficiency factor of
1.0
The Contractor shall furnish a document specifying the manufacturing procedure. This
procedure shall include but not be limited to the following information.

a) Material Quality, Full details and limits of ladle and check analysis (including residual
elements)
b) Material manufacture details
c) Method of plate forming
d) Welding Procedures
e) Method and degree of cold expansion. If applicable, details of heat treatment
f) Method of straightening, sizing and hydrostatic testing
g) Inside diameter.
h) Quality control and inspection procedures. The submitted procedure and any agreed
modifications shall be strictly followed in the production of the pipe. Any changes will
require immediate re-qualification tests, including weIding procedure and first day
production tests.
The Supplier shall carry out aII welding in accordance with an established welding procedure.
This procedure shall be supplied to the Purchaser's inspector prior to commencement of
production. The written procedure shall include the following:-
a) Details of joint design, method of plate forming and alignment, clamping, and/or tack
welding procedure together with details of coupons used and method of their
attachment to the pipe.
b) A description of the type, trade name and size of welding wire, grade of melt or fIux,
electrical polarity, volts, amperes and welding speed.
c) The number of passes and their disposition; the limits of external and internal
reinforcement; details of the method of guiding the welding head and other relevant
information.
d) FulI details of repair procedures
Procedure Qualification
For qualification of the welding procedure and repair procedure, the following tests shall be
executed on a test weld made in accordance with the manufacturing procedure specification
i.e. 100% ultrasonic, 100% radiography, 100% M.P.I and 100% visual, to the requirements of
this specification. Tensile and bend tests to API 5L, Charpy, macro and hardness tests as
required by this specification.
When Starting Production
The Supplier shall inform the Purchaser of the date regular production will start according to
Welding Procedure shown in the above Paragraph of this specification. On this day, ten
finished pipes shall be selected by the Purchaser's Inspector and will be examined and tested
as follows:-
a) Visual and dimensional check for surface faults and compliance with dimensional
tolerances. Pipes with diameters of 24 inch or larger shall also be inspected internally.
b) Each pipe shall be examined full length by an ultrasonic inspection device. These
pipes may contain ultrasonic indication of defects, which will be assessed by the
subsequent radiographic inspection to determine the reliability of the test system.
c) Each of the ten ultrasonically inspected pipes will be selected by the Purchaser's
Inspector and shall be radiographed and M.P.I. tested full length.
d) The physical properties of aII pipes shall be tested as specified here under:-
1) Weld Seam
On two pipes, the weld seam shall be physically tested as required by Section 4 of API
5L to include tensile and bend tests. Impact tests, macro and hardness shall be
executed as below.
2) Pipe Material
On two pipes, the material shall be physically tested as required by Section 4 of APl
5L to include tensile and bend tests. Impact test, macro and hardness shall be executed
as below.
e) Macro-examination
From one pipe, six specimens, three from close to each end, shall be removed from
locations selected by the Purchaser’s inspector and shall be cross sectioned, polished,
and etched for micro and macro-examination.
f) Hardness Test
One of the micro-etched specimens selected by the Purchaser's inspector shall be used
for making Vickers hardness surveys (10 kg load) as follows:
Three traverses shall be made with measurements about 2 mm apart extending from
unaffected base metal on one side, across the weld, to unaffected base metal on the
other side. One traverse shall be near the outer edge, the second across the centre, and
the third near the inner edge of the weld. Results of hardness tests shall be presented in
diagram form. For acceptance, no hardness value shaIl exceed 248 HV (10) for welds
and 210 HV (10) for plate.
g) Impact Tests
From the pipes selected for physical testing, the following transverse 10 x 6.7mm
Charpy vee notch samples shall be taken.
Three samples from the parent plate
Three samples from the weld metal centre line
Three samples from the heat-affected zone
For all samples, the notch shall be perpendicular to the pipe surface.

The test temperature shall be -10ºC. The average of the three tests shall be 30 Joules
minimum with no individual test being less than 24 Joules. The % shear valves will be
recorded for information. Where the pipe wall thickness will not permit the use of
6.7mm thick Charpy coupons only, the coupon thickness may be reduced to 5mm. The
average value for the three tests shall be 20 Joules with no individual test being less
than 12A Joules. All other conditions shall be as described above.
h) Mill Circumferential Weld Weldability Test
From the first day's production, two pipes should be selected, welded together, tested
as follows and witnessed by the Engineer or his representative. Welding shall take
place in the fixed 5G position.
i) Full length pipes shall be welded together using an external line-up clamp and two
welders. The speed of deposition shall be equivalent to 300mm per minute.
An internal line-up clamp may be used at the option of the Supplier.
ii) The gap shall be set at 2.5 mm
iii) Nil preheat shall be used for all welding. The temperature of the test material shall be
10°C or less.
iv) The root pass shall be deposited vertical down using 4 mm E7010 electrodes at 120-
150 amps.
v) The line-up clamp shall be removed when 40% of the root is complete.
vi) The root shall be ground and a five-minute additional time delay shall be taken before
the hot pass is started. This shall be completed vertical down using 4 mm E7010
electrodes at 180-200 amps.
vii) Discontinue welding after the hot pass and allow material to cool to 10ºC or less
viii) Complete the welding using E7010 4.8 mm electrodes vertical down at 160-200 amps.
After the compIeted weId has cooled to ambient and again after 48 hours, the
following tests shall be done, and weIdability judged acceptabIe if aII tests are
passed:-
i) 100% visual to API 1104
ii) 100% MPI to ASME V
iii) 100% Radiography to API 1104 using Iead screens
iv) 100% Ultrasonic to ASME V and ASME VIII. The ultrasonic technique employed
shall be capable of finding longitudinal and transverse defects.

The Engineer shall be notified immediately if cracks are found When the NDT is complete the
following tests shall be completed and carefully documented and refer:
i) Tensile Tests to API 1104
ii) Bend Tests to API 1104
iii) Charpy tests to the Section of this document
iv) Nick breaks to API 1104
v) Macro and hardness surveys to the Section on Macro and Hardness of this document.
The acceptance criteria of all mechanical tests shall be to API 5L Standard.
2A.1.3 CHEMICAL PROPERTIES & TESTS
Composition on Ladle Analysis
The chemical composition of the steel shall fall within the following limits,
Ladle Analysis
Carbon 0.20% max

Silicon 0.35% max
Manganese 1.35% max
Phosphorous 0.03% max
Sulphur 0.02% max
Alloying elements Niobium, Vanadium, Titanium may be added to a combined total not
exceeding 0.15%.
The addition of other elements such as Chromium, Nickel, Molybdenum, and Copper shall
only be as alloying elements with the written agreement of the Purchaser.
The ladle analysis chemical component percentages stated above may be modified in
accordance with the footnotes to table below within the context of their pertinence.
A certificate of ladle analysis is required for each heat of steel which shall conform to the
requirements of paragraph below. In addition, the following elements shall be analysed for:
Cr, Mo, Cu, Ni, V, Nb, Ti, N2. Check analyses shall be furnished for each heat of steel used in
producing the pipe. Two samples shall be analysed for product analyses, one from each of two
lengths of pipe from each heat of steel and smaller, whichever shall give the greater number
of samples, and one from each of two lengths from each heat of steel or lot of 100 lengths or
less of each size 14 inch and larger, whichever shall give the greater number of samples. The
presence of alloying elements shall be checked and reported in accordance with paragraph
below.
Check analyses shall be within the following allowable variations on ladle analysis limits.

ELEMENTS TOLERANCES
%C +0.02
%Mn +0.10
%P +0.01
%S +0.01
------------------------------------------------------------------------------
The product shall have a maximum Carbon equivalent of 0.43 based on
CE = C + Mn + Cr+Mo + V + Ni + Cu
6 5 15
The Supplier shall submit test data or demonstrate that the steel is suitable for field welding
by the vertical down technique using cellulose-coated electrodes.
2A.1.4 PHYSICAL PROPERTIES AND TESTS
Tensile Properties
The ratio of tensile strength to yield point shall not exceed 0.93. The actual tensile strength
shall not exceed API 5LX by more than 15 kg/mm2.
YieId Strength
Yield strength shall be the tensile stress required to produce a total strain of 0.5% as
determined by an extensometer.
Number of Tensile Tests
One transverse body tensile test shall be made on pipe representing each heat of steel. When
one heat corresponds to more than 200 pipes, two pipes will be selected for tensile tests.
Yield stress, tensile stress, elongation and yield/tensile ratio shall be determined. The
elongation shall not be less than 20%.
Number of Weld Tensile Tests
One transverse weld tensile test shall be made on pipe representing each heat of steel. When
one heat corresponds to more than 200 pipes, two pipes will be selected for tensile tests.
Fracture Toughness Tests
Charpy V-notch impact tests shall be made using 10 x 6.7 mm thickness V-notch specimens.
Specimens shall be cut so that the length of the specimen is transverse to the axis of the pipe,
with the notch through the wall thickness. Frequency of impact testing shall be as per 4.9
tensile tests. Three transverse samples shall be removed from the finished pipe, one from the
body of the pipe, one from the weld and one from the heat-affected zone. The sample
representing the body of the pipe shall be opposite the weld, adjacent to the location of the
transverse, tensile test specimen. Three 10 x 6.7 mm Charpy V-notch impact tests specimens
shall be machined from each of the three samples.
The impact tests shall be carried out at –10ºC. The average of the three tests shall be 30
Joules, minimum, with no individual test being less than 24 Joules, with % shear values
recorded for information.
The following additional tests shall be carried out:-
a) From a sample of first day production pipe, a transition temperature showing impact values
plotted against temperature shall be prepared from two thirds Charpy V-notch specimens with
the specimen length transverse to the direction of rolling and notched through the thickness of
the plate. Three samples shall be broken at the following temperatures:
-60°C, -40°C, -20C, -10°C, 0°C, 10°C, 20°C, 50°C, 100°C.
% Shear values shall be recorded for information.
This entire procedure shall be repeated on a first day production weld and similar transition
curves constructed for both the weld centre line and the heat-affected zone.
b) Drop Weight Tear Tests
From one pipe representing each heat of steel or two pipes when one heat corresponds to
more than 200 pipes, DWTT shall be done to the supplementary requirement SR6 of API 5L.
The specimens shall be heated to 100°C and retained at that temperature for one hour and then
allowed to cool to ambient temperature. The test temperature shall be -10°C and the
acceptance criteria shall be a minimum of 75% shear area fracture.
Submerged Arc Weld Tests
The guided bend test is required in addition to the weld tensile test.
Guided bend test dimensions shall be as specified in API Standard 5L -March 1980.
One face bend and one root bend test shall be made per each heat of steel.
One macro-etch specimen shall be taken from each test pipe representing each heat of steel.
After examination of the macro specimen, hardness of weld metal, fusion line, and heat-
affected zone shall be determined for each heat of steel (see as above in Hardness test. The
maximum hardness value allowed is 248 HV (10).
Charpy impact tests are required as in the Procedure for Welding qualification.

2A.1.5 HYDROSTATIC TEST
Supplier shall maintain a record of hydrostatic test for each pipe, and shall certify that every
length of delivered pipe has been tested in accordance with specified requirements. The test
pressure shall be held for not less than 20 seconds.
Test pressures shall be calculated from the formula shown in paragraph 5.3 of API 5LX and
shall represent the pressures corresponding to a fibre stress equal to 95% of the specified
minimum yield strength based on nominal wall thickness. The test information shall be
recorded on a suitable recording chart. The serial number of the pipe being tested shall be
legibly recorded at the side of the pressure trace on the chart. In cases where a pressure test is
discontinued because of a temporary failure of the test equipment, the serial number of the
pipe under test at the time of failure shall be recorded on the chart and it shall be shown
clearly that the pipe has been retested and has satisfactory results.
2A.1.6 DIMENSIONS. WEIGHTS AND LENGTHS
Diameter
The outside diameter of the body of the pipe, as measured by taping the circumference, shall
be within the acceptable tolerances.
The Wall Thickness Fabrication Tolerance shall be +19.5%, -8.0% for Welded Pipe and
+17.5%, -10.0% for Seamless Pipe
Length
Pipe shall be furnished in double random lengths. The maximum length of a single joint shall
not exceed 13.72 metres.
Straightness
The pipes shall be straight. Deviation shall be less than 0.2% of the length of a pipe.
Pipe Ends
The pipes supplied shall have bevelled ends to an angle of 30° + 50° measured from a
perpendicular drawn to the axis of the pipe and with a root face of 1.6mm +0.6mm (1/12A
+.0.025).
The ends shall be cut square within 1.6 mm (1/12A") and measured 3 times per working shift.
If, at the inspection, a pipe proves to be unsatisfactory, this pipe, as weII as aII the pipes
manufactured since the last test shall be examined individuaIIy in order to check their bevel
cutting. The burr shall be completely removed from the inside and outside of the pipe ends.
Undercutting shall be a cause for re-beveIIing or rejection. Finish on the bevel shall be
smooth and free from tool marks.
Jointers

Welded jointers will not be accepted unless otherwise agreed by the Engineer. Jointers shall
not be expanded after the circumferential weld has been completed.
2A.1.7 NON-DESTRUCTIVE INSPECTION
Methods of Inspection
The quality of the plate or coiled skelp shall be confirmed by ultrasonic examination of all
edges over a width of at least 75 mm after trimming the edges to the required plate width.
Shear and compression techniques shall be used to detect both laminations and longitudinal
and transverse cracks. The technique used shall be approved by the Engineer. The plate or
skelp surface shall also be subject to general ultrasonic examination using a sinusoidal scan
pattern or alternatively, along parallel lines pitched at 100 mm maximum spacing.
Each weld shall be examined ultrasonically full length by an automatic device. Both ends of
every weld shall be examined by X-Ray for a distance of nine (9) inches (228 mm) from the
end of the pipe.
For acceptance purpose, the ultrasonic X-Ray test shall be carried out, after, cold expansion
on hydrostatic test and the X-ray of ends shall be carried out, after, final end -facing
(beveling). The ends of each pipe shall be subject to ultrasonic examination after bevelling
over the full, circumference for a width of at least 50 mm. the bevelled end and the last, 50
mm. The number of welds on all finished pipes shall be inspected by M.P .I.
Radiographic Examination.
Radiographic examination shall be made using a single wall, single image technique generally
in accordance with that described in BS 2910, Technique 2 and with the following limitations.
a) Only X-radiation, using file grain, high contrast/direct film with lead screen shall be
used. Fluoroscopic method is not acceptable.
b) The IQI (image quality indicator) sensitivity, using a wire type IQI shall be 1.5%
measure at the extremities of the weld length under examination.
c) In mills where the pentameter is normally placed on the film side, the effectiveness of
the procedure shall be checked at least once per X-ray unit per shift with the
pentameter on the source side.
d) The density of the radiograph shall not be less than 2.0 so that the density through the
thickest portion of the weld metal shall not be less than 1.5 and shall be chosen to
provide the maximum contrast for the film used.
e) All processing shall be carried out in accordance with the film manufacturer’s
recommendations. The film shall be free from scratches and artefacts.
f) For examination of the radiographs, the Manufacturer shall provide a darkened

viewing room with properly designed sources of illumination.
Acceptance Limits
Faults disclose by ultrasonic and radiographic examination and exceeding the following limits
shall be deemed unacceptable.
a) Cracks and area of incomplete penetration or fusion of any size.

b) Porosity: any total area of porosity projected radially through the weld exceeding 6
mm or 20% of the wall thickness, whichever is the lesser. Porosity in the end 50 mm
of weld is not acceptable.
c) Slag inclusions: any single slag inclusion or a total cumulative length of slag inclusion
exceeding 6 mm in any 150 mm length of the weld. A slag inclusion exceeding 1.5
mm in width. Slag inclusions are not allowed in the end 50 mm of weld
d) Depth of defects: since radiography provides a qualitative assessment in two

dimensions only, it is possible that a weld having one or more defects within the limits
of acceptability set out in b) and c) above, shall nevertheless not be acceptable if it is
considered that the third dimension of any defect is sufficient to prejudice the
performance of that weld.
e) In the longitudinal edges of the plate, laminations or inclusions with a length of more
than 15 mm or extending from the edge for more than 10 mm into the plate are not
acceptable.
f) Laminations in the beveled pipe ends greater than 6 mm in length are not acceptable.
g) Isolated laminations in the plate well removed from the edges and with an area of
more than 10,000 mm2 or with a length exceeding 400 mm are not acceptable.
Clusters or small inclusions interfering with the ultrasonic inspection of the weld are
also not acceptable. Acceptance limit for laminations and inclusions in the pipe end
shall be in accordance with paragraph 9.16 Table 9.5. Any lamination not parallel to
the plate surface is unacceptable.
Acceptable levels
Ultrasonic indications in the longitudinal seam shall be re-inspected by radiography prior to

commencing any repairs.
Ultrasonic Equipment.
Each weld shall be examined full length by an automatic ultrasonic device after cold
expansion and hydrostatic test to detect and eliminate any defects formed during expansion
and testing. The probe assembly shall be so arranged that the weld is scanned along its full
length and cross section such that longitudinal and transverse defects shall be located. The
speed of testing shall not exceed that used to demonstrate the ability of the equipment to
detect a standard effect. Equipment which produces a strip chart record of each weld
inspected shall be used. A paint spray or other marking device shall also be used in
conjunction with the recorder chart. The equipment shall be fitted with a device which
monitors effectiveness of the acoustic.
Reference Standards
Calibration of the equipment shall be carried out, under the same conditions (i.e., speed, pitch,
etc) as those used on production testing, by the appropriate probes every time the test pipe is
passed through the equipment. During production testing, calibration checks shall be carried
out at least once per hour or every thirty pipes. The requirement for recalibration of
equipment at the intervals stated may be relaxed at the option of the Employer’s senior
inspector if he is such as would enable a greater interval between recalibration without
detriment to the line pipe. If on checking calibration during routine reduction testing, all
reference standards are not detected, then all pipes tested since the previous shall be re-tested
after the equipment has been correctly calibrated. The calibration standard shall be located on
pipe of the same diameter, thickness and composition as the pipe to be tested. calibration of
shear wave probes.
a) Reference standards: These shall be as indicated in paragraph 7.15 of API 5.L.
b) Longitudinal inspection: The reference targets shall consist of notches of depth equal
to 5% of the pipe thickness. One placed on the outside surface adjacent to the weld
edge, one on the inside surface adjacent to the weld root edge.
The notch dimension shall be as indicated in Fig 9.4 of API 5L. The notches shall be
displaced longitudinally to produce two separate and distinguishable signals. The
minimum length of the notches shall be 50 mm.
Transverse Inspection
The calibration standards shall consist of either one of the following:
a) A 1.5mm diameter hole drilled through the weld center line along a radius of the pipe.
b) Notches of depth 5% of pipe thickness, one placed on the outer surface of the weld
and at right angles to the weld centre line, and one on the internal surface of the weld
at right angles to the weld centre line. The minimum length of these notches shall be
13mm.
Weld Repairs
Injurious defects in the weld detected prior to expansion and hydrostatic test may be required
in accordance with paragraph 8.8 and 8.9 of API 5L. The repaired areas shall be re-inspected
by ultrasonic and radiography .Only one attempt at each repair will be allowed. Repair
welding of the parent plate and within 230mm of the ends of the longitudinal seam weld is not
acceptable. Repair by dents shall not be permitted. Repair by welding shall not be permitted
after the pipe has been cold expanded.
WORKMANSHIP VISUAL INSPECTION AND REPAIR OF DEFECTS

Inspection
Notice of not less than 30 days shall be given by the Supplier to the Purchaser’s inspector
prior to the beginning of manufacturing. The line pipe manufacture and quality control and
testing shall be witnessed by the Engineer's Inspectors.
Only pipes which prove satisfactory after the inspection of the Supplier and the Purchaser or
his representative shall be accepted. They shall be marked by the inspector as belonging to the
batch which has satisfied all specified tests. If more than 10% of the pipes in anyone day fails
to meet any or all of the specified requirements an immediate investigation shall be initiated
to establish the cause. The Engineer reserves the right to halt production on the event of
rejection of 10% or more pipes in any one day’s production.
Pipes showing injurious defects after the hydrostatic tests shall be rejected and the inspection
mark, if any, shall be removed from the pipe.
Visual Inspection
a) Plates
The superficial defects on plates shall be examined so as to determine their severity. Grinding
is permitted only if the thickness of the plate where ground is superior or equal to the minimal
thickness allowed. This shall be confirmed by ultrasonic testing.
The surface on which the grinding has been performed shall not make an acute angle with the
surface of the plate. Superficial defects which cannot be modified by grinding according to
the above conditions shall be considered as injurious defects. Repairing or filling by welding
shall not be allowed in the base metal.
b) Pipes
The visual tolerances of bare pipes are the following:
Straightness and deviation tolerances are indicated in paragraph under (Dimensions, Weights,
and Lengths and Widening). Narrowing at the ends of the pipe is not allowed.
A deformation shall be accepted only if its deviation measured with a rule, inside and outside
the pipe, does not exceed 1mm and provided that the requirements of the Table concerning
the overall diameter and ovalization are respected.
Local defects and dents shall be allowed provided that the theoretical I.D. is reduced by not
more than 3mm.
The length of the dent in any direction shall not exceed one half the pipe diameters. All cold
formed dents with a sharp bottom gouges, and all sharp gouges (without dents) deeper than
0.83 mm shall be considered injurious.
Any other visual defects, such as grooves, undercuts, scaling, lack of thickness shall not be
permitted and shall result in the rejection of the pipe.
c) Welding
The maximum radial offset of plate edges in the weld seam shall not exceed 1mm. The height
of the outside weld bead shall be 3.2mm max. and the height of the inside weld bead shall be
2 mm max.
Other Defects
All other defects, of which the depth measured from the surface of the pipe exceeds the
permissible under-thickness tolerances shall be considered injurious defects, and shall be
repaired in accordance with the paragraphs 10.8 and 10.9 of API 5L, with the exception that
the remaining wall thickness after repair shall not be less than the minimum thickness
specified, as confirmed by ultrasonic testing.
Repairs by welding shall not be permitted after expansion and hydrostatic test.
2A.1.9 MARKING AND COATINGS
Unless otherwise agreed, marking shall be stenciled on the inside of the pipe within 20cm of
the beveled ends. Identification markings shall include the following additional markings:
Pipe Length (m)

Manufacturer's Pipe Identification number.
Heat Number
Purchase Order Number.
Die-stamping
Die-stamping shall not be permitted, except when carried out by the Purchaser's inspector. It
shall then be carefully stamped on the bevelled end.
Coating
Pipe shall be supplied bare unless otherwise stated on a separate order.
The pre-heating temperature for all welding procedures shall be 150-200°C. Interpass
temperature shall not exceed 250°C. For shielded metal arc welding, low-hydrogen electrodes
shall be used. Six transverse Charpy V-notch specimens shall be prepared.
The test temperature and acceptance criteria shall be as for the longitudinal weld. One macro
hardness test will be carried out. Technique and acceptance for Charpy and hardness tests
shall be to requirement of this specification.
For each batch of pipe, the manufacturer shall provide bound and indexed dossiers detailing
all tests, inspection procedures, pipe numbers, heat and melt numbers. 10 copies of the
dossiers shall be provided for each batch. The level ends of all pipes shall be protected by
wedge-expanded bevel protectors which shall be located against the inner wall of the pipe by
rubber pads. Line-pipe shall be shipped only in the vessels’ holds; no line pipe shall be
shipped as deck cargo.
SECTION 2 STATION PIPING

The specification for station piping shall be the same as the preceding specification for API
5L Grade B or API 5LX 42
2A.2.1 Scope
All pipes shall comply with the requirements of ANSI B.31.3 code for Pressure Piping, as
may be supplemented by Nigerian Safety Regulations. The piping material shall be selected
for the category of fluid and service conditions stipulated in accordance with the limitations
imposed by the code and shall be seamless up to the limits or manufacture of seamless pipe.
2A.2.2 Dimensions
Dimensions shall be in accordance with the requirements for line pipe with the following
exceptions:
a) The tolerance for diameter shall be in accordance with API 5L B or ±1.6mm of the
normal specified diameter, whichever is the more stringent.
b) Unless otherwise agreed, the pipe shall be supplied in single random lengths 6m
(approx. 20 feet) in accordance with the tolerances on lengths stated in API 5L.
2A.2.3 Finish
In addition to the finish requirements of API 5L, pipe shall be furnished free of heavy and/or
loose scale on inside surfaces. Where necessary, pipe shall be shot blasted on inside surfaces
in order to comply with this requirement.
2A.4 WELDING FITTINGS
2A.4.1 Scope
a) This specification covers seamless and electric fusion welded carbon and low alloy steel
welding fittings.
b) All fittings shall be manufactured in accordance with ANSI B16.9 or- MSS-SP 75,
latest edition as applicable and as further specified below.
2A.4.2 Materials

a) Steel used in the manufacture of fittings to this specification shall be fully kilned and
made by the open hearth, electric furnace or basic oxygen processes.
b) The chemical composition of each heat of steel shall be determined by the

Manufacturer, and shall be within the maximum element requirements shown below:
Carbon Max % 0.20
Manganese Max % 1.50
Phosphorus Max % 0.03
Sulphur Max % 0.02
Silicon Max % 0.35
c) Alloying elements, (Vanadium, Niobium, Titanium) shall be determined and reported

by the manufacturer. These shall not exceed a combined total of 0.15 %. Nitrogen
content shall also be reported.
d) Residual elements comprising chromium, molybdenum, nickel, copper, shall not exceed
a combined total of 0.6 %, without prior approval of the Purchaser.
e) The carbon equivalent value of any heat used in the manufacture of pipe shall not
exceed 0.41 as determined by the following formula:
CE = C + Mn. + Cr+Mo+V + Ni+Cu

6 5 15
on ladle analysis. On check analysis the Carbon equivalent shall not exceed 0.43.
Tensile properties of all fittings supplied to this specification shall be determined in the
finished and heat treated condition, in accordance with the procedure shown in AFNOR
standard 003-151. Fittings supplied for attachment to Grade X70 pipe shall meet the
following tensile requirements:
Yield Strength (E): 4138 bar (60,000 psi)

Tensile Strength (R): 5379 bar (78,000 psi)
Elongation: in accordance with API STD 5L.
Yield to tensile ratio E/R = 0.93 max. The actual yield strength shall not exceed the specified
yield strength by more than 30%. For other grades of material, tensile properties shall be those
specified on the Purchase Order.

Fittings shall be furnished in the heat treated condition. The base material should be
normalised before welding and stress-relieved after. Details of the heat treatment performed
shall be included in the manufacturer's test report.
2A.4.5 Fracture Toughness Properties
a) Fracture toughness properties of each heat of steel shall be determined in accordance

with MSS-SP 75 procedure.
b) Fracture toughness properties of the weld metal and heat-affected zone of welds shall
also be determined. Two sets of three Charpy V-notch specimens shall be tested for
each lot.
c) Each set of 3 Charpy V-notch specimens shall be impact tested at -100C and shall show
a minimum average energy value of 30 Joules. No single value shall be less than 24
Joules. Percentage shear results shall also be reported.
2A.4.6 Process of Manufacture
a) Fittings may be manufactured by any of the following processes:
i) Solid forged.
ii) Extruded branch using heavy wall seamless or welded pipe.
iii) Formed and normalised branch butt welded into a machined opening in
normalised line pipe and stress relieved.
iv) Governing design standards for fittings manufactured to this specification shall
be: MSS-SP 75 High Test Wrought Welding Fittings.
b) All shop welding shall be carried out in accordance with the requirements of the ASME
Boiler and Pressure Vessel Code, Sections VIII and IX, latest edition.
c) Fillet welds shall not be permitted unless specifically approved by the Purchaser.
2A.4.7 Dimensions
a) Dimensions shall be generally in accordance with ANSI B16.9 or MSS-SP 75

requirements as applicable.
b) When specified on the purchase order, elbows intended for field segmenting shall be
supplied to out-of-round tolerance throughout the body of q 1/2 for sizes 600mm (24")
and larger, and to q 1% for size 100 - 500mm (12A" -22") O.D.
c) In all cases, fittings shall be suitable for butt welding into the adjacent pipework with
the internal diameter of ends and outlets matching that of the pipe.
d) Ends and outlets shall be bevelled for butt welding in compliance with MSS-SP 75
requirements.
e) The wall thickness of welding ends shall be as specified in the purchase order.
2A.4.8 Testing and Inspection
a) A certificate of ladle analysis is required for each heat of steel which shall conform with
the chemical requirements of this specification.
b) A check analysis shall be furnished for each heat of steel used in producing the fittings.
The presence of alloying and residual elements shall be determined and reported in
accordance with the requirements of these specifications.
c) Body tensile tests shall be performed and reported in accordance with MSS-SP 75
requirements.
d) For fittings containing welds, one transverse test of the weld shall be made from each
lot.
e) Transverse guided bend tests of welds shall be carried out and reported as described in
MSS-SP 75.
f) Non-destructive testing shall be in accordance with MSS-SP 75 requirements.
g) All fittings supplied in this specification shall be subject to inspection by the Purchaser
or his representative at Supplier’s works.
The Contractor shall obtain from the Supplier, certification of compliance with (ANSl B16.9)
MSS-SP 75 and with the requirements of this specification shall be furnished by the
Manufacturer.
2A.4.10 Marking
Each fitting shall be marked in accordance with ANSI B1 B16A.9 MSS-SP 75 requirements
and as may be further specified in the Purchase Order.
2A.5 FORGED STEEL BUTT WELDING FITTINGS
2A.5.1 Scope
This specification applies to butt welding fittings such as elbows, segments of elbows, caps,
tees, single or multiple outlet headers and reducers.

2A.5.2 Design
a) Governing design standards shall be:
ANSI B16A.9- LATEST EDITION

ANSI B31.3 LATEST EDITION
b) Fittings shall be designed to suit the grade, diameter and wall thickness of the rating
pipe as specified in the purchase order. Weld and preparation shall be in accordance
with B31.3.
2A.5.3 Material and Manufacture
a) All fittings shall be manufactured in compliance with the ANSI B16.9 standard and with
ASTM A234 where relevant.
b) The heat treatment requirement, fracture toughness testing, material chemistry,

properties and inspection shall be as per section referred above.
Where pipes of different material grades, or of different wall thicknesses (or both) are to be
joined, and where the mis-match of wall thickness cannot be rectified by grinding in
accordance with the tolerance of ANSI B31.3 or B31.8, then a transition piece shall be used.
The transition piece shall have a length of at least 2 pipe diameters and shall have a minimum
specified yield strength equivalent to the thinner of the two pipes to be joined. The ends of the
transition pieces shall be machined to suit the respective pipe wall thicknesses.
2A.5.5 Inspection
All fittings shall be subject to inspection by the Engineer or his representative.
2A.5.6 Marking
Marking shall be in accordance with ANSI B16.9 requirements and as may be further
specified in the purchase order.

