t6.5 Construction Plan - Rev.a

ENGINEERING, PROCUREMENT, CONSTRUCTION &
COMMISSIONING (EPCC) OF NPS 36 PULAU INDAH

LATERAL PIPELINE (TULIP) PROJECT FOR PETRONAS
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TENDER NO: RFP-000000000263
DOC TITLE: T6.5 – CONSTRUCTION PLAN

TECHNICAL
PAGE 1 of 86
PROPOSAL Rev. A
1 GENERAL................................................................................................................... 3
2 SCOPE OF WORK.....................................................................................................3
3 CONSTRUCTION ORGANIZATION...........................................................................4
3.1 CONSTRUCTION ORGANIZATION CHART..............................................................4
3.2 GENERAL RESPONSIBILITIES.................................................................................4
3.3 CONSTRUCTION STRATEGY...................................................................................4
3.4 CONSTRUCTION MANAGEMENT.............................................................................5
4 CONSTRUCTION PLANNING AND PROGRAMMING...............................................7
4.1 SEQUENCE OF ACTIVITIES.....................................................................................7
4.2 MANPOWER AND EQUIPMENT PLAN.....................................................................7
4.3 ESTIMATED ACTIVITY DURATION...........................................................................7
4.4 RESOURCE REQUIREMENT....................................................................................8
4.5 ALLOCATION OF CONSTRUCTION SPREAD..........................................................8
4.6 LOGISTIC PLAN.........................................................................................................8
4.6.1 HANDLING AND LIFTING...............................................................................................8
5 CONTRACTOR TEMPORARY SITE FACILITIES....................................................10
5.1 LAYDOWN AREA AND TEMPORARY WORKSHOP...............................................10
5.2 MATERIAL AND EQUIPMENT STORAGE...............................................................11
6 DEPLOYMENT PLAN FOR CONSTRUCTION TEAM..............................................11
7 PIPELINE CONSTRUCTION METHOD....................................................................12
7.1 SURVEY WORK.......................................................................................................12
7.2 RIGHT OF WAY (ROW)...........................................................................................15
7.3 TEMPORARY ACCESS ROAD................................................................................15
7.4 HSE REQUIREMENTS OF ROW & TEMPORARY ACCESS ROADS.....................16
7.5 EXCAVATION........................................................................................................... 17
7.6 HAULING AND STRINGING.....................................................................................21
7.7 COLD BENDING.......................................................................................................21
7.8 PRODUCTION WELDING........................................................................................22
7.9 NON-DESTRUCTIVE INSPECTION OF WELDS.....................................................23
7.10 FIELD JOINT COATING...........................................................................................28
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PROPOSAL Rev. A
7.11 LOWERING-IN......................................................................................................... 32
7.12 BACKFILLING.......................................................................................................... 35
7.13 HORIZONTAL DIRECTIONAL DRILLING (HDD).....................................................36
7.13.1 Horizontal Directional Drilling Method....................................................................37
7.13.2 HDD Installation Method........................................................................................37
7.13.3 HDD System.......................................................................................................... 41
7.13.4 Guided Boring....................................................................................................... 43
7.13.5 QC Requirements for HDD....................................................................................44
7.13.6 Chambering........................................................................................................... 46
7.14 JACKING / THRUST BORING..................................................................................48
7.15 OPEN CUT CROSSING...........................................................................................50
7.16 CROSSING BY PUSH PULL METHOD....................................................................52
7.17 CLEANING, GAUGING AND HYDROSTATIC TEST................................................57
8 COMMISSIONING....................................................................................................64
9 STATIONS WORK....................................................................................................66
ATTACHMENT - 1: CONSTRUCTION SCHEDULE (PIPELINE).........................................70
ATTACHMENT – 2: TIMELINE DIAGRAM...........................................................................74
ATTACHMENT – 3: MANPOWER HISTOGRAM.................................................................76
ATTACHMENT – 4: EQUIPMENT HISTOGRAM.................................................................78
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PROPOSAL Rev. A
1 GENERAL
The procedure presented in the following section is to define the methods for
construction execution of the Engineering, Procurement, Construction and
Commissioning (EPCC) of NPS 36 Pulau Indah Lateral Pipeline (Tulip) Project.
2 SCOPE OF WORK
CONTRACTOR’s scope of work will consist of Engineering, Procurement,

Construction and Commissioning of the facilities which generally consists of the
following:
a. NPS 36 Pulau Indah Lateral Pipeline from tie-in points at approximate location
CH198+950 of PGU II and Loop 2 in Puchong to Pulau Indah of approximate
distance 42 km.
b. Scrapper launcher station at KP0, two (2) Block Valve stations located along the
new NPS 36 Pulau Indah lateral pipeline with approximate location KP 14 and KP
26 respectively and scrapper receiver at KP 42.
c. Two (2) future Take-off station at approximate location KP 16 and KP 24.
d. Utilities, roads, highways and river crossings along the new NPS 36 Pulau Indah
lateral pipeline.
e. Pulau Indah Metering Station located within Pulau Indah Power Plant Sdn Bhd
(PIPP).
f. Coating works for the free issued line pipes.
Generally, the Right of Way (ROW) width is 20 m. The pipeline route will parallel with
ECRL for approximate distance of 19.5 km. The pipeline route also will parallel with
SKVE for about 9 km, and there will be 2 parallelism with TNB Transmission line for a
total distance of 7.4 km.
CONTRACTOR will perform engineering activity to establish detail engineering till AFC
and prepared as built drawing for the project. CONTRACTOR will perform
construction, installation and commissioning work with experienced workforce.
CONTRACTOR will perform procurement activity for all equipment and fabrication
item will be fabricated at CONTRACTOR workshop. CONTRACTOR will manage
overall project and do proper project coordination between all subcontractors and
supplier.
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PROPOSAL Rev. A
3 CONSTRUCTION ORGANIZATION
3.1 CONSTRUCTION ORGANIZATION CHART
CONTRACTOR’s Construction Organization Chart is provided separately in

Attachment T6.1.1. Organization Chart
3.2 GENERAL RESPONSIBILITIES
CONTRACTOR’s general responsibilities during construction including as follows:
a. Construct the facilities in accordance with the Contract requirements with proven
and accepted practices and procedures which take into consideration of safety
and operational requirement.
b. Provide all construction management supervision, technical support, labour,
transportation, tools, equipment, materials, consumables, machineries, temporary
works and construction services at Site and any other items or services required
for construction.
c. Provide all things necessary for the safe fabrication, construction and preparation
for all works strictly in accordance with the Project Specification and requirements.
d. Supply and maintain all equipment, tools, consumables and other resources
necessary to execute the Work, and shall comply with the requirements.
e. Ensure that preservation of all materials, devices and equipment are performed as
per approved preservation procedure prior to its installation at Site.
f. Update any field changes of the AFC drawings and record in the red lined mark-
up drawing, with verification and approval from COMPANY representative’s at
Site.
g. Perform construction activities in a manner as to minimize environmental impact
and as per approved Environmental Management Plan (EMP).
h. Provision, operation and maintenance of construction site and CONTRACTOR’s
equipment during construction, pre-commissioning and commissioning as
required for the performance of the Works.
i. Provide competent workers to perform Work.
3.3 CONSTRUCTION STRATEGY
CONTRACTOR intends to maximize the construction works within the

CONTRACTOR’s organization.
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PROPOSAL Rev. A
In order to meet the workability of the project such as sequence of work, construction
quality in accordance with engineering drawings and specifications, safety
requirements to achieve accident free, environmental requirements, and cost
effectiveness, CONTRACTOR shall apply the following strategy:
 Assignment of qualified personnel capable to perform their duties.

 Selection of Sub Contractor with known reliability and work experience.
 Application of proven and updated construction technology to maintain the quality.
 Construction driven scheduling.
 Promotion of safety awareness and safety enforcement including safe interface
with existing related facilities.
 In order to support Government programs, CONTRACTOR will maximize the
utilization of local resources.
3.4 CONSTRUCTION MANAGEMENT
The site construction organization for this project will be headed by a

CONTRACTOR’s Construction Manager. CONTRACTOR will undertake the overall
management, planning, coordination, inspection, and control of all construction
activities from the site survey, initial planning and design, to the actual construction,
through to the pre-commissioning, commissioning and performance testing of the
FACILITY. During each of these phases CONTRACTOR will define, prioritize and
schedule the engineering and procurement activities to ensure that this project’s
special requirements, especially in the schedule, material control, safety areas and
quality are met. Particular attention will be paid to relations with local authorities and
to the maintenance of good labour relations and at the same time every precaution will
be taken to mitigate the labour shortages in the area. Construction manpower
strategy shall be developed to ensure sufficient numbers and skills of manpower
available throughout the construction period.
CONTRACTOR’s construction management team will assist in finalizing the project
master schedule, the project milestone schedule, develop a path of construction, and
prepare a detailed construction plan.
Under the direction of the Construction Manager, a construction team will be assigned
to provide support, coordination, and liaison to the engineering team, and to provide
constructability input to engineering team. This team will finalize the construction
portion of the controls and procedures that will be required to run the project in the
field, and provide constructability input for detailed engineering. The team will ensure
that the engineering and procurement activities are accomplished in a way that will
best support the construction schedule.
The Site Management team will be responsible for the care and custody of all the units
until they are handed over to COMPANY upon FINAL ACCEPTANCE of the
FACILITY.
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PROPOSAL Rev. A
CONTRACTOR will submit Construction Execution Plan (CEP) to EMPLOYER for

approval three (3) months before actual Construction activities commence.
The CEP will detail the management methodology to be applied to the construction
phase of the PROJECT, along with a list of procedures to be utilized in undertaking
the WORK. This CEP will detail optimum procedures and methods for the
construction including, among others, the following:
a. Construction Execution
b. Site Organization
c. Subcontracting
d. Coordination Management
e. Project Administration
f. Labour Relations
g. Construction HSE
h. Tie-ins
i. Temporary Facilities
j. SITE Material Control and Handling
k. Construction Quality Assurance and Quality Control
l. Construction Schedule
m. Schedule Control
n. Pre-commissioning
o. Construction Engineering
p. Any other plans as required by PROJECT
The CEP will be prepared with sufficient coordination among CONTRACTOR’s project
management, construction, engineering, procurement and commissioning team for
this PROJECT.
The CEP will address how CONTRACTOR will execute the WORK and also address
how CONTRACTOR Construction team manage and support flawless
COMMISSIONING and start-up.
The CEP will be updated, revised or supplemented by CONTRACTOR as approved by

COMPANY from time to time throughout the PROJECT but within the overall time
schedule. CONTRACTOR will continuously adhere to the CEP until the completion of
the WORK.
CONTRACTOR will include:
a. CONTRACTOR's manpower and man-hour histogram by major section and

discipline and their manpower deployment schedule on monthly basis with
distribution of locals and expatriates.
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PROPOSAL Rev. A
b. Major equipment mobilization plan on monthly basis with description.

c. CONTRACTOR will submit other plans/procedures at least four (4) weeks prior to
the start of their activities for COMPANY’s approval, which includes the following:
i. Inspection and Test Plan for all Construction work inclusive of offsite
fabrication work
ii. Temporary facilities
iii. Piling plan (if applicable)
iv. Scaffolding plan (refer requirements in Section I “Health and Safety”)
v. Excavation and underground work plan.
vi. Heavy transport and heavy lifting plan
vii. Pre-fabrication plan
viii. Hydrostatic test plan
ix. Other activity plans e.g. piping, equipment and steel structure erection plan
etc.
x. Instrument loop check plan
xi. Preparation and counter measures for prolonged adverse weather condition
i.e. monsoon.
xii. Construction waste management
xiii. Any other Construction procedures, as required by PROJECT
4 CONSTRUCTION PLANNING AND PROGRAMMING
This is a basic yet challenging proceeding to manage the implementation of the

construction work. If necessitate the selection of techniques, defining of the work
activities, and evaluation of needed resources and time span for each task.
4.1 SEQUENCE OF ACTIVITIES
This specifies the relationship among the work activities that are already defined. The
priority relations between activities signify that the work is carried out in a specific
sequence as shown on a Construction Schedule (refer to Attachment – 1:
Construction Schedule).
There are many standard sequences for construction activities due to mandatory
requirements. A typical illustration of activities in a progression pattern is the Pipeline
Construction Time Line Diagram (see attachment 2).
4.2 MANPOWER AND EQUIPMENT PLAN

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PROPOSAL Rev. A
Estimating manpower and equipment requirements for the completion of the entire
work shall refer to Attachment – 3: Manpower Histogram and Attachment – 4
Equipment Histogram.
4.3 ESTIMATED ACTIVITY DURATION
Each work activity has associated time duration and are used considerably in the
preparation of schedule. Some estimates are based on general work conditions,
special site conditions, and adjustments due to overall effects of weather and other
unproductive causes. A number of work activities could be on a single succession for
period of time, while some task could be done in parallel where it could not affect the
foregoing activities.
4.4 RESOURCE REQUIREMENT
Estimating the resource requirement for the entire project could be determined by
defining particular requirements for each work activity. Identifying constraints and
possible hold-ups such as insufficiency of material, shortage of work force, scarcity of
equipment, should also be taken into consideration during the course of planning.
Occurrence of any of these drawbacks could hinder the activities to be done on
schedule.
4.5 ALLOCATION OF CONSTRUCTION SPREAD
There are two (2) spreads working on the mainline, with the one (1) team allocated for
the wet area. Special teams mainly from Subcontractors for Jacking (Thrust Boring)
and Horizontal Directional Drilling (HDD) with the supervision of the Contractor will be
working on crossings as indicated on the Pipeline Construction Timeline Diagram (see
Attachment – 3) and Construction Schedule (see Attachment – 1).
4.6 LOGISTIC PLAN
All line pipes, piping’s, and other construction materials will be stored at laydown area
until the construction is ready for stringing. From the laydown area, the line pipes will
be sent to the construction spread right away or temporary laydown areas along the
ROW (other than from main laydown area).
4.6.1 HANDLING AND LIFTING
The receipt, loading out and transportation of COMPANY’s free-issued line pipes will
be recorded based on heat no, pipe no and length and check the visual condition. All
above data will be marked on outside pipe wall for the purpose of readable after
welding. If found any defect will be reported and all defect pipes will be color marked,
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PROPOSAL Rev. A
and placed in different area. The accepted pipe at main pipe storage yard will
transport or hauled and store on the number of temporary pipe storage area along the
ROW, then pipe will be strung along the ROW.
For the purpose of pipe hauling CONTRACTOR will use following equipment;
- Crane 20 – 40 Ton at pipe yard.

- Pipe Trailers
- Side Boom or Excavator with vacuum lifting devices for unloads pipes at
temporary laydown area.
The pipe hauling/transport will be subject of permissible from the road/traffic authority
and the procedures with HSE concerned will be approved prior activities performed
accordingly.
Stringing will be performed using side boom and assisted by excavator.
Side boom will be use to unload pipe one by one from trailer and placed the pipes in
such manner to make the welding crew easily reach the pipe for jointing/welding. The
pipe will be strung about 3 to 4 meters away from center of pipeline to allow excavator
digging the trench later on. The stringing team will follow the survey stake out of the
pipe to be laid properly for welding jointing purpose. The pipe will be laid on the soft
material support (sandbag or dirt w/plastic covered) to ensure all body of pipe do not
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PROPOSAL Rev. A
touching the ground and ensure not laid on above hard material (rock or wooden
block), hard rock to be cleared from R.O.W.
5 CONTRACTOR TEMPORARY SITE FACILITIES
5.1 LAYDOWN AREA AND TEMPORARY WORKSHOP
a. CONTRACTOR shall prepare main laydown area for the purpose of stocking of
line pipes, piping’s and other construction materials. Location for proposed a main
laydown area at Kampung Olak Lempit, nearly distance with the ROW using main
road around 20 KM.
Proposed a laydown area route to Pipeline route.
b. Access route to proposed main laydown area from main road;

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PROPOSAL Rev. A
c. CONTRACTOR shall obtain approval from local counsel and any other relevant
authorities.
d. CONTRACTOR shall identify and prepare other temporary laydown areas along
the ROW for the line pipes.
e. All lifting equipment for loading and unloading activities shall be provided.
f. CONTRACTOR shall provide 24 hours security for the laydown areas, inclusive
any mini stockpile area.
g. All the incoming and outgoing transactions at laydown area shall be recorded and
documented.
h. CONTRACTOR shall propose the location of the main laydown area at maximum
of five (5) kilometers radius proximity from the project office that approved by
Company.
i. CONTRACTOR shall provide and maintain temporary workshop within / nearby
laydown area for pre-fabrication, maintenance and testing of equipment, etc.
required for the work.
5.2 MATERIAL AND EQUIPMENT STORAGE
a. CONTRACTOR shall provide and maintain warehouses and areas for storage of
material and equipment. These buildings and areas shall be designed and laid out
so as to prevent access by unauthorized persons.
b. Equipment and material shall be stored in accordance with manufacturer’s
recommendation, raised off the ground by at least 150 mm and adequately
protected from damage.
c. If storage is outside, equipment shall be completely and securely covered with
tarpaulins to prevent corrosion or weathering.
d. Security fencing shall also be provided to prevent access by unauthorized parties.
6 DEPLOYMENT PLAN FOR CONSTRUCTION TEAM

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PROPOSAL Rev. A
Refer to ITB Document, production rate of pipeline construction (Welding-Trenching-

Lowering-Backfilling) shall be minimum 3 km/month. CONTRACTOR shall define
deployment plan for construction teams to meet the production rate.
1. There are two (2) spreads working on the mainline, consist of:
1.1. Spread 1 from KP 0+000 to KP 20+000
1.2. Spread 2 from KP 20+000 to KP 42+000
Each spread shall consist of two (2) mainline welding teams. Each team consists
of 6 welders where the productivity is 3 joints per day per team.
2. Trenchless Crossing Team
2.1. Jacking / Thrust boring
To complete the crossing works with the jacking method within the time
requirement, CONTRACTOR shall provide three (3) jacking teams.
The work location and duration of each boring team can be seen in
Attachment – 1: Construction Schedule.
2.2. Horizontal Directional Drilling (HDD)
Crossing locations using the HDD method are as follows:
 Elite Highway + side drainages + Jalan Kampung Lombong at KP

0+350
 SKVE + IJM / Gamuda main road + side drainages at KP 6+450
 River crossing 1 at KP 17+000
7 PIPELINE CONSTRUCTION METHOD
7.1 SURVEY WORK
a. Bench Marker and Control Point
The reference bench marks will be constructed in each station/plant, which will
remain intact till completion of all works. The reference bench marks will be
masonry pillars of permanent nature, the local coordinates and levels will be
marked permanently on the bench marks
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PROPOSAL Rev. A
Control stakes shall be installed and lines limed to define the station/plant general
layout and facility foundations in accordance with the station/plant layout plan and
the drawings for facility foundations.
The elevations at different points of the plant and facility foundations shall be
measured and control stakes shall be installed in accordance with the
station/plant layout plan and the drawings for facility foundations.
Existing services (including underground and overhead services) likely to impact

on the work shall be identified and described in accordance with company
requirements.
All the foundation bolts for steel buildings are to be cross checked with Total
Station.
b. Survey and Set out
Prior to any site construction activity, CONTRACTOR will take over and check
from all the available (additional) information concerning route, topographical, soil,
hydrological and climatologically surveys.
CONTRACTOR will verify any data given by COMPANY during their site
investigation.
CONTRACTOR personnel will familiarize themselves with the construction

drawings, technical requirements and specifications.
CONTRACTOR will locate and mark the pipeline C/L, benchmarks, turning points
& all buried facilities by field survey prior to commencing any construction related
activity.
Any discrepancies discovered during or after the takeover and study of the
documents will be notified to COMPANY’s representative.
It will be essential to install the pipeline and associated works (draw pits) within
the acquired ROW. The position of pipeline centerline will be as per the approved
AFC typical drawings. After checking the alignment sheets and site conditions
CONTRACTOR will finalize the center it intends to follow. In case they intend to
change the center line.
Work will proceed on approved drawing. The changes will be incorporated in “As
Built Drawing”. Any land required for temporary works will be arranged by
CONTRACTOR. A drawing/Field Sketch showing the requirement will be
submitted to COMPANY for information/Record.
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PROPOSAL Rev. A
CONTRACTOR will only work or proceed with approved-for-construction

drawings. All rerouting will be approved by COMPANY prior to start of job.
c. Marking and Staking
CONTRACTOR will take over and check the existing markers and reference
points and will report any discrepancy to COMPANY’s representative.
The survey team will peg out the centerline of the pipeline at intervals of 100m.
Horizontal bends will be pegged out at maximum intervals of 10 meters (red
pegs/stakes/flags).
The approved ROW boundaries (edges) will be pegged out at 200m intervals and
at change of directions and at additional working areas (blue pegs/stakes/flags)
The wood pegs used for mark the pipeline C/L and the Edge line of the ROW is as
below figure Typical drawing for wood marker installation.
Typical drawing for wood marker installation
The change of pipe wall thickness and diameter will be indicated by a separate
post to indicate start and finishing of the required heavy wall area.
Underground foreign services/constructions will be clearly marked with warning

signs, indicating type, size and depth this will be maintained through the whole
construction process.
At regular intervals, e.g. every 100m at the edge of the ROW, a temporary
distance marker will be placed indicating the exact engineering chainages e.g.
KM1+400, this location indication can also be used for monitoring of daily
progress.
Every specific crossing will be provided with a marker indicating the name and
specific numbered.
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PROPOSAL Rev. A
Where the terrain changes seriously or structures are found on ground, the posts
will be installed in smaller intervals, if possible. The principles are to follow Figure
6.6-5 Typical drawing for post arrangement.
Typical drawing for post arrangement
Note: Set out the edge line of the ROW according to the above-mentioned
method. The line can be set by lime spay or other method which can mark the
ROW.
d. Survey for Concrete Foundations
Prior to excavations for concrete foundations a survey for centerline will be

checked. The centerline will be the reference point for excavation.
The surveyor will coordinate with the civil foreman for the size and depth
allowance of the foundation trench. Upon completion of the trench a re-survey for
the base and required layer will be checked. The civil foreman will prepare as per
the project drawing. Any deviation from the project drawings will be marked on As-
Built.
e. Survey for Road Crossings
Road crossings initial survey is conducted along with the pipeline route. Most road
crossings survey will be done after the pipeline welding has been completed. A re-
survey will be made against the new line for the road crossing. The surveyor will
give measurements for size and depth to the civil foreman in charge for
excavation. After excavation is completed the surveyor will make the final crossing
for base elevation and required level as shown on the standard drawings for road
crossings as per pipe diameter.
A joint survey will be done between CONTRACTOR and thrust boring
Subcontractor prior commencing of work.
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PROPOSAL Rev. A
f. Others for Survey Work
Excavation for cathodic protection, station marks, and supports will be done as
per survey work required on the project drawings. Any deviation to standards or
drawings will be reflected on the As-Build.
7.2 RIGHT OF WAY (ROW)
The pipeline will be set out by an experienced supervisor to the co-ordinates shown on
the approval for construction drawings.
The ROW will be pegged on each side of the center-line (the pipe route). After
sections of the ROW are complete the surveyor will re-establish the center-line. Size,
depth and width will be referred as typical drawing: PLF-DTY-002 Rev. P. ROW will be
check visually for quality.
The fill material will be obtained from borrow pits along the pipeline route.
The ROW that gets damaged during pipeline construction will be repaired. The
method for repair will be using the rolling operator. If during construction the ROW is
damaged, then a new layer of marl capping must be spread according to the damage
dimensions. Sprinkling the ROW by water must be done daily at regular intervals.
All operators and drivers used for the construction of the ROW will be competent and
hold a current license to drive /operate their equipment.
7.3 TEMPORARY ACCESS ROAD
There are mainly two cases: first, the existing road connecting the transportation road
with ROW, which is generally constructed every 3-5km with a width of 6-10m, turning
radius of the road will be more than 18m, and it is constructed mainly depending on
the existing road; second, if no existing road or the existing road is unable to meet the
transportation requirement, the temporary road will be constructed.
The existing road and flat ground, as well as desert will be utilized as much as
possible as construction passage for temporary road and try to be close to ROW or on
ROW, in order to reduce the construction work and make it easy to work.
Clean the sundries on the surface with bull-dozer while constructing temporary road,
and then a 300mm-thick sand and stone layer will be laid as the foundation. Then a
100mm-thick fine soil layer will be laid, watered and compacted. After the project is
completed, the temporary road unnecessary will be restored to the original landform.
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PROPOSAL Rev. A
When the temporary access passes willow buried underground pipeline, cable or
structures, CONTRACTOR will contact the relevant authorities in time and agree on
the protective measures.
The turning yard and the stockpiling yard will be constructed simultaneously with the
access road. Effective measures will be taken to protect the road and the road
shoulder at the adjoining location of access road and the road. Culvert pipes will be
buried for water drainage trench beside the road, road marks will be established
according to relevant road authorities.
7.4 HSE REQUIREMENTS OF ROW & TEMPORARY ACCESS ROADS
Maximum speed limit of 40 KMH will be observed on finished or unfinished ROW.
Pipe cross to overhead power lines. Work permit must be obtained from specified
department. CONTRACTOR will place warning signs located 50 meters at each
approach of overhead power lines “Danger - High Voltage Above" with directional
arrow.
Protection by means of goal post will be required and mandatory so that no parts of
any mobile crane, earth moving equipment and side-boom can approach the line
cable. Clearance distance will be agreed upon with COMPANY’s representative.
Access below the power lines will be restricted by barriers to where the Goal Post is
located
Asphalt & Rig Roads Crossing: CONTRACTOR will have an obligation to protect the
employees as well as the public in general from potential construction hazard at all
(day or night) times or weather condition. Specific road closure plans will be submitted
to PTW office and Loss Prevention for approval before the road are closed and an
efficient direction and control of traffic will be properly planned and executed.
A flagman equipped with a safety vest and a red flag will be posted at least 50 meters
from the work site at the entrance barricade and another flagman at the exit barricade.
It is the duty of the flagman to control the flow of traffic in a safe manner. Both flagmen
will be in sight of each other. If conditions do not permit this, then a third man will be
positioned where he can see and to be seen by the other two man in order to signal
them to start or stop traffic, Traffic control signal will be in accordance with HSE
requirement by COMPANY approved. At night, flagman will wear light reflecting vest I
gloves and use reflecting sign or flag. Flagman will be stationed in an illuminated area.
7.5 EXCAVATION
The CONTRACTOR shall stake the centerline of the pipeline ditch and excavate in
accordance with the Project Drawings. The minimum dimensions of the ditch shall be
as shown on the drawings, but shall be greater for concrete coating, bends, and
additional depth for approaches to roads, highways, buried utilities, etc.
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PROPOSAL Rev. A
Ditching operations shall be planned so that the ditch remains open for as short period
as practicable to minimize the danger and disruption to personnel and livestock.
a. Preparation of Trenching
All works will be undertaken under the Permit to Work System. All personnel
engaged to work will have Safety Induction prior to start work.
The trench will be excavated along the pegged centerline of the trench within the
ROW, duly taking into account the bend / curvature of the pipeline in accordance
with approved Alignment sheets. The lost center stakes will be restored.
Before starting of trenching operation, CONTRACTOR will locate and uncover all
buried services/structures crossing or adjacent to the projected pipeline location,
inspect underground services noticed/identified. Existing underground
pipelines/cables will be located by CONTRACTOR with the help of pipeline/cable
locator. CONTRACTOR will set obvious warning signs near roads, buildings,
underground pipelines, cables, and services before taking up trenching operation.
CONTRACTOR will notify to existing facilities Owners prior to any ditching

operations.
Hand excavation will be done to expose existing services, utilities etc. A minimum
distance of 3m from existing facilities will be considered to perform manual
excavation.
b. Trenching
The depth will meet the minimum design cover. The minimum cover will be
measured from the top of pipe to the top of undisturbed surface of the soil or top
graded working strip or top of road or top of rail whichever is lower.
Plan view for excavation activity.

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TECHNICAL
PAGE 19 of 86
PROPOSAL Rev. A
All the excavated material will not be temporarily or permanently stacked near
roads, tracks, ditches or drainages or in any other location where it might hinder
traffic or water flow.
In order to minimize the quantity of bends needed and to assure the minimum
required cover, at the places where roads, canals, cables, pipelines, water
drainage system and other underground structure crosses are encountered, the
trench will be gradually dug deeper. The ditch bottom will be finished in such a
manner to create a smooth and free from any sharp objects. The trench will be cut
to a grade that will provide a firm, uniform and continuous support for the pipe.
Movement of construction vehicles/equipment required for the digging process will

be carefully controlled.
1. Trenching in normal areas
Trench excavation to be executed as per typical drawing, CONTRACTOR will

determine the depth of the topsoil in agriculturally used area. Topsoil will be
carefully removed and stacked in order to avoid mixing with the excavated
subsoil or with any debris.
The trench obtained will be smooth and linear along its length to obtain as
near as possible to a straight line, in order to prevent unnecessary bending of
pipe between sag bends and over bends.
The excavated material will be stocked 1m minimum far from the edge of the
ditch to avoid subsidence, but always within the ROW boundaries. The
excavated material from the trench should not be contaminated with foreign
bodies as roots, rocks stones etc. The trench will be free of roots, stones or
another hard object, which may damage the pipe coating.
In normal excavation, the width of the trench bottom will be minimum 600 mm
greater than the outside diameter of the pipe for single pipeline trench.
2. Trenching in area with underground services
Investigations before the trench excavation will be undertaken to locate and

uncover all buried services / structures adjacent to the projected pipeline
location.
After verifying accurate location, warning signs with location, type, depth and
dimension of underground services will be placed and maintained during the
whole construction period.
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TECHNICAL
PAGE 20 of 86
PROPOSAL Rev. A
CONTRACTOR will protect the existing pipelines, telephone lines, power

lines, and other services by installing support beams etc.
CONTRACTOR will increase the trench depth when pipeline is in close

vicinity of the existing pipelines: telephone line, power line, and other services
as per typical drawings.
In locations where the trench is cut across roads, paths, walkways and other
access routes, CONTRACTOR will provide properly temporary road
diversions to allow the passage of normal pedestrian traffic with a minimum of
inconvenience and interruption. These pedestrian roads are subject to
COMPANY’s approval.
Existing pipelines, utilities and foreign installation will be excavated using

hand tools before allowing mechanical equipment to operate within three (3)
meters.
Precautions must be taken at these exposed services areas to ensure that no

erosion of the backfill takes place during trenching operations.
If jack hammers are required to be used within two (2) meters of any buried
pipelines and between any pipelines running in the same easement,
circumferential pipe protection approved by the service owner will be provided
by CONTRACTOR before commencement of work.
If jack-hammers are employed in close proximity to live electric cables they

must be operated and grounded.
The protection facilities will only be removed after backfilling. If any damage
may occur to any structures/utilities, CONTRACTOR will contact the
Owner/Authority concerned and repair it under the direction the
Owner/Authority and to the satisfaction of them.
3. Trenching in area with high water level
In these areas survey on site will be carried out to determine the means to
keep trench dry. The following systems may be adopted to keep the trench
free from water:
Removal of water by open trench pumping it in nearby drain, canal, river;

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TECHNICAL
PAGE 21 of 86
PROPOSAL Rev. A
Installing in advance a well pointing (filter drain) system and pump the water
into nearby drain, canal, river;
Installing in advance a deep well system (at locations of deep crossings) and
pump the water into nearby drain, canal and river.
In case of encountering surface water CONTRACTOR will ditch a drain to

guide the water outside of ROW. Ditching and lowering–in operation will be
arranged concurrently. The lowering–in, pipeline stabilization and backfilling
will be performed as soon as possible after trench acceptance.
4. Extra depth and clearance
At the point where the contour of earth may require extra depth to fit the
minimum radius of the bend as specified or to eliminate unnecessary bending
of the pipe or where a deep trench is required at the approaches to crossings
of roadways, railroads, rivers, streams, drainage ditches, and the like and in
transition between normal trench and deep trench, CONTRACTOR will
excavate such additional depth as may be necessary.
CONTRACTOR will excavate to additional depth where the pipeline
approaches and crosses other pipelines, sewers, drain pipes, water mains,
telephone conduits and other underground structures, so that the pipeline
may be laid with a minimum free clearance from the obstacle as specified in
the drawing, or as required by authorities having jurisdiction.
5. Trench inspection and acceptance