PART 2A PIPELINES AND PIPEWORK MATERIAL SPECIFICATIONS
2A.6 FLANGES
2A.6.1 Scope
a) This specification covers the manufacture, testing, and inspection of steel pipeline
flanges, for use in pipelines and associated installations.
b) All welding neck flanges shall comply with ANSI B.31.8 American Standard Codes for
Pressure Piping and with the requirements of this specification.
c) Design and manufacture shall be in accordance with ANSI B16.5, Steel Pipe Flanges
and flanged Fittings, MSS-SP 44, Steel Pipeline Flanges, and with the requirements of
this specification.
a) Welding neck flanges covered by this specification shall be in the range of nominal
sizes as follows:
(i) Welding neck flanges 50 to 406mm (2'' to 16'') incl.

(ii) Welding neck flanges 406 to 609mm (16'' to 24'') incl.
(iii) Blind flanges 50 to 609mm (2'' to 24'') incl.
2A.6.3 Temperature and Pressure Ratings
a) All flanges covered by this specification shall be to the pressure ratings set out below, as
specified in the purchase order, for the temperature range -29°C to 38°C.
Class Operating Pressure Test Pressure
150 18.96 bar 29.30 bar
300 49.64 bar 75.84 bar
400 66.18 bar 99.97 bar
600 99.29 bar 149.95 bar
a) All flanges shall be manufactured in accordance with the requirements of the

following relevant standards, and as further specified herein.
(i) ANSI B16.5, latest edition, Steel Pipe Flanges and Flanged Fittings.
(ii) ASME B 16.47, latest edition, Steel Pipeline Flanges.

(iii) Unless otherwise specified, flanges 24" and upwards shall be to ASME B
16.47dimensions.
2A.6.5 Flange Facings
Flanges shall be provided with raised faces in accordance with the latest edition of ASME B
16.5 or ASME B 16.47 unless otherwise specified in the Purchase Order.
2A.6.6 Material
a) The steel used shall be suitable welding quality carbon steel, or suitable welding quality
high strength low alloy steel.
The Steel shall be of such quality as to properly respond to the intended heat treatment,
and shall be fully kilned. Steels shall be made by the open hearth, basic oxygen, or
electric furnace processes, and shall be suitable for field welding to other fittings and
flanges and to pipe manufactured under the following specifications:
ASTM A53, ASTM A106, ASTM A381, API 5L, and API 5LX.
b) Chemical composition of the steel, as determined by ladle analysis, shall conform with
the following:
Carbon 0.20% Max.

Manganese 1.50% Max.
Phosporus 0.30% Max.
Sulphur 0.02% Max.
Silicon 0.35% Max.
c) The carbon equivalent shall be determined by formula:
CE = C + Mn
6
and shall not exceed a value of 0.41 on ladle and 0.43 on check analysis.
d) The addition of alloying elements shall be at the option of the manufacturer. Such
elements shall be checked and reported for each heat of steel.
a) In order to provide satisfactory transition of flange hubs to adjacent pipework, materials

of sufficiently high yield strength shall be selected.
b) All flanges intended for attachment of pipework having specified yield strength in
excess of 3585 bar shall have a guaranteed minimum yield strength not less than 2896
bar.
2A.6.8 Weldability
Where stated on the purchase order, proof of weldability shall be demonstrated by means of
the Battelle "bead on plate" test. The heat-affected zone hardness acceptance value shall be
agreed with the purchaser.
2A.6.9 Mechanical Testing and Chemical Analyses
The frequency and procedure for chemical check analyses and mechanical tests to determine
yield strength, tensile strength, and elongation shall be made in accordance with the
provisions of ASTM A105 and as required by this specification.
2A.6.10 Fracture Toughness Properties
a) Fracture toughness properties shall be determined, and reported, for the following
flanges:
All flanges 508mm (20'') and larger nominal size.
All flanges manufactured from material of specified minimum yield strength greater
than 42,000 psi.
b) Fracture toughness testing shall be carried out using 2/3 size Charpy V-notch impact
test specimens in accordance with ASTM E-23 type A. All specimens shall be taken
with the axis of specimen transverse to the flange, and with the notch normal to the hub
surface.
c) Three specimens shall be taken from each heat treatment charge. If more than one heat is
represented in a heat treatment charge, three specimens shall be taken from each heat.
d) Charpy specimens shall be tested at -10°C, and shall show a minimum average shear
value of 50%. Impact energy values shall also be reported. The average of three tests
shall be 30 Joules minimum with no individual test less than 24 Joules.
a) All flanges shall be furnished in the heat treated condition. The base material should be
normalised before welding and stress-relieved after.
b) Details of the heat treatment employed shall be reported on the manufacturer’s material
test certificates.
2A.6.12 Dimensions
a) All flange dimensions shall be in accordance with the requirements of the relevant
standards, due allowance being made for the use of high strength steels and for the
designated service as defined in the purchase order.
b) All flanges furnished to this specification shall be supplied with hub inside diameter
uniformly bored to suit dimensions of matching pipe and shall not exceed 1.5 x t, where
t is the run pipe thickness at the bevel of welding ends.
2A.6.13 Inspection, Non-Destructive Testing, Repair of Defects
a) Each flange shall be examined internally and externally for surface defects.
b) Repair by welding of injurious defects shall not be permitted after final heat treatment.
c) All flanges Class 600 and greater, and all flanges size 406m (16A") and larger, shall be
checked by dye penetrant crack detection test along the hub and around the welding
bevel.
d) All flanges shall be subject to inspection at supplier’s work by the Purchaser or his
representative.
2A.6.14 Hydrostatic Pressure Test
a) Hydrostatic pressure test of each flange is not required.
b) The manufacturer is required to furnish evidence that flanges of the same size, material,
dimensions and rating have successfully withstood the test pressures prescribed for the
relevant primary pressure rating.
2A.6.15 Marking
Marking shall be in accordance with the requirements of the relevant specifications and as
may be further specified in the purchase order.
2A.6.12A Certification
The Supplier shall furnish test certificates covering all tests carried out and shall certify
compliance with relevant specifications and standards.
2A.7 GASKETS
2A.7.1 SCOPE
a) This specification covers the following types of gaskets:-
(i) Non-metallic type consisting of flat continuous non-metallic ring.
(ii) Combination type consisting of either a metallic core and non metallic casing or a
metallic retainer with non-metallic inserts for use in a High Pressure Gas Pipeline
and its associated equipment.

2A.7.2 GENERAL REQUIREMENTS
(a) Type: The gaskets covered by this specification shall be suitable for use with Flanges
ASA and MSS raised face type, relevant pressure/temperature ratings.
(b) Size: 50mm (2 inch) and above
2A.7.3 PRESSURE/TEMPERATURE RATING
All gaskets covered by this specification shall be suitable for use with natural gas at the
maximum operating pressure and temperature given in the Data Sheets.
2A.7.4 GOVERNING SPECIFICATIONS
(a) Gaskets up to and including 610 mm (24 inch) size shall conform to ANSI B16.5 Annex
E latest edition, except as allowed for in sub-clause (c) below.
(b) Gaskets above 610 mm (24 inch) up to and including 915 mm (36 inch) size shall
conform to MSS SP-44 latest edition, except for the case in clause (c) below.
(c) If a proprietary combination gasket offered does not conform entirely to the standards
called for in sub-clause (a) and (b) above, the Manufacturer must provide sufficient
substantiating evidence with his Tender to enable the Purchaser to satisfy himself of the
gaskets suitability for use under all the conditions specified.
2A.7.5 DIMENSION
(a) Non-metallic and combination type:
(i) Gaskets up to and including 610 mm (24 inches) in size shall conform to the dimensions
given in: ANSI B16.5 Latest Edition.
(ii) Gaskets above 610 mm (24 inch) up to and including 915 mm (36 inches) size shall
conform to ASME B 16.47, series A Latest Edition.
(iii) I.D. of Gasket (G) shall be as listed.
(iv) O.D. of Gasket (R) shall be increased to the bolt P.C.D. minus one bolt diameter of the
flange.
(b) All gaskets shall be of the thickness and finish suitable for use at the design and service
conditions specified.
(c) All gaskets shall offer a continuous face to their adjacent flanges.

2A.7.6 MATERIALS.
(a) Non-metallic gaskets:
(i) Shall be made from any asbestos-free proprietary material recommended by the
manufacturer as suitable for use at the design and service conditions specified by
the Engineer.
(b) Combination gaskets:
(i) All metallic components shall be corrosion resistant.
(ii) All non-metallic components must be either creep resistant or suitably restrained
by the metallic parts, and free from any age hardening properties which would
ultimately impair their sealing properties.
(c) Spiral wound gaskets:
(i) Shall be provided with an inner ring for the following sizes:
Class NPS (Nominal Pipeline Sizes)

150# 24” and above
2A.7.7 INSPECTION
Visual inspection only at the Purchaser's option will be required.
2A.7.8 MARKING
Each gasket shall be clearly tagged by the Manufacturer with:
Flange size
Flange rating
Flange reference numbers supplied by Purchaser
2A.7.9 PACKING
Gaskets shall be packed so as to prevent damage during shipment.
2A.8 STUD BOLTS AND NUTS
2A.8.1 INTENDED SERVICE

The Stud bolts and nuts with which this specification is concerned are for connecting carbon
and low alloy steel pipe flanges on high-pressure pipelines and associated facilities. The
specification does not cover bolting for low- temperature service below --29°C (-20°F).
2A.8.2 SIZES
This specification covers sizes from 12.7 to 89mm (half" to three and half") bolt diameter.
2A.8.3 TYPE
Each stud bolt shall be threaded full length and supplied with two hexagonal head nuts.
2A.8.4 DIMENSIONS
Dimensions shall be in accordance with ANSI B18.2.
2A.8.5 MATERIALS
(a) Stud bolts shall be alloy steel; in accordance with ASTM A193 Grade B7.
(b) Nuts shall be carbon steel to ASTM A194 Grade 2H.
Nuts machined from bar stock in such a manner that the axis will be parallel to the
direction of rolling of the bar are not acceptable.
2A.8.6 THREADS
All bolting supplied to this specification shall be threaded in accordance with ANSI B1.1.
Stud bolts shall have Class 2A dimension. Nuts shall have Class 2B dimensions.
2A.8.7 PACKING
All stud/bolts shall be suitably protected so as to prevent rust and/or mechanical damage
during transit.
The method of protection shall be approved by the Purchaser.
2A.8.8 INSPECTION
Unless otherwise indicated in the Purchase Order, all material shall be subject to inspection by
the Purchaser or his representative.
2A.8.9 CERTIFICATION
The Supplier shall furnish certificates of compliance with the relevant specification and of
chemical analyses and mechanical tests carried out.

2A.9 PIPELINE ANCHOR FLANGES
2A.9.1 Scope
This Specification covers the design, manufacture, testing, packing and guarantee of materials
and workmanship of steel pipeline anchor flanges.
All work shall be carried out in accordance with this Specification which shall be read in
conjunction with the General Conditions of Contract, and any special requirements agreed
between the Purchaser and the Contractor as set out in the purchase order.
(a) Anchor flanges covered by this specification will be welded into a high and medium
pressure natural gas pipeline and embedded in reinforced concrete anchor blocks.
(b) All flanges covered by this specification shall be welding neck type.
2A.9.3 Pressure Ratings
All flanges covered by this Specification shall be to the primary service pressure ratings and
for service conditions given in the attached Data Sheets.
All flanges covered by this specification shall be to the following design standards:
(a) Weld Preparation

(ANSI B16.5 1961 Steel Pipe Flanges and Flanged Fittings ANSI B31.8 Latest Edition).
(b) Allowable Stresses:

ASME Boiler and Pressure Vessel Code Section VIII.
(c) B.S. 1515 Latest Edition
2A.9.5 Materials
a) Anchor flanges covered by this Specification shall be manufactured in a material which

shall give the tensile requirements stipulated below. The chemical properties shall
comply with Clause 12A.9.8. of this Specification.
(i) Tensile Requirements
Welding neck anchor flanges: minimum yield point 2897 bars (42,000 psi).
(ii) Test Specimens

For the purposes of making tension tests, the forging manufacturer shall supply test
specimens from the flange or, after agreement with the Engineer, furnish test blanks
from the billets or forging bar entering into the finished product, provided such test
blanks have undergone approximately the same working heat treatment as the finished
product.
(iii) Number of Tests
The following test specimens shall be taken from one flange forging selected from the
number being supplied.
i) Two tensile specimens taken from the disc of the flange; one specimen shall have its
lengthwise axis in a direction normal to the bore of the flange, and the second specimen
shall be taken with its lengthwise axis in the direction at right angles to the equivalent of
the first specimen i.e. parallel to the bore of the flange (ref. ASTM Standard A370-64
Figure 2 (C)).
ii) Three Charpy V-notch impact test specimens, each two-third size (0.262 in x 0.394 in).
Each specimen shall be taken from the hub.
iii) From each heat of steel, one tensile and three Charpy V-notch impact test specimens
may be from test blanks, as above.
iv) Each forging shall have its heat identification number legibly and permanently marked
on it in accordance with the governing Specification. Die-stamping will not be
permitted.
(iv) lmpact Test
Charpy V-notch impact test shall be made using specimen two-thirds the thickness of
the standard V-notch specimen as specified in ASTM E23-60. The impact test shall be
made at 14°F (-10°C). The average value obtained from the results of the three tests
shall be 30 Joules minimum with non individual test being less than 24 Joules.
(v) Weldability
The Contractor may offer at his option materials with a yield point of up to 4138 bar
(60,000 psi) to the Purchaser's approval. The carbon equivalent calculated as per the
Clause on Chemical Properties and Carbon equiv. below this specification shall be
equal to or less than 0.43 and evidence of weldability at 0oC without pre-heat shall be
provided at the tender stage.
2A.9.6 Detailed Requirements
a) Anchor flanges shall be supplied to carry anchor loads as specified in the Data
Sheets.
b) Each anchor flange will be embedded in reinforced concrete

c) Pipe material of adjoining pipe for all flanges covered by this Specification is
given in the Data Sheets.
d) The maximum allowable stress values shall be 25% of the specified tensile
strength of the flange material. Reference ASME Boiler and Pressure Vessel Code
Section VIII Par UCS 6.
e) Weld ends shall be prepared in accordance with ANSI B16.5 and ANSI B31.8 but
having a root face of 3/64" + 3/64 - 0.
a) The Contractor shall supply all flanges covered by this Specification complete with
transition pieces shop- welded to the hubs. The entire assembly shall be stress-relieved
and then X-rayed.
b) Each transition piece length shall be in accordance with the Data Sheets.
c) Transition piece material shall conform with the requirements of APl Std. 5L as
qualified by Clause on Material for transition pieces.
a) Chemical Properties
The chemical composition of the pipe material will on check analysis conform to the
following:-
Carbon 0.20 percent maximum

Manganese 1.50 percent maximum
Phosphorous 0.03 percent maximum
Sulphur 0.02 percent maximum
Silicon 0.35 percent maximum
(i) Carbon Equivalent
The Carbon Equivalent based on the formula:-
Carbon Equivalent = C + Mn
6
shall not exceed 0.41 on ladle and 0.43 on check analyses.
(ii) Alloying Elements
The addition of alloying elements such as Niobium, Vanadium, Titanium, etc. shall be
by written agreement of the Purchaser.

(iii) Residual Elements
Limitations on residual elements shall be by agreement of the Purchaser.
b) Notch Toughness
The steel shall show minimum average impact values of 30 Joules at -100C as measured
by two-thirds size Charpy V-notch transverse impact tests.
2A.9.9 Welding
All shop welding shall be carried out in accordance with the requirements of B.S 1515 Part 1:
1965 and ASME Boiler and Pressure Vessel Code Section VIII and IX
a) Welding Procedure
All welding shall be carried out following specific, qualified procedures as approved by
the Purchaser. The Contractor shall conduct all tests required to qualify procedures.
These shall be witnessed by the Purchaser. These tests shall include radiographs, macro
and micro examination hardness surveys and two-thirds Charpy V-notch impact tests as
detailed in B.S 1515: Part 1: 1965 Section 4 Clauses 4.3.1, 4.3.2 and 4.3.3.
Note: All Charpy V-notch impact tests shall be carried out on two-thirds size specimens at -
100C. Procedure qualification tests shall be carried out with test welds in the heated
condition.
b) Welder Qualification
All welders and welding machine operators engaged on the welding of pressure parts
shall pass the welder performance tests laid down under B.S 1515: Part 1: 1965, Section
Four, Clauses 4.3.2 and 4.3.3 Macro and Micro examination. Hardness surveys and
impact tests are not required for welder qualification tests.
c) Welding
Welding of shop fabricated fittings shall be by manual metallic-arc, automatic

submerged arc or gas-tungsten arc welding processes.
d) Inspection
Inspection and non-destructive testing shall be in accordance with B.S 1515:

Part 1 1965, Section Five, Inspection and Tests.
e) Pre-heating
In cases where, in the opinion of the Engineer, conditions exist that either limit the
welding technique that can be used or that tend to adversely affect the quality of the

weld, pre-heating procedures prescribed in ANSI B31.1 Section 6, Chapter IVshall be

subject to approval by the Purchaser/Engineer.
f) Heat Treatment
All welded joints connecting pressure parts of fabricated assemblies shall be heat treated
after welding is completed. The base material should be normalised before welding and
stress-relieved after. Heat treatment procedures shall be in accordance with the
requirements of B.S 1515: part 1: 1965, Section Four, Clause 4.4.
Proposed procedures shall be demonstrated to cause no deterioration to the physical

properties of the parent material and shall be subject to an approval by the Purchaser.
2A.9.10 Non - Destructive Inspection
Inspection and non-destructive testing of the flange assemblies shall be in accordance with the
requirements of Section IX of the ASME Boiler and Pressure Vessel Code and of B.S 1515
Part i: 1965, Section Five, Inspection and Tests.
a) All welds shall be subject to 100% X-ray radiography after hydrostatic testing.
b) Radiography shall be performed employing a technique which will identify the

penetrameter used. Radiographic quality level shall be equal to at least 2% penetrameter
sensitivity. The techniques employed shall be such that 2% sensitivity is shown on the
weld thickness as well as the plate thickness.
c) Reference Standard
The standard ASME penetrameter shall be employed and the thickness of the
penetrameter shall be 2% of the nominal wall thickness. Any penetrameter approved by
other specifications may be submitted after its capability to produce equivalent
sensitivity has been demonstrated. Penetrameters are to be placed on the side of the
plate opposite to the film and at the extreme ends of the film.
d) Acceptance
Radiographic and Ultrasonic testing of all welds shall be done in accordance with the
laid down procedure. The fitting shall not be acceptable if, as a result of non-destructive
testing, any of the following defects are evident:
i) Cracks
ii) Lack of penetration
iii) Laminations
iv) Continual occurrence of under-cutting, porosity or gas pocket regardless of
dimensions. The standard of testing and acceptance shall be in accordance
with ASME Section VIII for longitudinal welds and API 1104 for
circumferential welds.
d) Weld Repair
No welding repairs shall be made to a flange assembly after heat treatment or

hydrostatic test without the approval of the Purchaser. In the event of repair, subsequent
testing and inspection will be required which will also be to the Purchaser’s approval?
2A.9.11 Visual Inspection and Repair of Defects
Every flange assembly shall be examined internally and externally for surface faults in the
body and the welds.
a) Surface defects such as gouges, grooves, notches, lacerations, surface slag inclusions
etc., shall be removed, or the material rejected.
b) Workmanship -
In removing the inside burr, care shall be taken so as not to remove excess metal and
form an inside bevel. If excess metal is removed from the end of a flange assembly, the
end shall be re-bevelled.
c) Visual Inspection
Every assembly shall be examined internally and externally for surface faults in the
welds and in the body of the assembly. For internal examination, an inspector shall pass
through the bore of the assembly where possible and adequate illumination shall be
provided to facilitate proper examination.
d) Injurious Defects - Body
No welding will be permitted on the body of the assembly without Engineer's approval.
e) lnjurious Defects - Seams of Fitting
Any defect welds shall be radiographed including a distance of not less than 8" along
the unrepaired seam immediately adjoining each end of the repair.
f) Surface Defects
Surface defects may be removed by dressing to give a smooth contour provided that
after removal, the metal wall thickness has not been reduced below the minimum
permitted by the ruling negative tolerance.
g) Weld Repair
For repair of welds, see API Standard 5L. Identification marks shall be generally as
stipulated in ANSl B16.5 and B.S 1560: 1958 and 3292: 1960. Steel die stamping shall
not be permitted on the transition pieces. Identification marks shall be made with
synthetic resin paint using fast colours.

Flanges shall be supplied free from oil and grease and coated with a removable skin for
protection against corrosion.
2A.9.12 lnformation to be Submitted with Tender
a) Three copies of a list giving the leading dimensions of all flanges and flange assemblies.
b) Three prints of a sectional drawing showing the proposed flange assembly for nominal
sizes in the Data Sheets.
c) The Tenderer shall indicate precisely, the materials he intends to use in each case.
2A.9.13 Packing
Flanges shall be packed so as to prevent damage during shipment. Particular attention shall be
paid to the protection of the joints, faces and weld bevels.
2A.9.14 Guarantees
a) The Contractor shall guarantee that all equipment shall perform satisfactorily in
accordance with the design conditions specified in Schedules attached.
b) The Contractor shall at no cost to the Purchaser, guarantee that he will, during the
period specified in the General Conditions for Supply Agreement, replace all defective
parts, by air if necessary, and supply the service of a specialist to assist in correcting
such defect when mutually deemed necessary.
c) Before award of contract, the selected Contractor shall provide manufacturing and test
programme and satisfy the Purchaser that he has the necessary manufacturing capacity
to meet the above date. After approval by the Purchaser, this programme shall become
part of the final purchase order guarantee.
2A.10 INSULATING PIPE COUPLINGS (ELECTRICITY)
2A.10.1 Workmanship and General Design
The insulating coupling shall be new, of sound workmanship and good engineering design.
2A.11 SPECIFICATION FOR SCRAPER LAUNCHERS AND RECEIVERS
2A.11.1 GENERAL
This Specification covers the requirements for design, materials, construction and testing of
launcher and receiver traps for a natural gas pipeline. The traps are to handle spheres, scrapers
and intelligent pigs for pipe damage detection.

2A.11.2 SIZE
The traps are for connection into APl STD 5L line pipe of the grades and diameters as listed
in linepipes specification of this document.
2A.11.3 DESIGN PRESSURE AND TEMPERATURE
Scraper traps will normally be subject to a maximum working pressure of 90 bar gauge on the
gas gathering system and 75 bar gauge on the gas distribution system. However, all scraper
traps shall be designed and tested for the maximum pressure of ANSI Class 600. Flanged
connections shall be to ANSI B16.5 Class 600
Maximum operating temperature: 50.00C (122°F).
2A.11.4 TEST PRESSURE
Hydrostatic test pressures: 153 bar (2220 psi) gauge.
2A.11.5 CODE AND STANDARD
The scraper launchers and receivers specified herein shall be designed, fabricated and tested
in accordance with the Iatest edition of the following Codes and Standards and/or others as
applicable. These Codes and Standards are minimum requirements and Vendor's design shall
meet or exceed these requirements: ASME Boiler and Pressure Vessel Code Section VIII,
Rules for Construction of Pressure Vessels, Division 1, including certification and stamp.
American Natural Standards lnstitute (ANSl) B 31.8 - Gas Transmission and Distribution
Piping Systems.
American National Standard Institute (ANSI B16.5 - steel pipe, flanges, flanged valves and
fittings.
American National Standards Institute (ASI) B2A.9 Factory-made Wrought Steel Butt
Welding Fittings.
ASTM Designation A234WPB - Standard Specification for Piping Fitting of Wrought Carbon
Steel and Alloy Steel for Moderate and Elevated Temperature.
This Specification shall not be construed to eliminate the Manufacturer's standard design or
improvements, in general practice, which may receive approval by the Engineer if found to be
equivalent or superior to the criteria specified herein.
2A.11.6 DESCRIPTION
a) General
Each receiver and launcher assembly is to be ASME Code stamped for a design
pressure of 102 bar (1480 psi) and a design temperature of 50°C (122°F).
Each scraper assembly shall be equipped with a Huber-Yale, or approved equal, quick-
opening closure with a davit so designed as to permit one man to manually load or
remove scrapers from the assembly. The closure hinge pin shall be vertical with the
closure opening to be in the horizontal plane. The closure shall incorporate a pressure
alert valve to prevent operation of the closure under pressure. Each quick-opening
closure is also to be ASME Code stamped for the same design pressure and
temperature.
The internal diameter of the scraper assembly shall have a smooth continuous surface.
The internal diameter of the oversize barrel of the trap shall be generally line size plus
2" with a reducer providing a smooth transition between the two diameters. Launchers
16" diameter and above will have eccentric reducers (flat bottom).
Flanges shall be raised face welding neck in accordance with ANSI B16.5 Class 600.
b) Materials
Materials used in fabrication of these scraper assemblies shall be carbon steel, new and
in compliance with the above Codes and Standards.
O-rings shall be made of suitable natural gas resistant materials.
c) Welding
The base material should be normalised before welding and stress-relieved after. All
butt joints shall have a joint efficiency of 1.00 which shall be verified by full
radiography.
All internal welds shall be ground smooth.
d) Fabrication Tolerances
Fabrication Tolerances shall be in accordance with Part 10.6 (Volume 111).
e) Hydrostatic Test
All completed scraper assemblies shall satisfactorily pass a hydrostatic pressure test at
the pressure stated and in accordance with Codes and standards stated above for a
minimum period of eight (8) hours. The tests shall be witnessed by the Engineer or his
representative.
It should be noted by the Contractor that the completed scraper assemblies will undergo
a further field hydrostatic test for more than 24 hours when the pipelines are tested.

2A.11.7 OPERATING REQUIREMENTS
The oversize barrel of the launcher and receiver traps must be long enough to hold two full-
length scrapers, three spheres or an intelligent pigging system, whichever is the longer.
The Contractor shall give all principal dimensions for the traps in the Tender, including the
length allowed for scrapers and pigs.
The traps shall also be equipped with connections for vent, drain and pressure gauge, all
valved. Pig signallers are also required.
Pig signallers shall be capable of showing status on a station panel.
2A.12 SPHERE TEES
2A.12.1 SCOPE
This Specification applies to the design, manufacture, inspection, and testing of sphere tees
for high pressure pipeline service.
All work shall be carried out in accordance with this Specification and Specifications on
Welding Fittings.
2A.12.2 GENERAL REQUIREMETS
Where pipelines are constructed with facilities for the passage of scraper pigs or spheres, any
branch on the pipeline shall be constructed as a sphere tee.
Sphere Tees shall be used on piggable lines where Branch to main line ratio is equal to or
greater than 33%.
2A.12.3 MODE OF CONSTRUCTlON
The sphere tee shall comprise an oversize sleeve, attached to the run-off tee, containing the
branch connection. Flow into the branch from the run-off the tee shall be through
circumferential ports, the cumulative area of which shall not be less than the Cross-sectional
area of the branch pipe.
The sphere tee assembly shall be designed, constructed and tested in accordance with
A.S.M.E. Section VIII. The weld-ends of the tee assembly for connections to the pipelines
shall be in accordance with this specification.
2A.12.4 WELDING
All welding shall be carried out prior to final heat treatment of the tee and shall be in
accordance with the requirements of ASME Sections VIII and IX.

The base material should be normalised before welding and stress-relieved after. Stress relief
shall be at 5500C for optimum Charpy results.
2A.12.5 NON-DESTRUCTlVE TESTlNG
Non-destructive testing shall be in accordance with ASME Section V.
2A.13 VALVES - GENERAL
Valves, size 150mm (6") and over, must be supported at all times and at no time be carried on
the pipework alone.
Base Supports for valves must allow access to body drain plugs where fitted.
Valve and pipework mating flange faces must be parallel and concentric. The gaps between
flange faces must be just sufficient to insert the gasket before tightening the flange bolts.
2A.14 STEEL GATE, PLUG, BALL AND CHECK VALVES
2A.14.1 SCOPE
a) This specification covers flanged and welding end steel gate, plug, ball and check
valves, for use in process pipework and associated facilities.
b) All valves shall comply with the Requirements of ANSI B16.5.
c) Valves shall be made in accordance with API STD 6D, specification for steel gate, plug,
ball and check valves, latest edition, and with the requirements of this specification.
All valves shall have top entry body and with replaceable seats.
d) Valve size, type, rating, material, connection type(s) and, where possible, dimensions
for operating mechanisms will be specified on the purchase order.
e) In addition to the valves which are motorised for automatic operation in accordance
with the operating and control philosophy of the gas gathering, treatment, transmission
and distribution network, certain other valves shall be motorised in compliance with the
following principles:
(i) Size of the Valve.
Valves, 12" N.D. and greater, shall be motorised valves even if their actuation is not
part of the normal and emergency operating routines.
Full bore valves associated with pipeline pigging shall in any event, be motorised. All
valves, 12" and greater, must be installed with a pressure equalising bypass which shall
also depend on the inside pressure.