After completion of the trench, construction teams will carry out inspection of
trench bottom elevation and depth to get satisfactory results, then, trench
inspection and acceptance application reports will be submitted to supervising
engineer.
Before pipeline lowering-in operations trench bottom will be adjusted in

accordance with approved alignment sheets. Then trench survey (including
elevations and coordinates) will be done to align with the latest revision of as
built report specification for pipeline, intervals as follows:
Measured trench depth at each 12 meter intervals
Cover and grade elevations at 12 meter intervals
The location and degree of all points of intersection
During construction, top of the pipe levels and co-ordinates at each installed
joint location will be taken prior to backfilling operations, and the information
processed to produce as-built drawings.
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TECHNICAL
PAGE 22 of 86
PROPOSAL Rev. A
7.6 HAULING AND STRINGING
The CONTRACTOR shall be responsible for obtaining hauling permits and

authorizations from regulating authorities. The CONTRACTOR shall ensure that all
roads, bridge, and other transportation infrastructure are capable of handling
transportation loads and dimensions.
Only approved pipe end hooks and lifting belt which will not damage bevels, such as
those with aluminum inserts, shall be used for lifting pipe.
All booms, hooks, forks, supports, skids and tie-downs used in handling or storing the
pipe shall be properly padded to prevent damage to pipe and pipe coating.
Certified lifting equipment with sufficient power shall be used to maintain safe pipe
hauling and stringing activity.
Pipe shall be strung in a manner so as to minimize joint overlap and accumulation of

pipe, to leave gaps for access at roads and tracks, where necessary to accommodate
landowner local access, farming or livestock activities and local access. Pipe shall be
set on skids or sandbags; pipe set directly on the ground will not permitted. Pipe shall
not be strung near any blasting activity. No pipe may be rolled off a truck.
Pipe shall be strung accordingly to approved alignment sheet in case of discrepancy
between the alignment sheet and the actual requirement, CONTRACTOR shall
propose the revised alignment sheet for obtaining COMPANY approval. Each revision
shall be recorded in accordance with the field change notice procedure.
7.7 COLD BENDING
Direction changes to comply with the pipeline alignment shall be accomplished using
bends formed using the cold stretch method. Cold Field Bend shall be conducted by
CONTRACTOR and shall comply with the requirements of ASME B31.8.
A bending survey shall be conducted as soon as practical after grading is completed.

Following items shall be marked during the survey: pipe center, starts point of
bending, and welding seam.
During construction, pipe may be flexed for installation purposes to a radius of
curvature at their natural bend angle.
CONTRACTOR shall submit bending qualification procedure and calculation of

maximum bending angle for COMPANY approval.
Prior to site field bending, a “Bending Qualification Test (BQT)” shall be conducted on
pipe that is to be utilized in installation of the works. A minimum of 2.0 meter of straight
pipe shall be left at ends of pipe joints.
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TECHNICAL
PAGE 23 of 86
PROPOSAL Rev. A
Bends with wrinkles, buckles, flat spots or other mechanical damage and bends with
unacceptable ovality shall be rejected. Bends with ripples are acceptable provided the
peak-to-trough measurement of any ripple does not exceed one-half (1/2) of the pipe
wall thickness.
Cold Field Bend
7.8 PRODUCTION WELDING
Procedures and welders must be approved by COMPANY before commencing any

welding. During welding, welding speeds, voltage, and amperage shall not vary from
the setting used in WPS. Any other change in essential variables shall be qualified as
a new procedure.
External or internal line-up clamp shall be used for fit-up of pipe during production
welding. Line-up clamps shall not be removed until the root bead is completed. When
external line-up clamps are used, they may be removed when equivalent of 50% of the
root bead equally spaced in four quadrants around the weld joint has been completed.
Welding progression shall be vertically down for all passes, except for tie-in welds.
Manual welding shall be performed by a minimum of two (2) welders for each pass,
one (1) on each side of the welding joint. Weld deposits shall be made simultaneously
so as to keep heat input uniform.
The hot-pass shall be applied immediately within 5 minutes after the root bead is
completed. At least 50% of the weld joint thickness must be completed prior to leaving
an uncompleted weld for any reason.
During the welding process, care shall be taken to protect the coated pipe at either
side of the weld from damage due to weld spatter.
If for any reason a section of pipe has to be cut out of the pipe string, due to
unacceptable dent’s or arc strikes. The section of damage shall be cut out as a
cylinder having a minimum length of 1.5 times the pipe diameter. A pipe pup shall be
inserted and welded into the line having the same minimum dimensions as that of the
cut out portion.
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TECHNICAL
PAGE 24 of 86
PROPOSAL Rev. A
Night cap shall be installed on the ends of each pipe string at the ends of day’s work to
prevent the entrance of foreign matter.
7.9 NON-DESTRUCTIVE INSPECTION OF WELDS
CONTRACTOR shall be responsible for completing 100% radiographic inspection of

all welding joints to the satisfaction of the COMPANY. Radiography Test (RT) shall be
in accordance with API 1104 and project specification.
CONTRACTOR shall provide adequate personnel together with visible warning signs
to warn other personnel that the radiography is in progress and to install barricade
wherever necessary.
RT Operator who does not be qualified as RT Level II is not able to do the film
interpretation.
The CONTRACTOR’s inspector has his right to check if the personnel appointed to
perform the Non-destructive Test (NDT) are entitled to work in compliance with the
specifications.
Equipment performance should be in good condition, the ability to meet the needs of
the project, the quality of materials should meet the relevant requirements. And the
quantity of equipment and materials should meet the needs of construction.
a. RT Procedure
 X-Ray Machine
Mainline welds for NPS 12 and above shall be radiographed using a single
wall single image (SWSI) X-Ray technique.
Any x-ray machine will be used such that resultant radiography satisfies the
applicable Code and project specification.
 Films
Radiographic film will be within the manufacturer’s expiration date as marked

on each film container. If films are found to be beyond the expiration date,
pre-exposed or fogged, they will not be used for radiographic examination
any more.
All film shall be pre-packed. The film types are approved for X-Ray are ASTM
Class 1 or 2 Dupont, Gevaert, Kodak or Fuji.
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TECHNICAL
PAGE 25 of 86
PROPOSAL Rev. A
Use of the films is subject to COMPANY approval. Fogging test shall be

carrying out at random to ensure quality of radiograph films can be last more
than 25 years.
CONTRACTOR shall be responsible to ensure the films are available at all

time during the duration of the project.
 Film Identification
A system of radiographic identification acceptable to owner will be used to

produce permanent traceable record of radiographs to individual welds. As a
minimum requirement, identification on the radiograph will include project
code, unit No., equipment or pipeline No. weld No., section No., wall
thickness, pipe diameter (if applicable), welder No. and explosion date.
The image of identification will not interfere with the interpretation of the weld
image on the radiograph.
The number belt will be of sufficient length to cover the entire weld length
radiographed. They will be positioned adjacent to the weld. At number ‘0’
position, an arrow showing the direction of numbering will be marked on the
job surface with a permanent paint marker, in a manner permitting the area of
interest on a radiograph to be traced accurately on the weld.
 Surface Preparation
The surface will be clean and as welded condition with uniform crown
specified by the applicable code and specification. Any surface irregularities
in a weld will not cause such an image that will mask or be confused with any
discontinuity, otherwise the surface will be dressed.
 Film Processing
Processing of the films shall be carried out in accordance with the instructions
of the film manufacturer, with particular attention being paid to temperature
and development time. The processing facilities shall be adequate for the
maximum projected throughput or radiographs per day.
Chemical concentration shall be checked daily for compliance with

manufacturer’s recommendation.
 RT Procedure.
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TECHNICAL
PAGE 26 of 86
PROPOSAL Rev. A
Before commencement of RT, CONTRACTOR shall provide COMPANY with

details of its proposed RT procedures.
RT shall be produced for each diameter and wall thickness combination using
the RT equipment which will be used during construction and using pipes and
welds from the pipeline. Production of RT shall be performed simultaneously
with weld procedure qualification.
Approval of RT procedure shall only be granted when a RT has been

produced in accordance with the procedure which demonstrates compliance
with the specification.
 Film Treatment
The films will be developed according to the applicable code and specification
g or other methods proved to be effective. The chemicals will be kept in good
condition and be cautious to the results brought by developing temperature,
time and chemical cycling.
During developing, films processing speed and chemicals refilling in
developing, fixing, washing and drying will be under careful control. The
developing temperature and developing circle will be accurately adjusted to
acquire good result.
Radiographs Interpretation
The interpretation of the radiographs will be made by RT technician, RT Level

Ⅱ or higher personnel, and the inspection result will be recorded. The RT
report will include the work details, inspection result and the acceptability
judgment.
The report will be submitted to the Owner’s inspector when completed. The
final acceptability judgment will be formulated by the Owner’s inspector and
expressed by signature.
 Film Quality
The identification of the penetrometer and the designated wire will be clearly
visible.
All the marks will be completed and in right positions.
Films may have least mechanical, chemical or other forms of pollution or

damages and pseudo-images, on the condition that those defects will not
cover or affect the accurate appraisal within the marked margin.
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TECHNICAL
PAGE 27 of 86
PROPOSAL Rev. A
b. Ultrasonic Test (UT)
Verification for the Qualification of UT Personnel
Only UT Level II or Level III personnel is able to do the indication interpretation.
Instrument, Probe & Calibration Block
Level II, at least, personnel will select the instrument, probe and calibration block,
calibration and certificates will be available upon request.
 Instrument
Examination will be conducted with a pulse echo ultrasonic instrument

capable of generating frequencies over range of at least 1MHz to 5MHz and
providing linear vertical presentation within 5% of the full screen height for
20% to 80% of the calibrated screen height.
The ultrasonic instrument will be equipped with a stepped gain control in units
of 2.0 db or less, so that to allow measurement of indications if they beyond
the linear range of the vertical display on the screen.
 Probe
A nominal test frequency of 2.25 (2.5) MHz is recommended. Higher or lower

frequency may be used depending on the product material thickness, grain
structure, or the microstructure.
For angle beam examination, beam angle (K) will be selected as appropriate
for the configuration of the product being examined.
 System Performance
The effective sensitivity of the system will be over 10 dB than the evaluating
sensitivity.
 Calibration block
The requirements for material, heat treatment, surface, quality and

configuration of the block used in calibration will be in accordance with
applicable code and standard.
 Surface Preparation
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TECHNICAL
PAGE 28 of 86
PROPOSAL Rev. A
The scanning area will be free from the splash, iron filings and oil, etc. The
surface will be smooth, ground the surface when necessary.
The weld joint area will be cleaned of weld spatter and slag by a grinder. If
there is the presence of oil, grease, or other surface contaminants, clean the
exposed steel and adjacent pipe coating with an approved solvent cleanser.
Warm the joint area to 40-50°C (104-120°F) before abrasive blasting. During
high winds or cold ambient conditions (below 15°C (59°F)) pre-warm the joint
area to 70 (158°F) before abrasive blasting.
The preparation of pipe surface for coating will be done by the abrasive
blasting method using Coal slag or other COMPANY approved material.
Cleaning will be performed with preparation of the surface correspond to
Grade Sa 2.5 for abrasive blasting. The abrasive material will be always dry.
The adjacent surface of the mill coating will be thoroughly checked and in
case that it is damaged, the affected section will be removed. Ensure that the
mainline coating edges are beveled to 30°minimum. Abrade the mainline
coating (sweep-blasting method) adjacent to the weld area to a minimum
distance 50mm beyond the sleeve width.
Using a dry, grease and lint-free cloth, wipe clean or air blast the steel and
coated areas to remove foreign materials.
 Coupling Agent
The coupling agent should be well transparent and suitably fluidized. The
agent used could not be dangerous to either person or material. No residue
should remain on the pipe surface after the liquid has evaporated.
Normally, detergent (neutral), paste or machine oil could be used as coupling

agent. Some applicable amendment or activator could be added in to
enhance coupling.
 Inspection Technology
Using the probe scan the whole weld section from both sides. Refract angle &
front distance should ensure that straight beam (half skip) could scan the root
as possible.
 Calibration of the DAC curve
Calibrate the scanning scale and the DAC curve on the reference standard,
No less than two points, before inspecting.
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TECHNICAL
PAGE 29 of 86
PROPOSAL Rev. A
The temperature difference between the probe/reference standard and the

weld will be within ±15℃ in calibration.
 Re-calibrate of inspection
Scanning-line calibration: If back reflection amplitude deviates 10% from the

calibrated point or 5% of full scale (whichever is less), readjust scanning-line,
and record location parameter of the imperfections again from last calibration
on.
Sensitivity calibration: If the amplitude decreases 2dB or 20% than the DAC
curve, re-adjust sensitivity, all inspection is invalid from last calibration and re-
inspected. If the amplitude increases 2dB or 20% than the DAC curve, re-
adjust sensitivity, all recorded imperfections from last calibration need to be
re-sized and re-evaluated.
 Inspection procedure
Save the weld profile in the instrument.

The probe is vertical to the weld centre line and does the zigzag scan. To
detect the transverse defect in the weld and the HAZ do the lateral scan with
oblique angle. Scanning speed will be no more than 150mm/s. The adjacent
probe movement interval will ensure 10% of the probe with overlap at least.
Imperfection Sizing: When the peak of the indication, interpreted to be crack,

located in Section I will be sized till the amplitude is down to EL. Any other
indications will be sized by half-value method or tip half- value method.
Imperfection position:
 Circumferential.
 Length,
 Depth in the direction of diameter.
 Position in the axis.
 Field Joint Coating
7.10 FIELD JOINT COATING
CONTRACTOR shall install wrap-around type heat shrink sleeves or other method
obtained approval from COMPANY for coating all field welds on coated pipe.
Application procedures and personnel shall be obtained approval from COMPANY.
Field joint coating materials shall be stored in accordance with manufacturer’s

recommendations.
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TECHNICAL
PAGE 30 of 86
PROPOSAL Rev. A
Field joint coating shall be installed only after the welds is accepted by COMPANY and
cooled to ambient temperature.
a. Pre-heating
Preheat the epoxy to a temperature of 110°C (230°F) and the abraded mainline
coating to be covered by the sleeve to a minimum of 100°C (212°F) with the
appropriate propane torch. Do not use an intense flame on the mainline coating. If
a film develops on the mainline coating because of preheat, use a surface
abrasion tool to remove it.
Check the temperature to ensure preheat has been obtained on the entire pipe
circumference. This preheat will substantially cure the epoxy and ensure proper
flow and bonding of the sleeve adhesive. Ensure that the epoxy primer is dry to
the touch prior to sleeve installation.
b. Execution
The FJC material will be applied in a time frame (after liquid epoxy application)
compatible with the cure time of the liquid epoxy primer.
Each batch number of pre-cut FJC material will be recorded.
The FJC material will be wrapped loosely around the pipe from one end, so that
the closure patch is located on one side of the pipe at 10 or 2 O’clock position,
with the edge of the undergoing layer facing upward and an overlap of minimum
50mm after shrinkage.
Press the closure patch, centering over the exposed sleeve ends.
Gently heat by appropriate torch the closure patch and run a small roller over the
closure patch to seal the ends.
A heat shrinking procedure using heating torch or induction heaters will be applied
to shrink the sleeve in such a manner to start shrinkage beginning from the center
of the sleeve and heat circumferentially around the pipe, using a constant
paintbrush motion. Continue heating from the center towards one end of sleeve
until recovery is completed. In a similar manner, heat and shrink the other side.
Run a small roller over the sleeve to push out ant entrapped air.
If necessary entrapped area may be re-heated to roll out the entrapped air.
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TECHNICAL
PAGE 31 of 86
PROPOSAL Rev. A
Shrinking has been completed when the adhesive begins to ooze at the sleeve
edges all around the circumference and change in the visual indicator / other
means provided on the backing material, to signify proper shrinkage, will be
complete and uniform. During shrunk down of sleeve wrinkles disappear
automatically. The heating method, instruments and procedure will be according
to the SUPPLIER’s instructions.
The complete shrinking of the entire sleeves will be obtained without undue
heating of existing pipe coating and providing due bonding between pipes, sleeve
and pipe coating. The installed sleeve will not be disturbed until the adhesive has
solidified.
During coating, welding area will be free of contamination of coating material.
While the sleeve is still hot and soft, use a hand roller to gently roll the sleeve
surface and push any trapped air up and out of the sleeve, as shown above.
Continue the procedure by also firmly rolling the closure with long horizontal
strokes from the weld outwards.
In case there are air bubbles exceeding acceptable allowance, they will be
removed in the following way:
Heat the area with air bubbles in the direction of the nearest edge of the sleeve
until the melted adhesion appears;
Slowly press out the air bubble with the help of a soft roller or a gloved hand in the
direction to the nearest edge of the sleeve;
After removal of the air it is necessary to heat up once again this area of the
sleeve in order to smooth out the heat shrinkable sleeve for better fit to the pipe
steel surface.
c. Coating Repair
All field joint coating shall be checked with a direct current holiday detector set to
reliably detect a pinhole defect in accordance with NACE RP02-74. Defective field
joint coating shall be replaced or patched using manufacturer approved materials
acceptable to COMPANY.
The repair methods shall be in accordance with manufacturer's instruction and

minimum requirement specified below whichever are the more stringent.
 Repair of defects resulting in a holiday

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TECHNICAL
PAGE 32 of 86
PROPOSAL Rev. A
Coating from defect area shall be removed using a knife, scraper or power
brush. Area shall be cleaned to remove oil, grease, rust, dirt and moisture.
Exposed bare metal area and adjacent pipe coating shall be preheated to a
temperature required by with a torch moved back and forth over the surface.
Filler material shall be cut to size and applied over entire exposed metal
surface. The filler mastic shall be heated and smoothed down with a paint
scraper to remove any entrapped air.
A patch of size sufficient to extend 50 mm (2 inch) on to adjacent coated
surface shall be cut, positioned over the area and heated until the
temperature sensitive paint on the outside of the patch changes colour. The
repair patch shall then be smoothened to conform to the pipe contour and
remove any wrinkles, air bubbles etc. Roller shall be used to for this purpose.
 Repair of defects not resulting in a holiday (cosmetic defects)
Cosmetic defects such as tearing, scratches, etc. that are not picked-up
during holiday testing shall be repaired as follows:
 The defective area shall be roughened to remove loose polyethylene

coating and cleaned to remove oil, grease, dirt, etc.
 A patch of size sufficient to extend 50 mm (2 inch) on to adjacent
coated surface shall be cut, positioned over the area and heated
until the temperature sensitive paint on the outside of the patch
changes colour. The repair patch shall then be smoothened to
conform to the pipe contour and remove any wrinkles, air bubbles
etc.
 Damages Classification
Damages caused to coating shall be repaired as follows:
 Small damages not exceeding 100mm in length and 100mm2 in

area shall be repaired by PE melt sticks, epoxy primer will be applied
if bare metal is visible.
 Damages not exceeding 300mm in length or 10,000mm2 in area
shall be repaired by polyethylene repair patches pre-coated with hot-
melt adhesive, in conjunction with a hot-melt filler adhesive and
epoxy primer if bare metal is visible.
 Damages exceeding 300 in length or 10,000mm2 adhesive in area
shall be repaired by full encirclement heat shrink sleeve with epoxy
primer.
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TECHNICAL
PAGE 33 of 86
PROPOSAL Rev. A
 Repair Materials
Thermo-melting materials are used for repairing work, which are

characterized as convenient with perfect adhesive properties:
If any individual damaged area is smaller than 30mm, the damage area can
be repaired by using polyethylene heat shrink patch same to the backing
material of FJC. The overlap zone of the repair patch and the as-applied FJC
should be roughened, and be kept over a length of 100mm.
If any individual damaged area is greater than 30mm, apart from repair patch
as specified in Clause 1) above, another FJC should be wrapped over the
patch. The length of FJC after shrinkage will be 50mm each side more than
that of the patch.
Melt able chalks – thermo-melting adhesive in the form of rods. They are
applied to close up small scratches and cracks in coating, and also gaps
(damages) and chips of maximum 10x10mm.
Application of Repair Insulation Materials
The damaged area of the heat shrinkable sleeve or factory coating, will be
heated with a flame torch then cut off the damaged coating and then clean
the surface of this area.
Filling compound will be heated and then uniformly applied on the repair area
with a putty knife.
The adhesion side of a patch will be heated for 2 or 3 seconds and then apply
patch on the repair area over the filling compound.
The applied patch is uniformly heated with a torch. The crimps will be
smoothed out and air bubbles will be removed with a gloved hand or a Teflon
roller.
The thickness of the coating after repair will not be less than the thickness of
Normal anticorrosive coating.
7.11 LOWERING-IN
a. Preparation for Lower-in
All lifting equipment will be operated only by skilled, suitably qualified personnel.
The equipment used for lowering-in will be in good condition and documented
inspection prior to use by the HSSE department.
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TECHNICAL
PAGE 34 of 86
PROPOSAL Rev. A
Trench dimensions to be checked in accordance with the requirements of

approved drawings before lowering in.
Before lowering in, trench will be cleaned from any foreign bodies such as roots,
stones and any hard body that may cause damage to pipes coating, and the
bottom of the trench will give continuous support to the pipe through suitable soft
bedding material where necessary to attain adequate bedding.
The trench will be re-excavated if collapse has occurred.
The bedding in bottom of trench will meet to the requirements of backfilling work
procedure. Lowering-in will take place after all welds accepted and any defect
welding to replace or repair. All field joint coating completed and all coating
repairs carried out. Those have not been previously accepted will not be lowered
into the trench without prior permission of the Company’s Representative.
Pipe ends will be closed to prevent the ingress of any material into the pipeline
section. The pipe ends will remain in place until the sections are tied in.
If water or mud is present, CONTRACTOR will perform drying out and cleaning of
the trench before lowering in insofar as this is possible. If it is not possible to
remove the water, additional concrete weight as per approved construction
drawings will be applied to rest the pipe correctly on the trench bottom.
Before pipeline lowering-in operations, trench bottom will be adjusted in

accordance with project alignment sheets drawings. Only properly manufactured
slings belts and cradles suitable for handling coated pipe to be used. All pipes will
be inspected for coating flaws and/or damage as it is being lowered into the
trench. Any damage to the pipe or coating will be repaired
b. Lower-In Operation
No pipe will be lowered into the trench until:

 The trench has been inspected and approved for receiving the pipe by
COMPANY’s Representative
 After get the acceptance by COMPANY’s welding Representative.
 Coating has been checked using a dielectric test by CONTRACTOR.
 Prior to lifting of the pipeline all personnel will vacate the trench, leave the
area between the pipe string and the trench and the area between the
lifting equipment and the pipe string.
 Pipe will be lowered into the ditch without rubbing the top or sides of the
ditch.
 The pipe will be lowered into the trench gradually and uniformly. Extra
care will be taken to ensure that the pipe coating is not damaged when
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TECHNICAL
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PROPOSAL Rev. A
removing the lowering-in belts/rollers from the pipe. The equipment’s will
be calculated in order to have sufficient capacity for the lift, and will be
placed at close enough intervals to prevent sagging, sliding, overturning or
buckling of the pipe.
 During the process, the lowering-in foreman commands side boom
operators and controls the lifting height of each side boom in accordance
with lifting capacity of each side boom and deforming status of the pipeline
section. The side booms go forward slowly at same speed and at same
time until putting the other end of the pipeline section on centerline of the
trench.
 The pipe sections will be lowered in such a manner that the pipe bends
will fit the corresponding bends in the trench.
 Sections of pipe will not be dragged or pulled into position for tie-in into
the line. The length of pipe sections will be adjusted to allow tie-in
operations to be affected without resorting to dragging or pulling.
 It will be taken into consideration the presence of crossings (roads,
existing services), such crossings will be considered as the end of the one
lowering-in section and the start of adjacent one.
 The pipe will be laid so that each side of the pipe has a minimum
clearance of 200mm from each side of the pipeline trench to allow backfill
to flow around and under the pipe. The minimum clearance between
pipelines or between a pipeline and an obstruction will be as specified in
construction drawings.
 The whole process has to be under the supervision of the spread
Superintendent and the command of the lowering-in foreman.
 Prior to backfilling and during lowering, the pipeline will be supported at all
points inside the trench. Any voids below the pipe will be carefully
backfilled by CONTRACTOR.
Schematic for Lowering-in operation

c. Works after Lowering-in
After pipes lowering in operation completed, the lowering in inspect record will be
filled in and signed by CONTRACTOR and Company’s representatives.
CONTRACTOR shall backfill the ditch immediately after lowering, at locations

where the ditch is likely to fill with water and cause the pipe to float.
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PROPOSAL Rev. A
After pipeline lowering in, As-Built Survey will be done immediately. the cover
depth of the pipeline, ground level and the coordinates of the joints will be
measured. the starting point, the midpoint, and the end point of the bended pipe
will be also measured and collated by the CONTRACTOR’s surveyor.
CONTRACTOR will survey the co-ordinates at each weld joint of pipeline and
every crossing point. After as built survey is completed, the as-built survey record
will be filled in and signed by CONTRACTOR and COMPANY’s representatives.
Measure the minimum cover and check if the lowered-in pipeline has at the
bottom of the trench an equal support.
Padding /Backfilling should be carried out after the surveying work.
CONTRACTOR will install test leads and anodes in accordance with approved
drawings and at all crossings of existing pipelines.
At tie-in location, 2 to 3 pipe length should be remained uncovered.
At the end of each day's work, the open ends of pipelines will be capped with a
rubber, plastic, canvas, or other approved cap to prevent water, dirt or other
foreign matter from entering the pipe. Welding of metal caps will not be permitted.
The end will remain capped until work is resumed.
7.12 BACKFILLING
Sequence of work in the last pipeline construction crew is backfill. All backfilling
process shall be followed as COMPANY specification. For swampy and Hard/ rock
soil, shall be required sand bedding 300mm in the bottom of trench. For swampy area
and river crossing, will be installed buoyancy control such as set on weight (SOW),
screw anchor block, or concrete weight coated (CWC) pipe.
Backfilling will be as close as possible to the lowering and tie-in crew, to avoid trench
collapse into the pipe and water entering the trench. For safety reasons also, trench
shall not in open condition for long period.
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PROPOSAL Rev. A
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PROPOSAL Rev. A
7.13 HORIZONTAL DIRECTIONAL DRILLING (HDD)
Locations of the HDD method to be applied are as follows:
a. Elite Highway + side drainages + Jalan Kampung Lombong at KP 0+350, est.

length is 150 m.
b. SKVE + IJM/Gamuda main road + side drainages at KP 6+450, estimate length is
200 m.
c. River crossing at KP 17+000, est. length is 320 m.
d. River crossing at KP 21+500, est. length is 450 m.
e. River crossing at KP 22+250, est. length is 200 m.
f. Selat Lumut crossing at KP 40, est. length is 1500 m. (Critical Section)
CONTRACTOR will arrange survey to make sure length, depth and profile of each
location. The pipe string shall be welded and coated, and the pipebook with
traceability record shall be completed. Cleaning, gauging and pre-hydrostatic test of
the pipe string shall be performed and accepted prior to pulling.
Pilot hole drilling is the first stage in the drill process. The pilot drill string shall be
advance along a predetermined path from entry surface location to exit location.
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PROPOSAL Rev. A
After completion of pilot hole drilling, the bore holes will be enlarge using a sequence
of reamer. Once the hole has been sufficiently enlarged to accommodate the product
pipe (pipe string), a cleaning pass may be conducted by running a barrel reamer
through the hole to ensure that all loose material and cuttings are cleared out of the
hole and the hole is well lubricated with drilling mud to ensure a smooth pullback
operation.
The reamer will be recovered and disconnected. Pullback assembly will be connected
to the pre-fabricated pipe string ready for continuous pullback by drilling rig.
The product pipe shall be pulled back toward the rig side as the drill pipes are being
tripped out.
7.13.1 HORIZONTAL DIRECTIONAL DRILLING METHOD
HDD Contractor to qualified personnel under safe conditions and shall be installed in
accordance with drawings approved.by COMPANY, which satisfies all requirements of
the authorities having jurisdiction over the crossing. Impact on users of the crossing
shall be minimized and the safety of the crossing shall not be adversely affected.
CONTRACTOR shall obtain all permits necessary for all any crossings. Prior to
commencement of work, a joint survey will be carried out together with the COMPANY
to finalize and confirm the crossing alignment. CONTRACTOR shall determine the
precise location of all-subsurface utilities or structures in close proximity to the pipeline
or which the pipeline will cross. At the exact location of buried utilities, no mechanical
excavation shall be performed within manual excavation. A minimum of seven days
prior to commencing construction at any road crossing, CONTRACTOR shall notify the
COMPANY and submit a Traffic Management Plan. CONTRACTOR shall provide and
maintain signs, barricades, detours, flagmen, or watchmen as required by the
COMPANY and authorities to ensure the safe execution of the work. A minimum of 48
hours’ notice shall be given to the representative of the utility prior to commencement
of work on the HDD crossing CONTRACTOR shall use only appropriate plant and
equipment. All such plant shall inspect and accepted by main contractor to ensure safe
working condition. CONTRACTOR shall implement the using of Swivel Beacon during
pipe pulling to Indicate/measure the pipe depth as per COMPANY new requirement.
7.13.2 HDD INSTALLATION METHOD
This method of pipe installation shall be adopted at areas where the local authority and
the design and installation of pipeline along this area shall confirm to COMPANY
requirement and other relevant authority. Prior to any HDD activity, the site survey
would be conducted to determine the HDD design profile. All site preparation for the
welding of the Steel pipe shall be conducted initially to expedite the work. The HDD
method applied here encompasses the installation of “cased pipeline piping” whereby
the “process piping and carrier piping” would be installed and pulled together. The
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PROPOSAL Rev. A
following briefly describes a step by step method on the installation which is planned to
be adopted for the purpose of this project.
Step 1
Site survey: survey the crossing at site and marked the existing utilities.
Using paint marked the planned, route on the road surface.
Ensure marked the planned HDD location of the launch/entry pit and exit pit.
Step 2
Equipment set-up – Mobilize the drill unit and the field power unit to the job site.
Set-up the drill unit behind the launch/entry pit and secure the front end the dead-man
hold down and secure rear end with the rear outrigger and hold down stakes.
Set-up the electrical strike alarm system and the grounding system for maximum
safety.
Excavate the launch/entry pit and exit pit and shore the pit as necessary on the exit
site of the crossing. On the other side (exit) of the crossing, weld the entire required
pipe as required on the HDD proposed profile by the CONTRACTOR.
Step 3
Field Power Unit (FPU) preparation. Check all fluid level.
Check the hydraulic circuit.
Fill the mud tank with water and mix the bentonite/polymers as per mixing rate.
Connect all hydraulic and mud hoses from the FPU to drill unit.
Insert the leading piece of the drill pipe and attach the drill tool.
Step 4
Locator preparation: Check all batteries.
Calibrate the roll angel indicator of the transmitter with the locator.
Check the transmitter signal strength and all roll angel indicator.
Step 5
Drill preparation – Check all grease points of the drill unit and the trailing gear.
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PROPOSAL Rev. A
Rotate the carriage to warm-up the hydraulic oil as well as to check for any oil leaks.
Set the appropriate mud pressure at the FPU and also at the drill control console.
Clean out drill head nozzle with tip cleaner. The plugged drill can become too hot and
damage the probe.
Ensure the equipment in the good and safe condition, and then insert the transmitter
into the drill tool.
Step 6
Pilot hole drilling – Begin the drilling operation.
First push drill string until drill rod just enters the ground.
Stop pushing and rotate drill head until rod is centered in the rod guide rollers.
When centered, rotate and push the remainder of drill rod into ground. If the drill unit
moves during the bore, reposition drill unit so drill rod is centered in rod guide rollers
before continuing.
To prevent rod joint from pulling apart, never rotate drill rod counterclockwise while
drilling, pulling back or back reaming.
Complete the pilot hole drilling as planned job route and CONTRACTOR to complete
the piloting details form.
Step 7
Check drilling fluid – Frequently check drilling fluid level during the pilot hole drilling
and back reaming operations.
Refill the mud tank as necessary as per step 3.
Step 8
Set trailing gear – The exit pits removed the drill tool from the drill string and attach a
reamer.
At this point, pre reaming operation – reaming without pulling he product pipe behind –
is optional depending on the soil condition that has been encountered during the pilot
hole drilling operation.
Set-up the trailing gear and attach the pipe.
Step 9
Back reaming operation.