(ii) Frequency of Operation
Valves which are cycled in the course of daily system operation shall be motorised.
2A.14.2 GENERAL SERVICE CONDITIONS
a) Fluid handled: Natural Gas Process Fluids

b) Maximum Operating Temperature = 55°C gas transmission
c) Valves may be installed:
i) Underground with dirt cover over the pipe.
ii) Above ground unsheltered.
d) Valve stem may be positioned:
(a) Vertically
(b) Horizontally.
2A.14.3 MATERIALS
a) Bodies, including end flanges and welding ends, bonnets and covers of valves shall be
made of materials conforming to the specifications listed in APl STD 6D, and as further
specified in this specification.
b) Material selected for welding ends shall have a guaranteed minimum yield strength of
not less than 2897 bar- (42,000 psi) where these are intended for direct attachment to
pipe of SMYS greater than 3586 bar (52,000 psi).
c) Material selected for welding shall have a maximum carbon equivalent of 0.48 as
determined by the formula:
CE = C + Mn
6
d) Fracture toughness properties representative of material selected for welding ends shall
be reported, and shall show at least 50% shear at 00C.
e) Steel castings used for valve bodies shall be of X-ray quality, Class 2, as specified in
ASTM Specification E71 Industrial Radiographic Standards for Steel Casting.
2A.14.4 DESlGN AND CONSTRUCTlON
a) The design and construction of valves shall comply with the requirement of API
standard 6D, latest edition ANSI B16.5 American standard code for pressure piping.
b) Welding ends shall be bevelled for welding to pipe or fittings in accordance with ANSI
B31.3, Fig 327.3.1 unless otherwise specified, and shall be specified in the purchase
order.

c) Due consideration of differences in SMYS shall be taken when calculating wall

thickness at welding ends.
d) Flanged valve dimensions shall be in accordance with ANSI B16.5 'Steel Pipe Flanges
and Flanged Fittings' for sizes 2" to 24" inclusive and MSS-SP 44 'Steel Pipeline
Flanges' for sizes 26" to inclusive.
e) Where specified in the purchase order, valves shall be suitable for immediate or future
installation of a type of motor operator. The valve manufacturer shall supply such
gearing or adaptors as are necessary for those valves to be immediately equipped with
motor operators and shall supply the valve complete with operator mounted in place
when so specified. The valve manufacturer shall be responsible for coordinating with
the operator manufacturer on design dimensions of gearing and adaptors.
f) Valve operating mechanisms shall be fitted with suitable locking devices.
g) Plug valves shall be of the lubricated type. Lubrication systems shall be fitted with
'button head' type lubrication fittings. Valves shall be shipped with a lubricant suitable
for operation in the specified service conditions. The lubricant shall resist dissolving,
gumming, or chemical change in service.
h) All valves shall have the following appurtenances:
i) The valve body shall be provided with ribs or feet to support the valve in the
vertical position.
ii) Drain connection, by-pass and pressure gauge connections shall be provided as
specified in the purchase order or as may be otherwise agreed.
iii) Stem protectors and indicator rods shall be provided when so specified.
iv) A gear operator where the torque is to break or close the valve at a maximum
differential pressure exceeding 205 Nm
v) Valves shall be fitted with replaceable seats which shall be capable of removal
from the valve in-situ i.e. top entry body.
vi) All valves shall be fire safe.
vii) All welding shall be in accordance with the requirements of ASME Boiler and
Pressure Vessel Code, latest edition, Section V111 and 1X.
2A.14.5 TESTING
(a) All valves shall be subject to a shell hydrostatic pressure test in accordance with API 6D
requirements. The test shall be maintained for a period of 24hours during which time, a
pressure recorder shall be used to obtain a chart of the test. Three certified copies of this
chart shall be supplied to the purchaser.
(b) Hydrostatic seat tests shall be carried out as required by API 6D for gate, ball and plug
valves. While the test pressure is on each side of the valve, it shall be operated at least
twice to demonstrate satisfactory mechanical operation as well as continued tightness
after operation under differential pressure conditions.
(c) Valves shall be subjected to air seat tests in accordance with API 6D requirements.
(d) The valve manufacturer shall give sufficient advance notice satisfactory to the purchaser
of the time and place at which testing is to be performed.
(e) Fire safe tests shall be carried out as per API 6FA, latest edition, and for soft seated
quarter turn valves, the fire safe test shall be performed according to API 607, latest
edition.
(f) Valves shall be inspected according to API 598, latest edition
2A.14.6 INSPECTION.
(a) All welds shall be 100% radiographed to meet the acceptance standards of ASME
Boiler and pressure vessel code, latest Edition, section VIII.
(b) Where X-ray quality steel casting is specified, records of test shall be furnished to the
purchaser.
(c) All welding ends of valves, class 300 or greater, shall be checked by magnetic particle
inspection or dye penetrant crack test at the option of the manufacturer.
2A.14.7 DATA AND DRAWINGS.
(a) The manufacturer shall provide the following information.
(i) Outline dimensions and mechanical details for the valve.
(ii) Number of complete revolutions of handwheel or other operating device to close

or open the valve.
(iii) The maximum permissible torque and the rated torque required to close or open
the valve at the maximum pressure differential.
(iv) Actual time to fully open or close the valve.
(v) Head loss curve and data for the valve.
2A.14.8 MARKING
Each valve shall be marked in accordance with API 6D requirements and as may be further
specified on the purchase order.
2A.15 NEEDLE VALVES
a) Description
Needle Valves - 600 Rating
b) Function
These valves will be used on service piping including vents, drains, instrument
connections and thermal pressure-relief lines. However, where a fine control of small
quantities is required, the use of vents should not be allowed.
c) End Connections
AII valves shall be screwed female to APl Thread.
d) Materials
Valve bodies and all welded parts to be forged steel. Outside screw stem, 13 Cr. Trim
and to ANSl B16.11.
All materials of construction are to be specified in detail.
e) Construction
Valve operation is to be effected by an external thread isolated from the flow media.
f) Globe Type
Needle valves of the globe type in cast or forged steel may be considered for this
service.
g) Handwheels
Where valves are fitted with handwheels the wheel shall be clearly marked with arrows
indicating the direction in which the wheel is to turn to open or close the valve.
h) Body Marking
The following information is to be cast or forged upon the body.

Class
Body Size
Arrow (indicating direction of flow).

j) Valve Testing
Tests and test pressure shall be in accordance with the valve standards specified in API
6D.
2A.16 GATE VALVES
a) Description
Gate Valves.
b) Function
The valves will be installed on Fire Water Mains. The valves will be used for isolation
purposes only.
c) Materials
The valves will have bronze trim. The body and bonnet will be of high grade cast iron.
The gland, stem, disc and body seat are to be bronze. All materials of construction are to
be specified in detail.
d) Construction
The valve will be of the right-angled pattern, outside screw and yoke, and handwheel
operated. The end connections are to be flanged, flat face, and drilled to ANSl Class
150.
e) Handwheels
Valve handwheels are to be clearly marked with arrows indicating the direction of
opening or closing of the valve.
f) Testing
All valve bodies will be tested hydrostatically to Class limit. Both ends will be flanged
and the valve fully opened. This test will be carried out with the gland slackened or
packing removed in order to observe the stem seat for leakage and to ascertain that it is
possible to repack the valve under pressure.
Hydrostatic and air tests will also be carried out on the valve seat. Pressure will be
applied to the inlet side of the valve with the valve closed and the outlet open to the
atmosphere.
The seat hydrostatic test pressure will be 13.8 bars. The seat air test pressure will be 5.5
bars.
Testing shall be carried out in accordance with the relevant standard specifications
which are:
A.P.I. 595 for valves NPS 50-610 mm and 125h and 250h.
B.S. 5151 for parallel slide valves.
B.S. 5150 for wedge and double disc valves.
2A.17 FIRE VALVES
a) Function
These valves will be used on fire water service. They will be installed on standpipes
from the fire water mains and will be coupled to fire hoses when required.
b) Materials
Valves are to have bronze bodies and spindles. All materials of construction are to be
specified in detail.
c) Construction
Valves are to be generally in accordance with the requirements of ANSl-14 or equal

approved standard.
Valve inlet is to be flanged, flat face, and drilled to ANSI Class 150, hand wheel
operated. Valve spindle is to be vertical, at right angles to the inlet flow. The outlet
connection is to be instantaneous quick release.
d) Hand wheels
Valve hand wheels are to be clearly marked with arrows indicating the direction of
opening or closing of the valve.
e) Testing
AII valves are to be subjected to a hydrostatic test pressure of 21 bar (300 psi).
PART 2B PIPELINES AND PIPEWORK INSTALLATION SPECIFICATION
2B.1 GENERAL AND MISCELLANEOUS
2B.2 PIPELINE CONSTRUCTION
1 Right of Way
2 Transportation and Storing
3 Stringing
4 Ditching

5 Bending
6 Road and Rail Crossing
7 Waterway Crossing
8 Concrete Weight Coating
9 Lowering-In and backfilling
10 Pipeline Construction in Marsh and Swamp
11 Testing and Commissioning
12 Cleanliness of the Pipeline
13 Commissioning
14 Reinstatement and Clean-up
15 Pipeline Markers
16 Maintenance
17 Crossing other pipelines
PART 2B PIPELINES AND PIPEWORK INSTALLATION SPECIFICATIONS
2B.1 GENERAL AND MISCELLANEOUS
a) General
The General Conditions of Contract, Special Conditions of Contract and Scope of Work
shall be read in conjunction with this Specification and matters referred to shown, or
describe in any of the former are not necessarily repeated here.
Notwithstanding the sub-division of the Specification under different headings, every

part of it shall be deemed supplementary and complementary to every other part and
shall be read with it or into it so far as it may be practical to do so.
The construction of the pipeline shall being accordance with the applicable portions of
the of standards, codes and practices
ANSI B 31.8 - Latest Edition. Gas Transmission and

Distribution Piping System.
API 5L Specification for High-Strength

Line Pipe.
API RP 1102 Recommended Practice for

Liquid Petroleum Pipelines
crossing Railroads and
Highways.
API RP 1104 Standard for Welding Pipelines

and Related Facilities.
All works to be done hereunder by the Contractor shall be conducted diligently,

continuously, and in good faith in a thorough, full accordance with good pipeline
construction practices.
2B.2 PIPELINE CONSTRUCTION
2B.2.1 RIGHT OF WAY (R.O.W.)
a) The Employer shall provide continuous and contiguous Right-of-Way along the
complete length of the route selected by the Contractor at no cost to the Contractor and
shall ensure that the Right-of-Way is available to the Contractor sufficiently in advance
of construction to permit uninterrupted operation along the entire line. The Contractor
shall provide the Employer with necessary cadastral maps and data showing the land to
be acquired at least ninety days in advance of start of construction on said land.
b) The Right-of-Way shall generally be 25 metres wide. For anticipated future

development, the Contactor shall position the pipeline as close as possible to one side of
the R.O.W. However in the areas which require a greater width for construction
activities the Right-of-Way shall vary accordingly. The Contractor shall provide the
Employer with all necessary cadastral maps and data in respect of all such additional
lands. All such areas of additional width shall be kept to a minimum.
c) The Contractor, before starting any clearing operations, shall familiarise himself with all
provisions on the land secured by the Employer and shall use his best endeavours to
comply with such provisions and to avoid unnecessary damage to crops, trees and
property on or adjacent to the Right-of-Way. The Employer undertakes to provide the
Contractor with copies of all Right-of-Way land purchases timely to meet construction
schedule.
d) Land to provide access to Right-of-Way shall be provided by the Contractor but such
procurement shall be limited to obtaining the necessary land and the Contractor shall be
responsible for all construction costs in connection therewith, including the maintenance
of such routes and the eventual reinstatement of the land.
e) The Contractor shall also provide lands for access roads, camp sites, airstrips and
stockpile sites etc. and shall bear all costs of acquiring the same. The Contractor shall be

responsible for all the costs of improvements upon such lands and the cost of their
eventual reinstatement.
f) The Employer shall secure the necessary permit for all road, railway, stream and river
crossings as are required for the agreed pipe line route. The Contractor shall provide
prints of drawings, showing the details of all such crossings at least sixty days in
advance of construction to enable the Employer to obtain the necessary permits.
g) The Employer shall compensate Landowners and occupiers of land for crop and other
damage incidental to construction works within the Right-of-Way and other lands
provided by the Employer.
h) Notice of intention to commence work shall be served on owners and occupiers of land
along the route of the pipe line by the Engineer in accordance with the Contractor's
programme and the Contractor shall not enter onto any land for constructional purposes
without the permission of the Engineer.
i) The Contractor shall be responsible for day-to-day contact with owners and occupiers
immediately before and during the Construction of the Works, but shall not give any
undertaking on behalf of the Employer without prior approval in writing of the
Engineer. The Contractor shall employ a full-time liaison officer together with a number
of assistants for the purpose of maintaining such day-to-day contact with the various
owners and occupiers of lands.
j) Notwithstanding the provisions of sub-clause (a), the Contractor shall clear and grade
only sufficient portion of the Right-of-Way to enable of the pipe. His attention is drawn
to the problems which may arise from soil erosion, particularly in arid areas, where it is
important that the removal of vegetation and disturbance of the surface soil is kept to a
minimum to prevent subsequent exposure of the pipeline during to erosion. The
Contractor will be responsible for any such erosion problems which may occur due to
his negligence of this requirement.
k) The Contractor shall, wherever possible, avoid causing damage to any irrigation
installations. Where such installations are encountered on the Right-of-Way the
Contractor shall install temporary connections so as to avoid interruption of, or variation
in, the required flow of water. The Contractor shall as soon as possible construct or
reinstate on a permanent basis to the satisfaction of the Engineer, all satisfaction of the
Engineer, all installations connected with irrigation which have previously been
disturbed by the works.
Claims from farmers or other Landowners, arising from disturbance to irrigation works
occasioned by the Contractor's operations will be governed by the relevant clauses of
the General Conditions of Contract.
(m) The Contractor shall install temporary cultiverts in all drainage ditches, canals, creeks
and other drainage structures, which are dammed during operations, and where damage
to property may occur because of drainage being blocked. He shall, as soon as possible,
construct or reinstate, on a permanent basis, to the satisfaction of the Engineer, all such
installations which have arisen from such operations and will be governed by the
relevant clauses of the General Conditions of Contract.
(n) The Contractor shall install gates in all enclosure and these gates shall be kept closed at
all times, except during the passage of his construction equipment. He shall prevent
livestock from entering or leaving such enclosed property and, if so required by the
Engineer, provide a watchman or watchmen to ensure compliance with this
requirement.
(o) The Contractor shall provide, erect and maintain shockproof fencing along the Right-of-
Way wherever the pipe line route passes through farm or other lands which are grazed
or used by livestock. Where temporary fencing is erected, reasonable fenced access
across the Right-of-Way shall be provided to permit the passage of vehicles, farm
equipment and livestock. Should temporary water, then the Contractor shall ensure that
sufficient temporary supply of drinking water is provided for this purpose.
(p) The Contractor shall place in hand, repairs to any bridges, private roads, fences,
buildings or other property damaged in the course of his operations, where the repairs
cannot, in the opinion of the Engineer, await the arrival of the clean-up crew.
(q) Where the Right-of-Way passes over or through farmlands, gardens, estates, plantations,
or any other similar valuable property, the Contractor shall comply with any special care
to minimise damage, whilst passing through such lands. Hand ditching, if required in
such places, shall be at no additional cost to the Employer.
(r) In general, the Contractor shall clear the Right-of-Way by removal of all trees, brush,
stumps, boulders and other encumbrances down to the level of the ground surface. He
shall grub or otherwise remove stumps in the wax of the pipe line. All debris shall be
removed to the extreme edge of the Right-of-Way, as directed, so that there is no
possibility of it becoming mixed with trench back-fill materials.
In cultivated areas, top-soil shall be stripped only over the trench width and shall be
kept separate and replaced upon completion of the back-fill.
In all made roads, paved footpaths etc, the surfacing materials are to be removed only
over the width of the ditch, except where otherwise directed by the Engineer's
Representative. All road, metal or other surface materials and hardcore shall be kept
separately from other excavated materials.
(s) The Contractor shall grade the Right-of-Way in a manner which will permit the laying
of the pipe line in a normal ditch consistent with the maximum bending allowed by the
Specification and to facilitate subsequent pipe line operations.
(t) Where telephone, power, or utility lines interface with the access of the Contractor's
constructional plant to the Right-of-Way, the Contractor shall, at his own cost, make
the necessary arrangements to preserve the continuous use of such telephone, power,
or utility lines during the construction of the pipeline.

(u) When working on or near roads, railways or other traffic ways, the Contractor shall
maintain the necessary day and night warning signs to protect all persons from injury,
and to warn drivers of vehicles of the obstruction.
2B.2.2 TRANSPORATION AND STORING
a) Storage and Handling
Storing and handling, including taking delivery, loading, handling, unloading and
stringing of pipe, valves, fittings and other equipment shall be carried out by the
Contractor in such a manner as to avoid breakage, distortion, denting, gouging,
grooving, flattening, damage to pipe ends and other damage to pipe, valves, fittings and
other equipment. In the event of the pipe requiring stacking, this shall be done in such a
manner as to prevent damage to the pipe to the satisfaction of the Engineer.
b) Transportation
In the transport and stacking of pipe, the Contractor shall take exceptional care that no
damage whatsoever results to the pipe from such transport and stacking. All trucks,
wagons, stacking methods and devices, shall have the approval of the Engineer, this
approval in no way relieving the Contractor of his, responsibilities under the Contract.
During transportation of the pipe longitudinal welds shall be placed such that the
location of the weld is at the point of least stress, which is approximately forty-five
degrees (45°) to the vertical. In no case shall the weld contact the adjacent pipes.
c) Pipe Handling
Pipe shall not be allowed to drop or strike objects which may injure the pipe but shall be
lifted or lowered from one level to another by suitable approved equipment. When
lifting pipe, special lifting hooks equipped with a plate curved to fit the curvature of the
inside of the pipe shall be used. Bolsters of a suitable size and dimension shall be used
on all vehicles used for the transport of pipe. If pipe is being transported mounted in
pyramid fashion, bolsters shall be required under the bottom layer with an approved
yoke over the top layer and with a binding system such as to avoid damage of whatever
kind to the pipe and to the complete approval of the Engineer, who retains the right to
have replaced any binding system which in his opinion might cause damage to the pipe.
If pipe is being transported in layers of equal numbers, bolsters shall be required under
the bottom layer, between each successive layer and over the top layer and with a
binding system such as to avoid damage of whatever kind to the pipe and to the
complete approval of the Engineer, who retains the right to have replace any binding
system which in his opinion might cause damage to the pipe. The Contractor shall stack
pipe in a manner as to avoid damage to the pipe. All pipe shall be stacked in an
approved manner clear of the ground surface and be adequately protected to obviate
damage of whatever kind or accidental rolling. Any pipe lost or damaged shall be
replaced by the Contractor at no additional cost to the Contract.
d) Other Material Handling

Materials for pipe coating and wrapping shall be unloaded and stored in a manner to
prevent damage or loss and shall be stored in a manner to preserve their condition,
prevent loss and permit easy access for checking. Valves, flanged fittings or other
materials with finished surfaces shall always be placed on skids to prevent the finished
surfaces from coming into contact with the ground.
e) Exceptional Loads
In planning his transportation activities the Contractor shall give consideration to the
nature of the roads and bridges to be used and shall obtain from the Responsible
Authority permission for their use for the loads specified. Any conditions imposed upon
permission granted by the Responsible Authority shall be strictly followed by the
Contractor who will .retain the responsible for damage occurring to any road or bridge
as a result of his transportation activities, whether approve or not.
2B.2.3 STRINGING
Pipes shall be strung only on the Right-of-Way which has been cleared and where
necessary, graded as specified. The Contractor shall ensure that the pipe is strung for the
proper placement of the pipe size, weight and grade. Pipe shall not be padded to the
approval of the Engineer.
Pipe shall be strung in such a manner as to leave gaps across the Right-of-Way to
facilitate the movement for farm equipment or livestock.
After the pipe has been strung, it shall be examined by the Contractor and the Engineer,
and any damage which is found, shall be repaired or rejected as the Engineer directs.
The cost of repair shall be borne by the Contractor, who shall also replace, from his own
account, any pipe rejected on account of such damage.
Where rock is encountered along the ROW, no pipe shall be strung until all ditch
excavation by blasting has been completed.
2B.2.4 DITCHING
(a) General
Although this section of the Specification is intended to principally apply to the works
of the pipe line itself, the Contractor's general and specified obligations as contained in
this section shall also apply as appropriate to all excavation and reinstatement work to
be carried out under this Contract. The minimum dimensions of the trench shall be such
as will provide the following excluding any crown above the general ground level:
Depth of cover over pipe in soil - 0.9 metres

Depth of cover in rock - 0.6 metres
Width of trench in excess of Pipe diameter - 0.4 metres

When necessary to comply with the requirements of other clauses of this Specification
the trench shall be larger than is required by the above minimum dimensions.
Should the trench be excavated to a depth greater than in the opinion of the Engineer is
required, the Contractor shall at his own cost fill in the bottom of the trench to such
depth and with such materials as the Engineer may direct.
The bottom of the trench shall be uniformly graded and free from loose rock, gravel and
other objects which might damage the pipe. Where additional depth of ditch is required
such as for roads, railroads, ditches, tile drains, underground pipelines or utility
crossings and the like, it shall be provided at no additional expense to the Employer. At
locations where the contour of the ground may require addition depth to eliminate
unnecessary bending of the pipe the Contractor shall provide such extra depth at no
additional expense to the Employer.
The pipeline shall not be permitted to rest directly on a trench bottom which consists of,
rock, stone or other material which consists of, or contains, stones, rock fragments or
any other material which could damage the pipeline coating. In all such cases, the
pipeline shall be bedded on, and surrounded by a soft padding of a minimum thickness
of 150 mm, or as may be otherwise directed.
The Contractor shall also excavate the trench so as to allow the minimum thickness of
soft padding to be placed in the bottom of the trench without causing the cover to the
pipeline to be reduced below 0.9m in normal ground or 0.6 m in rock as the case may
be. Soft padding shall consist of sand, clay, soft earth or other approved material and
shall be free of stones, rock fragments, vegetable growth or other perishable materials
and shall not contain any other material which could damage the pipeline coating or
could set up corrosion.
b) Existing Pipelines and Services
Underground pipelines or utility crossings falling within the limit of the trench shall be
constructed generally and shown on the Standard Detail for Crossing Foreign Services,
Drawing NGC Station where the underside of the existing Foreign Service is less than
300 mm below existing ground level the pipeline trench shall be excavated such that the
normal pipeline cover of 900mm is maintained.
Where the underside of the existing Foreign Service is more than 700 mm below
existing ground level the pipeline trench shall be excavated such that the distance
between the underside of the existing Foreign Service and the top of the new pipeline
shall be a minimum of 600 mm.
Soft padding to the Foreign Service and any protective backfill, armouring etc shall be
reinstated. The new pipeline and the existing Foreign Service where required by the
responsible Authority, shall be protected by a series of 1000 mm wide precast
reinforced concrete slabs. The slabs shall incorporate lifting eyes and shall be laid side
by side over the full length shown on drawing NGC Station.

Notwithstanding anything else contained herein, the Contractor shall take all measures
necessary to locate the precise position of all existing pipelines, electricity cables, gas
and water mains, telephone cables, pipes, ducts sewers, drains and all other underground
services and structures of any kind.
When any service etc. is located, the Contractor shall mark the position of it by means
of a peg, to an approved colour-code, over the service on both sides of the trench and
shall accurately note the position, line and depth at that service and mark it on the
Drawings.
At the end of every working day, the Contractor shall submit a list of all services etc.
encountered during that day to the Engineer's Representative, enumerating the type,
diameter, position, and depth of each service. The pegs marking the services shall not be
removed without the permission of the Engineer's Representative. Excavation around
existing services shall be carried out with such care and diligence as is necessary to
avoid and prevent damage to services and the Contractor shall take all necessary
measure to support and temporarily protect services. Should any service be damaged by
the Contractor, the service shall be made good by the Contractor, at his own expense.
The Contractor shall ensure that all services in the Right-o-f-Way, Working Area,
accesses, etc. are protected at all times from being damaged by his plant or any of his
operations. Where the pipeline route or any access route passes, under electricity or
telephone cables, the Contractor shall erect height gauges. All locations where the
pipeline crosses overhead cables, the Contractor shall notify the National Electric Power
Authority when any work is to take place under or around such cables and shall obtain
and abide by any regulations that may be imposed by the Authority.
In a case where any pipe, drain, culvert, gulley, cable, bridge, of other work, or structure
shall be damaged during the construction of the works or shall be found to need
alteration to allow the works to proceed. The Contractor shall immediately inform the
Engineer in writing, who shall communicate with the owner or authority responsible for
the maintenance thereof and may instruct the Contractor to repair or alter the same or
give assistance to the authority or its Contractor, and the cost of so doing will be
deemed to be included in the Lump Sum Contract Price.
The construction works for the gas pipeline project is likely to be carried out in the
proximity of pipelines, compressor stations and flow stations belonging to the
Concession Holders. Contractor will be required, therefore, to observe the standard
specifications and safety regulations issued by the Concession Holders concerned.
The pipelines, where applicable will be laid parallel with existing pipelines. The exact
position of the existing pipeline(s) must be continually determined, by means of pipe
locators or trial pits. Extreme care must be exercised throughout all pipe laying
activities to ensure that damage is not incurred to existing pipelines
All road crossing whether cased or uncased shall have a minimum of 1.5 m cover.

Major road crossings, and such others as are deemed Necessary, shall be uncased and
the design shall conform to API 1102.
c) Road Crossings
Deleted.
d) Access
The Contractor shall provide safe access across the ditch at reasonable intervals. In
addition, when the trench is excavated through lands where livestock is confined or
through cultivated fields where the land owner or tenant desires to have a passage-way
across the trench, the Contractor shall provide a safe access across the trench.
e) Soil Conditions
The lump Sum Contract price will be deemed to include for all excavation required to
be carried out under this contract through any material including rock.
f) Explosives
The use of explosives will be permitted subject to regulations imposed by the Nigerian
Government on the importation, storage and use of explosives and the written authority
of the Engineer being obtained. Each authority will be limited to
a specific length of line. When blasting is permitted the Contractor shall exercise
extreme care to safeguard against loss of life, injury, accident, damage to pipe line or
other installations, adjacent property, underground structures, springs irrigation facilities
or water sources.
The Contractor will be responsible for obtaining all necessary local permits and shall
conform with all legal requirements in connection with the use and storage of
explosives. The Contractor shall use only experienced workmen to supervise, handle,
haul load and shoot explosives. Proper disposition must be made to any and all refuse
from explosives containers and cartridges, and in no case shall they be disposed of in
the back-fill to the trench.
g) Drainage
All ditches, open drains or water courses interfered with by the pipe line shall be
maintained in effective condition during construction and finally restored to as good a
condition as before the commencement of the works. The Contractor shall take care that
the minimum of damage or disturbance is caused to land drains. Immediately any land
drain is located during excavation its position shall be prominently marked by a peg at
each side of the trench.
The Contractor shall replace land drains over the trench and for a distance of 500 mm
on each side of the trench. Damage to land drains outside these widths shall be made
good to the satisfaction of the Engineer at the expense of the Contractor.