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PROPOSAL Rev. A
There should be an installation of swivel beacon between the reamer and the rod to
prevent the rods behind from rotating during the back-reaming activity.
Begin back-reaming operation.
At the time to adding more rod to continue the back reaming DO NOT ROTATE THE
DRILL STRING. Make sure the adding rod to be done through manual method.
If condition will not allow rod to push through the bore hole without rotation,
discontinue the push through method and use the manual method.
After that continue back reaming as per standard construction method. Shut down
drilling machine after back reaming completed.
At this point, if the drill unit experiences excessive drag of the pipe pull back (due
possibly to a collapsed tunnels or poor soil condition) a heavy vehicle can be placed
behind the product pipe and assist in pushing the pipe until the difficult pull back
section is overcome. CONTRACTOR to complete the back-reaming details form.
Step 10
Pipe Pulling Operation.
Install the swivel beacon between reamer and pulling head. Do not direct connect the
swivel beacon to reamer because the reamer and swivel beacon will move together.
This part will be longer and the possibility of rod breaking is higher during pipe pulling
operation.
CONTRACTOR to use swivel which allow the reamer to move/ rotate first and will be
followed by swivel beacon.
During pipe pulling operation, pipe locator to be used to indicate/ locate the pipe and at
the same time the depth can be measured based on depth of swivel beacon to ground
level that appeared on pipe locator.
Prior to pipe pulling the reamer used should not be bigger in diameter than pipe size.
CONTRACTOR to complete the pipe pulling form.
Step 11
Inspection – After pipe installation is completed, inspect the product pipe for surface
damage or water leaks.
Step 12
Break-down and clean-up.

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PROPOSAL Rev. A
Break down the FPU and drill unit.
Clean up the job-site.
Transport out any excessive soil from the launch pit and exit pit.
7.13.3 HDD SYSTEM

The HDD system is a guided horizontal boring system capable of installing utilities. Its
primary application is in developed areas where surface disruption is a consideration,
not only because of cost but also because of traffic flow and customer satisfaction. The
equipment can produce tunnels ranging in size from 50 to 550 mm with a typical run of
210-m (70 lengths) depending on soil condition and tunnel sizes.
This system uses drilling bit with high-pressure fluid jets for cutting. These drilling bits
are sometimes augmented with carbide cutting blades to help penetrate the more
consolidated sentiments and permit operation in chalk, some shale and occasional
encounters with rubble and gravel up to 30% in volume.
The fluid is a mixture of bentonite clay and water. Drill bit cutting with bentonite
provides a means of excavating sediment while at the same time leaving a lubricated
tunnel for installing the utility. The bentonite solution is a viscous fluid that suspends
the sediment particles and transports them back to the surface.
The drilling bit themselves will cut the sediment adjacent utilities whether they be
concrete, metal or plastic. With the cutting head and back-reamer arrangement used,
the maximum fluid consumption is 114 lifters per minute when producing tunnels up to
200mm. The drill bit penetrates about 259mm into normal sediments. This means that
drill bit with high pressure fluid cutting is substantially different from water boring
techniques, which use much larger quantities of fluids that can cause substantial voids
and results in surface subsidence.
The system uses the orientation of the drill head and head shape to control the path of
the boring tool. A separate piece of equipment above the ground in combination with a
transmitter located in the boring tool head, determines the position of the tool at any
placement depths of about 1m to 15m. The tunnel placement accuracy can be held to
15cm depending on the requirements of the job and the sediment type. A contoured
path of minimum radius 40 m or more can be maintained with the equipment.
With this placement accuracy capability, the directional boring system can be used in
the vicinity of other utilities after first locating the existing utilities in the ground
either electronically or by means of small excavation pits. Once the utilities are
exposed, a course can then be carefully laid out to avoid running into existing utilities.
Since no trenching is involved, the course can be above, under or to the side of the
existing utilities, allowing much more flexibility in placement of the new utility. Unlike
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PROPOSAL Rev. A
trenching, there is generally no difficulty in going deeper to get under a sewer, water
pipe or other utility. The depth of the tool can be accurately measured down to 15 m
with the electronic locating equipment. Because of the accurate placement capability,
many utility companies will allow Drill with directional boring next to active primary
electric cables, while contractors using conventional techniques have to de-energize
the cable, which contributes to further customer disruption.
The hardware for the system consists of four major components: the filed power unit,
the drilling unit, the locating system and the safety system. The filed power unit
provides the high-pressure fluid and the hydraulic, pneumatic and electric power
required operating the drilling unit.
The power to drive these circuits is supplied by an internal engine, which is located
within the power unit, which is located within the power unit with appropriate noise
isolation and exhaust system. An unbiblical cable conveys the power and high-
pressure fluid from the field power unit to the remotely located drilling unit. The field
power unit provides the capability to mix the water/bentonite fluid as well as to store it
in an 1893-liter tank.
For most applications, a single tank of fluid is sufficient to operate the tool for one day.
For small-diameter boring, the system can be operated for several days without the
need to mix additional drilling fluid. Fluid mixing can be done at a job site without
disturbing the equipment set-up.
The drill units are driven hydraulic umbilical. An umbilical between the mobile unit and
the field power unit allows the two units to be separated by up to 30 m (or 60 m with an
extension kit) The mobile units were designed to pass through a standard residential
fence gate 82 cm wide. Many applications require boring in narrow streets or limited
set-up space where this capability is necessary. The drill units provide all the thrust
and rotation action required to perform the guided boring operation including the
steering function.
The located system for determine the position of the drilling head during operation
consists of a sub site 66TKR hand held locator and transmitter (sub site 84 BRP
beacon) located in the drilling head. The locator displays the lateral position, the
distance out and the depth of the tool. It has an accuracy of 1.5 cm up to depth 15 m.
A recent development extends the range of this equipment. Its application is
particularly important on projects such as river and canal function.
The locating system for determine the position of the drilling head during operation
consists of a sub site 66 TKR hand held locator and transmitter (sub site 84 BRP
beacon) located in the drilling head. The locator displays the lateral position, the
distance out and the dept of the tool. It has an accuracy of 1.5 cm up to depth 15 m. A
recent development extends the rage of this equipment. Its application is particularly
important on projects such as river and canal crossings.
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PROPOSAL Rev. A
7.13.4 GUIDED BORING
The typical operating crew consists of three people to run the HDD boring system plus
additional helper to handle cable and provide necessary starting and exit pits for
termination on some jobs. The three people consists of one individual to do the
locating one to control the advancing and steering of the tool and one to help add and
remove of drill pipe bin.
After the existing utilities have been located and the boring path has been laid out, the
usual operation consists of first excavating pits at the connection points. The purpose
of the pits is to make cable or pipe termination points. Since no boring equipment
needs to be lowered into the ground, these pits need only be large enough to permit
access for the connections.
Once these pits have been dug, the drill units are brought to the site. The unit us set
up 1 m behind the first access pit. The tool and the first 3-m section of drill pipe are
auto loaded on the drill frame, which is angled at about 15 degrees to the ground. The
guided boring process begins by drilling into the undisturbed surface at his 15-degree
angle.
As the tool penetrates the ground, the second section of drill pipe is added. The
process continues with the steering controlled so that the boring tool will enter the first
pit level at the proper depth. The directional boring procedure then continues toward
the second pit as shown in Figure attached.
The locater operator continually monitors the progress and position of the drilling head,
transmitting steering commands back to the steering operator at the HDD boring unit
via a two-way radio. The steering operator controls the tool through orientation of the
drill and by applying thrust force on the end of the drill head. Since the head is
asymmetrical the tool produces side forces for steering. Continuous rotation allow the
tool to advance in a straight line, while holding the tool to advance in a straight line
while holding the tool head in a particular orientation forces the tool to turn.
Once the tool has advanced to the termination pit, the drilling head, which contains the
transmitter, is removed and a back-reamer is attached to the drill pipes. The initial hole
size is 100 mm; the back-reamer allow the hole to be expanded up to 550 mm. The
back-reamer will over cut by rotating the initial hole size required which is 50 mm to
100 mm large than the utilities pipe. By withdraws the drill pipe, after each 3 m section
of the drill section is decoupled, removed and reconnected to the back of the back-
reamer has advanced to the drilling pit.
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PROPOSAL Rev. A
Decoupled removed and reconnected to the drill pipe at termination pit and attached at
to the end of the reamer is a swivel joint and gripping mechanism for pulling the utility
pipe. The back-reaming process is merely the reserve of the drilling process with no
need for guidance. The drill frame withdraws the drill pipe at same time as the utility is
being installed.
The utility can be a cable, as depicted in the figure, or it can be conduit or pipe after
each 3 m section of the drill pipe withdrawn, the pipe section is decoupled and
removed the carriage on the drill frame then advances to pick up the end of the drill
string and withdrawn another 3 m section.
During the two-path drilling and back-reamer process, the spoils (cut soil mixed with
drilling fluid) flow to the pits. For smaller diameter holes in porous sediments, very little
spoils are produced. Three small quantities may not even appear at the termination pit.
For larger diameter back reaming and in consolidated sediments where the porosity is
low, the soil disposal pits may be necessary.
Where the porosity is low, the spoil disposal pits may be necessary.
During the entire boring and back-reaming operation, the safety equipment
procedures, protect the operators from any possible injury caused by inadvertent
contact with the energized electric cables in the ground. Although this rarely occurs,
the safety equipment and procedures ensure that operators are protected from
electrical hazards.
Because of the safety equipment and procedures, most utility companies will allow
HDD drilling operations next to their life’s utilities, while other contractors using surface
trenching and unguided moiling techniques are required to disconnect utilities in the
vicinity of the installation. This means that new electric cables or pipes can be installed
adjacent to the live electric cables or pipes throughout an entire city section with only
the new utilities system. Similar benefits can also be experienced with the installation
of gas pipes in common trenches with other utilities.
7.13.5 QC REQUIREMENTS FOR HDD

Site Quality Control
- The primary responsibility for quality control shall be with the supervisor at the site
with the assistance of the QC inspector and the Safety Officer. The
CONTRACTOR Representative and HDD crew shall be provided with and well
versed in this procedure, and shall have on site the relevant approved drawings for
the crossing before any HDD / jacking activity commences. The following items
shall be inspected and documented.
- All equipment shall be in good working condition and adequate to do the work.
- All safety requirements for the protection of the working crew and the protection of
the public shall be observed and recorded by the safety supervisor.
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PROPOSAL Rev. A
- All permits from regulatory bodies and local principal authorities are to be
approved before commencing the crossing and copies shall be available on site. A
minimum of seven days’ notice is required and shall be given to the COMPANY
and the authorities concerned before commencing work on any crossing.
- All special conditions that may be attached to the permits are to be strictly
observed.
- All underground facilities shall be located by the use of Search Detector with the
relevant authorities. Digging shall be done carefully by hand to locate known or
suspected underground facilities and their location shall be carefully recorded. Any
damage to underground facilities shall be reported to the Project Manager and the
relevant authorities as soon as possible.
- All materials to be used in the installation shall be verified to the Construction
drawings and recorded.
- Where approved open cut methods are employed for the crossing all carrier pipe
shall be placed in prepared trenches to the designed depth and with bedding as
required by the specifications. This depth and conditions shall be documented and
verified.
- Backfill shall be completed as required in the procedure and the authority having
control over the road or railroad concerned shall re-instate to Local/Relevant
Authorities. If required by the conditions of the permit these authorities shall be
notified when necessary to conduct their own inspections and copies of their
reports should be obtained to include in the final documentation.
- All installed carrier pipe shall be swabbed and capped to exclude debris and
animals until the tie-in is completed.
- All fusion alignment, fusion welding, and visual NDT shall be inspected and
approved by an authorized inspector appointment by the COMPANY. Surface
integrity shall be verified by holiday detector on both the pipe and welded joints
before installation.
- Surface integrity shall be inspected after installation and if proven to lack the
required integrity the carrier pipe may be required to be withdrawn and reinstalled
after repairs have been retested and approved.
- Permanent warning signs, fabricated to the contract requirements shall be installed
and documented as the crossing is completed.
- All drainage ditches, tiles, and culverts shall be left intact and replaced or repaired
as necessary. As these works will be verified by the local authorities’ full
documentation shall be reported for the QA/QC records.
- Documentation shall be the responsibility of the supervisor assigned to the
crossing. Reports shall be made daily to the QA/QC Inspector who shall obtain the
necessary COMPANY approvals and a summary of the prepared documentation at
the completion of the crossing. Tie-in documentation shall be added to the
documentation package when completed. All inspection and testing shall be strictly
in accordance to QA/QC requirement.
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PROPOSAL Rev. A
HDD Construction Schematic
Measurement and setting out
Road and site preparation
Slurry preparation Equipment preparation Pipe prefabrication
Pulling back ditch excavation

Pilot hole
Lower-in
Chambering and pipe pulling Pipe connection
Completion
7.13.6 CHAMBERING
After the completion of the construction of guide hole, it is available to unload the
direction controlling driller and connect the reamer and start the chambering after the
slurry inspection. This crossing adopts the grade 4 anti-chambering plus grade 1
cleaning hole. The chambering uses the fly-cutter reamer, grade 1 chambering is 28
inches, grade 2 chambering is 36 inches, grade 3 chambering is 44 inches and grade
4 chambering is 48 inches. The 40-inch bucket reamer is used after the grade 4
chambering is completed to conduct the cleaning. In principle, when the stratum is the
rock, the rock reamer is adopted. When the stratum is the sand, then the cutter rotary
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PROPOSAL Rev. A
reamer is adopted. The cutter reamer might be adopted for small-level chambering
(18″,24″) and cutter reamer + centering guide might be adopted as much as possible
for big level chambering (30″~34″), to reduce the submerging degree of the reamer in
the sand layer for small bearing area for the reamer because of its weight and the soil
layer. Duct forming shall be ensured as good and the total curve shall not be out of
shape. Please refer to Figure 1: Describe of Chambering Process as following: -
Figure 1 - Describe of Chambering Process
Solutions and schemes to the problems that might occur in the drilling process
If in the crossing process, the crossing is very difficult because of some unpredictable
reasons, we shall immediately organize experts to demonstrate and actively discuss
the methods and measures of solving the problems. Meanwhile, we shall make good
preparations for the conduction once determined.
Pulling back pipeline

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PROPOSAL Rev. A
Fi
gure 2
Pulling back is the last step and the most important step of directional crossing. The
drilling assembly adopted by the pulling back is 5 1/2″S-135 drilling rod +36-inch
bucket reamer + cardan joint + crossing pipeline. It is required to conduct the
continuous operation during the pulling back to avoid the increase resistance caused
by the shutdown. It is required to inspect if each connection part is firm before the
pulling back.
To ensure smooth pulling back and undamaged anticorrosive coating, the following
measures shall be adopted: during the pulling back operation, it is required to increase
the highly lubricating slurry and stick the slurry to the surface of the anticorrosive
coating just like the thin film so as to protect the anticorrosive coating.
7.14 JACKING / THRUST BORING
Location of the Jacking / Thrust Boring method to be applied are as follows:
a. Jalan Jurutera at KP 0+072, est. length is 60 m.

b. Future road (Jalan Lombong Timah 3) at KP 2+822, est. length is 24 m.
c. Future road (Jalan Lombong Emas 3) + drainage at KP 2+836, est. length is 84
m.
d. Road crossing at KP 6+780, est. length is 24 m.
e. Road crossing at KP 8+540, est. length is 60 m.
f. WCE flyover at KP 10+440, est. length is 60 m.
g. Jalan Waiman at KP 13+150, est. length 24 m.
h. Jalan Surau Muzir at KP 13+450, est. length is 36 m.
i. Jalan Sukepi + BV station 1 at KP 13+950, est. length is 50 m.
j. Jalan Klang – Banting + Tee Off at KP 16+600, est. length is 60 m.
k. Jalan Pusara at KP 21+050, est. length is 48 m.
l. Jalan Pulau Carey + Tee Off at KP 24+400, est. length is 60 m.
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PROPOSAL Rev. A
Pits are excavated at both ends of the crossing to be installed. One pit which holds all
the equipment is larger and is known as the starting pit, the pit at the opposite end of
the crossing is known as the arrival pit.
a. Set-up Equipment
The control cabins, generator(s), jacking product pipes are located on the surface.
Prior to the commencement of thrusting boring works, the main thrust frame and
thrust ring will be placed into the jacking shaft, lined out and leveled.
A thrust wall is to be cast between the main thrust frame and the back wall of the
shaft in order to distribute the thrust forces on the back wall. In total, certain tons
of jacking force by meeting the construction requirements will be created out of 2
jacking cylinders, each cylinder capable of pushing with enough tons.
A steel entrance seal is accurately positioned and set onto the shaft sheeting; the
purpose of this entrance seal is to seal the face of the cutting head upon
commencement of cutting in order to avoid the loss of water from the 'pressure
zone’ around the cutter head.
Prior to commencement the axe of the thrusting boring machine is to be

independently checked by a topographer. After this check has been carried out
the machine can be positioned within the jacking frame and a 'full systems check'
of the machine is to be carried out prior to works commencing.
b. Work Pit for Thrust/Auger Boring
Launching and retrieval pits will be made ready for use when the tunneling crew
arrives. The surface will be protected by collective protection fencing and shaft
bottom will be permanently accessible (secure ladder, proper scaffolding or others
access means). All shafts will be made to be watertight, with a concrete floor at a
level of 50 cm under the underside of the jacking pipe. Free area has to be
available around the shafts to:
 Set up the thrusting boring machine;

 Lower or retrieve the thrusting boring machine;
 Store and lower the jacking product pipes;
 Thrusting Boring Machine;
 Guidance System for Thrust/Auger Boring
 The automatic thrusting boring machine will be equipped with dry
material removal and will remotely controlled from a control
container.
 For pipe jacking in rock, the machine will be equipped with a cutter
head with cutter disks. The cutting disk is driven by a hydraulic motor
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with the power supply located on the surface, behind the cutting disc
is a chamber where the excavated material is loaded onto an auger,
in order for a dry removal of the soil.
 The head of the thrusting boring machine is steerable and is
equipped with 3 or 4 hydro motors for the cutting head, steering
cylinders with integrated linear measuring system, high pressure
nozzles for cohesive soils and 3 nos. bentonite nozzles for injection
of betonies in order to lubricate the thrusting boring machine.
 All controls are controlled from a cabin located on the surface
adjacent to the drive shaft.
c. Spoils Removal System
The excavated material that is cut off by the rotation of the full-face cutter head
falls down on the auger and is transported out of the tunnel by the rotation of the
auger.
Loading and Unloading of Coated Pipe
Loading and unloading operation of coated line pipes will be carried out with care.
It is prohibited to handle the coated pipes by rolling; skidding or dragging of pipe
will be strictly forbidden.
Lifting hooks, when used, will be equipped with a plate bent to fit the curvature of
the pipe and will be fitted with a soft insert to prevent damage to the pipe or the
beveled ends. During hoisting, cables/wire ropes will have sufficient inclination
compared to the centerline of the pipe so that the cables/wire ropes do not come
into contact with external coating.
Coated pipe will be handled by means of slings and belts of proper width made of
non-metallic/non-abrasive materials. The use of round sectional slings is
prohibited.
7.15 OPEN CUT CROSSING
The method of roads, ditch, water ways and track crossing by open cut shall be based
on the approval from the jurisdictional authorities.
7.15.1 OPEN CUT ASPHALT / MAJOR ROAD CROSSINGS
a. An initial survey, with the help of relevant authorities; shall be made for the
presence of utilities and service pipelines and cables in the area based on the
construction drawings with their approximate location clearly marked.
b. A temporary crossing layout (sketch) shall be developed by surveyor, showing
the positions of various entities and the diversion plan.
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c. The pipe string of suitable length and wall thickness mentioned in alignment
sheet, with bends to suit at site if required, shall be prepared before the open
cut. The pipe string shall be welded, NDT performed, joint coating completed
and holiday test done as per the relevant approved procedure.
d. Pipe string shall be ready in all aspects for lowering.
e. Open cut shall be performed only after clearance from relevant authorities
responsible. Open cut shall be excavated to the required width and depth with
the excavators and confirmed for the minimum requirement. If required in the
rocky area sufficient bedding material as per ditch configuration shall be used
the bedding material shall be placed around over the pipe, with care being
taken to avoid damage to the pipe coating and to assure that there are no
voids in the padding.
f. For open cut operation, the pipe string is lifted and lowered in to the trench
using crane and / or pipe layer. Suitable lifting accessories like soft nylon
choker belts or rolling cradles shall be used. Lifting equipment shall have
suitable certificate.
g. Sufficient number of the lifting equipment shall be used so that the pipe string
is lifted comfortably not to cause inordinate deflection of the pipe and induce
stress on it. The number of the lifting equipment shall be based on approved
calculation.
h. The open cut operation shall be scheduled during the day time, if the traffic on
the particular road is thin, giving more importance to safety during the
operations. The operation may be scheduled during night if the road is having
heavy unavoidable traffic during the daytime. In such case more attention is to
be given to the safety of the working groups as well as the public and
environment.
i. Open cut road and track crossings shall be provided with road, where required,
to re-route traffic during construction.
j. Alignment of the trench shall be set out from the nearest bench marks.
k. Trenching shall be performed manually, initially, near the location of suspect
utilities and service pipeline and cables. Once they are exposed, the
excavation may be continued using the excavators without damaging the
utilities. Trench excavation will be done in such a way to have uniform smooth
profile to enable proper support to the pipeline string when lowered.
l. Pipe string will be positioned in its desired place, the as-built levels and
positions recorded.
m. The exposed pipeline string ends shall have both exposed ends protected with
nightcap to prevent intrusion of animals or foreign materials until final tie-in of
the section.
n. Backfill shall soon commence once the as-built readings are taken.
o. Backfill shall consist of excavated soil or material similar to the existing
excavated soil. It shall be placed in maximum lifts of 150 mm and compacted
sufficiently to minimize any settlement of the travel surface through the ditch
cut. Backfill along the crossing shall be compacted layer by layer by hand
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PROPOSAL Rev. A
compactor or equivalent. Any track crossing that exhibit unacceptable

settlement shall be repaired.
p. The specification of restoration of roads will be as per the local authority’s
requirement. All the work shall be carried out in coordination with local
authorities.
q. Diversion and other barricades shall be removed and the bypass road shall be
dismantled and restored back to the original / near original form.
7.15.2 OPEN CUT WATER CROSSINGS
a. Minor water crossings are crossings of ditches, canals, watercourses, rivers,

stream etc. Whether the bed contains water or not, and not being specified as
“Major Water Crossings”.
b. In crossings of water courses with either moderate flow rate or of torrential
nature with marked and unpredictable flooding, an adequate survey shall be
carried out before starting the work with the object of determining what
precautions are necessary and the most favorable period for executing the
work.
c. In case of crossings of watercourses for which no special methods of laying
are required, a pipe section of size as per the approved drawings shall be
assembled and subsequently laid. Bends shall be of cold field type.
d. The depth of the existing bottom of a minor water course shall be determined
in relation to the adjacent ground level by taking the average of four
measurement.
e. Minimum cover over the pipe shall not be less than as required in approved
drawing. The pipe section shall be made in such a way that it conforms to the
existing or future bed as indicated in the drawings. Whenever the crossing
requires a straight section of pipe between the lower beds coinciding with river
bed, this section shall be laid at a single horizontal level.
f. Concrete coated pipes shall be provided for negative buoyancy control in
crossings of rivers, stream and swamp locations as per the alignment sheets.
g. Temporary installation of diversions may be arranged if necessary, to ensure
the effective functioning of these watercourses crossed.
h. Banks and trenches of water crossings shall be backfilled with suitable soil and
shall be thoroughly compacted to prevent soil and bank erosion. In any case
rock, gravel, and other hard objects shall not be placed directly on the pipe.
Padding initially around and over the pipe shall be provided.
i. After the trench has been backfilled and during the cleanup work, the water
crossings shall be cleaned across the whole width of the ROW.
j. Original banks shall be restored and the level of flow shall be as per near to
original, before open cut. In the case of lined canal crossings upon compaction
and dressing of the banks, concrete slabs are casted to the required thickness
to match with the adjacent banks in coordination with the local authority.
7.16 CROSSING BY PUSH PULL METHOD

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PROPOSAL Rev. A
Location of the push pull installation method to be applied are as follows:
a. Pond at KP 3+200, est. length is 150 m.
7.16.1 PREPARATION WORKS
Construction work area along the ROW shall be prepared and whenever possible in
sufficient width for the construction of the pipeline in the swampy areas.
Disturbances to vegetation shall be to the least extent possible.
Construction area shall be cleared by cutting the vegetation at ground level, leaving
the existing root system intact. In areas of the pipe trench, tree stumps shall be
removed and cleared.
Access roads, wherever required, shall be constructed to allow passage of
construction equipment, permanent materials and movement of manpower.
If existing private roads are used as access to ROW, necessary permit shall be
obtained from landowners and caution shall be takes to keep the said roads in good
condition.
7.16.2 PIPE TRANSPORT AND STORAGE AREAS
Concrete coated pipe shall be handled in such a way that no damage is caused to
the coating during transportation to actual site locations.
Pipes required for the swamp areas shall be stored in nearby dry onshore area for
welding and preparation of the strings.
Loading, transportation, unloading and storage of line pipes shall be carried out in
accordance with the approved procedure.
7.16.3 SWAMP TRENCHING
The swamp trenching activity shall be executed by utilizing swamp excavator.

Swamp trench width at the top will be as required depending upon the soil condition
to maintain a stable trench with a depth shall be such that the top of pipe is
minimum 2 m meter below the natural ground level. The excavated soil shall be
deposited on the spoil side of the ditch in a suitable manner for future backfilling.
7.16.4 LINE-UP, WELDING AND NON-DESTRUCTION TEST (NDT)
Before alignment of the pipe, pipe number, heat number, length and thickness shall
be verified. Pipe without identification number shall not be used and shall be
quarantined till further investigation.
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PROPOSAL Rev. A
Before welding into a string each joint of the pipe shall be inspected in order to
removed dirt, sand or other extraneous loose debris accumulated inside the pipe.
After cleaning, the pipes shall be lined up by using an internal or external clamp
and welded with qualified welders using approved WPS.
The welded joints shall be marked with welder identification number and the
progressive number of the weld. Nightcaps shall be provided at each end of the
pipe string to prevent foreign objects or animals from entering into the pipe.
For the swamp sections, pipeline string of 3 to 5 pipes (approximately 36–60 m

length) each shall be made in a normal way of onshore pipeline welding. Each
string shall be welded and kept in parallel to each other in the dry area before the
swamp location from where it is to be pushed into the swamp trench.
Visual inspection of the welding shall be carried out after completion of the weld.
NDT of welds in accordance with API 1104 and approved NDT procedure shall be
take place following the completion of the weld. The report shall be interpreted to
identify possible defects and carry out the relevant repairs, within the shortest
possible time. The pipe book shall be completed for the relevant section and signed
off prior to carrying out push pull operation.
7.16.5 FIELD JOINT COATING
The field joints shall be coated using heat shrink sleeves in accordance with the
manufacturer’s recommendations and specification and approved procedures.
Inspection of the field joint coating shall include passing a holiday detector over the
pipe immediately after coating applications as per NACE RP0274 and visual
observation as the pipe is being coated. Defective coating shall be clearly marked
and repaired as per the manufacturer’s recommended instruction for repairs. All
repairs shall be inspected visually and holiday testing shall be performed again to
confirm that they are acceptable.
Once the strings are cleared in NDT and joint coated, blind end shall be welded on
the first string to facilitate pulling.
7.16.6 PILING, CROSS – BEAM AND ROLLER INSTALLATION
From the edge of the swamp trenching at the pushing side of the pipeline pair of
piles shall be driven to install rollers along the centerline of the trench. If required
piling shall be carried out with piling hammer / excavator and crane.
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PROPOSAL Rev. A
Once the piles are driven crossbeams will be welded over which rollers will be
fixed. Rollers shall be suitable capacity to withstand the concrete coated pipe load
during pushing.
Piling and rollers shall be installed at 6m to 14m intervals each up to a length of 50

meters from the edge of the swamp trench towards dry area. The level of the rollers
will be at height of 500 mm more than the trench water top level or the existing
swamp ground elevation.
7.16.7 PRE-LAYING SURVEY
Survey of the trench bottom will be carried out to assess the final trench level
before pushing the pipe string. Rectification required if any for the level of the
trench shall be carried out using the swamp excavators prior to pushing the string.
If collapse of the trench while pushing occurs, depth will be checked and rectified
using swamp excavators.
7.16.8 PUSH PULL OF PIPE STRING
Push pull method for the laying of pipeline in swamp areas will begin once the
preparatory works are completed and the swamp string is cleared for lowering. The
sequence of operation is as follows.
Before starting the push pull operation water in the swamp trench shall be ensured
for free floating of the pipe string during push pull.
In the first section of the string 4 pipes shall be normal pipes (without concrete
coating) with blind end welded and shall be lifted by sufficient side booms / cranes
and kept over the rollers installed on the pipe supports. No. of side booms / cranes
will be decided on the basis of string length. The pipe string shall be lifted and
marched and positioned on the rollers using side booms.
Swamp excavators and crane shall be kept ready at the edge of the swamp trench
to receive the first string in the trench.
Sufficient buoyancy drums shall be tied (using metallic strips and clips) to the
pipeline string before pushing the pipe in the trench.
Pulling end of the string shall be fixed using D-Shackle arrangement to swamp
excavator for pulling and initiation of push pull while the side booms pushes from
dry land.
While the push pull operation is in progress side boom shall be released one by
one and utilized to lift the next string.
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PROPOSAL Rev. A
When the first string is pulled inside swamp trench up to 40 m, all side booms shall
be released to lift the next string. Crane shall hold the string if necessary.
Second string shall be lifted and shifted to the roller for fit-up and welding the
second string with the firs string.
Fit-up between first string and second string shall be done by external clamp and
welded by qualified welders using approved Welding Procedure Specifications
(WPS) over the roller itself.
NDT and field joint coating shall be carried out and sequence of buoyancy drum
fixing, push pull shall start in similar fashion as mentioned above till the completion
of the swamp wet area section.
Second swamp excavator shall be utilized to pull if the first excavator is not in a
position to pull after a lengthy section has been pushed in the trench.
Depending on the number of strings side booms shall shifting the string many times
before placing it on the rollers.
The operation shall be continued until complete length as required is welded and
pulled into swamp trench.
7.16.9 LOWERING AND BACKFILLING
Drums tied to the concrete coated pipes shall be remove by cutting metal strips tied
to the drum using metal scissor from one end to another and concrete coated pipe
string shall be lowered due to its own weight.
Swamp excavator shall be used to position the pipeline string on the centerline of
trench.
Rock armor / dumping of appropriate size shall be used for protection the pipeline
prior to backfilling. Rock armor / dumping shall be installed in such manner that no
damage is caused to the installed pipeline.
7.16.10 TIE-IN
Pigging with gauging plate shall be run prior to tie-in to the mainline to ascertain
there is no dent or buckle on the installed pipeline. The pipeline shall then be
hydrostatically tested to full hydrostatic pressure for not less than 2 hours.
After the implementation of hydrostatic test is completed, the water in the pipeline
shall be dewatered by carrying out pigging for further tie-in.
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Cross beams shall be cut from the piles and the piles shall be pulled out by crane /
side boom from the dry land area.
Trenching shall be carried out for the dry area and pipe string cleared for lowering
shall be lowered in the trench.
After lowering of the pipe string in the dry area, water in the swamp location
(exposed 3 pipes), shall be dewatered from the trench.
Tie-in operation shall start after cutting and beveling the blind end of swamp string.
Fit-up / welding with external clamp shall be carried out between swamp and dry
land area string.
Visual inspection and NDT of the welding shall be carried out after completion of
the weld.
7.16.11 CLEAN-UP AND RESTORATION
Swamp excavator shall do the clean-up and maintenance of ROW damage due to
trenching in swamp to the original condition.
The river bank shall be reinstated back to its original condition and to the
satisfaction of the COMPANY. Any sheet piles used shall be pulled out upon
completion of the activities.
7.17 CLEANING, GAUGING AND HYDROSTATIC TEST
7.17.1 GENERAL
All work on the pipeline, including crossings, trenching, lowering in, backfilling etc.
shall be completed before the testing commences. Pipe book shall be prepared and
signed by the Company before carrying out water filling and testing operation.
Hydrostatic test shall include those section also, which have been previously pre-
hydro tested like crossing/HDD section etc.
7.17.2 TEST EQUIPMENT AND CALIBRATED MEASURING INSTRUMENTS