When replacement of land drains has been completed, the Contractor shall so inform the
Engineer and shall not begin backfilling around the reinstated drain until so instructed
by the Engineer. The Engineer may afford the owner or occupier of the land an
opportunity of inspection before backfilling is begun and any delay arising therefrom
shall be the liability of the Contractor.
The Contractor shall take care that no damage is caused to the reinstated drain during
backfilling.
The entire cost of reinstating any land drain will be deemed to have been included in the
Lump Sum Contract Price.
The Contractor shall take all necessary precautions to secure the efficient protection of
all streams and waterways against pollution arising from ditching operations which may
cause injury to animal, fish or plant life and shall indemnify the Employer against any
claim arising from such pollution during the excavation of the Works.
Wherever necessary, the Contractor shall provide, maintain and use piling, shoring
Materials, jacks pumps, well-pointing and other de-watering facilities as are necessary
to excavate and maintain the trench in good and safe working condition, until the line is
laid and backfilled.
h) Restriction on Ditching
When owing to the narrowness of the site in which pipelining is being carried out under
this Contract or owing to the necessity of providing for the passage or traffic or for any
other reason it may be considered necessary or convenient by the Engineer to do so, the
Contractor shall temporarily remove wither wholly or partially the material excavated
and bring back that portion thereof which may be required for filling in. Such removal,
storing and bringing back shall be carried out in such a manner and by such means as
are most suitable and approved by the Engineer and the material to be eventually
brought back shall be temporarily deposited either in the rear of the trench or (with
consent of the Local Authorities) in adjacent streets, or in depots to be provided by the
Contractor or in any other manner approved by the Engineer.
Alternatively, it may be found necessary or convenient to remove excavated material

from the forward part of the trench and to cart or run it back directly to the rear of the
trench for the purpose of backfilling.
Any change in the method of performing the work as a consequence of such order shall
be at the cost of the Contractor who shall have no cause for claim against the Employer
on account of having to carry out the work by another method or for the idleness or
removal of any mechanical plant.
2B.2.5 BENDING
The Contractor shall lay all pipes so that it conforms to the contour of the trench or in the case
of above ground construction with the ground surface or sleepers supports and anchors. All
over bends in buried line shall fit snugly to the bottom of the ditch and the side bends shall
press firmly against the outer wall of the ditch.
All bends shall be made cold and uniform by the use of an approved bending machine with
bending shoes of proper size and or a design suitable for bending uncoated pipe. No stretching
or thinning of the pipe wall thickness shall be permitted. All bends shall be made to as long a
radius as possible and no bend shall be made within 11/2 pipe diameters of a completed
circumferential butt weld.
No field bends shall have a radius of less than 24 times the outside diameter of the pipe. The
radius shall be reasonably uniform throughout the arc and shall be checked by measurement
of the middle. All bends shall be gauge tested in the presence of the Engineer with a gauging
pig fitted with a sizing plate 95% of the internal diameter of the pipe before they are
incorporated into the pipeline. Field bends shall only be made on bare pipe, and the angle of
the bend shall be clearly marked on it immediately after manufacture.
Each joint of pipe shall be swabbed with a leather or canvas belt disc of the proper diameter
or cleaned to the satisfaction of the Engineer to remove dirt loose mill scale or other foreign
substances before placing in alignment for welding. The open ends of the pipe shall be
securely closed at the end of each day's work and shall not be opened until work is resumed.
The elastic flexion of the pipeline shall be determined by the Contractor in accordance with
the provisions of ANSI B 31.8. Factors to be considered in the determination of the radius of
elastic flexion shall include stresses in the pipe due to bending, stresses in the pipe during
hydrostatic test and compressive stresses in any concrete weight coating to be applied.
The Contractor is to keep records of all cold pipe bends made by him in the course of pipeline
construction. The records shall include details of location, pipe size, pipe number, angle of
bend, place of bend and such other details as the Employer may require.
2B.2.6 ROAD AND RAIL CROSSING
a) General
All road and rail crossing shall be carried out in accordance with the approved
Drawings. The Employer will obtain basic approval from all relevant authorities for
carrying out all crossings in the positions shown on the Drawings. The Employer does
not, however, guarantee that such basic approvals are either final or complete, as many
of them may be subjected to the Contractor's proposed method of working and his
temporary works drawings. It is the responsibility of the Contractor to obtain such
further approval as may be necessary from the Authorities concerned. The Contractor
shall strictly abide by all restrictions and provisions accompanying such approval and
shall give adequate notice, which shall in any case be not less than fourteen (14) days,
of his intention to commence any crossing.
Each crossing for which there is a separate crossing detail shall be marked up separately
in the Contractor's Programme, and he shall obtain all necessary permission from the
Authorities concerned before making any such crossing. Such permissions may
necessitate submission of proposed working drawings to the authorities concerned, and
the responsibility and cost of so doing, together with any delays that may be
experienced in obtaining such permissions shall entirely rest with the Contractor.
b) Method of installation
Where the pipeline crosses any major road or railway the crossing shall be installed by
thrust (auger) boring and shall be uncased. For the purposes of definition any road
which has a tar-macadam wearing surface shall be considered as major. Minor road
crossings may be installed by thrust bore or by open cut and need not be sleeved.
Valved casing vents and drains shall be provided with connecting pipework extending
above grade and supported by concrete marker posts. Electrical access to the casing and
carrier pipes shall be provided by means of a standard test/marker post. The minimum
cover to the pipe at any road or rail crossing, whether in rock or other materials, shall be
1.5 metres.
I The location and precautions to be taken must be agreed by the Engineer, the Police
and Local Authorities before any work at the crossing commences.
c) Crossings by Thrust Boring
Prior to the commencement of any auger boring the Contractor shall submit to the
Engineer complete details of the construction methods to be adopted. The Contractor
shall ensure that great care is taken to avoid damage to the sleeve pipe during thrust
bore operations. Thrust bores shall be carried out using a length of scrap sleeve pipe to
precede the sleeve.
Before the Contractor commences a boring operation he shall ensure that a sufficient
quantity of pipe, extension bars, and adequate welding and lighting equipment are
available on site to allow the work to proceed in one continuous operation. If necessary,
but with the approval of the Engineer, work shall continue through the hours of
darkness until the auger bore is completed.
Every precaution shall be taken by the Contractor to ensure that the line and level of the
first pipe is set accurately. The Contractor shall control the rate of penetration of the
pipe to suit the rate of progress of the auger. Under no circumstances shall the auger
project forward of the pipe. Precautions shall be taken by the Contractor to ensure that
the coating of the carrier pipe is not damaged during the insertion of the carrier pipe
assembly and upon completion but before backfill the Contractor shall test the casing
and carrier pipes for electrical discontinuity. If electrical continuity is apparent the
carrier pipe shall be withdrawn completely, inspected and any defect remedied.
d) Chance in Direction from Thrust Bores

All changes in direction from Auger bores shall be achieved by one of the following
methods:-
(i) 2 No.45° bends, min. 8 x D radius

(ii) 2 No. bends, each less than 45°, min 8 x D radius
(iii) Field bends
The angles and types of bends to be used shall be discussed and agreed between the
Engineer's Representative and the Contractor. Under no circumstances will the
Contractor be permitted to place either a horizontal or vertical 900 bend or any elastic
bend immediately alter an auger bore.
e) Crossings by Open Cut
The Contractor shall ensure that his operations interfere with the flow of traffic and the
access of pedestrians only to the minimum extent necessary to make the crossing.
During peak traffic periods, overnight and through holidays the whole of the road width
shall be available for the flow of traffic and during construction at least half of the road
width shall be open for the passage of traffic at all times.
The edges of the existing road surface forming the trench shall be cut square and
vertical and left free of loose materials. The Contractor shall ensure that adequate
bearing and location are provided for steel plates of other materials placed over the open
cut for the passage of traffic.
Where road traffic is to be diverted during pipeline crossing work the pipeline(s)
crossed by the road diversion shall be satisfactorily protected against loads imposed by
the road and pipeline construction traffic. The Contractor shall, at his own expense,
provide, erect, maintain and man as necessary all warning signs, traffic lights and stop-
go boards as may be required by the Police or Local Authorities concerned.
f) Welding and Protective Coating for Sleeve and Carrier Pipes
The protective coating on all sleeve and carrier pipes to be incorporated in road and rail
crossings shall be double coat and wrap as described in (Types of Coating (a)) of this
specification. The Contractor must allow in his programme and method of working for
all time periods required to permit the testing of welds and the application and testing of
the pipeline coating at the welded joints prior to the installation of the crossing.
2B.2.7 WATERWAY CROSSINGS
a) Small Crossings
Crossings of depressions liable to Flooding, ruts, ditches and small streams of depth less
than 0.5 m which are not the subject of special drawings shall be treated as normal pipe
laying except that the cover shall in no case be less than 1 metre below the lowest bed-
level of the channel, over the whole width of the channel, or to a greater degree if in the
opinion of the Engineer such precautions are necessary to protect pipe line against
scour, floods and the like. Weight coating shall be applied where necessary to produce
negative buoyancy.
b) Small Waterway and River Crossings

Crossings or small waterways and rivers of width less than 60 metres and depth greater
than 0.5 m which are not the subject of special drawings shall be constructed as follows
over the full length of the crossing.
(i) Minimum cover to the pipe below the natural bed-level of the channel at any point, over
the whole width of the channel, shall be 0.6metres for rock and 1.5 metres for other
materials.
(ii) Pipe wall thickness shall be as calculated for the adjacent sections of pipeline plus a
minimum of one wall thickness increment as given in API 5L Table 6.1.
(iii) Coat and wrap shall be as described in Part below on "Type of Coating".
(iv) Concrete weight coating shall be applied to give negative buoyancy in the worst soil
condition prevailing. For the purposes of the Mandatory Tender design, the soil fluid
density shall be taken as 1600 kg/m3. ( 100 Ibs/ft3) for both swamp and river crossings.
The density of concrete coating shall be taken as 2400 kg/m3 (150 Ib/ft3).
(v) At crossings within 100 metres of villages or other habitation the right-of-way shall be
fenced over its full width at the top of the river bank to prevent unauthorised access to
the crossing.
(vi) Armouring of the pipeline in the bed of the' river is not a mandatory requirement.
Contractor will, however, be responsible for the proper backfilling of the river bed and
there-instatement of the river banks.
The trench shall be graded to give the maximum amount of support to the pipe line
when being lowered or pulled into place. After the pipeline is in the trench the
Contractor shall take the necessary measurements to determine the location and length
of underwater spans. Any spans found to be in excess of five (5) metres shall be
remedied in a manner acceptable to the Engineer.
c) Large River Crossings
Crossings of large rivers of width greater than 60 metres or which is the subject of
special drawings, of actual or known future oil or gas well locations and of actual or
known future access slots, shall be constructed as specified in para. On (Waterway
Crossings (b)) except that the minimum cover to the pipe shall be 4.5 m below LLWS at
the lowest bed level or 1.5 m below the natural bed-level of the channel at any point,
whichever results in the greater depth.
d) Major Navigable and Marine Waterway Crossings
Crossings of major navigable rivers and marine waterways shall be constructed as

specified in para (Referred above (b)) except that the minimum cover to the pipe shall
be 4.5 m below LLWS at the lowest bed level or 3.5 m below the natural bed of the
channel at any point, whichever results in the greater depth.

Note: The permissible stresses allowed under ANSI Code B31.8 shall not be exceeded
in laying pipeline crossings a) to d) above utilising elastic flexion of the line
pipe.
(b) Ditching
In the crossing situations specified above, the pipeline is to be laid to depths as specified
of as indicated on the Drawings, and all ditches shall exactly follow the course surveyed
and staked, unless the Engineer shall specifically approve variances therefrom. It is
anticipated that waterway crossings may be dug by Suction dredgers and and/or
backhoes. For excavation by clam dredgers or backhoes the spoil may be deposited on
the sides of the ditch depending on tidal flow, always keeping the channel open for
traffic. For excavation by suction dredger the spoil may be deposited on the edge of the
river bank. The spoil is then recovered for backfill. Any spoil remaining after backfill
shall then be removed and disposed beyond the river bank.
The Contractor shall be responsible for the setting-up of all necessary line grades, and
range poles. Such poles shall be of a solid nature, conspicuously painted and firmly set
in the ground. The Contractor shall be responsible for regular soundings and survey of
the digging operation, the results of which shall be transcribed on graph paper sheets
and submitted in a form and manner acceptable to the engineer. No spanning or
bridging of ditches, drains, ravines or water courses will be permitted unless so
indicated on Plans and Drawings or specified by the Engineer. For the "Push-Pull"
method the Contractor shall dig the ditch so that no vertical machine bending of the pipe
will be required unless so indicated on Plans and Drawings. The ditch shall be out
deeper in approaches to minor rivers, creeks, streams, drainage ditches, canals and other
water-courses in accordance with the Drawings, or as otherwise instructed by the
Engineer. All pipes shall conform to the bottom of the ditch.
The ditch shall be dug to a depth such that the minimum cover between the top of the
pipe and normal marsh or swamp ground level, or normal creek, river, channel etc.
bottom is as specified.
Where over-dig may be required to compensate for silting-up of the pipe trench the
over-dig shall be uniform throughout. A final "sweep" shall be made throughout the
entire length or the ditch immediately prior to the setting-in of the pipe. Where the ditch
has been dug with a clam-bucket the final sweep shall be made with a drag-bucket in
order to ensure that no sharp bumps or holes are left in the ditch, and that an even
bottom is obtained throughout.
All ditches shall be backfilled with the same type of materials as existed before the
excavation, including bank reinstatement, compaction, sandbagging, sheet piling if
required, unless otherwise specified by the Engineer.
f) Laying of Underwater Pipelines
If the underwater pipeline is pulled into place, the Contractor shall follow the following
procedures

(i) The pulling line shall be attached to an approved pulling head welded to the pipeline
such that no bending stresses of any magnitude are introduced into the pipe as a result of
the pulling operation.
(ii) The Contractor shall ensure that his method of pulling is such as to avoid the possibility
of the pipe line being pulled into the bottom of the water crossing.
lf the underwater pipeline is laid or lowered into position the Contractor shall have sole
responsibility for the proper performance of the method he employs.
Irrespective of the method the Contractor elects to use, he shall submit to the Engineer
for his approval details of the method to be used, including the equipment to be used,
calculations of the loads, of the maximum bending stresses in the pipe, timing of the
operations, and any other information the Engineer may require. During pulling, laying
or lowering-in of the pipeline the stresses in the pipe shall not exceed 50% of the
minimum yield.
On completion of the lowering-in of the pipe the trench shall be backfilled such that the
level of the water course is restored to its original level. Banks shall be replaced to their
original lines and levels and compacted, and bank protection works carried out to the
satisfaction of the Engineer. All welds will be tested by radiography and the section
shall be hydrostatically tested before laying in the trench.
Particular care shall be given to the protection of coal tar enamel/ bituminous coating or
3LPE (3 Layers Polyethylene) coating applied to the pipe sections for installation at a
later date. This coating shall be whitewashed in order to retard flowing or sagging due
to excessive temperature. All major river crossings shall be surveyed, designed and
engineered as a part of the design work to be undertaken by the Contractor; this will
include the amount of ditch, location and dimension of bends and concrete coating if
required.
Survey data shall include high and low water levels in tidal waterways. The Contractor
shall submit to the Engineer details of all records and tests carried out at waterways to
substantiate his design.
g) Block Valves at Large River Crossings and at Major Navigable and Marine Waterway
Crossings
At crossings of rivers, major navigable and marine waterways as defined by applicable

paragraph on (WATERWAY CROSSINGS) in the specification above. Block valves
shall be installed in the pipeline upstream and downstream of the crossing. The block
valves shall be provided with gas operated actuator which shall close the valve
automatically upon rate of change of pipeline pressure in excess of a pre-determined set
point. The actuator shall also open the valve upon authorised manual command and
have the facility for manual operation of the valve.
2B.2.8 CONCRETE WEIGHT COATlNG

(a) General
Concrete coating of thickness to provide adequate negative buoyancy is to be applied to

the full horizontal length of pipe at river crossings, water courses, marsh, swamp, flood
prone areas and generally where quicksand or fluidised soil conditions may arise.
Concrete weight coating shall be yard-applied by the use of purpose-built coating

equipment operated in accordance with a qualified coating procedure to be proposed by
the Contractor and approved by the Engineer. A quality control, defect repair and pipe
identification system shall be proposed by the Contractor and approved by the Engineer.
A layer of reinforcing fabric 50 x 50 mm mesh formed form 2. 5 mm high tensile steel

wire to B.S 4483 shall be incorporated into the concrete coating and shall be placed
centrally within the coating. The mesh shall be lapped in both the longitudinal and
transverse directions and the length of the lap shall be 200 mm in both cases.
Alternatively a spiral wrap of reinforcement may be used. The reinforcing fabric shall
be galvanised steel wire with chemical and physical properties conforming to ASTM A-
82, A-185, A-390 and A-641, latest editions, woven to form a hexagonal mesh of 1 1/2
inches and having wire diameters as listed below.
Pipe Outside Diameter Wire Diameter Wire Diameter

Up to 12 3/4 inches 12B SWG
14 to 28 inches 15 SWG
30 inches and above 14 SWG
When reinforcing wire mesh is spool applied an overlap of not less than 1 inch shall
result. Double layers of reinforcement shall be used where the concrete thickness is
greater than 2 inches.
(b) Field Joints and Coating Repairs
After the individual coated pipe lengths have been welded and the joints hand wrapped
the joints shall be concrete coated by hand to ensure a completely continuous coating
over the whole length. Concrete for the joints shall contain the same type and size or
aggregated as that used on the coated pipe; however, rapid-hardening cement and
approved additives may be used.
Spalling of the concrete coating of more than 25% of the total thickness of the coating at
the point of damage shall be repaired as follows:-
(i) An Area of less than 900 cm2 will be accepted without repair if the remaining
coating is sound.
(ii) An Area less than 2,500 cm but greater than 900 cm2 shall be repaired by
removing the defective concrete to enable a good locking face, and filling the area
with a trowelled mixture. Before making the repair the edges of the sound
concrete shall be wetted and brushed with 1:3 sand/cement grout immediately
before making the repair.
(iii) For damaged areas greater than 2,500 cm2, the concrete coating shall be removed
from the pipe completely over the length of the damaged section and a new
coating applied as hitherto described.
(iv) At the discretion of the Engineer, cracks in excess of 3mm wide extending more
than 180° around the pipe or cracks of any width extending more than 30 cm in
length shall be repaired by chipping out the crack to a width of at least 2 cm and
replacing the defective concrete with 1:3 sand cement grout rammed into place
using wooden tools.
2B.2.9 LOWERING-IN AND BACKFILLlNG
(a) Lowering-in
No lowering operation shall be undertaken except in the presence of the Engineer.

Lowering into the trench shall be carried out by a method to be agreed between the
Contractor and the Engineer prior to the commencement of the work and shall take
place as soon as possible alter the trench has been dug. ln this operation, special care
shall be taken to ensure that the pipe coating sustains no damage and that the pipe is not
laid in tension. Any damage to the pipe coating during the lowering operation shall be
repaired before backfilling commences.
All brush, skids, pipe protectors, rocks, large clods, sticks, projecting rocks and other
hard objects shall be removed from the bottom of the trench into which the coated and
wrapped pipeline is to be lowered so that the protective coating shall not be punctured
or abraded. The Contractor shall crumb out the entire ditch line and grade at the bottom
of the trench where the ditch has been conglomerate, and the pipe shall be protected
with padding as previously described.
Wide non-abrasive slings, belts or cradles shall be used in all lowering operations and
care shall be taken when removing slings from around the coated pipe after it has been
lowered into the trench. Any damage caused to the pipe-coating assuring the lowering
operation shall be repaired before backfilling commences.
Holiday detection is to be carried out to the coating whilst the pipe is suspended above
the trench. As holiday detection cannot be carried out in wet weather or whilst the pipe
is wet, the Contractor shall make allowance in his Lump Sum Contract Price for all
delay occasioned thereby.
The welded up line shall be lowered into the ditch as soon as possible after the coating
is applied, tested and approved. Normally the pipe must be lowered immediately
following the final coating application and testing rather than being allowed to return to
the skids before lowering. If for any reason pipe is returned to skids after coating, bags
of soil or sand or other acceptable material shall be placed on the skids so as to provide
a cushion on which the pipe may rest without damaging the coating. All such pipe shall
be rechecked with a holiday detector immediately prior to it being lowered into the
trench.
(b) Backfilling
Before any backfilling is started the Engineer must be notified and must be satisfied that
the pipe is evenly bedded upon the bottom of the trench throughout its length and is not
riding upon any stones, rock or other material which may be harmful to the pipe.
The Engineer will also ensure that, if necessary, the soft padding to the fill specified
thickness has been laid in the bottom of the trench and that the depth of the trench
including the soft padding if required is sufficient to provide the minimum cover to the
pipeline as specified. If soft padding has not been laid in the bottom of the trench and if
in the opinion of the Engineer it is reasonable and necessary for such padding to be
provided, then the Contractor shall provide such padding at his own expense.
If the soft padding cannot then be placed in the trench without the cover to the pipeline
becoming less than that specified, then the Contractor shall further excavate the trench
in order to ensure that the padding can be placed whilst the specified minimum cover is
maintained, and the cost for so doing will be deemed to have been included in the Lump
Sum Contract Price.
If soft padding has been placed in the bottom of the trench then, after the pipe has been
lowered into the trench, the soft padding shall be laid around the sides of and to a depth
of 150 mm the crown of the pipe.
The padding shall be compacted to the satisfaction of the Engineer. Such padding shall
in any case be provided wherever tape coating has been approved in lieu of coal tar
enamel. If it has not been necessary to provide soft padding in the bottom of the trench
then, after the pipe has been laid, a surround to the pipe shall be placed and compacted
as specified above using the best of the material that has been excavated from the
trench, if considered suitable by the Engineer, or else imported soft padding shall be
used. The selected excavated material shall not contain any rock fragments, stone, or
any other material which could harm the coating on the pipe.
After the soft padding or selected excavated material as the case may be has been
brought up to a level of 150mm above the crown of the pipe, and has been properly
compacted, the remainder of the trench shall be backfilled with the remainder of the
material that has been excavated from the trench hand properly compacted. In roads and
footpaths the backfilled material shall be thoroughly consolidated using mechanical
power rammers and water where necessary.
Compaction of backfilling by an approved method shall be such as to prevent any

subsequent settlement. Where topsoil has been stripped, it shall be replaced after
backfilling has been completed, and if so instructed by the Engineer, the Contractor
shall loosen, by approved means, the last 300mm of subsoil before returning the topsoil,
and the cost for so doing will be deemed to be included in the Lump Sum Contract
Price. It is solely the Contractor's responsibility to prevent any settlement, scouring or
erosion from occurring over the Trench Width and the Right-of-way and he shall take
all necessary measures to do so. The Contractor shall submit his proposals in this regard
to the Engineer for approval, but such approval, if given, shall not in any way relieve
the Contractor of his responsibilities under this clause.
Any settlement, scouring or erosion that may take place up to the end of the
Maintenance Period shall be promptly made good by the Contractor at his own expense.
Should the Contractor fail to make good such settlement within the time given in the
Engineer's instruction to remedy the settlement, scouring or erosion, the Engineer may
carry out such remedial works as may be required and recover the cost thereof from the
Contractor.
On steep slopes or other sections subject to severe erosion where, in the opinion of the
Engineer, there is danger of the backfill being washed out of the trench, sandbag
breakers as shown on the drawings shall be installed prior to backfilling as directed by
the Engineer. Terracing may also be required across the pipeline ditch to direct flow of
water into natural drainage courses and away from the pipeline ditch, but in no case
shall surface drainage be diverted into channels other than those it followed before the
pipeline was laid.
2B.2.10 PIPELINE CONSTRUCTION IN MARSH AND SWAMP AREA
(a) General
The Contractor shall furnish a river patrol, as necessary, to warn river traffic of anchor
lines and movements of floating equipment, and shall comply with any and all
regulations imposed by the Nigerian Ports Authorities and Inland Waterways and other
governing bodies. The Contractor shall take special care that traffic lanes in open water
and in all rivers and creeks shall be kept open for traffic. Any obstruction which might
create a navigational hazard shall exist only with positive permission of local, Federal or
other Governing Agencies and shall be marked and maintained in accordance with
instructions issued by these agencies and also as approved by the Engineer.
The Contractor shall Supply and maintain permanent sign boards on each side of any
river, creek or waterway crossed. The lettering shall be legible from a distance of 500
metres.
All dredging shall be carried out in accordance with good and accepted dredging
practice and to the satisfaction of the Nigerian Ports Authorities, inland Waterways and
the Engineer.
Upon completion of the work the Contractor shall submit to the Engineer a
hydrographic survey map of the river bed within 50 metres of each side of the pipeline
centre line.
Construction requirements for pipeline crossing in marsh, swamp, quicksand and

fluidised soils shall be as specified in para 12B.2.7 (b) above except that the minimum
cover shall be 0.6 metres.
(b) Minimum Clearance Between Lines

The following horizontal clearances shall be observed between new and existing
pipelines:
(i) in mash and swamp = 15m
(ii) at water crossings, including well location slots = 60 m
The vertical clearance between new and existing pipelines shall be 1.2m. The crossing
shall be constructed such that the new pipeline passes below the existing pipeline whilst
maintaining the minimum specified cover for both lines.
(c) Push-Pull Method of Pipeline lnstallation
Where the pipe is installed by the "Push-Pull" flotation method the Contractor shall dig
the ditch in which the pipe is to be laid to the minimum widths listed below:-
Outside Diameter Minimum Width of Pipe Ditch

(inches) (m)
6 5/8" 0.45
8 5/8" 0.45
10 3/4" 0.76
12 3/4" 0.76
18" 1.07
24" 1.22
30" 1.52
36" 1.76
The Contractor shall dig the flotation ditch wide enough and deep enough to
accommodate pontoons or other flotation equipment. When the pipe is laid and settled
in the pipe ditch the minimum distance from marsh or swamp ground level to top of
pipe shall be 0.6m. The pipe shall be protected against floating from the ditch during
high water periods by the prior application of concrete weight coating.
(d) Lowering In
All pipes shall be floated into position and lowered into place with adequate floats or
pontoons, where necessary. Care shall be taken to guide the pipe through the ditch and
prevent the pipe from rubbing against the wall of the ditch. In lowering the line into the
water portion of the floatation ditch and into the ditch at water crossings, the Contractor
shall use sufficient number of floats or pontoons and take all other precautions
necessary to eliminate stresses in the suspended pipe. The manner and method of
lowering shall be approved by the Engineer prior to the start of operations. At the time
of the operation, the minimum bending radii shall not be less than specified.

After the pipe is in position the floats shall be removed in such a manner as not to
damage the coating. Close observation of the sinking pipe shall be maintained to ensure
that the pipe is centering in the ditch and that the line is sinking uniformly.
The pipe shall be lowered into the ditch in such a manner that the concrete sheath shall
not be overstressed on cracked due to excessive deflection or in any way be damaged.
The pipe shall lie naturally and be continuously supported along its entire length in the
bottom of the ditch.
(e) Backfill and clean-up
Where tracked equipment is used for backfilling operations such equipments shall at no
time be allowed to transverse along, across or in any way over the installed pipe(s). In
each case where the Contractor has no option but to cross already installed lines he may
do so only when he has fully satisfied the Engineer that adequate precaution have been
taken to protect the line(s).
2B.2.11 TESTING AND COMMISSIONING
(a) General
The Contractor shall be required to carry out hydraulic strength and leakage tests before
the pipe line is commissioned, and the Contractor shall provide all test rigs, gauges,
pressure raising equipment, pressure recording instruments, dead weight testers,
gauging pigs, blank flanges, welding caps, temporary pig traps, vents drains and all
other necessary equipment to satisfactorily carry out the tests as specified. All
equipment is to be approved by the Engineer and all gauges, recorders and testers shall
be supplied with current certificates proving their accuracy.
The Contractor shall develop his proposals and programme for the hydraulic testing of
the pipeline for the approval of the Engineer so that approval may be obtained at least 4
weeks prior to the start of testing. The proposals shall take due consideration of the
overall construction programme, the availability of test water and source of gas for
dewatering the main pipeline sections.
Testing shall be carried out after backfilling the pipe trench, including the sections
within the terminals and which are to be buried, and should any section fail to pass the
tests, the Contractor shall locate, excavate and repair any damage or leakage sustained
by the pipeline during any tests. The cost of any such repair work and the abortive test
shall be borne by the Contractor.
During testing operations all main valves shall be in the OPEN position. The cost of all
work associated with testing shall be deemed to be included in the Lump Sum Contract
Price.
For the purposes of hydraulic tests, the pipe line shall be filled with clean water only
and the source thereof shall be approved by the Engineer, and supplied by the
Contractor. The use of salt water will not be permitted.
The Engineer will require the addition of approved inhibitors to the testing water to
obviate the possibility of corrosion to the internal surface of the pipeline. All costs
associated with the supply and use of such an inhibitor will be deemed to be included in
the Lump Sum Contract Price.
The Contractor shall also arrange for the disposal of the testing water and shall
indemnify the Employer against any claim resulting from damage caused of
inconvenience due to the method used.
The hydraulic tests which are to be carried out on the pipeline are of two types:
(i) Sectional tests, which will be carried out from time to time, in lengths to be agreed
with the Engineer, as construction proceeds on the main pipeline route.
(ii) Testing of all compressor station, treatment plant and metering station pipework.
After both types of tests have been fully completed the final tie-in welds or flanged
connections between the main pipeline route and the station/plant pipework shall be
made by the Contractor, using non-destructively tested materials and equipment to be
supplied by the Contractor, but these final connections only will not be subjected to any
hydraulic test.
The Contractor will also be required to carry out air tests on above-ground pipework at
compressor stations, treatment plant and metering station. and shall provide all
equipment, apparatus, labour and materials necessary to do so. Air testing will not be
required on the main pipeline.
(b) Sectional Hydraulic Tests
The sectional hydraulic tests shall be carried out on the pipeline in sections which shall
be determined in conjunction with the Engineer, having regard to altitude variations,
availability of water and available means of disposal of water.
In principle, the sectional tests shall be carried out from permanent pig traps to
permanent pig trap in so far as this is possible. Otherwise, the Contractor shall provide
temporary pig traps as necessary.
Immediately before the setting up of a test, a brushing pig, of the type incorporating
both cups and brushes, shall be passed through the section to clear any water or
extraneous matter and thereafter a gauging pig, fitted with a sizing plate 95% of the
internal diameter of the pipe and previously inspected by the Engineer, shall be passed
through the section. The pipeline shall be filled with water which shall drive two
swabbing pigs, which shall be of a type that will ensure that the air is swept out of the
pipeline, and the two pigs shall be separated in their travel to ensure the non-aeration of
the test water. Pressure indicating and pressure recording instruments shall be connected
to the pipeline before pumping commences. A suitable test pump shall be used, capable
of raising the pressure to the test pressure specified. The testing procedure shall then be
as follows:-
(i) After filling the pipe with water, the pressure shall be quickly raised to 70% of the
test pressure.
(ii) The pressure shall then be slowly increased to the specified test pressure and the
quantity of water pumped into the pipe shall be measured and plotted against
pressure ascertained by dead weight gauges. This pressure shall be held for one
hour. If, during pressurising, it becomes apparent that there is still a significant
amount of air in the line (as shown by a deviation from a straight line on the
pressure versus volume plot) the Engineer will order the line to be re-swabbed to
remove the air and the test re-commenced.
(iii) The pressure shall then be quickly reduced to half the test pressure and slowly
increased to the full test pressure by the addition of measured quantities of water
for plotting against pressure rise.
(iv) The pipe shall hold the full test pressure for 24 hours. During the 24 hours test
period, 100 percent leak tightness of the test section shall be established to the
satisfaction of the Engineer, that is, there shall be no observable drop in pressure
that cannot be accounted for by changes in temperature.
(v) At the discretion of the Engineer, the pressure shall be released to the maximum
working pressure of the test section, and the pressure held for such further period
as determined by the Engineer, in order to establish leak tightness of the test
section to the satisfaction of the Engineer.
(vi) At each of the above stages, wherever the pressure is to be held steady at any
given pressure, the pressurising equipment shall be disconnected from the
pipeline.
(vii) The pipeline shall be deemed to have failed the test for leakage if any loss is
recorded when the pipeline is held at full test pressure. The Contractor shall
identify and rectify any such leakage and shall then re-commence the test as
stated above.
(c) Test Pressures
(i) Sectional Tests
The length, elevation and location of any section shall be so chosen as to ensure that the
hoop stress developed at the lowest point of the section is not more than that achieved at
Mill Test and at the highest point is not less than required by Code, ANSI B31.8. The
sections for testing shall also be chosen so as to ensure that in general only pipes of a
single wall thickness are tested together. Where short lengths of a thicker wall pipe
occur, e.g. at crossings, in a length of otherwise thinner wall pipe then the section may
be chosen so as to include such short lengths of thicker wall pipe and the test pressure
for that section shall be calculated on the basis of the thinner wall pipe.

The mill test pressure for all line pipes has been specified as 95% SMY.
(ii) Station/Plant Pipework Tests
The station/Plant pipework shall be tested hydraulically to pressures which shall be

calculated as one and a half times the design pressure of each class of pipework.
(d) Test Reports
A test report shall be submitted in triplicate in a manner approved by the Engineer as

soon as possible after the completion of each test, but in any case not later than 14 days
after such completion. The reports shall contain all relevant information, including
details of failures, repairs and re-testing.
(e) Pigging
Dewatering of the tested pipeline sections will be part of the commissioning phase and
will be carried out from permanent pig trap to permanent pig trap, except for special
crossing sections which shall be dewatered upon completion of hydrostatic testing.
Dewatering of special crossing sections shall be by the repeated passage of swabbing

pigs until the section is deemed to be dry to the satisfaction of the Engineer.
The Contractor shall ensure that temporary pig traps for launching and receiving pigs
are used for pigging the special crossing sections.
The Contractor will be required to make at least one successful gauging pig run
throughout the completed length of the pipeline before the pipeline is accepted by the
Employer from the Contractor.
Radioactive markers may be used only with due approval of the Engineer.
(f) Programme of Testing
The Contractor- shall keep the Engineer fully informed of all his proposed testing
activities by means of a programme which shall be regularly updated, and which shall
show the proposed test lengths, their locations, maximum and minimum pressure and
water source.
No piping runs, filling pipelines with air or water, or any testing shall be carried out
except in the presence of the Engineer.
The Contractor shall give not less than 72 hours' notice of any such proposed operation
to be carried out at any particular location, stating the test lengths, the calculated
pressure at the highest and lowest points, the source of the water to be used, and the
manner of its disposal.
(g) Station/Plant Pipework Testing

i) General
All station/plant pipework shall be subject to hydraulic testing which shall be carried
out in accordance with ANSI B31.3 pressure Testing, incorporating the requirements for
both hydraulic and air testing, except as modified hereafter, and the full test pressure
shall be maintained without further pumping, for a period of not less than 24 hours. All
station/plant buried pipework shall be backfilled before any testing commences.
Temporary vents and drains shall be provided where necessary.
ii) Hydraulic Testing
The Contractor shall provide thermometers during each test and shall take and record
hourly readings of them. Before any such test will be deemed to have been passed
satisfactorily, it will be the responsibility of the Contractor to show that any pressure
loss over the 24 hours period is entirely due to atmospheric temperature variations.
Separate tests shall be carried out on each class and diameter of station/plant pipe woks,
and shall be so arranged as to leave the minimum, number of final tie-in connections
that it will not be possible to test other than by non-destructive means, and the number
and location of all such connections shall be clearly identified in the testing programme
to be produced by the Contractor.
(iii) Air Testing
All station/plant pipework shall be subject to air testing, subsequent to the pipework
having been completely emptied of water remaining from the hydraulic testing.
Air tests may be carried out concurrently over varying diameters and classes of
pipework.
The purpose of the air test is solely as a leak-detection test for above ground pipework.
The Contractor shall carry out air tests at a pressure of 1.38 bar (20 psi). The pressure
shall be maintained throughout the duration of the test.
When the pressure has been reached, the Contractor shall, in the presence of the
Engineer, carry out a soap and bubble test on every above ground weld, flange or fitting.
For this test the Contractor will provide a suitable soap solution which he shall brush
onto every weld, flange or fitting and any leak will show up as a bubble in the solution.
Any leak so discovered shall be rectified by the Contractor at his own expense, and the
test shall be carried out again on the flange, weld or fitting concerned.
The duration of the test shall be minimum time consistent with good workmanship, to
carry out the soap and bubble tests on every above ground joint.

(h) Safety During Conduct of Tests
It shall be the duty of the Contractor to ensure the safety of all persons employed in or
about the conduct of all tests and to take all necessary and proper precautions to prevent
damage or injury to any persons of property arising out of any test. Any venting points
for the release of air or water must be manned at the Contractor's expense for the duration
of any such venting operation. Before commencing any hydraulic test, the Contractor
must submit to the Engineer the details of how he intends to ensure such safety during the
tests and these details must include, inter alia, the permanent manning of each test end
throughout the duration of the test, such other manning and patrolling of the test length as
may be reasonably necessary on account of the location of the test length, provision of
warning boards at both sides of every road and rail crossing and permanent manning of
every major crossing, and adequate notice of the intended tests is to be given to all
relevant authorities, landowners and tenants.
(i) Valves
During any pipeline testing or pigging runs, all permanent valves shall be left locked in
the fully open position. No such valve is to tie closed except with the approval of the
Engineer.
(j) Pre-testing for Pipeline
Where the main pipeline passes under any paved road, any watercourse other than an
irrigation ditch, and any railway, the pipe and bends shall be pre-tested. The pipes and
bends which are to be used at such specified locations shall be delivered to a testing area
to be provided by the Contractor and approved by the Engineer, and welded together to
form test assemblies each of not less than 50m run of straight pipes or equivalent, have
end closures welded on and filled with water and all air removed. Such assemblies shall
then be hydraulically tested to the maximum pressures stated and in accordance with the
requirements of the applicable Clauses on Testing and Commissioning.
All welds in every such assembly shall be radiographed fully. On successful conclusion
of such a pre-test, the pipe assembly shall be cut up into required lengths and transported
to the location at which they are required, and all such pipes shall have a distinctly
coloured band painted on them to the approval of the Engineer to indicate that they are
pre-tested pipes. Any welds accepted as satisfactory for the purpose of pre-testing will be
accepted as satisfactory as a field production weld without further inspection, but the
Contractor shall take a careful note and record of the weld identification number and its
proposed location and fully inform the Engineer of any pretest weld which is to be
subsequently incorporated into the main pipeline route. Every pipe and bend which is to
be pre-tested shall be carefully noted by the Contractor as to its identification and batch
number and a list of all such numbers shall be handed to the Engineer before pre-testing
commences.
The Engineer will not permit any pipe or bend to be incorporated into the main pipeline
at the hazardous locations herein before specified unless:

i) the identification number of such pipe or bend appears on the list of numbers
which have been pre-tested, and
ii) the pipe or bend has the approved colour code band for pre-tested pipe painted
upon it.
2B.2.12 CLEANLINESS OF PIPELINES
Before the pipeline is commissioned, the Contractor will be required to satisfy the
Engineer of the cleanliness of the pipe.
For this reason the Engineer will require to be present at the end of each pigging run in
order to observe the foreign matter that is brought out by the pig on each run. The
Contractor must ensure that the Engineer is fully informed, with adequate notice, to
enable him to observe the completion of each pigging run.
The Contractor is advised that the Engineer will insist on a very high standard of
cleanliness of the pipeline and if any pigging run indicates, in the opinion of the
Engineer, standard of cleanliness is inadequate, then he will order the Contractor to
carry out such further pigging runs as may be necessary in order to attain a satisfactory
standard of cleanliness.
2B.2.13 COMMlSSlONlNG
The Contractor will undertake full responsibility for the commissioning of the
complete pipeline system. At least 3 months prior to the programmed date for
commissioning to commence, the Contractor will submit for the Engineer's approval a
detailed procedure and programme for the commissioning of the complete Pipeline
System.
The Contractor will nominate, and with the Engineer's approval appoint a
Commissioning Engineer who will be made responsible overall for commissioning
and for the implementation of the agreed procedure and programme.
The Contractor will be entirely responsible that operating and maintenance personnel,
adequate in skills and numbers, are detailed, briefed and positioned to ensure the safe
and proper commissioning of the System.
The Contractor will, however, make use to the maximum extent of Employer's
personnel whom he will, by that time, have trained in their operating and maintenance
duties. Throughout the period of commissioning, such Employer's personnel will be
placed under the operational control and discipline of the Contractor's Commissioning
Engineer.
The Employer will make available, at his expense, timely to meet the commissioning
programme, associated or non-associated gas in the quantities necessary for the
purpose of commissioning the Pipeline System.
From the commencement of commissioning of each pipeline section, the Employer

will meet the full cost of energy, water and other services required to operate the

pipeline system, however, the Contractor shall Supply all consumables spare parts and
equipment to be used in the commissioning.
Commissioning in gas will be combined with the dewatering and drying of the
sections of the pipeline system and will be undertaken from pig-trap to pig-trap in a
logical sequence complying with the availability of product gas.
Commissioning will be achieved by a train of pigs propelled by product gas such that
the hydraulic test water is displaced from the line, the interior of the pipe is dried by
two or more methanol slugs, and the pipeline section is in gas at low pressure.
The methanol removed at the end of the commissioning run shall be sampled and shall
not contain more than 30% water, as measured by a hydrometer, if the pipeline is to be
considered as dry.
If the water content in the sample methanol is greater than 30% further drying runs
using methanol slugs propelled by product gas shall be carried out until the required
dryness is achieved. The Contractor shall provide all methanols, in the quantities
necessary to meet the dryness specified, and shall provide such temporary works as are
necessary for its storage, transportation, loading and disposal. Upon completion of the
commissioning, in accordance with the programme and procedures, to the satisfaction
of the Engineer, the Pipeline System will be taken over for operation by the Employer
.The taking over of the Pipeline System by the Employer will not relieve the
Contractor in any way from his obligations to carry out further tests as may be
required on the pipeline system to demonstrate and fulfill his overall responsibility for
performance of the system.
Upon completion and commission as aforementioned and when the machines and
equipment are in such a condition that they can be expected to run at full design
capacity without stoppage, the Contractor shall conduct a 72 hours' continuous running
test of the whole plant at full capacity and shall thereby demonstrate to the Engineer's
satisfaction that the performance and operation of the various items of equipment of
the plant is in accordance with Contract requirements.
2B.2.14 REINSTATEMENT AND CLEAN-UP
a) General
As soon as the pipe is laid and backfilled, the Contractor shall clean up the Right-of-
Way and all working areas, used by him and shall make good the lands traversed as far
as possible.
b) Topsoil and Vegetation

Where topsoil has been stripped from the surface of the Trench Width, it shall be
replaced, after backfilling has been completed, to the correct contours and thickness
and in a loose workable condition. Over the remainder of the Right-of-Way, the
Contractor shall reinstate the ground to its original contours, filling in any holes or ruts
etc. and replacing any topsoil that has been lost.
Where topsoil has not been stripped from the Trench Width, except for track, road, rail
and water crossings, the Contractor will only be required to reinstate the whole of the
Right-of-Way, including the Trench Width, by leaving it in a tidy and workmanlike
condition, free of all scrap and surplus materials. The Contractor will not be required
in any instance to replace or provide new, any form of vegetation which has of
necessity been removed for the purposes of this Contract.
Notwithstanding anything contained in this sub-clause, it is the Contractor's

responsibility to prevent erosion, scouring and settlement of the pipeline, backfill and
Right-of-Way until the end of the Maintenance Period which is 24 months.
The Contractor shall promptly rectify any erosion, Scour or settlement and, where
necessary to prevent further deterioration. He shall provide gabions, terracing or other
permanent protection, the cost of which shall be deemed to be included in the Lump
Sum Price.
c) Backfilling
Backfilling of trenches through roads shall be carried out immediately after the pipe
has been laid and the backfill shall be compacted in layers not exceeding 15
centimetres and finished level with the road surface.
The Contractor shall carry out permanent reinstatement of all verges. Thereafter he
shall, at his own cost, maintain the surface of the trench and make good all sinkages
and other defects for a period of 24 months from the issue of the Certificate of
Completion.
d) Third Parties
Any work which any local authority may lawfully elect to carry out shall be excluded
from the works, but no deduction of the Lump Sum Contract Price will be made in
respect of such work, but the Contractor will be required to pay all charges for work
carried out by such authority at his own cost.
All private roads bridges and other private structures used by the Contractor for access
or haulage shall be restored to a condition which is not inferior to that which existed
prior to the commencement of the Contractor's operations.
The Contractor shall carry out the permanent reinstatement of all rail crossings to the
levels, dimensions, standards and specification of the railway that was existing before
the rail crossing was commenced. The Contractor shall carry out the permanent
reinstatement of all water courses, which have been crossed by the pipeline, in
accordance with the reasonable requirements of the water authority concerned and the
instructions of the Engineer, and the cost of so doing will be deemed to have been
included in the Lump Sum Contract Price.

Where the line runs through permanently irrigated cultivated land the backfill shall be
thoroughly compacted and the surface shall be finished so as to permit normal
irrigation to continue after installation of the pipe. This compaction may be
accomplished by flooding or tamping by running a crawler tractor along the Right-of-
Way with one track running on top of the fill. This finished backfill shall be
sufficiently level to permit normal irrigation. All enclosures, walls, gates etc. shall be
restored to at least as good a condition as they were in originally except insofar as
permanent access requires gates to be installed in all enclosures walls and the like.
i) Field boundaries other than hedges will be reinstated with similar materials and
to a standard of the best parts of the boundaries on either side of the Working
Width.
ii) Hedges which have been removed for the purposes of this Contract shall be
replaced by fences.
iii) The Contractor shall provide all new materials required for reinstating field
boundaries at his own expense.
The Contractor shall construct dry stone terraces to the satisfaction of the Engineer at
all locations where washes may be caused by water or to protect the backfill from
washing out. Particular care shall be taken by the Contractor to ensure that all drainage
structures of whatever kind are maintained and left unobstructed. The Contractor shall
reinstate the surface of all storage areas, working areas and access routes obtained by
himself in accordance with the signed agreement between the landowner and the
Contractor, but in any case to a condition not less than equal to that subsisting before
the commencement of the Works.
After the completion of any such wok as is described in the foregoing provisions of
this Clauses, the Contractor shall at his own cost maintain the surface of the trench and
make good all sinkages, scouring, erosion or other defects until the expiry of the
period of Maintenance.
2B.2.15 PIPELINE MARKERS
The marking of the route shall be by standard markers in accordance with API
standards, as follows:
i) At inter visible intervals of not more than 2km wherever the pipeline route runs
across open grassland or in savannah where vehicle access is maintained along
the route.
ii) At inter visible intervals of not more than 1km in cultivated areas.
iii) At points where the pipeline changes direction.
iv) At points where the pipe wall thickness or grade of steel changes.

v) At road, rail and river crossings.
The marker posts shall be inscribed in 20cm numerals to indicate their individual
distances from the origin of the pipeline.
At the mainline valve locations, including the metering Stations, a concrete helipad 5
metres in diameter shall be placed suitable for the landing of a helicopter and as a
guide to serial reconnaissance of the pipeline route.
2B.2.16 MAINTENANCE
Throughout the Maintenance Period the Contractor shall inspect the pipeline route to
ensure that no settlement, scouring, erosion or other defects have occurred and he shall
immediately rectify any such defects. The Contractor shall be required to make routine
inspections and no less frequently than once a month during the dry season and
fortnightly during the rainy season.
The Contractor shall ensure as far as is possible that his access along the pipeline
Right-of-Way and on roads and tracks adjacent thereto and any tracks or access roads
constructed or improved by him shall be preserved as access to the pipeline for
maintenance purposes, and the standard of such access at the time of acceptance of the
Clean-up by the Engineer shall be of no less standard than that prepared by the
Contractor for his own use. The requirement for access to the pipeline route will vary
according to the vegetation along the route as follows:
i) Where the pipeline route runs at some distance from the road across open
grassland, the ground beside the route should be graded to provide vehicle
access along the route.
ii) Where the pipeline route runs through tropical rain forest or heavily wooded
savannah it is necessary to cut and maintain a wide swathe through the
vegetation.
iii) In areas where the ground is cultivated, but there is reasonable access to the
pipeline route by small lanes and tracks the land will be returned to the owner
(or tenant) for cultivation.
2B.2.17 Crossing Other Pipelines
i) Where the pipeline route runs through third party R.O.W. the Contractor shall
submit in the third party, a list of known buried pipelines and third party
R.O.W. that they will be crossing during Construction.
ii) ln order to greatly reduce the possibility of damage to third party lines during
construction period the Contractor shall request that the list be checked for
omissions and necessary corrections.

iii) The third party should be requested to indicate the type of fluid, number, size
and whether the lines are above or below ground.
iv) The Contractor shall enclose a complete set of main line OPL maps.
SECTION 3 WELDING OF PIPELINE
CONTENTS
2B.3.1 GENERAL
2B.3.2 WELDING PROCEDURE APPROVAL
2B.3.3 WELDER QUALIFICATION TESTS
2B.3.4 WELDING PROCEDURE
2B.3.5 STANDARDS OF WELD ACCEPTABILITY
2B.3.6 ALIGNMENT
2B.3.7 BREAKS IN CONSTRUCTION
2B.3.8 CUTTING PIPES
2B.3.9 CLEANING PIPES
2B.3.10 COMPLETED WELDS
2B.3.11 INSPECTION
2B.3.12 AUTHORISATION FOR REPAIRS
2B.3.13 PIPELINE TO BE KEPT FRE FROM EXRANEOUS MATERIAL
2B.3.15 NON-DESTRUCTIVE TESTING INSPECTION OF WELDS
2B.3.16 RADIOGRAPHY
2B.3.17 ULTRASONIC TESTING
2B.3.18 MAGNETIC CRACK DETECTION

SECTION 3 WELDING OF PIPELINE
2B.3.1 GENERAL
This specification covers the requirements for pipeline butt welds which shall be in
accordance with A.P.I .Standard No.1104 Latest Edition, modified as hereinafter.
Before welding, all rust and foreign matter shall be removed from the bevelled ends by
power operated tools. This shall be effected inside and out and for a minimum distance
of 40mm from the edge of the weld bevel. If any of the ends of the pipe joints are
damaged to the extent that, in the opinion of the Engineer satisfactory welding spacing
cannot be obtained, the damaged ends shall be cut and bevelled to the Engineers
satisfaction with an approved bevelling machine at the Contractor's expense. Manual
cutting shall not be used. Should laminations, split ends or inherent manufacturing
defects in the pipe be discovered, the lengths of pipe containing such defects shall be
removed from the line to the satisfaction of the Engineer. on Pipes which have been
cut back a zone extending 100mm back from the new field bevel shall be
ultrasonically tested to the requirement of the Line Pipe Specification to ensure
freedom from laminations.
In general, ultrasonic tests shall be carried out before cutting to save time.
Pipe for welding shall be set up. properly spaced, allowing for thermal changes during
welding, in correct alignment and shall in no circumstances be sprung into position.
The method used for lining up pipe shall be such as not to damage the lining.
The Contractor shall provide sufficient trestles, roller supports and line-up clamps as
required.
Pipe welding shall be carried out in accordance with the requirements of the approved
procedure specification.
Where C.P. saddles or sleeves are welded to the carrier pipe, these welds shall be
made using low hydrogen electrodes and no longitudinal welding onto the pipe shall
be permitted. The welding techniques shall be vertical up. No saddles shall be fixed
within 250mm of any pipeline welds (whether circumferential, longitudinal or spiral).
Pipes shall be set up for welding so that the longitudinal seams of adjacent pipes are
offset by at least 200mm and both longitudinal seams are kept in the upper third of the
pipe.
In the case of adjoining field bends, the seams shall be offset by 180°.

2B.3.2 WELDING PROCEDURE APPROVAL
(a) The contractor shall use the welding electrodes, machines and equipment he proposes
to use for the works and all butt welds shall be prepared and tested in the presence of
the Engineer's Representative in accordance with A.P.I. 1104 Latest Edition and this
specification by both mechanical and radiographic means.
Welding may be performed by any of the following processes or agreed combination

of processes, provided that the necessary approval procedure has been satisfied.
i) Manual metal arc welding using covered electrodes.
ii) Fully automatic gas shielded metal arc welding will be considered but the
Engineer will require previous experience and will specify an extensive series
of tests to be completed successfully before agreement can be given.
iii) Fully automatic submerged arc welding, provided that the formation of
Austenitic crystals can be limited.
(b) The Contractor shall submit his proposed welding procedure in writing to the Engineer
for approval. The sheet detailed at the end of this specification shall be used for this
purpose. The Contractor shall carry out, at his own cost, tests based on the approved
procedure and they shall be witnessed by the Engineer and all relevant data recorded.
Separate welding procedures shall be submitted and qualified for line welding, tie in
welding, welding of fittings, repair welding and fillet welds. Test welds shall be made
under full simulated site conditions using full length pipe. The test shall also indicate
removal of the line up clamp and cooling as specified in the procedure.
(c) The mechanical tests shall be carried out at the Contractor's expense in an independent
laboratory nominated by him and approved by the Engineer and all test coupons shall
be submitted to the Engineer for approval and retention along with the laboratory
report. All mechanical tests to APl 1104 shall be completed and in addition Charpy
tests, macro and hardness tests will be done as detailed in this specification.
The radiography of the welding procedure test welds shall be carried out by the
Contractor and the developed films shall be submitted to the Engineer for his
inspection and interpretation. All X-ray equipment, sources, films and other materials
and all labour necessary to carry out the radiographic examination shall be supplied by
the Contractor and the procedure for taking radiographs shall be in accordance with
the requirements for Radiographic inspection.
(d) The acceptance standards for radiographic tests shall be as given for the standards of
weld acceptabilities specified herein.
(e) The procedure, if satisfactory to the Engineer, shall be adopted for all field welds. lf
the Contractor wishes to make any variation whatsoever to the procedure, he shall

submit the new procedure for approval and carry out further tests to the satisfaction of
the Engineer.
(f) Welders who are involved in the welding of a procedure which is subsequently proved
to be acceptable will automatically be qualified to carry out that procedure.
(g) Once the procedure has been agreed it may only be modified by agreement, in writing,
with the Engineer.
2B.3.3 WELDER QUALIFICATION TESTS
The Contractor shall ensure that all welding is carried out under competent and skilled
supervision. Skilled welders experienced on pipework shall be employed for all
welding including tack welding and they will be required to pass the qualification tests
laid down in A.P.I Standard No 1104 latest Edition as hereinafter modified. Each
welder shall have his test welds tested by mechanical and radiographic means.
Each welder shall complete a test weld by the approved procedure and preparation.
Welding and testing of all the test welds shall be done in the presence of the Engineer.
The mechanical tests shall be carried out at the Contractor's expense in an independent
laboratory nominated by him and approved by the Engineer and all test coupons and
laboratory reports shall be submitted to the Engineer for approval. Radiographic
examination of all test welds shall be carried out in an identical manner to that
specified for the Welding Procedure Tests. Upon satisfactorily passing a test the
welder shall be given a copy of the procedure which he has passed and he shall carry it
whilst welding, or an alternative system shall be instituted to facilitate welder
identification, such as Barger to indicate welder number and Procedure number(s)
which shall be approved by the Engineer. Welders must quality separately for each
welding procedure.
2B.3.4 WELDING PROCEDURE
In formulating his welding procedure the Contractor shall be guided by the following
points, which shall apply to Clause 2.3 of A.P.I Standard 1104, 15th Edition.
(a) Process
The welding shall be carried out by the manual metal arc process. Other processes will
require the Engineer's approval
(b) Pipe and Fitting Material
All pipes and fittings shall be in accordance with the Specifications and Drawings.
(c) Joint Design
The angle of bevel at pipe ends shall be 300 plus 50 minus 00 Measured from the
vertical plane. The root face shall be 1.6mm plus or minus 0.8mm.
For vertical downward welding (stovepipe) the root gap shall not exceed 1.6mm or be
less than 0.8mm.
For vertical up welding (conventional) the root gap shall not exceed 3.2mm nor be less
than 2.4mm.
(d) Filler Metal and Number of Beads
The filler metal used shall conform to the requirements of ASTM E6010, ASTM
E7010, ASTM E7016 and ASTM E7018 and three welding beads or more shall be
deposited. Fillet welds shall be multi-pass. Electrodes containing more than 1% nickel
shall not be used.
The hot pass shall be applied immediately the stringer bead has been deposited, and
always within 3 minutes. The storage, handling, drying and baking of electrodes shall
be to the manufacturers recommendations.
(e) Electrical Characteristics
Electrical Polarity shall be according to manufacturers’ recommendation. Equipment

must be able to deliver the Open Circuit Voltage (OCV) specified for the Electrode by
the manufacturers .
(f) Position of Welding
Position or roll welding shall be permitted, in accordance with the procedure test. For
Manual metal arc welding, the 5G position shall be favoured for normal pipeline
welding.
(g) Direction of Welding
The vertical up method of welding shall be used for the root pass of: - tie-ins, special
crossings, fittings, fillet welds, repairs and when an external line-up clamp is being
used. Welders carrying out this work shall be qualified in the appropriate method.
Vertically down (or stovepipe) shall be used for normal pipeline welding.
(h) Number of Welders

The root bead and second pass for pipe over 300mm diameter shall each be deposited
by a minimum of two welders working simultaneously, one on each side of the pipe.
For pipe less than 300mm diameter a single welder will suffice.
(i) Time Lapse Between Passes
The hot pass shall follow immediately upon completion of the stringer bead and no
weld shall be left uncompleted overnight. Time lapse between stringer lead and hot
pass shall be specified in the welding procedure specifications. No pipe shall be cooled
until three runs are complete. Any cooling shall be slow and under insulation. Preheat
shall be re-established before welding is again started. The welding of fittings, tie-ins,
repairs and fillet welds shall be completed in one heat cycle.
(j) Type of Line-up Clamp
An internal line-up clamp shall be used for all line circumferential welds except at tie-
ins and other points where it would be impractical -in which instances an external
clamp shall be used. The Contractor shall ensure that internal clamps used on line pipe
do not in any way damage the lining. The use of internal line up clamps for all
nominal pipe sizes of 12 inches and larger is mandatory.
(k) Removal of Line-up Clamp
The internal line-up clamp shall not be removed until the root bead is 100%
completed.
Tack: welds shall not be allowed when an internal line-up clamp is used.
The external clamp can be removed when the root bead is at least 50% completed. The
root bead shall be spaced evenly around the circumference. ln both cases the pipe shall
not be moved until three weld runs are completed. Tack welds shall have a minimum
length of 50mm and these shall be a minimum of 4 equally spaced around the
circumference.
(l) Cleaning
All slag and spatter shall be removed from the weld prior to deposition of the next
pass or run. The root pass shall be ground. Power tools, chisels and hammers shall be
used for cleaning between each pass.
(m) Preheat
Welding shall not be carried out when the ambient temperature is 100C or below when
the pipe is wet, unless the parent metal is heated to 600C at the weld and for 10cm on
each side of the weld.
Preheat may be required on all field welds. This will be dependant upon material, wall
thickness and welding technique and will be the subject of agreement with the
Engineer before welding procedure tests commence. For repair welds, welding of
fittings, tie-ins and fillet welds the preheat shall be 1500C. Hand held torches shall not
be Used for preheating. Preheat shall be effective 10 cm on each side of the weld,
around the entire circumference and for all weld passes. The minimum preheat
temperature shall be measured by crayons which will melt when the temperature is
reached or with a digital readout Thermocouple. The temperature shall be measured at
least 15 seconds after the removal of the heaters and immediately prior to the
commencement of welding and also around the whole of the joint while welding is
taking place. The maximum preheat temperature shall not exceed the minimum
required by more than 500C. The maximum interpass temperature shall not exceed
2500C.
2B.3.5 STANDARDS OF WELD ACCEPTABILITY
(a) General
Standard of weld acceptability to be in accordance with API 1104 Latest Edition

except as detailed below:-
i) Field of Application
These standards of acceptability are applicable to the determination of the size

and type of defects located by non-destructive testing methods and visual
examination.
ii) Rights of Rejection
Since non-destruction test methods give two dimensional results only, welds
may be rejected even though they appear to meet the standards of acceptability
if there are reasonable grounds to anticipate that the depth of a defect might in
any way prejudice the integrity of the welds.
(b) Weld Geometry
i) External Reinforcement
The external weld reinforcement shall be uniform and not more than 3 mm in
height. In no area shall be weld cap be lower than the adjacent pipe wall.
ii) Internal Penetration
The root penetration shall not exceed 3 mm for the largest pipe size.
(c) Defect Acceptance
i) Specific Defects -Girth Welds
Defects shall be classified for acceptance into four categories:-
Category 1 Cracks: Cracks including crater cracks are not allowed.
Category 2 Inadequate Penetration: incomplete root fusion and root

undercut. Permitted up to a length of 25mm in any 300mm.
Category 3 Slag less than 3mm wide (also parallel having a combined total
width of less than 3mm), hollowed bead, lack of inter-run

fusion lack of side wall fusion cap under cup. Permitted up to a

length of 50mm in any 300mm.
Category 4 Slag more than 3. mm wide, porosity (other than hollow bead).
Slag and porosity shall be assessed from distribution diagrams,
lugs. l and 2. Burn through shall not exceed 5mm in any
dimension and only one burn-through in 300mm of weld is
permitted. Tungsten inclusions shall not exceed three per weld
and shall be separated by a minimum of 50mm
ii) Accumulation of Defects
Any accumulation of defects having a total length of 50mm or more in any

continuous weld length of 300mm or a total length of l5%. or more of the welds
length whichever is the greater is unacceptable.
d) Repair Procedures
i) With the prior permission of the Engineer welds which do not comply with the
standards of acceptability shall be repaired or joint cut and re-welded. No
repairs shall be made before full nondestructive testing inspection has been
made in accordance with the Specification.
A separate welding procedure specification sheet shall be formulated by the
Contractor for repair welds. The root pass for root breaking defects shall be
welded by the satisfactory procedure tests to API 1104, and shall also be
subjected to metallo-graphic examination hardness surveys and Chary tests to
determine the effects of repair welding on the associated structure (see
Attachment I and Attachment LL) .All documentation pertaining to procedure
for repair of welds, including test results, shall be submitted to the Engineer for
approval prior to the commencement of additional welder qualification. Arc-air
gouging or chipping shall not be allowed for defect removal.
Root sealing or single pass repair deposits shall not be practiced. Root repairs
shall be a minimum of two passes, and this shall be tested for on the procedure
qualification test (macro hardness).
The repair shall be subjected as a minimum requirement to the same testing

and inspection requirements as the original weld, plus 1005 M.P.I test.
Only one attempt at repair is permitted. Welds not meeting the specification
after one repair shall be cut out and re-welded at the Contractor's expense. A
report of all repairs shall be maintained by the Contractor.
ii) Cut-outs and Repairs
Welds having indications positively identified as cracks shall be cut out. All
other defects may be repaired Doubtful or suspected cracks shall be tested with
ultrasonic testing for confirmation. Arc burns shall result in cut out.
iii) Limitations on Repairs
Repairs are limited to 30% of the weld length. For internal repairs or external
repairs which open the weld root, only 20% of the weld length may be carried
out in the presence of the Engineer. The minimum length of a repaired area
shall be 100mm.
If the repairs cannot be carried out without exceeding these limitations, or are
not effected successfully, the weld must be cut out.
iv) Weld Rejected by Accumulation of Defects
Where a weld is rejected by the accumulation of defect clause, repairs within

these limitations are permitted Defects in the filing and capping passes should
be repaired preferentially.
2B.3.6 ALIGNMENT
Every effort shall be made to reduce misalignment by the use of an hydraulic expander
and rotation of the pipes to the best lit. For pipe of same nominal wall thickness the
off-set should not exceed l.5mms. Any greater off-set shall be equally distributed
around the pipe circumference. Any branch connection shall be at Least l50mm from
any weld. When longitudinally welded pipes are to be welded together the weld seams
must not be in Line with each other. They shall be 10 minutes to l2 O’clock and 10
minutes past l2 o'clock positions. When this is not possible, a pup piece as specified in
l2B.3.7 shall be inserted to remove the alignment of seams. Cold dressing is
permissible only in cases of slight misalignment and may be carried out with a bronze-
headed hammer. Hot dressing shall not be permitted. The classification of
misalignment shall be decided by the Engineer. When welding pipes of different wall
thickness (as directed by the Engineer) a special transition piece shall be used, (1:4
taper).
2B.3.7 BREAKS IN CONSTRUCTI ON
Subject to the instructions of the Engineer the pipe line shall be continuously
constructed in accordance with the approved programme for the work Breaks shall be
Left for the purpose of testing. The minimum length of matching pieces( "pups") shall
be twice the outside diameter of the pipe, but in no case less than 600mm unless
otherwise agreed by the Engineer in writing, and the Use of Line-Up clamps is
mandatory.
2B.3.8 CUTTING PIPES
Pipe ends when prepared for welding are to be regular and beveled to be correct angle.
If cut by automatic torch they shall be dressed smooth by filing or grinding, and axial
alignment must be within the limits laid down in B.S 2633. Mitred joints will not be
permitted. Manual cutting is not permitted.
2B.3.9 CLEANING PIPE AND FITTINGS
The Contractor shall clean the inside of each fitting and pipe length immediately prior
to welding and shall swab all fitting and pipe lengths to remove all dirt, sand or other
matter that may clog the line or contaminate the commodity to be transported in the
pipeline. The entire absence of foreign matter from the completed line shall be a
condition precedent to acceptance.
2B.3.10 COMPLETED WELDS
completed welds shall be free of pin holes, Lack of fusion or other defects and shall
have a smooth uniform appearance. The root pass in a weld shall be ground before the
hot pass is started. For all other weld runs all slag and spatter shall be removed by
mechanical wire brushing. Deposited metal shall be properly fused with the parent
metal at all parts. It is important that "icicles" are not formed in the bore, and welds
showing such defects on ultrasonic or radiographic examination will be regarded as
faulty.
2B.3.11 INSPECTION
Weld preparations shall be examined by the Engineer and all welding will be subject
to stringent examination by the Engineer and in particular the root run.
The Contractor shall co-operate to the fullest extent by giving adequate advance notice
of welding operations. Welds shall be visually inspected by the Engineer during and
after welding operations.
Each joint in the pipeline, whether radiographed or not, shall be uniquely identified by
the Contractor in a form to be approved by the Engineer and such identification shall
be carried forward throughout the Contract and incorporated on the' As-built
‘drawings . The Contractor's records shall be kept in such a way that the identification
number of the pipe, bend or fitting on each of any joint can be determined. Use shall
be made of Attachment IV found at the end of this specification.
Each joint shall be thoroughly cleaned and burnished by means of a mechanical buffer
and weld spatter removed. This works shall be carried out to the entire satisfaction of
the Engineer.
The Contractor will arrange for the non-destructive` testing of welds in accordance
with this Specification. Any weld which, in the Engineer's opinion is not satisfactory
as indicated by these tests shall be repaired or cut out and re-welded at the Contractor's
expense.
2B.3.12 AUTHORISATION FOR REPAIRS
Defects may be repaired only after a repair procedure has been approved by the
Engineer.
Welding repair procedures shall be qualified by the same testing and inspection as the
original weld procedure.
All repairs must meet the Standards of Weld Acceptability.
2B.3.13 PIPELINE TO BE KEPT FREE FROM EXTRANEOUS MATERIAL
The pipeline shall at all times be kept free of extraneous material, and when work is
not in progress the open ends of the pipeline shall be securely plugged with an
approved Water-tight plug or stopper firmly fixed to resist unauthorised removal.
Claw type plugs or any type liable to damage the pipe will not be approved.
All such stoppers plugs or caps shall be provided with a vent incorporating a valve for
the purpose of testing whether the pipeline is under pressure or vacuum and to enable
pressures to be equalized prior to its removal.
Flanged joints shall only be made with the speckled welding neck or slip on flanges.
The pipes shall be aligned so that flanged faces are paralleled. flanged joints shall be
made with the specified graphite free compressed asbestos fibre gaskets. No jointing
compound is to be used. The bolts shall be tightened up in a manner to ensure that an
even pressure is exerted around the circumference of the joint at all times. Standard
Length spanners only shall be used for tightened bolts.
2B.3.15 NON-DESTRUCTIVE TESTING INSPECTION OF WELDS
General
The Contractor shall visually examine and take radiographs of welds in accordance
with the following schedule:
(i) Visual examination shall essentially be carried out whilst the weld is still above
the minimum interpass temperature recorded in the weld procedure, so that
remedial work necessary to the non-destructive testing
(ii) All butt welds shall be visually examined.
(iii) 100% radiography will be carried out by the Contractor at the following points:
a) Road, river rail and designated special crossings.

b) All pipelines laid in swamp areas.
c) Tie-in welds.
d) Welds which have been fully or partially repaired.
e) Connection joints on pipes of different grades or thickness valves,
flanges, sleeves etc.
All other field joints and double-jointed welds shall be radiographed 100% by
the Contractor at the start or re-commencement of each and every different
welding procedure, whenever a new root bead welder is assigned or whenever
production welding recommences after a cessation of more than 48 hours for
whatever reason.
The 100% inspection shall be carried over 50 joints or one days' work,
performed at normal rate whichever is the greater.
If, in the opinion of the Engineer the percentage of welds showing defects is
acceptable then the level of radiograph may be reduced to 100% The full
length of each weld shall be radiographed. The Engineer will select welds to be
radiographed following visual inspection. The Engineer reserves the right to
increase the level of radiographic inspection at any time should the rate of
defective welds be unacceptable.
iv) As soon as the radiographs have been taken by the Contractor and this shall be
within 24 hours of weld completion they shall be developed by him and then
submitted to the Engineer for examination. The radiographs shall be submitted
in a separate folder for each weld, clearly marked on the outside with the weld
identification number the date on which the radiograph(s) was made and any
other information that the Engineer may from time to time required.
Every day Contractor shall submit with his radiographs a list in triplicate of all
radiographs that he has submitted to the Engineer for examination on that day.
The format of the list shall have been previously agreed with the Engineer and
shall, in any case, contain sufficient space against each weld identification
number for- the Engineer to state his conclusions as to the acceptability or
otherwise of the weld. These conclusions will state whether the weld is passed
or has to be repaired or has to be cut out, and will be contained on the copy of
the welding list that will be returned to the Contractor not less than l2 hours
and, in general, not more than 24 hours after the Contractors submission of the
list. The Contractor shall forth with repair or cut out and re-weld the welds in
accordance with the instructions on the list returned to him. At all times, the
Contractor shall 100% re-radiograph the entire weld and these radiographs
shall be submitted as hereinafter specified, and the daily radiography list shall
be clearly marked to show that such welds are repairs or re-welds.
The Contractor shall provide sufficient empty radiographic film boxes or other
approved containers for the storage of radiographs in the office of the
Engineer.
(v) The manner of taking 10%. Radiography will be decided from time to time by
the Engineer. If any defects, necessitating either a repair or a cutout, appear on
a radiograph during a period of 10% radiography, then 100% radiography will
be automatically re-imposed on the welds made by the front end welding team
concerned.
If during any period of 10% radiography, any radiography shows a defect

requiring either a repair or a cutout, then the whole of the immediately adjacent
weld on each side of the defective weld shall be radiographed by the
Contractor. If by so doing any additional defects are shown to be present, then
the whole of that day's welding for that welding team shall be 100%.
radiographed.
The Contractor will be required to have readily available, on the demand of the
Engineer approved ultrasonic and magnetic crack detection equipment in
satisfactory working order for the use of the Engineer.
The Engineer also reserves the right to carry out magnetic crack detection or
ultrasonic examination of the weld if this is considered necessary. ultrasonic
examination will be carried out:
a) At a joint where wall thickness differs by more than50%

b) At fittings.
c) After any cut back of pipe.
d) When checking for laminations in any area where an attachment or
fitting will be welded. billet welds for attachments shall be examined
by magnetic particle inspection. Where fittings are attached by butt
welds the weld shall be M.P.I tests if there is access.
vi) The Engineer reserves the right to carry out magnetic crack detection or
ultrasonic examination of the weld if this is considered necessary to
assist radiographic interpretation.
(b) Labour and Materials
The Contractor shall supply all labour and materials necessary to carry out his
obligations with regard to inspection and non destructive testing. All such labour
hereinafter referred to as the Contractor's inspectors, shall be fully conversant with and
experienced in the work for which they will be employed; shall have previously
worked on similar projects in similar capacities and shall pass the appropriate tests
before they are employed on the pipeline. No Contractor's Inspector shall be employed
at any time on any work other than inspection.
The Contractor shall appoint a Chief Contractor's Inspector whose duties shall be to
liaise with the Engineer organize the Contractor's Inspectors so that they carry out
their duties in an efficient manner and prepare all necessary reports. The Chief
Contractor's Inspector shall carry out no inspection work himself, other than in
supervision of the Contractor's Inspectors work but shall at all times keep the Engineer
fully informed as to his whereabouts.
The Contractor shall supply all materials and equipment necessary to carry out his
obligations with regard to inspection and also such materials and equipment as are
necessary for the interpretation of radiographs and all other records of inspection.
These materials and equipment shall include but not be limited to radiographic
sources, films, dark-rooms, chemicals, viewing equipment, ultrasonic and magnetic

crack detection equipment. The Contractor shall provide mobile viewing rooms for the
use of the Engineer's staff only, together with all internal equipment necessary for
viewing and interpreting radiographic films. They shall be provided in sufficient
numbers and in such locations as to ensure that each viewing room is not more than
4km away from any front end welding team.
All equipment supplied by him shall be maintained by the Contractor in satisfactory

working orderly and the Contractor shall also be responsible for maintaining the
supply of all consumable materials.
(c) Engineer's Inspection Staff
Notwithstanding anything contained herein before, the Engineer shall have the right at
all times to inspect all welds by non-destructive means and visually whilst the weld is
being made and after the weld has been completed to ensure that the weld meets the
standard of acceptance. The Engineer shall have the right to order the removal of any
weld for the purpose of carrying out destructive tests.
The Engineer's staff shall include inspectors (hereinafter referred to as Resident

Inspectors) who will inspect the workmanship being carried out by the Contractor. The
Resident Inspectors will not normally carry out any of the inspection work which has
been specified herein before as being the obligation of the Contractor but they may,
from time to time; carry out checks on the work of the Contractor's Inspectors. For this
purpose, the Contractor shall always have available for the use of the Resident
Inspectors a complete set of every piece of equipment, films, consumables, dark-room,
facilities and every other thing necessary for carrying out the inspection work which is
the Contractor's responsibility.
The Engineer will appoint a Chief Resident Inspector who will be responsible for the
work of the Resident Inspectors, and who may be empowered, by written delegation
from the Engineer to act as the Engineer's Representative for the purposes of this
Clause.
2B.3.16 RADIOGRAPHY
a) Radiographic Technique – General
Radiographic practice shall comply with the provision of API STD 1104; Latest
Edition except as detailed hereunder which is in accordance with British Standards
Institution BS 2910. The recommendations of the international Commission on
radiological Protection are to be observed. In particular attention is drawn to the
necessity for audible and visual warning arrangements and for regular monitoring of
radiation levels.
Approved pre-packaged films or llouri metallic intensifying screens may be used only
at the discretion of the Engineer subject to his prior approval and continuing
satisfactory field performance. Care shall be taken to ensure good contact between the
film and the intensifying scream particularly where pre-packed or fluorometallic

screens are used. Loss of contact, even if local, may be cause for rejection of the
radiograph.
The preferred method of radiography is by means of X-ray equipment and if the

Contractor wishes to use a gamma source he shall obtain the Engineer's permission
prior to doing so. If such permission is refused, the Contractor shall revert to the use of
X-rays and the cost of so doing will be deemed to have been included in the lump sum
Contract Price.
(b) Girth welds
With reference to B.S 2910 technique B (X-rays single wall exposure Using line grain
high contract direct type film or technique l4 (X-rays double wall exposure using line
grain high contrast direct type film shall be Used. For fitting attachment butt welders
technique 2 (X-rays single wall exposure but with the film against the inner pipe
fitting surface and the X-ray head outside may also be used. Where technique 14 is
used the double wall or double image system shall be used on pipe diameters of 90mm
or less and the double wall single image system on greater diameters.
Where the Engineer has approved the use of a gamma source, technique ll (gamma-
rays, single wall using fine grain, high contrast, direct type film shall normally be used
with iridium 192 as a source. Technique 17 (gamma-rays, double wall using fine grain
high contrast, direct type film will only be permitted where other preferred techniques
cannot be implemented.
c) Branches, Forced Set-in Type
Panoramic type techniques where the complete weld is examined in one exposure are
not permitted. The weld shall be examined in separate exposures with the X-ray focal
spot positioned at normal incidence to the area being examined to within q 5°. Either
single wall, single image or double wall single image techniques are permitted. When
the single image techniques are permitted. When the single wall, single image
technique is used, the film shall be placed against the inner pipe/fitting surface and the
X-ray focal spot outside. The focal spot to film distance shall not be Less than 690
mm. Where access and. /or other fittings prevent correct alignment of the beam, the
double wall, single image technique shall be used. Branches up to l5.l mm nominal
bore required a minimum of 4 exposures, equidistant around the weld circumference.
Branches of 200 mm nominal bore require a minimum of 6 exposures, equidistant
around the weld circumference. Exposures of art 2 larger branches shall be subject to
agreement by the Engineer.
Exposure Conditions
The requirements in technique B for an exposure of 20mA min may be relaxed at the
discretion of the Engineer but where Lead screens are used this shall not be Less than
5 mA mins. Where flouri metallic screens are used the minimum exposure time shall
be l.5mA mins.
Film Density
The minimum film density over the pipe/fitting immediately adjacent to the weld
reinforcement shall be 2.3. Viewing conditions shall be suitable for viewing films of
density up to 3.3. With some type of fitting there may be substantial differences in
wall thickness between the pipe and the fitting. If a film density range within the
aforementioned values cannot be obtained in one exposure then either two separate
exposures or alternatively a sandwich technique using a fine grain film and an
Ultimate grain film shall be made.
Penetrameter Sensitivity
Contrast sensitivity shall be monitored with a DIN type 10 -16 wire penetrameter. The
contrast shall not be worse than:-
Technique 8 and 2: 1.5% on piper penetrameter on film side.
Technique 14: 1.8% on pipe expressed in terms of the single

wall being examined, penetrameter on film side.
Technique 11: 20% on pipe, penetrameter on film side.
Technique 17: 2.6% on pipe, penetrameter on film side.
g) Film processing
Chemicals used for processing films shall be of a manufacture approved by the

Engineer and shall be used in strict accordance with the manufacturers’
recommendations including efficient replenishment of developer. Films shall be
developed in approved solutions for not less than 4 min or more than 5 min. at a
temperature of 20°C. 1° Radiographs shall be processed to allow storage of film
without deterioration for at least thee years. The radio shall be free for imperfections
due to processing or other defects which could interfere with satisfactory
interpretation. The Contractor may be required at any time to demonstrate that the film
can be processed using the site faculties to have a fog level of not more than 0.3.
Approved automatic processing may be
Permitted at the discretion of the Engineer.
h) Film Storage
All unexposed films shall be stored in a clean dry place where the surrounding
conditions will not detrimentally affect the emulsion. if there is any question regarding
the condition of the Line exposed film, sheets from the front and back; of each
package (or a 900mm length from the front of each roofs shall be processed in the
normal manner without exposure to light or radiation to -satisfy the inherent fog
requirements of (g).

i) Film Viewing
The viewer shall be suitable for films with densities up to 3.3.
j) Radiographic procedure Specification
The Contractor shall submit his proposed radiographic procedure to the Engineer for
approval.
The radiographic procedure shall include the following details:
Type of X-ray equipment and KV ranges to be used, or source of radiation. (external

or internal)
Type of film.
• Type of intensifying screens.

• Arrangements if shielding against scatter (if any).
• Geometric relationships (focal spot size or source diameter generating voltage
or source strength focus to film distance object to film distance beam angler
tolerances on location of X-ray head.
• Film coverage.
• Exposure (mA min., curie/min.)
• Material thickness range.
• Processing.
The Contractor shall made and process, in the presence of the Engineer three
radiographs of a weld, preferably the procedure test weld, to establish consistency of
radiographic procedure. Radiographically similar material to that which will be used
for production will be employed. The test radiographs shall be submitted to the
Engineer who shall decide whether the procedure is satisfactory. Change in any of the
above variables shall cause the procedure to be re-qualified.
k) Production Radiography
Only approved radiographic procedures shall be used. Radiography must not be

carried out until the weld has reached ambient temperature. When a complete
circumferential weld is radiographed in a sing le exposure from the inside of the pipe ,
two IQI’s to be placed outside the pipe at the six o'clock and nine o'clock positions
shall be used. When a circumferential weld is radiographed using a multiple exposure
procedure, a IQI shall be located within 25 mm of each end of the applicable limits of
film coverage.
The Engineer shall determine the acceptance or rejection of the weld. When double
wall single image exposure is used and the diagnostic film length requirements as
detailed in API ll04 Latest Edition can be achieved in four shots, these shall be
centered on the 3, 6, 9 and l2 O clock positions

l) Identification and Marking
- Location of Weld in Radiograph. Where the weld is dressed, markers in a form

to be approved by the Engineer shall be placed alongside but just clear of the
outer edges of the weld to identify its position.
- All radiographs shall be adequately identified to the welds they represent. All
measurements Used for defect location shall be metric. Spacing of locations
shall be at intervals not more than 100 mm origin shall be at the 12 o'clock
position. Every radiograph shall identify, in an approved manner the welder(s)
responsible for depositing the root of the weld and the radiographer who took;
the radiograph. The weld shall be marked using indelible material to provide
reference points for the accurate relocation of the position of each radiograph.
m) Rejection of Radiographs
The Engineer will reject any radiograph that does not fully comply with the approved
radiographic procedure or which, in his opinion is for any other reason unsuitable for
viewing and judging the acceptability of the weld it portrays. The Contractor shall re-
take and process any radiograph so rejected at his own expense.
2B.3.17 ULTRASONIC TESTING
As a minimum ultrasonic operators shall be qualified to CSWIP 3.2 level.
(a) Testing of welds
When ultrasonic testing of welds is to be carried out the following procedures shall be
adhered to:
i. Before ultrasonic testing, it is necessary to thoroughly clean a zone not less

than 50mm wide on each side of the weld. Spatter shall be removed, and the
weld zone allowed to cool, if hot.
ii. Calibration of the probes for beam angles is required on the .W.W. test block
or suitable alternative (for example the V2 block at Least dally. Calibration of
the flaw detector time base and amplification is required before examining
each weld.
iii. A probe of 65° to 30° refraction angle, 4MHz frequency and approximately 8
to l0 MHz should be used. welds shall be scanned in a zig zag manual the
probe being moved between the weld reinforcement and one skip distance. The
beam shall be pointed at the weld Length normally. The weld shall be scanned
from both sides. Amplification should be set so that the echo from the hole in
the V2 block is 75% F.S.H. Either Liquid detergent or petroleum jelly paste
and water should be used as coolant.

iv. Defects shall be identified primarily by accurate positioning of the source of the echo in
the weld cross section and their approximate orientation is determined by comparing
the echoes received iron each side of the weld. Identification of defects by the shape
of the echo on the CRO (cathode ray oscilloscope) screens alone is not
recommended.
(b) Testing of Pipe material
Ultrasonic testing practice shall be in accordance with BS 4336: Part 1A using

technique 2 (flaw echo/bottom echo ration for sizing the lamination) or technique 3
(multiple echo pattern) depending on wall thickness and type of lamination (if any)
encountered. The probe shall be scanned in a zigzag fashion in a zone 100mm wide
around planned cutouts for nozzles, and back from the new end of pipes which have
been cut. No lamefier defect shall be accepted if it exceeds 25mm in any dimension
2B.3.18 MAGNETIC CRACK DETECTION
a) The weld and adjoining area at the toes of the root bead shall be prepared for
magnetic crack detection by wire brushing.
b) Wet methods only shall be used. Either water-based fluorescent inks viewed
with ultra-violet light, or black, paraffin-based ink on white background paint
may be used. The inks shall conform to BS 4069. For fluorescent inks the
concentration of suspended magnetic material shall be within the range 0.1% to
0.3% by volume, whilst for black inks the concentration shall be aerosol
containers shall be shaken frequently to ensure consistent concentrations. The
concentrations should be checked regularly and at any time at the discretion of
the Engineer. When white background paint is used it shall be applied as thinly
as possible consistent with satisfactory viewing.
c) A "U" section permanent magnet shall be used for magnetization. Its shape and
size shall be such that the weld area being examined can be viewed whilst the
magnet is still in position. The magnet shall be fitted with pole pieces shaped to
the profile of the pipe being examined. The magnet shall have sufficient
strength to ensure detection of relevant defects. Convenient methods of
measuring strength in engineering terms are not available at present, but as a
guideline, a magnet with pole pieces l2.5mm x 5Omm in area and which is able
to lift a piece of mild steel weighing 11kg would be suitable.
d) Initially the magnet shall be set to straddle the weld at the 6 o'clock position
the fluid applied and the weld viewed whilst the magnet is still in position.
Thereafter the examination proceeding progressively towards the 6 o'clock
position.

PART 2B PIPELINE AND PIPEWORK INSTALLATION SPECIFICATION
SECTION 4 COATING
2B.4.1 PROTECTION OF PIPEWORK:
This section applies to all underground pipelines including valve assembles, flanges,
etc. in the pipeline system including compressor stations, treatment plants and
metering stations.
Line pipe will normally be supplied as bare pipe both internally and externally. The
Contractor will be required to coat all pipework that is subsequently to
be buried in accordance with the relevant Clause of this section.
2B.4.2 BURIED PIPEWORK
CONTENTS
GENERAL
CODES, STANDARDS AND SPECIFICATIONS
QUALITY PROGRAM
DESIGN REQUIREMENTS
QUALIFICATION REQUIREMENTS
MATERIALS
COATING APPLICATION
INSPECTION
TESTING

COATING REPAIRS
IDENTIFICATION AND MARKING
STORAGE, HANDLING AND SHIPPING
DOCUMENTS SUBMITTALS

1.0 GENERAL
1.1 Scope
1.1.1 This specification covers the supply and application of 3-layer

polyethylene (3LPE) Corrosion Protection Coating on steel pipe API
5L Gr. X 60, 16 mm thk NB 24 inch., for the Nigeria Gas Company
Pipeline Project. The minimum coating thickness shall be 3200
microns (3.2 mm) as per shell standard DEP 31.40.30.31-GEN
consisting of:
150 micron Fusion Bonded Epoxy (FBE)

300 micron Copolymer Adhesive
2750 micron High Density Polyethylene (HDPE).
The work includes the furnishing of all labour, materials (except line
pipe), tools and equipment and the performance of all operations and
incidentals necessary for the coating, handling, storing and shipping of
coated line pipe.
1.2 Definitions
The following definitions shall apply throughout this Specification:
Owner - Nigerian Gas Company Ltd.
Supplier - The Company responsible for coating the line

pipe including the manufacturer of materials and
their authorized representatives.
Pipe Supplier - The party responsible for delivery of the pipe to

the coating yard.
1.3 Environmental Data
The site environmental conditions are as follows:
Ambient Temperature
− Maximum 50 ºC
− Minimum 20 ºC

Humidity
− Maximum 100%
− Minimum 50%
Average monthly rainfall 25 mm to 460 mm
Soil Temperature 20 – 30 ºC
1.4 Errors or Omissions
1.4.1 The review and comment by the Owner of any drawings, procedures or
documents referred to in this Specification shall only indicate
acceptance of general requirements and shall not relieve the Supplier of
its obligations to comply with the requirements of the contract.
1.4.2 Any errors of omissions noted by the Supplier in this Specification

shall be immediately brought to the attention of the Owner.
1.5 Deviations
All deviations to this Specification and other specifications or attachments

listed in the Purchase Order shall be made in writing and shall require the
written approval of the Owner prior to executing the work.
1.6 Reporting Procedure
A full reporting and recording system, to be agreed with the Owner, shall be
implemented and maintained throughout the duration of the Purchase Order.
1.7 Pipe Bending
The pipe will be bent in the field to the following radii:
24” NPS,60’-0” radius. (ASME B31.8section 841.231© page 36)
The Supplier shall confirm that the radius for cold bending the completed
coated pipe can be achieved without loss of integrity.

2.0 CODES, STANDARDS AND SPECIFICATIONS
All materials and equipment supplied and work performed

under this Specification shall conform to the latest edition of the
industry standards, codes, references and recommended
practices listed below:
ASME B31.8 Gas Transmission and Distribution Piping

Systems
ISO 9000/9001/9002 Quality Systems
API Spec 5L Specification for Line Pipe
API RP 5L1 Recommended Practice for Railroad

Transportation of Line Pipe
API RP 5LW Recommended Practice for Marine

Transportation of Line Pipe
ASTM E 337 Test for Relative Humidity by Wet

And Dry Bulb Psychrometer
ASTM G8 Cathodic Disbonding of Pipeline Coatings
NACE RP-02-74 Recommended Practice. High Voltage Electrical

Inspection of Pipeline Coatings Prior to
Installation.
NACE RP-01-88 Discontinuity (Holiday) Testing of Protective

Coatings.
SSPC-PA-2 Measurement of Dry Paint Thickness With

Magnetic Gauges.
SSPC-SP-1 Solvent Cleaning
SSPC-SP-10 Mechanical Cleaning

3.0 QUALITY PROGRAM
A quality control program shall be submitted to the Owner for review and approval
prior to first production. The program shall be in accordance with ISO
9000/9001/9002 as the appropriate standard.
The quality program shall, as a minimum, include the following:
a) Raw material handling procedures

b) Raw material testing
c) Coating application procedures
d) Inspection and testing procedures
e) Inspection and testing equipment calibration
f) Coating repair procedure
g) Handling and stockpiling
h) Personnel qualification
4.0 DESIGN REQUIREMENTS
4.1 The 3LPE coating shall be capable of withstanding a maximum continuous

operating temperature (i.e. design temperature) of 70 ºC.
4.2 The 3LPE shall be capable of withstanding the cyclic operating temperature
range between 20 ºC and 45 ºC over the design life.
4.3 The total coating thickness shall be not less than 3.2 mm (3200 microns).
4.4 The 3LPE coated pipe will be installed using conventional lifting and laying
equipment.
4.5 The axial bond between the FBE, and outer HDPE coating shall be adequate to
withstand the shear forces that may be inflicted during the course of
transportation and installation.
4.6 Supplier shall at the time of bidding state and guarantee the maximum
interfacial shear stresses between FBE/HDPE before failure can occur on the
coated pipe for evaluation and acceptance by the Owner.

5.0 QUALIFICATION REQUIREMENTS
5.1 General
The coating procedure shall address the following points as a minimum:
Line pipe handling, storage and inspection at all stages of application work.
Complete details of the coating materials together with quality control,

storage of materials, Manufacturer’s certification and safety sheets.
Application of FBE coating intermediate copolymer adhesive and outer

HDPE coating, including details of thickness, density, bonding strengths
and details of application equipment.
Inspection and testing including instrument and equipment types,

frequency and acceptance criteria.
Details of instrument and equipment calibration methods including relevant

standards and examples of calibration certificates.
Complete details of inventory of laboratory and testing equipment.
Quality control procedures including documentation, batch identification

and qualification of personnel for all aspects of the work.
Coating repair procedures and acceptance criteria for repair and rejection.
First day production Tests.
Field testing.
5.2 Coating Procedure Specification
5.2.1 A detailed coating procedure shall be prepared by the Supplier for

qualification and Owner's approval.
5.2.2 The coating procedure shall be qualified by coating five different pipe
spools in strict accordance with the coating procedure and
Specification.
5.2.3 The Supplier may use first day production tests for purposes of
qualification.
5.2.4 The Supplier shall submit certified records of all aspects of the
qualification procedure to the Owner for approval.

5.2.5 Failure to meet any part of the qualification procedure shall require the
Supplier to revise the procedure and repeat the qualification process.
6.0 MATERIALS
6.1 The FBE material shall be a fast gel time material and have the following
properties:
Powder Density 1450 kg/m3 ASTM D2370
Tensile Strength @ 45 ºC 40 Mpa ASTM D2370
Elongation 6% ASTM D2370
Hardness (1/8” ball, 100 kg load) 48-50 Rockwell ASTM D1002
Adhension (lap shear) 185 kg/cm2 ASTM D1002
Impact Resistance at 25 ºC 18J ASTM G14-72
Water Absorbtion at 65 ºC 3.0% ASTM D570
6.2 Copolymer adhesive shall conform to the following specifications:
Density 920 - 930 kg/m3 ASTM D1238
Melt Index 1.0 – 2.0 g/10 min. ASTM D 1238

19º C / 2.16 kg
Vicat Softening Point 19º C ASTM D 1525
Ultimate Tensile Strength 18 MPa ASTM D 638

@ 50 mm / min.
Ultimate Elongation 600% ASTM D 638
6.3 The polyethylene material prior to extrusion shall be granular:
Density 950 kg/m3 ASTM D 1505
Tensile Strength (@ 50mm/min) 18 MPa ASTM D 638
Elongation 600% ASTM D 638

Hardness (Shore D) 60 ASTM D 2240
Vicat Softening Point 120º C ASTM D 1525
Stress Cracking Resistance 300 hours ASTM D 1693
Moisture Absorbency 0.01% max. ASTM D 1693
Dielectric Breakdown Voltage 30 kV min. ASTM D 1693
7.0 COATING APPLICATION
7.1 Surface Preparation
7.1.1 The pipe supplied will be of mill coating.
7.1.2 The external surface of the pipe shall be cleaned of all oil grease and
paint by the Supplier prior to abrasive cleaning. A solvent shall be
used in accordance with SSPC-SP-1.
7.1.3 Each joint of pipe shall be uniformly heated to completely remove all
moisture and to prevent any condensation of moisture on the pipe, prior
to abrasive cleaning. The temperature of the substrate shall be a
minimum of 3ºC above the dew point during surface preparation,
application and drying. The temperature, dew point, and relative
humidity shall be determined with a sling psychrometer or other
approved equal following procedures in ASTM E-337. Readings shall
be taken at the start of work and every four (4) hours thereafter.
Preheated pipe temperatures shall not exceed 66ºC. Any abrasive
entering the pipe shall be removed prior to coating.
7.1.4 The exterior pipe surface shall be abrasive cleaned to a “near white
metal finish” Class 2½ using steel grit or dry sand as described in
SSPC-SP-10 to remove all dirt, mill scale, rust, corrosion products,
oxides, paint and other foreign and deleterious matter. The compressed
air for cleaning shall be free of water and oil. Adequate separators,
filters, or traps shall be provided.
7.1.5 The abrasive working mix shall be selected to produce an anchor

pattern profile of not less than 0.038 mm and not greater than 0.064
mm.
7.1.6 To ensure a consistent surface finish and anchor pattern a stabilized

abrasive working mix shall be maintained by frequent small additions
of new grit (dry sand or steel) commensurate with abrasive
consumption. Infrequent large additions shall be avoided.
7.1.7 The abrasive working mix shall be maintained clear of contaminants by

a continuous and effective operation of the abrasive machine scalping
and air wash separators.
7.1.8 After cleaning and prior to coating, the cleaned pipe shall be inspected
by Supplier under ample lighting conditions to ensure that all the
cleaning steps have been adequately performed.
7.1.9 The abrasive cleaned surface shall not be contaminated with dirt, dust,
metal particles, oil, water or any other foreign matter from any source,
nor shall the anchor pattern be destroyed or burnished by pipe transport
systems, processing equipment, tools, or follow-up cleaning with
abrasive sanders.
7.1.10 Following abrasive cleaning and prior to the coating application, all
dust, grit, metal particles or other loose contaminants remaining on the
surface or entering the interior of the pipe shall be blown off with
clean, dry, oil-free compressed air in a manner not affecting the other
cleaned pipe or pipe to be coated. When compressed air cleaning
facilities are not available, vacuum cleaning or other suitable methods
may be used.
7.1.11 Improperly cleaned pipe shall be re-cleaned at the expense of the

Supplier. The cleaned pipe shall be immediately transferred to the
coating racks. Under no circumstances shall the total elapsed time from
the start of cleaning to the application of coating exceed the following
time humidity table:
Relative humidity % Time hours
90 1
85 2
80 4
70 10
7.1.12 Any raised sliver, scabs, laminations or bristles of steel remaining on

the newly cleaned pipe surface shall be removed using abrasive
sanders. This operation shall not burnish or destroy the surface anchor
pattern.
7.1.13 Any surface preparation which does not conform to these specifications
(just prior to coating) shall be rejected. Grease-free chalk shall be used
to mark areas which do not meet the specified requirements.

7.1.14 The external pipe surface shall be abrasive cleaned to SIS standard 05
5900-Sa 2½.
7.1.15 It is very important that the specified surface cleanliness exists at the
point of coating application. The period between cleaning and coating
shall be kept to a minimum.
7.2 FBE Coating Application
7.2.1 The FBE coating shall be applied to the preheated pipe in a uniform
manner by electrostatic powder spray to produce the specified
thickness.
7.2.2 On no event shall the percentage of recycled powder mixed with new
powder exceed 25 percent.
7.2.3 The FBE coating shall be applied over the full length of each pipe.
7.2.4 Frothing of the coating at the steel/coating interface shall be avoided.
7.2.5 All compressed air used for delivery of FBE in the coating chamber
shall be free from moisture, oil and other contaminants.
7.2.6 Quenching with water shall be performed only after the recommended
minimum cure time has elapsed.
7.3 Copolymer Adhesive
7.3.1 The copolymer adhesive shall only be applied after the FBE is fully
cured and inspected in accordance with Section 8.0.
7.3.2 The FBE cutback shall be taped to prevent the adhesive from adhering
to the cut back during foam coating. The cut back in the adhesive layer
shall be 100 mm.
7.3.3 Immediately prior to adhesive application, the entire surface of the FBE
coating shall be cleaned and degreased using a solvent compatible with
the FBE coating.
7.3.4 The copolymer adhesive shall be applied to give a uniform layer of the
specified thickness. The method of application shall be specified by
Supplier for review and acceptance by the Owner.

7.4 High Density Polyethylene Application
7.4.1 A HDPE outer jacket shall enclose the copolymer adhesive and provide
a water proof barrier capable of withstanding external hydrostatic
pressure to water depths of upto 20 m.
7.4.2 The HDPE outer coating shall provide the balance thickness of the
coating system and shall be able to withstand impact without
deterioration of HDPE coating during backfilling of the trench after
installation.
7.4.3 The cutback shall be 100 mm and square to the pipe axis. Care shall be
taken not to damage the FBE corrosion protection coating when
preparing cutbacks.
8.0 INSPECTION
The quality program shall define the inspection plan which shall include the following:
8.1 Each pipe shall be visually inspected over 100 percent of the surface both after
the application of FBE and HDPE.
The FBE coating shall be visually inspected for defects under adequate lighting
and shall be free of voids, loss of adhesion, blistering, excess powder mounds,
peeling, blueing, lifted pipe scabs, and discoloration from burning or rusting of
substrate.
If the Supplier fails to promptly correct causes of regularly recurring holidays

or other coating defects, the pipe coating may be rejected for any number of
such regularly recurring holidays or defects.
8.2 The dry coating thickness of FBE shall be measured with a magnetic film
thickness gauge such as magnetic film thickness gauge. The gauge shall have
a zero to 1.0 mm working range and shall be calibrated frequently against the
approximately 0.4 mm standard of the U.S. Department of Commerce Certified
Coating Thickness Calibration Standards for non-magnetic Coating of Steel or
Owner accepted alternative standards. The standards shall be in the 0.35 mm
to 0.45 mm range, unless other wise specified.
A minimum of twelve (12) dry film thickness measurements
shall be taken on each pipe. Three sets of readings shall be
taken evenly spaced along the length of each pipe. Each set of
readings shall consist of four readings equally spaced around
the circumference of the pipe. All dry thickness readings shall
be performed in accordance with SSPC-PA2 using the spot
reading frequency specified herein.
8.3 All FBE coated pipe shall be 100% inspected for holidays using a spiral coil or
brush operated according to the requirements of NACE Recommended
Practice RP-02-74. A 150 volts/mil, or as recommended by the coating

manufacturer, shall be used. In no case shall voltage be below 2100 VDC.
The holiday detector shall have an audible alarm.
The holiday detector voltage shall be measured and recorded every hour with
an accurate DC voltmeter. The holiday detector shall be re-calibrated as
necessary after recording its voltage or during noticeable changes in handling.
The detector electrode shall be in direct contact with the entire surface of the
coating being inspected. There shall be no gaps in the electrode or separations
between the electrode and the surface of the coating, including the surfaces on
either side of the seam of the pipe.
The travel rate of the detector’s electrode shall not exceed 0.30 metres/second
and shall not be allowed to remain stationary while the power is on. (Refer to
NACE RP-02-74 to determine rate of travel).
All holidays and other coating defects shall be marked with a grease-free
marker and the number nature of holidays and coating defects in each pipe
recorded.
Pipe spools not meeting the requirements below shall be rejected:
The number of holidays shall be limited to one per 1.86 square metres for
any given pipe. The size of the holiday shall not exceed 25 mm2
8.4 The ends of each pipe shall be inspected after each coating has been cut back.
The inspection shall check that the fusion bonded epoxy coating has not been
damaged. Cut backs shall be free from FBE, HDPE or other foreign material.
8.5 Each 3LPE coated pipe shall be dimensionally checked to include:
Outer diameter
Coating thickness
Cut back lengths
9.0 TESTING
9.1 General
9.1.1 Material and production testing shall be performed at regular intervals

as per the Supplier’s procedure approved by Owner.
9.1.2 All tests shall be performed by qualified personnel.
9.1.3 Any pipes not meeting the requirement of this Specification shall be
stripped, cleaned and re-coated.
9.1.4 The Supplier shall prepare a prototype test procedure for the field joint
coating system to qualify the application procedures.
9.1.5 The Supplier may provide documentation supporting a similar system

used for a previous contract in lieu of complying with clause 9.1.4, if
the design requirements were similar to those defined in Section 4.0.
9.2 Prototype Testing
The Supplier shall prepare a testing procedure and perform tests to qualify the
field joint materials and application procedure. The testing shall cover the
following:
a) Coating and field joint material compatibility
b) Field application procedures
c) Structural integrity during and after installation
d) Cut back design
10.0 COATING REPAIRS
10.1 General
10.1.1 The Supplier shall submit a repair procedure for the approval of the Owner prior
to the start of production.
10.1.2 The Supplier shall demonstrate that the repair is as strong as the parent
material.
10.1.3 Where a pipe is to be stripped and re-coated, the pipe shall in no

circumstances be heated above 246 ºC.
10.2 Field Repair of Coating
10.2.1 The vendor shall include in his bid a comprehensive procedure for field
repair of coating, and specifications of all the repair materials involved.
10.2.2 Vendor shall include in his supply, repair materials to adequately cover
the coating damage normally expected during transportation.
10.3 Repair of Bare Pipe
10.3.1 Scratches, grooves, gouges and silvers may be removed by filling or grinding, in
accordance with procedures approved by the Owner.

10.3.2 The Supplier shall grind or otherwise repair damaged bevels and pipe
found to have been damaged, in accordance with the Line Pipe
Specification.
10.3.3 All ends of pipes which are damaged to such an extent that they cannot
be repaired by grinding or filing shall be re-beveled by the Supplier.
10.3.4 The Supplier shall furnish a beveling machine for repair of the pipe
ends.
10.4 Repair of FBE Coating
10.4.1 Areas of pipe requiring small spot repairs shall be cleaned to remove
dirt, scale and damaged coating using surface grinders or other suitable
means. The adjacent coating shall be feathered. All dust shall be
wiped off. For pinholes only, surface preparation is not required other
than removing surface dirt, oil, grease and other detrimental
contaminants which impair the adhesive of the repair material.
10.4.2 Pipe with major coating defects such as uneven coating, disbanding or
inadequate film thickness shall be set aside for stripping and re-coating.
All repairs shall be re-subjected to the original acceptance criteria.
10.4.3 When stripping a pipe for re-coating the pipe shall not be heated above
246 ºC.
10.4.4 For all defects a two part liquid epoxy compound shall be applied using
a hand gun applicator. The defect area must be first abraded by hand
using a carbonndum cloth. The compound shall be applied to a
minimum thickness of 100 micron above the specified FBE thickness
and over lap the undamaged area by 25 mm.
10.4.5 Pipe having major coating defects (e.g. partially coated, disbanding or
inadequate film thickness) shall be set aside for reprocessing.
10.5 Repair of FBE Coating
Small defects, less than 100 mm in length shall be repaired using heat shrink
sleeves approved by Owner, or by the use of melt sticks.
11.0 IDENTIFICATION AND MARKING
11.1 The pipe will be delivered to the Supplier marked in accordance with the
marking system. The Supplier shall maintain the pipe identification
throughout the process of cleaning and coating of the pipe. If the pipe
identification is removed during the coating operation, it shall be replaced.

11.2 Additional markings shall be applied 50 mm from the end of the coating and
outside the pipe at each end. Letters and numerals shall be 25 mm in height.
11.3 Pipe which has undergone repair in accordance with section 9.0 shall be
marked with a band painted around the entire circumference of the coated pipe
and not more than 75 mm from the cut back at each end.
11.4 All markings shall be stenciled and spray applied with paint compatible with
the coating material and of a contrasting color.
12.0 STORAGE, HANDLING AND SHIPPING
12.1 The coated pipe shall at all times be handled in a manner

to avoid damage to the coating.
12.2 The coated pipe shall be supported only by the uncoated ends until the coating
has cooled to ambient temperature.
12.3 The coated FBE shall be stored in an area which will not result in accumulation
of dust or dirt either from the environment or surrounding.
12.4 The FBE coated pipe shall be protected to avoid degradation from ultraviolet
light radiation.
12.5Any coated pipe section that shows contamination in any form whatsoever from
the environment or surrounding shall be adequately grinded and completely re-
coating the pipe as considered appropriate by Owner's representative.
12.6 All coated pipe which has undergone repair shall be stockpiled separately from
non repaired pipes or shall be colored coded for ease of identification.
12.7 The handling and shipping of coated and uncoated pipe shall be in strict
accordance with the applicable Specifications. Supplier shall ensure that all
coated pipe is loaded into containers and is in accordance with procedures
approved by the Owner.
13.0 DOCUMENT SUBMITTALS
13.1 The Supplier shall submit copies each of the following

documents to the Owner as set forth below:
Document Submittal No. copies
Quality Control and With Bid 2

Application Procedures

Coating Repair Procedures With Bid 2
Storage, Handling and Prior to Coating 2

Transportation Procedures
Qualification Test Report Prior to Coating 2
Certified Material Test Prior to Coating 2

Certificates
Certified Inspection Weekly 1

Report
Tally Recorded of Pipe Weekly 1

Received
Tally Recorded of Pipe Prior to Shipping 6

Coated/Loaded Out
Coating Repairs Undertaken Reported Daily 1
All certificates shall be in English language and with SI units of measure.

Certificates shall be visibly signed by the Supplier.
13.2 The Supplier shall maintain a complete record of the

pipe from the time it first enters the coating yard until the
completion of load-out of coated pipe. Pipe joint length and
date of the coating application shall be recorded for each joint
of pipe. The Supplier shall provide this information to the
Owner according to the schedule specified above.
b) HEAT SHRINK SLEEVES
The application of heat shrink sleeves for field joint coating shall be made to the
Manufacturer’s recommendations and the Engineer’s requirements .The completed
sleeve coating shall overlap the coal tar yard wrap by 50mm and present a smooth
even appearance free from bubbles, scorch marks and end curl with a recovered sleeve
thickness of 2mm minimum.
2B.4.7 INSPECTION AND REPAIRS OF COATING
a) HOLIDAY DETECTION
The Contractor shall furnish and operate approved high tension electric holiday
detectors which will be passed over all coated pipes, field joints, specials and valves.
The Contractor shall also supply for the duration of the Contract 4 No. approved high
tension electric holiday detectors with spare batteries Battery Chargers and electrodes,
both rolling spring and brush for the excessive use of the Engineer's Representative.
The rolling spring shall be for a 360O coverage.
Holiday detectors shall have a range 2-20kV and incorporate a voltage control and a
voltmeter and be provided with an audible and visual signal to operate when faults are
detected. Special thin film holiday detectors providing voltages between 0-2000 volts
shall be used for- epoxy coated structures.
They shall have a trailing earth and be used in conjunction with a rolling spring
electrode. A brush type electrode shall be available at all times and be utilized when
the use of the rolling spring electrode is not practicable.
2B.4.8 PERFORMANCE TESTS
a) GENERAL
Before commencement of the Works, the Contractor shall satisfy himself that the
required standard and the requirements set out below can be achieved.
The coating shall be completely continuous and free from all holidays, voids, pinholes
or other defects. The thickness of the coating, the degree of adhesion to the pipe and
the standard of workmanship generally shall be regularly checked by the Contractor
and witnessed by the Engineer
Adhesion tests wilI also be carried out by the Engineer's Representative and the
damage so called is to be made good by the Contractor at his own cost.
If in the opinion of the Engineer's Representative, holidays or other defects,

including lifting edges, lack of adhesion etc, are so frequent as to indicate poor
application the coating shall be stripped, the pipe cleaned, primed and recoated.
b) CURRENT DRAINAGE
On completion of the work, the Engineer's Representative will test the effectiveness of
the coating in the following manner:
i) Cathodic protection drainage surveys will be carried out: Firstly, as soon as

possible after laying the pipeline and before commissioning and again,
immediately before completion of the Maintenance Period and the quality of the
coating shall be such that the following minimum results shall be obtained in
both surveys.
ii) The test will be carried Out on the whole pipeline with no bonds made to
magnesium anodes or other structures .If it is not possible to test the whole line,
the test will be carried out in lengths not less than 32Km Iong. Before
commencement, natural pipe/soil potentials shall be measured at representative
points along the pipeline section.

iii) Direct current will be drained from one point on the section at a set level for a
minimum of forty-eight (48) hours continuously before readings are taken. The
point will be known as the drainage point and the current shall be such that :
- the pipe/soiI potentiaI at the drainage point will not exceed two point five (2.5)
volts negative measured with respect to a standard copper/copper sulphate half
cell;
- the potentiaI change at all other points on the pipeIine will be at Ieast four
hundred (400) negative millivolts or the reading will be more negative than
point eight five (0.85) volts referred to a copper/ copper sulphate half cell.
iv) The total current necessary to achieve the above shall not exceed 80 milli-
amperes per linear km of pipeline.
In the event that the coating fails to meet the above requirements, the
Contractor shall investigate in the presence of the Engineers Representative by
conducting a survey of the line and utilizing whatever means are necessary to
locate the cause of the failure including Pearson Detector Survey at his own
cost. He shall report his findings on the failure; make proposals to the
Engineer’s Representative for their rectification at his own cost, to meet the
specified cathodic protection drainage requirements. This may include adding
additional cathodic protection stations if necessary.
2B.4.9 TERMINAT ION OF UNDERGROUND PIPEWORK
Wherever the pipeline emerges from the ground, the underground coating and
wrapping system shall be retained for a distance of not less than 0.5m along the above
ground pipework measured along the centre line of the pipe from the point where it
emerges from the ground. At its termination, the coating, if coal tar shall be chamfered
off with a sharp knife and heated with a flame if necessary to produce a smooth
adherent feather edge.
It is the intention that where "above ground" pipework may become covered in sand or
water (e.g. in valve chambers or beside road crossings) the buried coating specification
should apply.

SECTION 5 PROTECTlVE COATlNG OF ABOVE GROUND PlPEWORK
CONTENTS
2B.5.1 SCOPE
2B.5.2 GENERAL
2B.5.3 PREPARATION OF SURFACES BEFORE PAINTING
2B.5.4 PAINTING
2B.5.5 LINE IDENTIFICATION
2B.5.6 EQUIPMENT IDENTICATION
2B.5.7 COLOUR IDENTIFICATION
2B.5.8 CHANGE OF COLOUR CODING

SECTION 5: PROTECTIVE COATING OF ABOVE GROUND PIPEWORK
2B.5.1 SCOPE
This specification covers the preparation and painting of above ground pipework
vaIves and other in-line equipment incorporated in the project.
The scope of this specification is to the general painting standards required for above
ground pipework etc and is not intended to cover the full extent of painting work.; that
may be executed on the project which may be specified else where on the drawings, or
orders, separately.
2B.5.2 GENERAL
Materials: All paints and other coating covered in this specification shall be the best of
their types, and delivered to the sites in seaIed containers. They shall not be thinned
down mixed or otherwise adulterated except in strict compliance with the
manufacturer’s instructions. The contents of aIl containers shall be thoroughly stirred
to even consistencies before and during use.
Source of supply: The paint shall be obtained direct from the manufacturers and shall
be of the qualities, types and colours scheduled, each coat being of a different shade.
All coats of a point system shall be obtained from the same manufacturer wherever
practicable and shall be ordered for use together and wherever possible shall be
obtained on one order in sufficient quantity for complete portions of the work
particularly in the case of finishing colours. Contractor shall obtain advice from
manufacturer on compatibility of the coatings same documents shall be presented to
the Engineer for approval.
All paint used shall have been ordered specifically for this contract, and shall be in
accordance with the appropriate British Standard or equivalent international standards.
Paint shall be delivered to the site in original sealed containers not exceeding 5 litres
capacity and bearing the manufacturer's name, specification number method of
application colour quantity, batch number and date of manufacture. The paints shall be
accompanied by the relevant documents giving the paint specification and application.
Labour: All painting work shall be executed to accepted good trade practice by skilled
tradesmen working in accordance with Latest Edition of B.S. CP 5493, Protective
Coating of Iron and Steel Structures against corrosion.
2B.5.3 PREPARATION OF SURFACE BEFORE PAINTING
No paint shall be applied to any surface which is in the sIightest degree damp or
greasy and painting shall be carried out only under favourable conditions. Should any
atmospheric, dust, handling or any other cause during or following painting result in
damage to the paint fiIm, the damaged area shall be rubbed down smooth and
repainted at the Contractor’s expense, and to the satisfaction of the Engineer. No paint
shall be applied over rust or dirt. Pipework shall be prepared by one of the following
methods:
a) Blast cleaning by means of approved abrasives and in accordance with BS 4232; or

Swedish Standard SIS 055900 Grade SA 2 1/2 to be executed either in the fabricating
shop or on site. Surfaces must be primed within four hours of bIast cleaning.
b) Joints couplings, valves and fittings shall be prepared for painting in accordance with
the foregoing directions given for pipework unless the assembly has been painted prior
to site delivery then it shall be painted to the pipework specification.
2B.5.4 PAINTING
Pipework shall be painted to the recommedations of BS 5493 Latest Edition for a table
1 category "No Polluted Coastal, in all areas of saline swamp or within 3.Km of the
coast.
In other areas, schemes suitable for 'Non Polluted Inland' conditions shall be applied
other than at the transmission Fine terminals which shall be cIassified as 'Poluted
InIand’
All paint systems shall be designed for a medium life to first maintenance (5 to 10
years) .Detailed paint system specifications shall be approved by the Engineer before
application commences.
All paints shall be applied as recommended by the manufacturer and shall be stored,
mixed and applied as recommended in BS 5493, Latest Edition Section 21, 22 and 23.
Contractor shall suppIy for the Engineer's use, the following equipment:
i) Wet Film Thickness (WFT) and Dry Film Thickness ( DFT)
ii) Paint adhesion tests
iii) Wet and dry bulb temperature measurement (Thermometers)
LINE IDENTIFICATION
All pipe lines shall be identified by displaying the line number as shown on the
relevant flowsheet.
Stencilled characters shall not be less than l2mm high on lines up to 4 inch NB, not
less than 25mm high on lines 6 inch NB and over.
As an alternative, self-adhesive labels 9.5mm wide may be used for the line
identification. Such adhesive labels shall be placed only after the final coat of
paint has dried up.
Line identification shall appear at each change of direction at termination of lines on

equipment and at junctions of lines of different number.
Where changes of fine direction visibIy occur within two metres of one another, the
identification shall appear on the most readily visibIe change.
2B.5.5 EQUIPMENT IDENTIFICATION
All drums, tanks, heat exchanger, etc., shall be identified by having the equipment
item number as shown on the flowsheet displayed in a prominent position.
Characters shall be not less than 30mm high, with legs 10m wide.
It will not be necessary to display the equipment description in similar fashion where a
description appears on the nameplate.
2B.5.6 COLOUR IDENTIFICATION
The following schedule of finishes shall apply to this project.
Plant, Equipment, Machinery and Structure -Schedule of Finishes
Item Description of Item to be Colour & BS 2660

Painted Ref. No.
a) Insulated pipes and equipment

above ground IeveI Aluminium
b) UninsuIated pipework straps

and supports above ground
IeveI temperature up to 200oF Aluminium
c) Engine exhaust pipes and silencers Aluminium
d) External Surfaces of Pressure

Vessels, Air Receivers, Scrubbers,
Air filters, Heat Exchangers. Aluminium
e) External surfaces of water and oil

Storage Tanks White
f) Internal surfaces of Steel oil and

Fuel Tanks White
g) Internal surfaces of Raw and Treated

Water Tanks Black
h) Internal Surfaces of Cooling Water

Tanks Black
i) Obstructions to headroom less than

2 metres high over walkways
including pipework to extend
350mm each side of walkway. Yellow 0-002.
2B.5.7 CHANGE OF COLOUR CODING
The Employer may wish to change the colour coding detailed to comply with his
company standards.
NOTE The following equivalent shall apply in cleaning;
British Standard BS' 4232 = Swedish Standard SIS 05.50.00

Grades 1st quality = SA 3.0
2nd Quality = SA 2.5

PART 2B PIPELINES AND PIPEWORK INSTALLATION

SPECIFICATION
SECTION 6 CATHODIC PROTECTION
CONTENTS
2B.6.1 General
2B.6.2 Description of Works
2B.6.3 Corrosion Survey
2B.6.4 Cathodic Protection Design
2B.6.5 Temporary Cathodic Protection
2B.6.6 Equipment Specification/General
2B.6.7 Transformer-Rectifiers
2B.6.8 Alternative C.P. Power sources
2B.6.9 Silicon Iron Anodes
2B.6.10 Carbonaceous Backfill
2B.6.11 Cables
2B.6.12 Surge Diverters
2B.6.13 Magnesium Anodes
2B.6.14 Zinc Anodes
2B.6.15 Potential/Marker Post
2B.6.16 Negative Current Distribution Station
2B.6.17 Installation Specification
2B.6.18 Ground Beds
2B.6.19 Cable Laying and Pipeline Connections
2B.6.20 Scotch/cast Splicing kits
2B.6.21 Groundbed Marker
2B.6.22 Magnesium Anodes
2B.6.23 Current Measurement Location
2B.6.24 Isolating Joints./Flanges
2B.6.25 Parallelisms with Overhead H.T Power Line
2B.6.26 Foreign Service Crossings
2B.6.27 Construction Records
2B.6.28 Pre-commissioning, Testing and Inspection
2B.6.29 Installation Programming for Cathodic Protection
2B.6.30 Spare Equipment
2B.6.31 Commissioning
2B.6.32 Test Instruments

SECTION 6 CATHODIC PROTECTION
2B.6.1 GENERAL
This specification describes the works required to design, supply and install a cathodic
protection scheme for a gas transmission pipeline system in Nigeria.
The cathodic protection will include all buried or immersed pipes of the pipeline and
plant installations.
The gasline cathodic protection scheme shall not reduce the level of protection
available on existing parallel, cathodically protected pipeline. The Contractor will be
required to demonstrate this at the time of commissioning. Where the pipeline suffers
excessive changes in potential arising from the cathodic protection of any parallel
pipeline, the Contractor will be required to modify the parallel pipeline CP system to
the satisfaction of its owners and the Engineer.
The cathodic protection design shall give consideration to the limitations existing in
the operation of impressed current cathodic protection schemes due to absence of ac
power supplies lack or difficulty of access for cathodic protection station generator re-
fueling and maintenance and the difficulty of recording and thus regulating pipe to soil
potentials in immersed pipe areas.
However, in generaI a power impressed scheme is required for cathodic protection and
the designer should use, whenever possibIe, pipeline gas as a cathodic protection
station generator fueI wherever plant or nationally generated a.c. supplies are not
available.
The cathodic protection scheme will of necessity be an amalgam of impressed current

and galvanic installation and the contractor shall survey the pipeline in detail to
determine the resistivity of soils and water to be able to provide the most effective
galvanic and impressed current cathodic protection installations allowing for seasonal
and any other changes.
The design of the cathodic protection system shall give consideration to the cathodic
operation schemes operating on adjacent parallel pipelines
The design of the cathodic design shall be such that the scheme designed shall
provide cathodic protection to the gas pipeline irrespective of the operation of adjacent
and parallel schemes on other services but shall provide facilities for controlled
bonding between the gas and other pipelines cathodic scheme if the owners so require.
2B.6.2 DESCRIPTION OF WORK
Cathodic protection shall be provided to buried pipelines and buried plant steel
pipeworks.
Cathodic protection shall be applied so as to achieve steel structure to environment

potential depression, referred to a copper/copper sulphate reference of minimum -0.95
volts and maximum -1.7 volts.
The principle works to achieve this are:
a) Complete a corrosion and electrical soil/water resistivity survey of the pipe

route and plant areas as specified.
b) From the information gathered on the survey, prepare a design for a cathodic
protection scheme within the outline specified covering the whole gas system
installation from the field location to the gas transmission line termination for
approval by the Engineer.
c) On approval, implement the designed scheme by installing the cathodic

protection stations, galvanic anodes and other cathodic protection facilities of
the approved design.
d) Install potential measurement test stations with a maximum separation of 2kms

along the buried pipeline sections and at other locations required by the
Engineer in plant areas. Install current measurement stations at cathodic
protection station and midpoints.
e) Provide test stations and high voltage protective devices at all pipeline isolating
joints, insulating flanges or instrumentation/pipe insulation.
f) Provide galvanic bracelet and cast billet anodes on the pipelines and in the
plant areas for permanent cathodic protection where impressed current
installations are impractical or where potential test stations cannot be provided
or be made accessible for monitoring as detailed in (d).
g) Provide galvanic anodes on the pipeline to give temporary cathodic protection

for a minimum of 2 years where the survey demonstrates that the pipeline
environment resistivities, either permanently or seasonally, are less than 3000-
ohm cms.
h) Complete and record pre-commissioning tests to confirm satisfactory

installation and operation of the equipment, cable continuity and cable
identification.
i) Complete and record the commissioning of the system, conduct interaction

tests on adjacent steel structures, provide remedial interaction measures and
prepare and issue 12 copies of the commissioning results, operating procedures
maintenance, recommendations and 'as installed drawings in the form of a
Manual.

j) Provide operating, test and spare equipment (as detailed in the spare equipment
schedule).
2B.6.3 CORROSION SURVEY
The Contractor shall carry out a corrosion and resistivity survey along the route of the
pipeline and including ‘in plant' areas and shall prepare and supply to the Employer six
copies of a report detailing:
a) Soil resistivities representative of condition. at intervals of not more than 2km along
the route of the buried pipeline and at not more than 50m centres in pIant areas. The
measurements shall be carried out by the Wenner-4-pinn method using an instrument
approved by the Engineer as a 'megger' null balance earth tester to record average soil
resistivities to depths of 1.5m and 3m at each location.
b) On immersed pipeline routes, the survey shall record, by sampling the water resistivity
at representative intervals along the pipe route and will determine and record from
local records the seasonal variations, tabling the highest and lowest values of salinity.
c) The location of any unusual features which would affect operation of the cathodic
protection system particularly crossings with other metallic services or pipelines, areas
of permanent or seasonal inundation by fresh or salt water on land routes, other
cathodic protection schemes, crossings or parallelisms with overhead high voltage
electricity distribution systems, etc, etc.
d) A schedule of galvanic anode installations by location size, number and method of

connection to provide temporary cathodic protection during construction for a
minimum two year period on pipe lengths laid in soils with resistivities of 3000-ohm
cm and crossings or affected by other cathodically protected pipelines.
e) A schedule of zinc electrode installations by location size, number and method of

connection to provide earthing of any possible ac induced from parallel or crossing
overhead HT electricity supply cables.
f) Locations for proposed permanent cathodic protection stations, detailing the nearest
source of ac power and not less than four electrical resistivity measurements of the
soil at and nearby the location of each proposed groundbed. These measurements
shall record average soil resistivities of depths of 5, 10 and 20 metres. Groundbed
locations must be proposed and selected on the basis of achieving a minimum
resistance to remote earth of the groundbed cables and pipe equal to the internal
resistance of the proposed power source.
g) Where soil resistivities preclude the economic construction of l ohm groundbeds, the
resistance of the groundbed constructed shall be such that the minimum current
available from the station shall be and to the cathodic protection current calculated to
be required for a coating deteriorated to 3000 ohms/m2 or 5 times the initial
calculated current which ever is the larger.

2B.6.4 CATHODIC PROTECTION DESIGN
On acceptance and approval of the survey report, the Contractor shall prepare and
submit to the Engineer 6 copies of the proposed design for the cathodic protection
scheme which will include, but not be limited to:
a) The calculations on the basis of which cathodic protection current requirement, CP

station location and CP station capacity have been made. Available output capacity
from each groundbed shall be not less than 5 times the current output at
commissioning.
b) Exact locations and construction of the cathodic protection stations proposed.
c) Extent and method of installation of groundbed and method of calculating resistances

of groundbed to remote earth. Groundbed shall be constructed using inert anodes in
carbonaceous backfill or saline water and designed for a life on full CP station output
of not less than 20 years.
d) Provide details of the physical size and eIectricaI rating for the cathodic protection
current source, anodes and cabIes, with circuit diagrams, Manufacturers technical
literature etc.
e) The design of the cathodic protection station shall be on the assumption that no
power suppIy is available from outside sources.
f) Provide details of the fuel type fuel storage and replenishment frequency for self-
contained cathodic protection power sources (i.e. propane or butane if not pipeline
gas).
g) Plot pIans sufficient for IegaI acquisition by owner of any Iand required outside
pIant, stations of pipeline easement limits for groundbeds, cabIe runs and cathodic
protection power sources. incIuding the proposed fenced area.
h) Construction drawings showing details of the cathodic protection station and pipeline
monitoring and surge voltage protective installations proposed.
i) Design proposals for the cathodic protection of tank bottoms and station/pIant
pipework.
j) Design for facilities for interconnecting between the gas and other cathodically
protected pipelines to enable jointly operated cathodic protection schemes.
k) Proposed procedure for commissioning, testing and interaction remedial measures

including demonstration that potentials are within prescribed limits.
2B.6.5 TEMPORARY CATHODIC PROTECTION

During the construction of the pipelines, temporary cathodic protection shall be

proposed in the form of galvanic anodes designed to provide an effective life of not
less than 2 years from the date of laying the pipeline on all sections laid in areas where
the soil resistivity is less than 3000 ohms cms or where other cathodically protected
pipelines are crossed or paralleled.
Prior to the cathodic protection scheme commissioning, the Contractor shall provide
monthly potential monitoring reports to the Engineer demonstrating that the level of
protection required for the permanent scheme is being maintained by the temporary
scheme and shall take such steps as are necessary to ensure this.
2B.6.6 EQUIPMENT SPECIFICATION /GENERAL
All equipment shall be suitable for continuous use under the conditions for operating
prevailing in Nigeria.
2B.6.7 TRANSFORMER-RECTIFIERS
All transformer-rectifier units shall be oil cooled and designed and constructed to
operate outdoors. The transformer-rectifiers will be mounted on concrete plinths,
inside plant buildings where possible and within safety fenced area outside plant
locations.
All units shall be of the same manufacturer and shall be interchangeable on their plinth
mountings.
Transformer-rectifier units shall comprise of a transformer and rectifier circuit with

manual output regulation. All shall be installed in a welded steel earthproof tank which
shall be oil-filled such that all components of the transformer, rectifier- and regulation
equipment are below oil level. The transformer and rectifier shall be continuously
rated and the transformer suitable for connection to a 240 volt, single phase 5O Hz ac
supply. An earthed shield shall be placed between primary and secondary windings of
the transformer.
The rectifier materials shall be selenium. Fuse protection shall be provided on both ac
and dc sides of the rectifier.
The rectifier circuit shall provide full wave rectification and the assembly shall be
continuously rated at the maximum output current. Easily accessible output regulation
controls shall be provided to allow for continuous on-load variation by auto-
transformer of the output uniformly over the whole voltage range.
A suitably rated single-pole neutral-linked ac switch fuse capable of being locked in

either the 'ON' or 'OFF' position shall be located in an accessible position.
A control box shall be fitted on the outside of the tank and shall be fitted with a hinged
lockable door suitably stiffened to prevent distortion and provided with a reinforced
glass window for viewing the meters

The doors aperture shall be fitted with a seal suitable to prevent the ingress of moisture
or dust in the conditions to be met on site Not more than four screw fittings shall
however be used in addition to the lock assembly, to ensure the sealing of the door.
The control box shall house the following:
- The manual control of the output regulation equipment.
- One suitably scaled moving coil dc ammeter and one voltmeter.
- All the protective fuse carriers and spare fuse links.
- Synchronous timer
- DC output terminals
The meters shall be mounted within the control box such that they are cIearIy visibIe
through the reinforced glass window in the paneI door with the instrument cases
earthed unIess constructed in insulating materiaI .
Output terminals shall be cIearIy marked to indicate polarity with '+ GROUNDBED'
and '-PIPE' in 10mm letters.
The single phase timer-witch shall be capable of switching the unit at full output on a
'3 minute ON', 2 minute OFF' cycle. A double pole change-over switch shall be
provided to enabIe a seIection to be made of either continuous operation or time
controlled operation of the unit.
A surge diverter rate at 200-300 volts shall be mounted directIy across the main dc
output terminaIs of the unit on the output side of the dc fuse.
Each Unit shall have:
i) An enclosed steel channel underbase or side bracket providing 75mm

underside clearance minimum for plinth mounting.
ii) Lifting lugs of suitabIe size and Iocation to facilitate lifting of the unit when
full of oil
iii) An oil filling hole with screw cap.
iv) An oil IeveI sight gauge
v) An oil drain with a valve.
vi) An oil tank breather provided with silica geI cartridge and breather oil sealed,
complete with a spare desiccant cartridge

vii) A dial type thermometer graduated in degree Celsius with a red mark on the
scale at the maximum operating temperature, fitted through a gland in the
tank to facilitate removal.
viii) A rating plate indicating Manufacturers name, ac rating, dc rating, rectifier

material and maximum operating temperature of the unit. A 100mm x 75mm
blank or additional plate provided for works identification.
ix) A circuit diagram engraved white on black on a laminated plate.
x) An Earthing Terminal
All fabricated ferrous items other than of approved stainless steel alloys shall be
adequately protected from corrosion by a paint system approved by the Engineer.
Testing at Manufacturer's Works
The tests shall be arranged to represent the working conditions as closely as possible.
Unless otherwise specified, all electrical tests shall be carried out in manner approved
by the Engineer.
Test Procedures
i) All circuits and apparatus shall withstand a power "frequency voltage test at
2000 volts for one minute between the following circuits and casing earth.
a) On the primary with the output earthed to case.
b) On the output with the primary case earthed to case.
1,000 volt megger insuIation test comprising
Primary to Secondary} The vaIues

of insuIation } resistance shall not be
Primary to Earth } less than 10 megaohm
DC Positive to Earth }
DC Negative to Earth}
iii) The unit shall be connected up and run for at Ieast 12 hours continuously at
maximum current and voltage output and the top oil temperature recorded at
the beginning and end of the test period. The temperature rise should not
exceed 50°C.
iv) Ratio and polarity test.
v) Efficiency tests. of 25%, 60% and 100% of maximum current output through a
fixed resistive load. The efficiency shall not be less than 50%.
Packing: Each unit shall be suitably packed to prevent damage during transport to site
2B.6.8 ALTERNATIVE CP POWER SOURCES
Where ac supplies are not available, alternative eIectric power suppIy equipment shall
be included. The alternative types of generator may incIude:
i) Thermo-electric generators(as Global Thermo-Electric Power Sources )
ii) Closed Circuit Vapour Turbines (as Ormat)
iii) Photo-voltaic panels with storage batteries.
iv) Diesel generators with standby facilities.
v) Gas engines operating from pipeline gas
Where possible, pipeline gas shall be used as generator fuel .The alternative power
unit design shall incIude calculations to show that the power available is adequate for
the proposed current requirement and that the internal impedance of the power source
can be matched by the external circuit (groundbed, cabIes pipeline. Details of the fueI
Supply and storage system provided shall include methods of indicating fuel levels
and refueling methods.
Drawings and details shall be provided of security buildings and fences for the
generator and fuel store.
Consideration is to be given to taking gas from the pipeline via pressure reducers to
fuel gas powered units such as TEGS, CCVTS or gas engines.
The design shall give full consideration to the difficulty of access to remote CP
stations for the purpose for maintenance and refueling and the need to limit refueling
operations to a maximum of bi-monthly operations.
2B.6.9 SILICON IRON ANODES
The anodes shall be of cast high silicon iron with 14-15% weight silicon content. The
diameter of the anodes shall be nominally 75mm except at the cabIe connection end
where the diameter shall be a minimum of 100mm.
The length of the anode shall be normally 1,500mm and the weight excluding the
cable shall not be less than 50kg
The anodes shall be generally free from shrinkage, porosity, blow holes and surface
cracks. Any surface defect having a penetration in excess of 6mm shall render the
anodes unacceptable.
The anodes shall be supplied with a single core 16mm2 (7/1.70mm) copper cabIe
PVC, insulated PVC sheathed, 300/500 volt grade having a length of 1,500mm for
those installed horizontally and with additional lengths for any vertical anodes.
Anodes shall be provided with a 0.3m length flexible neoprene sleeving over the
anode cabIe which shall be potted into the anode head with the anode cabIe.
Anodes will be inseparated by the Engineer before despatch to site. Any anode
demonstrating surface defects in excess of the specified limit may be accepted
provided the contractor demonstrates by breaking other similar anodes that the internal
cast structure of the batch is acceptable.
Each individual anode shall be tested and certified for satisfactory electrical continuity
between the anode and cable
2B.6.10 CARBONACEOUS BACKFILL
The backfill shall be of high temperature fired coke breeze or calcined petroleum
coke, not less than 75% of the dry weight to carbon with a maximum resistivity of 0.5
ohm cm when lightly tamped dry and prior to the addition of lime.
The physical analysis of the coke breeze backfill shall be such that 100% will pass a
16mm aperture, 90% will pass an 8mm aperture and not more than 15% will pass a
1mm aperture. All percentages are by weight.
The coke breeze shall be thoroughly mixed with 5% by weight of slaked lime.
Calcined refinery coke shall be granular and contain no more than 15% of fines
passing a 1mm sieve. Details of the physical and electrical properties of calcined
petroleum coke shall be provided for acceptance by the Engineer.
The water content of the coke shall not exceed 5% by weight at the time of shipping.
Two 2.5 kg samples of the coke breeze or refinery coke shall be provided for
inspection by the Engineer's Representative prior to despatch to site. One sample of
coke breeze shall be with and one without the slaked lime addition. These samples
shall be certified as being representative of the material to be dispatched to site and
shall be supplied in good time to ensure that if the sample is not acceptable and then
alternative supplies can be arranged.
2B.6.11 CABLES
The direct current positive and negative cabIes at the cathodic protection stations and
all bonding cabIes shall be 35mm2 single core, muItipIe strand copper cabIe, PVC
300/500 volt grade.
The test post potential measurement cables shall be 16mm2 copper PVC 300/500 volt
grade.
CabIes for alternating current to equipment shall be 3.core, 255mm2 copper PVC,
PVC steel wire armoured (SWA) PVC 300/500 volt grade. In
all cases, the PVC shall be treated for protection against termites.
2B.6.12 SURGE DIVERTERS
Surge diverters shall be installed Underground adjacent to each pipeline insulating

coupling. They shall be installed in a plastic tube and encapsulated in an approved
insulating compound.
Each surge diverter shall be provided with two 5metre Iong 25mm2 copper PVC cabIe
ends shall be connected one to each side of the isolating joint.
2B.6.13 MAGNESIUM ANODES
The anodes Supplied shall be suitable for operation buried in soil within a
gypsum/bentonite backfill in which the magnesium shall be prepared.
The weight of magnesium shall not be less than 14.6kg of High purity, grade of the
following composition:
Element Percentage by weight
Aluminum 5.3-6.7
Zinc: 2.6-3.5
Manganese 0.15 min
Silicon 0.10 max
Copper 0.02 max
Iron 0.003 max
NickeI 0.003 max
Magnesium Remainder
Five metres of single multi-strand copper, copper cross sectional area 6mm2 copper
PVC red cable shall be brazed or welded to the core.
The recess in the casting shall then be filled with a hard setting insulating and sealing
compound. The anode shall be supplied prepackaged and weigh a minimum of 3.kg
with the following backfill:
Powered Gypsum 75%
Granular Bentonite 20%
Sodium SuIphate 5%
which shall be contained in a cotton bag.
2B.6.14 ZINC ANODES
Zinc anodes may be supplied as cast rod billets or segments formed as

pipeline bracelet of half shell assemblies.
The anode weight shall be such as to provide a minimum 20 year life at the Iocation
on or adjacent to the pipeline or pIant installation and shall conform to the US Mll
Specification MFL-A-l800 lZT detailed as folIows:
Copper 0.005% max

Lead 0.006% max

Iron 0.005% max
Aluminium 0.1 -0.5%
Cadmium 0.025 - 0.15%
Zinc Remainder
Silicon 0.125% max
Each anode will be provided with a cable connector of minimum l6mm dimensions
connected to a substantial steel anode core by brazing. A S metre length of cable is to
be supplied on rod or billet shaped anodes and 2 x 300mm cable lengths on bracelet or
shell constructions. Bracelet and shell anode designs shall be approved by the
Engineer.
2B.6.15 POTENTIAL/MARKER POST
Potential./marker posts shall reconstructed from a l.5m length of 100mm diameter

steel pipe .The post shall be capped with a roof pitched at 30oc and of dimensions 250
x l50mm on each side .Cable termination studs shall be located in the gable ends of the
roof and the roof shall be secured to the pole by bolt fixing. The post shall be painted
to the standard specified for above-ground pipework. The final coat shall be green and
the chainage shall be stenciled on the roof in yellow; numerals shall be 200mm in
height.
2B.6.16 NEGATIVE CURRENT DISTRIBUTION STATION
Where the current at a CP station is to be drained from more than one pipeIine the
pipeline cabIes will be terminated on separate terminals which will be connected to the
negative pole busbar via a suitably rated current shunt.
2B.6.17 INSTALLATION SPECIFICATION
Power Sources
Cathodic protection installations at pIant stations shall be plinth mounted and shall be
energised iron the station/plant electric power supply. Cathodic protection installations
which are outside main pipeline facilities but at which NEPA mains electric power is
available will be provided with power at 240 volts ac 50 Hz. At such locations,
transformer-rectifiers shall be plinth mounted within a security fence. The contractor
will be required to liaise with NEPA for the supply and connection of the AC supply
to the transformer-rectifier. Where it is not practical or economical to provider. NEPA
power supply, the contractor shall propose an alternative power supply unit as outlined
in Section 'under- alternative CP Power Sources' for the Engineer's approval.
2B.6.18 GROUNDBEDS
Groundbeds shall be constructed as horizontal vertical or boreholes system. as
determined by soil conditions and resistivity. The groundbed shall be designed such

that the resistance of the groundbeds cables and pipeline match the internal resistance
of the power source.
Where this is not practicable the CP station shall be capable of operating at current
required to protect the pipeIine when the coating has a resistance of 300 ohm/m2 or
five times the initial operating current, whichever is the larger.
Groundbed designs and calculations will be provided to the Engineer for approvaI.
Groundbeds shall be installed as to cause minimum disturbance to occupied land.
The proposed sizing and method of groundbed construction shall be shown on
drawing(s) and shall be to the approvaI of the Engineer.
All anodes in other than borehole groundbeds shall be connected by a cabIe forming a
ring main.
2B.6.19 CABLE LAYING AND PIPELINE CONNECTIONS
Negative and bonding cable connections to the pipeline shall be 3. 5mm made to
threaded studs welded to pads on encirclement collars previously welded to the
pipeline.
Test cable connections to the pipeline shall be 16mm made by, direct soldering. The
joint should be made using 50/50 lead/tin solder, and non-corrosive flux.
All cables shall be identified where they terminate in transformer-rectifiers or anode

boxes and potential marker posts. All cables shall be laid in trenches with a minimum
cover of 750mm .and with .a surround of sand or selected fine backfill
The following identification shall be used:
+ve = Positive Cable

-ve = Negative Cable
s = Sleeve
M = magnesium Anode
O = oil
G = Gas
W = Water
P = Protected Pipe
UP = Unprotected side of Isolating Joint
SD = Surge Diverter
CMN = Negative Current Measurement cable
connection
CMU = Upstream Current Measurement Cable
connection
CMD = Downstream Current measurement cable
Z = Zinc Anode
The negative cable shall be connected by a sweated or machine crimped cable lug
bolted to a welded pad on the pipeline.

2B.6.20 SCOTHCAST SPLICING KITS
Scothcast splicing kits type 90-Bl are to be used at all anode/ring main cable
connections and all other cable connections underground. The anode cable to the ring
main connection shall be made by paring the sheathing and exposing but not cutting
the conductor of the ring main cable and fixing both cables into a tinned brass line
trap.
The cable connection shall be inserted into the joint box and filled with compound
supplied with the splicing .kit, all in accordance with the instructions supplied. All
bare copper exposed shall be covered by the junction box and compound.
2B.6.21 GROUNDBED MARKER
A Groundbed marker of precast concrete shall be installed at each end of the

groundbed.
2B.6.22 MAGNESIUM ANODES
Magnesium anodes shall be installed at crossing of foreign metallic services at each

end of sleeved crossings and at the ends of protected sections just prior to insulating
couplings.
The anodes shall be installed at pipe depth at not less than 1m from the pipeline. The
anode cables shall be brought into the potential/marker post and shall be connected
initially to the lower of the two terminals prior to commissioning.
2B.6.23 CURRENT MEASUREMENT LOCATIONS
Current measurement facilities shall be installed at cathodic protection stations. They

shall consist of two l6mm2 PVC cabIes attached to the pipeline exactly 30m from the
negative cabIe connection and a further 16mm2 cabIe attached to the negative cabIe.
/pipe connection point. The 3 cabIes shall be terminated in a Single potential/marker
post and correctly Iabelled as detailed in Section 'CabIe Laying and pipeline
connections
2B.6.24 ISOLATING JOINTS./FLANGES
These shall be installed to prevent current leakage to the plant and where directed by
the Engineer.
2B.6.25 PARALLELISM WITH OVERHEAD HT POWER LINE
In order to prevent voltage peaks due to induction from paralleI overhead HT power
Line on the pipeline zinc anodes shall be connected to the pipe or power line crossings
with the pipeline and at the ends of parallelisms.

Induction from overhead power lines may be considerable when Iong sections of
welded pipes are above ground and running paralleI close to the power Iine during
laying .This may result in conditions hazardous to personnel.
During laying, sections of continuously welded pipe above-ground SHALL BE

ALLOWED TO EXCEED 400 METRES WITHIN 95 METRES OF OVERHEAD
HIGH VOLTAGE POWER LINES and shall be effectively earthed.
2B.6.26 FOREIGN SERVICE CROSSINGS
At all locations where the pipeline crosses other metallic services, one cable shall be
attached to the pipeline and one to the foreign service. It shall be the Contractor's
responsibility to arrange for the services' owner to be notified so that the test lead may
be attached to his service while the trench is open. The Contractor must establish
whether the owner- wishes to make the connection himself or have his Representative
present during the work.
The cabIes shall be 16mm2 PVC and shall be terminated in a potential /marker post.
2B.6.27 CONSTRUCTION RECORDS
The Contractor shall maintain records, including schedules tabbies, drawings, etc to be
made available to the Engineer and which shall detail all the following:
The exact location of a magnesium or zinc anodes fitted together with the position of
all cables.
The location of all crossing or other buried metallic services, detailing the nature of
the other service, the Authority concerned and an indication of whether they are
connected.
The Contractor shall be responsible for clearly marking the exact chainage at every
potential/marker post bond box or current measurements post.
2B.6.28 PRE-COMMISSIONING TESTING AND INSPECTION
The Contractor shall carry out aIl tests in the presence of the Engineer to confirm
satisfactory installation and operation of all equipment. Such tests shall include trial
operation of power sources to their maximum capacity and measurement of cathodic
protection circuits to confirm satisfactory connections. The Contractor shall inspect all
installed equipment in company with the Engineer to confirm that aIl markings
comply with the Specification.
2B.6.29 INSTALLATION PROGRAMMING FOR CATHODIC PROTECTION
It is intended that no section of the pipeline shall be in the ground without being
cathodically protected. The contractor shall commence insulation of the permanent
ground beds in ample time to meet this requirement and shall supply temporary
cathodic protection as specified

It is also stipulated that test cables and Potential Marker posts shall be installed
immediately on completion of each pipeline section to facilitate testing and the
contractor shall install and maintain temporary cable bonds across breaks on the
pipeline (tie-ins test section etc) to obtain electrical continuity of the pipeline.
2B.6.30 SPARE EQUIPMENT.
Spare equipment which shall be in addition to the specific requirements as detailed in

the Contract Documents.
SCHEDULE OF SPARE EQUIPMENT
A quantity of ten percent of the total equipment supplied shall be provided of the
following items:
ITEM SPECIFICATION EQUIPMENT

1) Alt. Power CP Power
Source Generators
2) Silicon Iron Anodes Silicon iron
Anodes
3) Scothcast Splicing Kits Cable Splicing
kits Complete
4) Cables 35mm2 Single
Core Copper
cable PVC
5) Cable 16mm2 single
core copper
cable PVC
6) Surge Diverters Surge Diverters
7) Magnesium Anodes Magnesium
Anodes
8) Carbonaceous Carbonaceous
Backfill Backfill
9) Transformer- Transformer-
Rectifier rectifier
2B.6.31 COMMISSIONING
The Contractor shall carry out commissioning as follows:
(a) GENERAL

On completion of pre-commissioning as specified in clause under Foreign Service

crossing the commissioning works service shall be carried out. All pipes to soil
potentials shall be measured with reference to copper/copper sulphate half cell using a
high resistance voltmeter/potential meter and recorded as volts negative. All results
shall be recorded and the commissioning Report shall include all the results.
The commissioning works shall include all interaction testing in accordance with
British Standard Code of Practice for cathodic protection CP 1021
(b) PROCEDURE
Commissioning works shall be carried out under the following procedure.
(i) Natural potentials (as found)
Natural (as found) pipe to soil potential shall be measure at all potential/ marker
post and at all insulating joints tanks etc and all foreign services crossing or
adjacent to the pipeline. All groundbed and all sacrificial anodes shall be
disconnected from the pipeline for the 48 hours prior to these potential being
measure
ii) Preliminary Commissioning
All impressed current groundbeds shall be energised initially to give a 2.0 volt
pipe to soil potential at their drain points. Midpoint potentials between stations
shall then be measured. It is required that the midpoint potentials Should be no
less negative than 110 volt and the station current outputs Should then be adjusted
to achieve the required midpoint potential. The station current output should not
be increased however to produce a more negative potential at the drain point than
-1.7 volts for coaI tar wrapped pipe and -l.5 Volts for cold tape wrapped pipe.
iii) Potential Measurements

Following the measurement of cathodic protection station outputs to meet the
midpoint and end of pipelines pipe to soil potential a compIete set of potentials
shall be recorded at all potential/marker posts and other positions measured before
.
iv) Interaction Testing
The Contractor shall carry out all interaction testing in accordance with the British
Standard Code of Practice of Cathodic Protection CP l (l2l or similar code if
approved by the Engineer. He shall be responsible for contacting all the
Authorities concerned and arranging for their presence at such tests if they so
desire.
The tests shall be carried out with the cathodic protection system switched 'ON'
and 'OFF' when the pipe to soil potential of the foreign service or structure shall
be measured with the reference half cell positioned over the crossing.
Where the foreign service does not actually cross the pipeline, the half cell shall
be positioned close to the foreign service at its closest position to the pipeline.
Where time switches have been installed at transformer rectifiers the cathodic
protection may be switched 'ON' and 'OFF' automatically but where these
facilities are not available the switching shall be carried out manually.
Should any interaction test results show a positive change in potential of a Foreign
Service or structure of more than 20 millivolts, the Contractor shall take such
remedial action as to eliminate the interaction.
It is preferable, where practicable; to overcome the interaction by the use of

magnesium anode(s) attached to the foreign structure and, provided the Authority
concerned is agreeable the anode specified shall be connected to the Foreign
Service within the potential/marker post. Should this, however not eliminate the
interaction additional anodes may be necessary, installed in a group or a resistance
may be installed in the potential/marker post between the potential cable from the
pipeline and that from Foreign Service.
The resistance shall be such that it allows sufficient current to pass through it to
eliminate the interaction on the foreign service.
The contractor shall be responsibIe for confirming the results of interaction testing
with Authorities concerned and obtaining written confirmation from them that
results are acceptable to them and they have no objection to the operation of the
cathodic protection system.
v) Final commissioning
On completion of interaction testing and remedial action all sacrificial anodes

which have been installed as specified which have not been utilized to over-come
interaction shall be connected to the pipeline the potential/marker posts and any
final adjustment necessary shall be made to the current outputs at the cathodic
protection stations to achieve pipe to soil potentials throughout the system of
between -l.0 and -1.7 volts (-0.7 volts for cold tape wrapped pipe).
The final commissioning shall consist of (i) Measuring pipe to soil potentials at all
Potential/Marker Posts; (ii) Measuring total current outputs from each station and
the current in each direction where current measurement points are installed; (iii)
Measuring settings of power sources e.g. Transformer-Rectifiers; (iv) Measuring
current through bond boxes; (v) Measuring current from remedial anodes to
foreign services or current and resistance if remedial bond fitted and current from
magnesium anodes attached to the pipeline; (vi) Calibrating all current
measurements points; (vii) Measuring all inter-pipeline bond currents. Twelve
(12) copies of an operating and maintenance report incorporating all the above test
records shall be issued.
2B.6.32 TEST INSTRUMENTS
The Contractor shall supply a complete set of new instruments for the sole use of the
Employer to maintain and operate the protection system and carry out all
measurements necessary for operations, following completion of the Contract. These
instruments shall include at Ieast the following items or equivalent approved by the
Engineer.
ITEM NO INSTRUMENT
1) 4 Copper/copper sulphate reference
half cell
2) 2 Voltmeter Potentiometer min. resistance
100,000ohm per volt.
3) 3 Multi combination corrosion meter
4) 2 Null balance Earth megger complete with
cable and pins.
5) 2 Holiday detector with combined voltmeter
complete with wand, 2 No. 14 inch rolling
spring electrodes and 2 No. brush electrodes.
6) 2 Pearson detector complete with fittings
7) 2 Microvolt meter
8) 2 Portable battery operation current
interrupter
PART 2B PIPELINE AND PIPELINE INSTALLATION SPECIFICATION
SECTION 7 HOT TAPPING
2B.7.1 HOT TAPPING
Where necessary for tie-in to existing facilities, hot-tapping methods shall be generally
done as described below.
Each hot-tap shall be the subject of a separate proposal which shall be prepared by the
contractor for the approval of the Engineer and the facility operator. The proposal shall
include, but not by way of limitation
- Access to the hot-tap location.

- Safety exit from the area.
- Space available for plant and equipment.
- Excavation (which shall be by hand)
- Type and rating of equipment to be used
- Safety procedures.
- Weld procedure and welder qualifications.
- Inspection of the piping to be hot-tapped.
- Non-destructive and physical test on the hot-tap connection.
- Detailed hot-tapping operational procedure

Hot-tapping operations will be stringently controlled and will be the subject of work
permits to be issued by the facility operator.
The contractor shall allow for and comply to all permit restrictions imposed by the
Engineer and the operator of the facility.

Nigerian Gas Company Limited: Tender Document FOR Engineering, Procurement and

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Nigerian Gas Company Limited: Tender Document FOR Engineering, Procurement and

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NIGERIAN GAS COMPANY LIMITED

(A SUBSIDIARY OF NIGERIAN NATIONAL PETROLEUM CORPORATION)

ENGINEERING, PROCUREMENT AND

GAS SUPPLY FROM IBAFO TO SAGAMU

VOLUME IV Page 2 of 210

PART 1B MECHANICAL INSTALLATION SPECIFICATION

PART 2A PIPELINES AND PIPEWORK MATERIALS SPECIFICATION

SECTION 1 Line pipe

VOLUME IV Page 3 of 210

2B PIPELINES AND PIPEWORK INSTALLATION SPECIFICATION

SECTION 1 General and Miscellaneous

VOLUME IV Page 4 of 210

PART 1A MECHANICAL AND PROCESS EQUIPMENT

SECTION 1 GENERAL AND MISCELLANEOUS

VOLUME IV Page 5 of 210

PART 1A MECHANICAL AND PROCESS EQUIPMENT

SECTION 1 GENERAL AND MISCELLANEOUS

1A.1.2 INSTALLATION AND SUPERVISION

1A.1.3 WORKMANSHIP AND GENERAL DESIGN

i) Manufacturer's Name and Manogram

VOLUME IV Page 7 of 210

Any damage to equipment shall be made good at Contractor's expense.

1A.1.4 DRAWINGS AND INFORMATION TO BE PROVIDED

A) By the Bidder with his Tender

i) Preliminary arrangement drawings of paint and sectional elevation of the paint to be

iii) A detailed specification of the various main items of equipment.

iv) The Schedules of Technical Information fully completed.

vi) Estimated performance curves and type test certificates.

B) By the Contractor when the Contract is Let

iv) GeneraI arrangement drawings of pipework and also isometric drawings.

C) By the Contractor Prior to Taking-Over by the Employer

Five (5) copies plus 1 elecronic copy of the following documents:

D) By the Contractor during the Maintenance Period

iii) General arrangement drawings.

VOLUME IV Page 9 of 210

1A.1.6 WORKS TESTING AND INSPECTION

1A.1.7 INITIAL CHARGES OF OILS ETC.

1A.1.8 SPARE PARTS AND TOOLS

1A.1.9 RELEASE OF EOUIPMENT FOR DELIVERY

1A.1.10 PACKING FOR SHIPMENT

b) The following preparations shall be Made prior to any shipment.

vii) Flanges shall be covered with steel covers. Wood is prohibited.

viii) Threaded openings shall be plugged.

VOLUME IV Page 12 of 210

1A.1.12 SITE STORAGE

For machinery Units, an installation specialist employed by the Machinery or plant

d) Storage of materials and Equipment

No shipping cases of equipment shall be unpacked or uncrated without authorization and

Rotating machinery must be stored in accordance with the manufacturer’s instructions.

VOLUME IV Page 14 of 210

Ultrasonic equipment and an operator qualified to C.S.W.I.P Level 3 or acceptable equivalent

1A.1.13 PLANT IDENTIFICATION

1A.1.14 LOCKS, PADLOCKS AND KEY CABINETS

VOLUME IV Page 16 of 210

1A.1.15 MAINTENANCE EQUIPMENT

VOLUME IV Page 17 of 210

PART 1A MECHANICAL AND PROCESS EQUIPMENT

SECTION 2 BOILER & HEAT EXCHANGERS

1A.2.3 Process Design

1A.2.4 Mechanical Design

1A.2.6 Control and Instrumentation

1A.2.8 Services Available

1A.2.9 Preparation for Shipment