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PROPOSAL Rev. A
Following equipment / measuring instruments shall be utilized for hydrostatic testing

activities:
a. Pigs for filling, cleaning, gauging and dewatering.

b. Gauging pig with gauge plate made of aluminum and 6 mm – 10 mm thick,
diameter equal to 95% I.D of thickness heavy wall pipe in the section to be
tested.
c. Fill pump with differential head 20% greater than the maximum required and a
flow rate preferably between 300 m3/hr to 1000 m3/hr.
d. Positive displacement pump equipped with a stroke counter and equipped with
pressure relief valves and capable of exceeding the maximum test pressure by
at least 20%.
e. Portable tank of sufficient size to provide continuous supply of water to the
pump during pressurization.
f. Oil free compressor
g. Test manifolds
h. Dead weight tester; range 100 – 25,000 kPa at 1 kPa intervals measuring
accuracy of 0.5% of the pipeline test pressure.
i. Pressure recorder; range 0 – 25,000 kPa, 24 hours rotation, mechanical drive,
8 days wind, 1.0% accuracy, single sensor with single pen inking system.
j. Temperature recorders; range 10oC to 50oC, 24 hours rotation, mechanical
drive, 8 days wind, ~3.0oC accuracy, dual sensors with dual pen inking system.
k. Flow meter; measuring accuracy of 5%.
l. Thermometers; range 10oC to 50oC with accuracy of ~0.5oC.
m. Pressure gauges.
All instruments shall be calibrated to confirm their accuracy prior to their initial use
and every 6 months thereafter, and a record of calibrations shall be supplied with
the instrument and included in the test certificates.
The colour of ink used in recorder shall be as follows:
a. Pressure – blue
b. Pipe wall temperature or water temperature – red
c. Ground temperature – green.
7.17.3 PIG LAUNCHER AND RECEIVER
Pre-fabricated pig launcher and receiver having diameter greater than 4” or more
than the line pipe to be cleaned and gauged shall be welded, once the sections are
decided by the Contractor for cleaning and gauging activities.
7.17.4 CLEANING AND GAUGING

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PROPOSAL Rev. A
For hydrostatic test, before filling the section, the section shall be cleaned, flushed
and gauged with a gauging plate having diameter equal to 95% of the pipe inside
diameter (ID).
Cleaning and gauging operation shall be performed by passing on air driven pigs
with brushes to remove all mill scales, rust/sand or other debris from inside the
pipeline.
Contractor may flood the pipeline with water (approximately 20-30 m3) before
passing the cleaning pig for easy removal of the sand / debris that may be intact
with the inside surface of the pipe and for the smooth flow of the pigs without any
obstruction.
The acceptance criteria of cleaning before gauging plate running shall be visually
acceptable to the respective inspectors of the COMPANY.
The gauging and cleaning pigs shall be propelled at nominal speed of 1.6 – 5.5
km/hr.
The results of the gauge pig run shall be analyzed by the COMPANY to evaluate
the internal status of the pipeline. A deformed, bend or damage pig shall be
evidence of gauging pig run failure and the same shall not be acceptable. In such
cases
a. If there is no HDD included in the section to be gauged then Contractor shall

re-run the gauging pig with similar diameter, 10 mm thick plate and pig
transmitter arrangement to confirm and locate dent.
Pressure gauge shall be observed continuously by a dedicated person to

observe for an abrupt change in pressure beyond 1.5 bar, which is an
indication of the pig stuck at the location of dimensional defect.
Further pressurization will be stopped and all pressure behind the pig shall be
released.
Personnel with pig locator indicator device shall walk along the line to locate
the stuck pig.
Exact location of the stuck pig shall be identified from the signal of the pig
locator while walking along the pipeline.
Identified location shall be analyzed and rectified by replacing the pipe and the
aluminum plate gauge re-run shall be carried out.
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PROPOSAL Rev. A
In case the dent location could not be identified alternate solution such as
caliper gauging technique shall be used to identify the dent.
b. If there is any HDD included in the section to be gauged then Contractor shall
run the caliper pig to confirm and locate dent. After launching this pig, the line
pipe will be rectified and repeat the gauging pig run to the satisfaction of the
COMPANY.
After acceptance of the gauging operation by the COMPANY, the gauging

plate shall be signed and a photograph of the plate shall be taken and attached
to the gauging report.
7.17.5 TEST MANIFOLDS
The test manifolds shall be fabricated with the same diameter, heaviest wall
thickness and equivalent or higher grade of the pipe to be hydrostatic tested.
All welds shall be subjected to radiography and other NDT methods to prove the
integrity of the welds. Manifolds after complete assembly shall be pressure tested
at a pressure of min.1.25 times the test pressure for minimum of 2 hours and shall
be witnessed by the COMPANY.
Test end manifolds and assemblies shall be inspected prior to each re-use. Flexible
hoses used shall be armored and shall have a safe working pressure at least equal
to the test pressure of the test end manifolds.
7.17.6 TEST MEDIUM
Cleaning, filling and hydrostatic testing shall be performed using water, free from
sand and silt withdrawn from suitable source in the pipeline route. The water shall
not be contaminated. The water shall be tested in an independent laboratory for
using as the test medium. The test report shall be submitted to the COMPANY for
review before water filling.
7.17.7 TEST PRESSURE
The pipeline shall be hydrostatically tested in accordance with ASME B31.8. and
the test pressure of as specified in design consideration on hydrostatic test
pressure. The test pressure calculated shall be generated at the highest point in the
section under test.
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PROPOSAL Rev. A
The minimum test pressure is achieved at the highest point and the maximum test
pressure achieved at the lowest point shall not exceed 90% of the SMYS of the
pipe material based upon the minimum wall thickness in the test section.
7.17.8 TEST SECTION FILLING
On acceptance of gauging, the air pigging headers shall be cut and the temporary
test heads already pre tested at the pressure of minimum 1.25 test pressure, shall
be welded to the test section.
The filling end test header shall be preloaded with minimum numbers of filling pigs
and dewatering pigs.
The filling operation shall begin with pumping of water (approximately 20-30m 3
without any chemicals added) in the test section in front of the first pig for flushing.
After pumping water launch the first pig by pumping in approximately 20-30m 3 of
water behind the first Pig. The water column before and after this pig shall act as
cushion to control the movement of the filling pig (2nd Pig) and hence minimize air
entrapment. In addition to this venting shall be carried out at the launcher header at
regular intervals to remove any air, which may accumulate. Suitable backpressure
shall be maintained at the receiver header by throttling the valve on the header.
Depending on the pipeline elevation, the Contractor shall determine the actual
backpressure at the site prior to pigging.
Second pig shall be launched by pumping water in the actual line, filling with water
behind the pig. The filling continue till the second pig reaches the other end of the
test section and the pressure at the test end rises to the static head.
During the whole filling operation, the valves at the receiving end test headers shall
be throttled suitably to maintain adequate backpressure and thus control the pig
movement.
The first two columns of water shall be drained out from the receiving end.
7.17.9 THERMAL STABILIZATION
Once the test section has been completely filled and a minimum pressure of 1 bar
has been achieved at the highest point, the thermal stabilization period shall be
started. A temperature recorder shall be installed on each test section at minimum
of 500 meters away from the exposed pipes at one end of the test section. One
sensing element shall be placed against the pipe wall, suitably insulated and
backfilled. The second element shall be installed in the pipe backfill material a
minimum of 0.3 meter from the pipe wall and suitably insulated and backfilled.
Temperature recorders shall be checked every six hours during filling and testing to
ensure they are functioning properly.
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PROPOSAL Rev. A
7.17.10 TESTING
Water consumption for pressurization of the test section shall be calculated

depending upon the water volumetric compressibility and pressure value.
As soon as the temperature stabilization is achieved, the pressure connections

shall be established.
The pressure shall be raised at a moderate and constant rate up to 100% of the
test pressure. The pressurization shall be cycled with the sequence of pressure in
accordance with the approved procedure.
After the section has been pressurized up to 100% of test pressure and the air
volume calculation has been accepted, the test pressure shall be hold for a period
of 24 hours. After temperature and pressure has stabilized, the injection pump shall
be stopped and all connections at the test heads shall be checked for leakage.
Throughout the hold period care shall be taken that the maximum test pressure is
not exceeded. Should it become necessary to depressurize, the volume of the test
medium bleed of shall be accurately measured and recorded.
The pressure test is acceptable, if the final recorded pressure after making
necessary correction due to temperature fluctuation is equal or more than the test
pressure minus 0.2% of the test pressure.
On successful completion and acceptance of the hydrotest the pipeline shall be

slowly depressurized at a moderate and constant rate.
7.17.11 DEWATERING
Upon successful completion of the hydrotest and depressurization, dewatering pig

shall be propelled in the test header to dewater the section, making suitable drains
for safe disposal of hydrotest water.
The dewatering shall be done in such a way as to provide adequate control of pigs
during dewatering. The line should be dewatered up to touch dry state.
7.17.12 SWABBING
The swabbing of the pipeline would commence after the pipeline has been
successfully hydrostatic tested and dewatering is completely accepted.
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PROPOSAL Rev. A
In this phase the residual water remaining after bulk dewatering would be pushed
out using foam pigs.
The weight of the foam pigs will be measured before insertion into the line and
upon arrival. The number of runs for the foam pigs shall be as many as when in the
final pig run no further water, debris are pushed in front of the pigs and the pig shall
be touch dry.
Upon completion of swabbing, night caps shall be installed at both ends of pipeline
with full welding to prevent entry of foreign material such as water.
Subsequent to dewatering and swabbing, golden joint weld tie-in between the test
sections shall be taken.
7.18 CALIPER PIGGING
The caliper tool continuously measures the inside diameter of the pipeline through an
array of sensors that are spring loaded to hold them in contact with the pipe wall. As
the tool moves through the pipeline, very small radial movements in the sensors are
detected and recorded. Two odometer wheels riding on the pipe wall measure the
distance the tool travels through the line.
In data storage unit contains all power, processing and recording circuits in a sealed
module within the body of the tool. The multi sensing fingers translate the geometry of
the pipe inside diameter to a displacement of a single linear potentiometer. Data from
potentiometer is stored in solid state memory using microprocessor technology. Data
from external marker system is likewise stored in solid state memory. The size of the
on-board memory is sufficient to allow very long runs to be recorded in a single pass.
During the survey run, the caliper data are gathered in the solid-state memory inside
the pig. The basic data are as the following:
a. The caliper information (internal pipe diameter changes)

b. Time interval indicator.
After the survey run, the recording module is connected to a portable computer and all
the data transferred to a disk for storage and further data treatment.
For interpretation, the data is first transferred to a printer and a paper chart is
produced. This chart contains all information recorded during the survey run as
detailed above.
Before interpretation begins, a minimum acceptable diameter reduction is agreed by

all parties. The interpreter scans the chart for deflections which exceed the agreed
value and compiles a features list.
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PROPOSAL Rev. A
7.19 DRYING AND PURGING
All work related to the pipeline, station including hydrostatic test, dewatering,
swabbing, final tie-ins, installation of block valve, take off valve, etc. shall be
completed before commencing the drying activity and then after completion of drying
activity, Nitrogen purging can be commenced
7.19.1 DRYING
Following the installation of assemblies and meter station, and internal inspection of
the line, Contractor shall dry the pipeline. The pipeline shall be dried to produce a
maximum dewpoint at any point in the pipeline of -10oC.
For air drying operation, oil free air compressor, desiccant drier and hoses as
required will be set ap near launcher station.
The drying unit is capable of delivering super dry air of 1000 CFM at maximum 10
bar (145 psig) pressure with dew point temperature between -15 deg C to – 45 deg
C. The number of drying units will depend upon the section length of pipeline and
will be decided by the Contractor.
If the drying is achieved to -10oC or less, dry air will be passed freely through the
pipeline for another one hour, and ensured for consistent dew point or further
decrease in dew point of dry air measured at the receiver end.
If the drying is achieved to -10oC or less, all the check points in the pipeline will be
closed and the dry air will be packed inside the pipeline and held for 24 hours. After
24 hours hold period, dew point will be measured at both ends by exhausting
soaked dry air from the line. The measured dew point shall not rise above -10oC
measured over complete exhausting period and the pipeline shall be accepted for
nitrogen purging.
7.19.2 NITROGEN PURGING
Nitrogen purging will be done immediately after the end of soaking period and dry
air exhausting.
Upon completion of air-drying operation using super dry air, all temporary
connection used for drying shall be disconnected and remove from the line.
The evaporators with necessary piping will be set up and nitrogen will be introduced
into the pipeline. Nitrogen purity certificate shall be available for every batch.
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PROPOSAL Rev. A
All connection necessary for nitrogen purging shall be in place. The pipeline will be
inserted by nitrogen supplied from N2 road tankers or through ISO tank complete
through external evaporator. The passing nitrogen into the pipeline will displace
compressed dry air.
Continue to push the nitrogen till the entire pipeline is filled with nitrogen and
nitrogen comes out of receiving point. Once the entire pipeline achieves some
positive pressure some nitrogen will be vented out and the nitrogen filling will
continue until acceptance criteria are met.
8 COMMISSIONING
Commissioning phase will be carried out after pre-commissioning stage where the
testing facilities had been conducted. During the commissioning stage Contractor to
provide personnel, equipment, services and other services required continuously for
24 hours a day. Commissioning team will work under the coordination of Contractors
or authorized person commissioning.
Commissioning including injection or supplying natural gas pipeline into the already
dry pipeline. Instrumentation must be calibrated in advance by an independent body or
equipment that has a valid certificate. The Contractor will prepare a communications
system that will be used during the commissioning for personnel coordination.
8.1 REINSTATEMENT AND RESTORATION
Contractor shall clean-up the Site and any additional areas used in any phase of the
work in a manner and to a condition satisfactory to COMPANY, landowners, property
COMPANYs, tenants, and any relevant authority.
Area disturbed during construction activities like ROW clearing and grading and ditch
excavation shall be reinstated to its original condition.
Any existing facility that may have been altered or damaged by the Contractor activity
shall be repaired to their original condition.
Special consideration shall be given to fences, dikes, irrigation, drainage, and road or
track crossings, general public facilities.
The clean-up operation shall begin immediately after backfilling and be completed so
as to minimize the overall period of disturbance to the relevant parties.
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PROPOSAL Rev. A
All areas where earth has been moved to facilitate the construction of the pipeline
shall be restored to their original profile and condition unless otherwise approved by
COMPANY.
In agricultural land and other land that could be used for agricultural purposes, subsoil
shall be loosened and all rocks, temporary access roads, fill materials, and other
debris shall be removed and the top soil shall be replaced and prepared for seeding.
In rocky areas, unless otherwise directed by COMPANY, surplus rocks, including

broken or fractured rocks from ROW and those resulted from trench blasting shall be
removed to COMPANY approved disposal areas.
Damaged trees or trees that are leaning into the ROW after construction shall be cut
off at ground level and disposed of by methods acceptable to COMPANY. If the trees
are located outside of ROW, Contractor shall negotiate with the Company of the trees
for such cutting including paying any required compensation.
Unless otherwise directed by COMPANY all access roads constructed on ROW and
all temporary access roads (including timber rip-rap roads) used during construction
shall be removed and disposed of using methods approved by Company. In areas
where the rip-rap is to be left in place for future access requirements, it shall be
covered with a minimum of 300 mm of soil with no protruding portion of rip-rap.
All damaged properties including buildings, fences, hedges, survey monuments,

roads, railroads, bridges, culverts, drainage ditches, terraces, drainage tiles, water
crossings and dikes disturbed during construction shall be restored to their original
conditions before disturbance occurred.
Permanent repair shall be made to all fences by using quality material similar to
existing fences.
All off ROW claims for damages due to movement of the Contractor’s equipment, the
transportation of materials or the actual construction of the Facilities shall be the
responsibility of the Contractor. In the event that Contractor causes, accidentally or
otherwise, pipes or any other materials of any kind to be delivered into roadsides, into
the sea, or any place other than Site, those materials shall be recovered by Contractor
and the area, if damaged or adversely affected, shall be promptly cleaned and
restored by Contractor.
Slopes shall be restored to their original condition or as otherwise approved by

Company. Contractor shall provide adequate drainage and erosion control measures.
Contractor shall ensure that all slopes are geotechnically stable.
The river bank shall be restored to its original condition, to the requirements of
authorities having jurisdiction, or as otherwise approved by Company. Contractor shall
provide adequate armoring and erosion control measures as required.
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PROPOSAL Rev. A
8.2 REVEGETATION
Revegetation shall commence immediately after clean-up is completed, when erosion

control structures are installed, chisel plowing is completed and organic and topsoil
have been replaced. Revegetation operations shall not be conducted during monsoon
or excessively rainy periods.
On all lands to be revegetated, the species of vegetative to be applied shall be as

specified and approved by Company.
9 STATIONS WORK
In consideration of requirements given in the ITB, CONTRACTOR’s prime objectives in

executing construction work for the metering station will be to achieve high quality
workmanship, on schedule and construct in a quick and efficient way.
The entire construction phase for station work is divided into 3 stages:
1. on-site preparation.
2. off-site preparation.
3. transportation and installation of equipment at site.
The construction work will be carried out at site and fabrication yard. Works at
fabrication yard include spool preparation and fabrication, measurement and control
system (MCS), hydrostatic testing and FAT.
Works at site will include civil and structure, electrical and instrumentation installation,
receiving of completed skid and pipe spools, SAT and commissioning.
a. First Stage –On Site Preparation
CONTRACTOR will mobilise to site all the necessary facilities before commencement
of actual site work. CONTRACTOR will carry out initial site survey to ascertain the
actual layout. Requirement of piling for the proposed foundation of skid and control
room will be identified by carry out soil investigation survey.
The site will be cleared and leveled to begin the next phase of construction. The
foundation of skids and other civil works will be constructed at site while the
mechanical piping and equipment will be fabricated in CONTRACTOR’s fabrication
yard in Kulai, Johor. The construction of control building will be done according to
CONTRACTOR proposal, followed by drainage and fencing work for site safety and
security.
Installation of electrical and instrumentation cables from the station to the control
building is expected to start after completed installation of control building construction
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PROPOSAL Rev. A
work. The cables will run on cable trays at the skid station and below/inside rise floor
of control building. Sufficient length of cables will be allocated for termination at the
equipment on skid.
b. Second Stage – Off Site Fabrication Work
The station and its associated piping works would be fabricated off-site at
CONTRACTOR’s own fabrication yard in Kulai, Johor. CONTRACTOR will complete
the spools inclusive of non-destructive testing, hydrostatic testing, blasting and
painting.
The spools will be fabricated in sections according to the propose design approved
by COMPANY.
Following receiving of pipe spools after completed blasting and painting work, spools
will be lifted and placed into position onto skid for fitting of all valves, meters, filters,
regulators and fittings.
c.Third Stage – Transportation and Installation at Site.
The third phase of the work, electrical and instrumentation team will move in to carry
out installation of electrical and instrumentation underground cables. The
measurement and control system which is expected to be delivered to site will be
installed to a designated location within the control room and connected to the existing
electrical switchboard.
All field instruments will be installed accordingly, running on cable tray or cable turning
or underground as specified. Balance work including the grounding system to the
fencing, meter shelter, gate, piping and structural will be installed. At this stage, the
system is ready for pre-commissioning of dry system.
On the civil work side, heavy machine will be de-mobilized from the site and the site
will be laid with a layer of gravel, followed with the necessary reinstatement work. The
construction crew would be de-mobilized from site while the commissioning work is in
progress.
d. Temporary Facilities
During construction stage at site, a well-equipped site office with sufficient facilities will
be allocated for COMPANY and CONTRACTOR’s engineering personnel. An open
storage yard with adequate space within the Station area will be cleared for the placing
of civil material and some heavy equipment (parking of mobile crane, backhoes,
lorries, etc.)
e. Specific Station Construction Plans
Construction Work for Hot Tap Station

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PROPOSAL Rev. A
The station work involves mechanical, piping and hot-tapping as per tie-in point TP-01
and TP-02, installation of aboveground ball valves, fabrication and section of above
ground valves. The entire station shall be constructed with anti-cut and anti-climb
fencing and gate system.
Construction Work for Scraper Launcher Station
The work shall cover the expansion of existing Pulau Indah Lateral Pipeline Scraper
Launcher Station and the EPCC of one (1) new scrapper launcher station with bi-
directional capability. The Scrapper barrel shall be equipped with quick-opening
closure. The new scraper launcher station shall be tie-in to the existing pipeline PGU 2
and LOOP 2 via Hot-tapping (TP-01 & 2). NPS 30 piping from underground to
aboveground will be installed with MIJ (Monolithic Insulation Joint) as insulated from
unprotected surface. Furthermore, in order to control of the new scraper with existing
station, the new SCADA building has to be constructed complete with new utility such
as water supply, flood light and new venting line. In this new scraper station, all the
existing fencing and gate will be demolished and replaced with new anti-climb and
anti-cut fencing and gate system as per description of work in ITB. Beside of this, new
access road design shall be finalized and built as per specification. All the existing
underground blowdown piping shall be modified into above ground piping with a
common vent stack connecting therewith. All existing aboveground piping will be
undergoing in-situ blasting and painting.
Construction Work for Block Valve Station
The work shall cover the expansion of existing Pulau Indah Lateral Pipeline Block
Valve station and the EPCC of two (2) new block valve stations to be located side-by-
side at KP 14 and KP 26 to the existing Pulau Indah Lateral block valve with single
cross-over. All the existing fencing and gate will be demolished and replaced with new
anti-climb and anti-cut fencing and gate system as per description of work in ITB. All
the existing underground blowdown piping shall be modified into above ground piping
with a common vent stack connecting therewith. All existing aboveground piping will
be undergoing in-situ blasting and painting.
Construction Work for Take-off Valve Station
The work shall cover the expansion of existing Pulau Indah Lateral Pipeline Take-off
Valve station and the EPCC of two (2) new take-off valve stations at KP 16.6 and KP
24. The work shall limit to Civil & Structural works only whereby all the existing fencing
and gate will be demolished and replaced with new anti-climb and anti-cut fencing and
gate system as per description of work in ITB. The new take-off valve station shall be
tie-in to the existing take-off valve via tie-in with. NPS 12 pipe from underground to
aboveground piping. All existing aboveground piping will be undergoing in-situ blasting
and painting.
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PROPOSAL Rev. A
Construction Work for Scraper Receiver and Meter Stations
The work shall cover the EPCC of one (1) new scrapper receiver station with bi-
directional capability. The Scrapper barrel shall be equipped with quick-opening
closure. Furthermore, in order to control and monitor the unmanned new scraper and
other facilities inside the meter station, a new SCADA building has to be constructed
complete with new utility such as water supply, flood light and new venting line. In this
new scraper receiver and meter station, new fencing and gate, road and drainage
system, mechanical and piping, shelter and platform, jib crane, electrical and
instrumentation, SCADA, Cathodic Protection systems etc. will be constructed in
accordance with the design approved by COMPANY. The limit of work shall be
terminated at the tie-in point between the station and the power plant that near to the
fence line located at West side of the Station.
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PROPOSAL Rev. A
ATTACHMENT - 1: CONSTRUCTION SCHEDULE (PIPELINE)

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PROPOSAL Rev. A
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PROPOSAL Rev. A
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PROPOSAL Rev. A
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PROPOSAL Rev. A
ATTACHMENT – 2: TIMELINE DIAGRAM

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PROPOSAL Rev. A
PAGE 80 of 86
EPCC OF NPS 36 PULAU INDAH LATERAL PIPELINE PROJECT

TIME LINE DIAGRAM - PIPELINE ONSHORE
13 13
12 12
Mar
Mar
11 11
10 10
9 9
8 8
2023
2023
Feb
Feb
7 7
6 6
5 5
4 4
3 3
Jan
Jan
2 2
1 1
52 52
51 51
Dec
Dec
50 50
49 49
48 48
47 47
Nov
Nov
46 46
45 45
44 44
43 43
Oct
42 42
Oct
41 41
40 40
39 39
38 38
Sep
Sep
37 37
36 36
35 35
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34 34
Aug
Aug
33 33
32 32
31 31
Rev. A
30 30
29 29
Jul
Jul
28 28
27 27
2022
2022
26 26
25 25
Jun
Jun
24 24
23 23
22 22
21 21
May
May
20 20
19 19
18 18
17 17
16 16
Apr
Apr
15 15
14 14
13 13
12 12
Mar
Mar
11 11
10 10
9 9
8 8
7 7
Feb
Feb 6 6
5 5
4 4
3 3
Jan
Jan
2 2
1 1
10+000
11+000
12+000
13+000
14+000
15+000
16+000
17+000
18+000
19+000
20+000
21+000
22+000
23+000
24+000
25+000
26+000
27+000
28+000
29+000
30+000
31+000
32+000
33+000
34+000
35+000
36+000
37+000
38+000
39+000
40+000
41+000
42+000
0+000
1+000
2+000
3+000
4+000
5+000
6+000
7+000
8+000
9+000
0,0 0.5 1,0 1.5 2,0 2.5 3,0 3.5 4,0 4.5 5,0 5.5 6,0 6.5 7,0 7.5 8,0 8.5 9,0 9.5 10,0 10.5 11,0 11.5 12,0 12.5 13,0 13.5 14,0 14.5 15,0 15.5 16,0 16.5 17,0 17.5 18,0 18.5 19,0 19.5 20,0 20.5 21,0 21.5 22,0 22.5 23,0 23.5 24,0 24.5 25,0 25.5 26,0 26.5 27,0 27.5 28,0 28.5 29,0 29.5 30,0 30.5 31,0 31.5 32,0 32.5 33,0 33.5 34,0 34.5 35,0 35.5 36,0 36.5 37,0 37.5 38,0 38.5 39,0 39.5 40,0 40.5 41,0 41.5 42,0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
SPREAD 1 (KP 0 - KP 20) SPREAD 2 (KP 20 - KP 42) CROSSING TEAM
Pipe Stringing Pipe Stringing Pipe Jacking Team#1
Line-up Welding, NDT & FJC Line-up Welding, NDT & FJC Pipe Jacking Team#2
Excavation Excavation Pipe Jacking Team#3
Holiday Test & Lowering-in Holiday Test & Lowering-in HDD Team#1
Install CP & Backfilling Install CP & Backfilling HDD Team#2
TECHNICAL
PROPOSAL
.
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PROPOSAL Rev. A
ATTACHMENT – 3: MANPOWER HISTOGRAM

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PROPOSAL Rev. A
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PROPOSAL Rev. A
ATTACHMENT – 4: EQUIPMENT HISTOGRAM

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PROPOSAL Rev. A
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PROPOSAL Rev. A

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ENGINEERING, PROCUREMENT, CONSTRUCTION &

COMMISSIONING (EPCC) OF NPS 36 PULAU INDAH

TENDER NO: RFP-000000000263

DOC TITLE: T6.5 – CONSTRUCTION PLAN

TENDER NO: RFP-000000000263

DOC TITLE: T6.5 – CONSTRUCTION PLAN

TENDER NO: RFP-000000000263

DOC TITLE: T6.5 – CONSTRUCTION PLAN

CONTRACTOR’s scope of work will consist of Engineering, Procurement,

TENDER NO: RFP-000000000263

DOC TITLE: T6.5 – CONSTRUCTION PLAN

3.1 CONSTRUCTION ORGANIZATION CHART

CONTRACTOR’s Construction Organization Chart is provided separately in

3.2 GENERAL RESPONSIBILITIES

CONTRACTOR’s general responsibilities during construction including as follows:

3.3 CONSTRUCTION STRATEGY

CONTRACTOR intends to maximize the construction works within the

TENDER NO: RFP-000000000263

DOC TITLE: T6.5 – CONSTRUCTION PLAN

 Assignment of qualified personnel capable to perform their duties.

3.4 CONSTRUCTION MANAGEMENT

The site construction organization for this project will be headed by a

TENDER NO: RFP-000000000263

DOC TITLE: T6.5 – CONSTRUCTION PLAN

CONTRACTOR will submit Construction Execution Plan (CEP) to EMPLOYER for

The CEP will be updated, revised or supplemented by CONTRACTOR as approved by

CONTRACTOR will include:

a. CONTRACTOR's manpower and man-hour histogram by major section and

TENDER NO: RFP-000000000263

DOC TITLE: T6.5 – CONSTRUCTION PLAN

b. Major equipment mobilization plan on monthly basis with description.

4 CONSTRUCTION PLANNING AND PROGRAMMING

This is a basic yet challenging proceeding to manage the implementation of the

4.1 SEQUENCE OF ACTIVITIES

4.2 MANPOWER AND EQUIPMENT PLAN

TENDER NO: RFP-000000000263

DOC TITLE: T6.5 – CONSTRUCTION PLAN

4.3 ESTIMATED ACTIVITY DURATION

4.5 ALLOCATION OF CONSTRUCTION SPREAD

4.6 LOGISTIC PLAN

4.6.1 HANDLING AND LIFTING

TENDER NO: RFP-000000000263

DOC TITLE: T6.5 – CONSTRUCTION PLAN

- Crane 20 – 40 Ton at pipe yard.

Stringing will be performed using side boom and assisted by excavator.

TENDER NO: RFP-000000000263

DOC TITLE: T6.5 – CONSTRUCTION PLAN

5 CONTRACTOR TEMPORARY SITE FACILITIES

5.1 LAYDOWN AREA AND TEMPORARY WORKSHOP

Proposed a laydown area route to Pipeline route.

b. Access route to proposed main laydown area from main road;

TENDER NO: RFP-000000000263

DOC TITLE: T6.5 – CONSTRUCTION PLAN

5.2 MATERIAL AND EQUIPMENT STORAGE

6 DEPLOYMENT PLAN FOR CONSTRUCTION TEAM

TENDER NO: RFP-000000000263

DOC TITLE: T6.5 – CONSTRUCTION PLAN

Refer to ITB Document, production rate of pipeline construction (Welding-Trenching-

2. Trenchless Crossing Team

2.1. Jacking / Thrust boring

2.2. Horizontal Directional Drilling (HDD)

Crossing locations using the HDD method are as follows: