Sched-plcp

Engineering Schedule
SYRIA
Technical Specification for

Pipeline Construction
Schedule PL-CP
February 1997
Controlled Document Ref.: Custodian: TES/5

Schedule PL-CP Revision 02
TES/5 TES/55 TES /D TES TEP TEN/1 TEN
Reason for Revision: Reformatting

Inclusion of river crossings
PL-CP
AFPC CONSTRUCTION PRACTICES FOR PIPELINES
Rev 2
SYRIA
TABLE OF CONTENTS
1 SCOPE AND DEFINITIONS

1.1 Scope
1.2 General
1.3 Definitions
2 MATERIAL HANDLING & CONTROL

2.1 Scope
2.2 General
2.3 Handling of Materials
2.3.1 Line Pipe
2.3.1.1 Lifting
2.3.1.2 Transport
2.3.1.3 Storage
2.3.1.4 Handling of Duplex Linepipe
2.3.2 Materials Other than Line Pipe
2.3.2.1 Lifting
2.3.2.2 Transport
2.3.2.3 Storage
2.4 Inspection of COMPANY Supplied Materials
2.4.1 General
2.4.2 Crated Material
2.5 Reconciliation of COMPANY Supplied Materials
3 SURVEY, ROW CLEARING & GRADING

3.1 Survey and Right-of-Way (ROW)
3.1.1 Scope and Definition
3.1.2 Pipeline Route and Survey
3.1.2.1 General
3.1.2.2 Field Survey
3.1.2.3 Profile
3.1.2.4 Strip Topography, Crossing and Underground Structures
3.1.3 Maps and Drawings
3.1.3.1 Route Maps
3.1.3.2 Alignment Sheet
3.1.3.3 Property Plot Drawings
3.1.3.4 Crossing Permit Drawings
3.2 Staking, Clearing and Grading
3.2.1 Scope
3.2.2 Definitions
3.2.3 Staking
3.2.3.1 Pipeline Indicator (PI) Markers
3.2.3.2 Construction Reference (CR) Markers
3.2.3.3 Establishing Survey Data
3.2.3.4 Temporary Markers
3.2.3.5 Preservation of Survey Stakes
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3.2.4 Clearing Within the ROW

3.2.4.1 Preconstruction Requirements
3.2.4.2 Crossings
3.2.4.3 Existing Pipelines and Other Facilities
3.2.4.4 Monuments
3.2.4.5 Above-ground Markers
3.2.4.6 Underground Obstacles
3.2.4.7 Overhead Obstacles
3.2.4.8 Explosives
3.2.5 Grading Within the ROW
3.2.5.1 General
3.2.5.2 Wadis and Water Courses
3.2.5.3 Access Roads
4 TRENCHING, LOWERING, CLEAN UP & ACCESS

4.1 Trenching
4.1.2 Trenching
4.1.2.1 General
4.1.2.2 Depth of Trench
4.1.2.3 Trench Width
4.1.2.4 Trench Cleaning and Maintenance
4.1.2.5 Maintenance and Safety of Traffic
4.1.2.6 Restoration of Road Surface
4.1.3 Blasting
4.1.3.1 General
4.1.3.2 Classification of Blasted Areas
4.1.3.3 Vibration Monitoring and Limitation
4.1.3.4 Safety
4.2 Pipe Lowering, Trench Padding, and Back-filling
4.2.1 Scope
4.2.2 Lowering the Pipe
4.2.2.1 General
4.2.2.2 Holiday Detection
4.2.2.3 Handling of Pipe
4.2.2.4 Lowering of Tie-ins
4.2.3 Padding
4.2.3.1 Pre-Padding
4.2.3.2 Post Padding
4.2.3.3 Plugging
4.2.3.4 Padding at Road Crossings
4.2.4 Back-filling of the Trench
4.2.4.1 General
4.2.4.2 Buried Service Crossings
4.2.4.3 Back Fill Material
4.2.4.4 Road Crossings
4.2.5 Stabilizing Sand Area
4.3 Clean-up of the Permanent Right-of-Way
4.3.1 Scope
4.3.2 Clean up
4.3.3 Restoration
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4.4 Vehicle Access Strip alongside the Permanent ROW
5 STRINGING AND BENDING

5.1 Scope
5.2 Stringing
5.2.1 General
5.2.2 String Location
5.2.3 Handling of Welded Pipe Section
5.2.4 Length of Welded Section
5.3 Pipe Bending
5.3.1 Procedure
5.3.2 Design
5.3.3 Fabrication
5.3.4 Examination
5.3.5 Elastic Bends
6 WELDING AND TESTING OF WELDS

6.1 Introduction
6.1.1 Scope
6.1.2 Applicable Standards, Specifications and Codes
6.1.3 Compliance with Specification
6.2 Terminology and Abbreviations
6.2.1 Terminology
6.2.2 Abbreviations
6.3 Materials
6.3.1 Scope
6.3.2 Condition and Certification of Material
6.3.3 Inspection
6.3.4 Disposal of Damaged Material
6.4 Qualification of Welding Procedures
6.4.1 General
6.4.2 WPS
6.4.2.1 Essential Variables
6.4.2.2 Reporting
6.4.3 CONTRACTOR's Responsibility
6.4.4 Welding of the Test Assembly
6.4.5 Examination of the Test Assembly
6.4.6 Additional Mechanical Testing Requirements to API 1104
6.4.6.1 Macro/Hardness Testing
6.4.6.2 Charpy V-Notch Impact Testing
6.4.7 Re-tests
6.4.8 Qualified Procedures
6.5 Welder Qualification
6.5.1 Introduction
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6.5.2 Qualified Welders

6.5.4 Qualification Tests
6.5.5 Termination of Test
6.5.7 Retests
6.5.8 Records
6.5.9 Renewal of Qualifications
6.5.10 Positions Qualified
6.5.11 Limits of Qualification
6.6 Welding Consumables
6.6.1 Approvals
6.6.2 Identification and Traceability
6.6.3 Deposited Weld Metal
6.6.4 Storage of Welding Consumables
6.6.5 Drying of Welding Consumables
6.6.6 Electrode Handling and Control
6.6.7 Filler Metal
6.7 Fabrication and Erection
6.7.1 Outline
6.7.2 Cutting and Preparation
6.7.3 Installation and Erection
6.7.3.1 General
6.7.3.2 Line-up Clamps
6.7.3.3 Pipe Orientation
6.7.3.4 Transition Pieces
6.7.3.5 Fit-up and Alignment
6.7.3.6 Pipe Lifting and Skidding
6.7.3.7 Threaded Connections
6.7.3.8 Cleaning Pipe and Fittings
6.7.3.9 Flanged and Bolted Connections
6.8 Production Welding
6.8.1 Scope
6.8.2 Qualifications
6.8.3 Welding Technique
6.8.3.1 Welding Process
6.8.3.2 Position of Welding
6.8.3.3 Direction of Welding
6.8.3.4 Number of Welders
6.8.3.5 Welding
6.8.3.6 Time Lapse between Passes and Interruption of Welding
6.8.3.7 Electrical Characteristics
6.8.4 Earthing Cables
6.8.5 Weather Protection
6.8.6 Tack Welding
6.8.7 Weld Cleaning
6.8.8 GTAW
6.8.9 Socket and Fillet Welds
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6.8.10 Preheat, Interpass, Cap Pass and Reheat Temperatures

6.8.11 Post Weld Heat Treatment
6.9 Quality Control
6.9.1 Scope
6.9.2 Documentation
6.9.2.1 Quality Control Manual
6.9.2.2 Procedures
6.9.2.3 Records and Certificates
6.9.4 Standards of Acceptability
6.9.5 Extent of Inspection
6.9.6 Visual and Radiography Inspection
6.9.6.1 Safety
6.9.6.2 Visual Examination
6.9.6.3 Radiography
6.9.6.4 Film
6.9.6.5 X-Ray Equipment
6.9.6.6 Film Density
6.9.6.7 Penetrameter Sensitivity
6.9.6.8 Film Processing
6.9.6.9 Film Viewing
6.9.6.10 Radiographic Procedure Specification
6.9.6.11 Radiography Identification
6.9.6.12 Image Quality Indicator
6.9.6.13 Radiography Procedures and Interpretation
6.9.6.14 Film Identification/Storage
6.9.6.15 Rejection of Radiographs
6.9.7 Ultrasonic Inspection
6.9.7.1 General
6.9.7.2 Ultrasonic Testing Procedure
6.9.8 Magnetic Particle and Dye Penetrant Inspection
6.9.9 Hardness Testing
6.9.10 NDE Requirements for Joints other than Butts
6.9.11 Reports
6.10 Weld Repair Procedures
6.10.1 Scope
6.10.2 Approvals
6.10.3 Sequence of Repair
6.10.4 Limitation of Repairs
6.10.5 Weld Rejected by Accumulation of Defects
6.10.6 Repair Rates
6.11 Welding and Inspection of Duplex Stainless Steel
6.11.1 General
6.11.2 Welding
6.11.2.1 Process
6.11.2.2 Backing Gas
6.11.2.3 Bevel Preparation
6.11.3 Inspection
6.11.3.1 Radiography
6.11.3.2 Ferrite Content
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6.12 Standard of Weld Acceptability

6.12.1 General
6.12.2 Right of Rejection
6.12.3 Visual Examination Acceptance
6.12.4 Magnetic Particle and Dye Penetrant Inspection Acceptance
6.12.5 Site Hardness Checks Acceptance
6.12.6 Radiographic and Ultrasonic Acceptance
7 PIPE LINE ANTI-CORROSION COATING

7.1 Scope
7.2 General
7.3 Material and Equipment
7.3.1 Scope of Supply
7.3.2 Condition of Supplied Material
7.3.3 Handling and Storage
7.4 Field Joints
7.4.1 General
7.4.2 Shrink Sleeve Method
7.4.2.1 Material Specification
7.4.2.2 Coating Application Procedure
7.4.2.3 Surface Preparation for Coating
7.4.2.4 Application of Coating
7.4.2.5 Inspection of Coating
7.4.3 Other Methods
7.5 Coating Repair Procedures
7.5.1 General
7.5.2 Repair Procedure
7.6 Testing, Inspection and Acceptance
7.6.1 General
7.6.2 Surface Inspection
7.6.3 Shrink Sleeves
7.6.3.1 Visual Inspection
7.6.3.2 Destructive Testing
7.6.4 Epoxy Coating Inspection
7.6.4.1 Thickness
7.6.4.2 Adhesion
7.6.4.3 Cure test
7.6.5 Holiday Detection
8 CATHODIC PROTECTION
8.1 Scope
8.2 Materials
8.3 Installation
8.4 Insulating Couplings/Insulating Flanges
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9 PIPELINE CONCRETE COATING

9.1 Scope
9.2 General
9.3 Concrete Specification
9.4 Concrete Materials
9.4.1 Cement
9.4.2 Aggregates
9.4.3 Water
9.4.4 Reinforcement
9.5 Performance
9.5.1 Barrier Coat
9.5.2 Concrete Mixing
9.5.3 Surface Condition
9.5.4 Application
9.5.5 Curing
9.6 Inspection and Testing
10 PERMANENT PIPELINE MARKERS

10.1 Scope
10.2 General
10.3 Chainage Markers
10.4 Block Valve Markers
10.5 Road Crossing Markers
10.6 Wadi Crossing Markers
10.7 Pipeline Crossing Markers
10.8 Cable Crossing Markers
10.9 Markers at Horizontal Bends
10.10 Cathodic Protection Markers
11 STATION PIPEWORK
11.1 Scope
11.2 Performance
11.2.1 General
11.2.2 Fabrication
11.2.3 Construction
11.2.4 Valve Actuators
11.2.5 Buried Valves
11.2.6 Block Valve Station
11.3 Cast-in Materials
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12 QUALITY AND TREATMENT OF FLUSHING AND HYDROTESTING WATER

12.1 Scope
12.2 CONTRACTOR Responsibilities
12.2.1 Water Source
12.2.2 Water Testing
12.2.3 Water Treatment
12.3 Water Quality
12.3.1 Introduction of Air after Hydrotest
12.3.2 Exclusion of Air after Hydrotest
12.4 Chemical Treatment
12.4.1 Cocktail Treatment
12.4.2 Individual Chemical Treatment
12.4.3 Special Treatment
12.5 Approved Cocktail Treatments
13 HYDROSTATIC TESTING
13.1 Scope
13.1.1 General Provisions
13.1.2 Sequence of Operations
13.1.2.1 Pipeline
13.1.2.2 Station Piping
13.2 CONTRACTOR's Responsibilities
13.3 Safety
13.3.1 General
13.3.2 Personnel
13.3.3 The Public
13.3.4 Work Performed on Test Section
13.4 Procedures
13.5 Testing Materials and Equipment
13.5.1 Materials
13.5.2 Test Instruments
13.6 Pre-test and Test Requirements
13.6.1 Pre-test Requirements
13.6.2 Test requirements
13.7 Pipeline Cleaning
13.7.1 Air Blowing
13.7.2 Brush Pig Cleaning
13.7.3 Acceptance Criteria
13.7.4 Pigging with Air
13.8 Gauging
13.9 Filling
13.9.1 Material and Equipment
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13.9.2 Execution
13.10 Stabilization, Entrapped Air Test and Pressurisation
13.10.1 Stabilization
13.10.2 Volume of Entrapped Air
13.10.3 Pressurization Requirements
13.11 Strength Test
13.11.1 General
13.11.2 Strength Test Pressure
13.11.3 Execution
13.12 Leak Test
13.12.1 General
13.12.2 Leak Test Pressure
13.12.3 Execution
13.13 Assessment of Strength and Leak Tests
13.14 Depressurization and Bulk Dewatering
13.14.1 Depressurization
13.14.2 Bulk Dewatering
13.15 Station Works Testing
13.15.1 General
13.15.2 Performance
13.16 Reporting
14 AS-BUILT RECORDS
14.1 Scope
14.2 As-Built Drawings
14.2.1 CONTRACTOR's Commitments
14.2.2 Scope of Submittal
14.2.3 Performance
15 PRECOMMISSIONING OF GAS LINES

15.1 Scope
15.2 General
15.3 Final Dewatering
15.3.1 General
15.3.2 Dewatering Pig Runs
15.3.4 Dewatering Records
15.4 Cleaning and Initial Drying
15.4.1 General
15.4.2 Cleaning and Initial Drying Pig Runs
15.4.4 Cleaning and Initial Drying Records
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15.5 Final Drying by Air Drying

15.5.1 Air Specification
15.5.2 Equipment Specification
15.5.2.1 Compressor
15.5.2.2 Air Manifold
15.5.2.3 Instrumentation
15.5.2.4 Air Disposal Equipment
15.5.3 Execution
15.5.4 Acceptance Criteria for Air Drying
15.6 Final Drying by Vacuum Drying
15.6.1 Vacuum Specification
15.6.2.1 Compressors
15.6.2.2 Vacuum Pumps
15.6.2.3 Manifolds
15.6.3 Vacuum Drying Procedure
15.6.4 Execution
15.6.4.1 Pre-drying checks
15.6.4.2 Leak test
15.6.4.3 Pump-down
15.6.4.4 Evaporation/evacuation
15.6.4.5 Soak test/acceptance test
15.6.5 Acceptance Criteria for Vacuum Drying
15.6.6 Filling Phase
15.7 Detailed Procedure for Drying on-Plot Piping
15.7.1 Dewatering
15.7.2 Cleaning and Drying
15.7.3 Completion
16 ROAD, RAILWAY, WADI & RIVER CROSSINGS

16.1 Scope
16.2 Road and Railway Crossings
16.2.1 General
16.2.2 Cased Crossings
16.2.2.1 Design
16.2.2.2 Materials
16.2.2.3 Construction
16.2.2.4 Inspection
16.2.3 Diversion Roads
16.2.4 CONTRACTOR's Proposal
16.3 Wadi and Escarpment Crossings
16.3.1 Definitions
16.3.2 Wadi Crossing Classification
16.3.3 Construction
16.4 River Crossings
16.4.1 Design & Engineering
16.4.1.1 Design
16.4.1.2 Block Valve Stations
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16.4.1.3 Engineering Study

16.4.1.4 Execution Plan
16.4.2 Survey Requirements for the Excavate & Pull Method
16.4.2.1 PRELIMINARY Survey
16.4.2.2 River Level
16.4.2.3 River Bank Survey
16.4.2.4 IN Survey
16.4.2.5 POST TRENCH Survey
16.4.2.6 POST PULL Survey
16.4.2.7 POST BACKFILL Survey
16.4.3 Survey Equipment
16.4.4 Execution Requirements
16.4.4.1 Pull Requirements
16.4.4.2 Communications
16.4.4.3 Transportation across the River
16.4.4.4 Pre pull meeting
16.4.5 River Bank Consolidation
16.4.6 Safety
APPENDIX "A" - TECHNICAL SCHEDULE USER FEEDBACK PAGE
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CONSTRUCTION PRACTICES FOR PIPELINES
AL FURAT PETROLEUM COMPANY
1 SCOPE AND DEFINITIONS
1.1 Scope
This Specification defines the minimum requirements of Al Furat Petroleum Company for
the installation of pipelines, flowlines and related facilities for use with onshore production
facilities.
1.2 General
Anything contained herein or the omission of any essential provisions herefrom shall not be
construed to relieve CONTRACTOR of any duty or obligation necessary for the complete
installation of said facilities ready for use and operation.
This Specification and the project Scope of Work are intended to be complementary and
anything listed in this Specification but not shown on the Drawings or shown on the
Drawings but not listed in this Specification shall be of like effect as if shown and
mentioned in both.
1.3 Definitions
Within this Specification the following definitions shall apply:
COMPANY: Al Furat Petroleum Company or a designated representative
performing Work on behalf of Al Furat Petroleum Company.
CONTRACTOR: The Contractor, Vendor or Manufacturer selected by
COMPANY to perform the Work or provide equipment and
services as described in this Specification.
INSPECTOR: The individual(s) designated by COMPANY to act on
COMPANY's behalf for all matters relating to Quality
Control, Testing, and Acceptance of the Work described in
this Specification.
Shall: A mandatory requirement or course of action
Should: A recommended requirement or course of action
Could: A possible course of action
2 MATERIAL HANDLING & CONTROL
2.1 Scope
This Article covers the minimum requirements for handling, storage and administration of
all materials required for the Work.
2.2 General
Handling of materials, including but not necessarily limited to receipt, checking, lifting,
loading, transport, unloading, stacking, storage and control (including documentation) shall
be carried out by CONTRACTOR in such a manner as to avoid any damage and/or loss of
Materials.
CONTRACTOR shall exert full control on material and shall report on the receipt, issue,
and stock status of the CONTRACTOR and COMPANY supplied materials.
CONTRACTOR's procedures for material receipt, storage, handling and return of
surplus/rejected materials shall conform to COMPANY's procedures.
2.3 Handling of Materials

2.3.1 Line Pipe
2.3.1.1 Lifting
The pipe shall be handled in such a manner that it does not strike objects which may
damage the pipe and/or coating. Pipe shall be lifted, moved and lowered from one
position to another by suitable and certified equipment. When lifting pipe, non-abrasive
wide nylon pipe slings or special lifting hooks equipped with a non-metallic bevel
protector, such as Teflon inserts, shall be used.
For large diameter pipe (>20 in.) pipe hooks shall be curved to fit ID of pipe.
Furthermore, when windy conditions prevail, a tug line shall be used to prevent pipe
from swinging.
Temporary attachments for handling or lifting shall not be welded to any pipe.
Pipe bevel protectors removed for handling shall be replaced to prevent ingress of dirt
and sand.
2.3.1.2 Transport
Trucks used to transport coated or bare pipes shall have an uninterrupted flat bed of
approximately 12 metres length and 2.4 metres. width equipped with side stanchions of
about 0.9 m height. Pipes shall be protected against truck bed by means of at least five
nonmetallic cross beams. Non-metallic separation shall be provided to avoid any
damage to coating by side stanchions.
After loading, suitable non-metallic slings shall be used to tie the load securely to the
truck. During transport the tension of these slings shall be regularly checked. Pipe ends
shall be protected from contact with other metallic materials.
CONTRACTOR shall ensure that no bevel protectors can be lost during transport.
Pipes shall only be transported on trucks (lifting equipment shall not be used to
transport pipe).
2.3.1.3 Storage
Ground surfaces to be used for stacking of pipe shall be reasonably flat. Stacked pipes
shall be raised above ground surfaces and prevented from movement by 3 berms of
screened sand covered by polyethylene sheeting or by using timber. When stacked, the
outer pipes of the bottom layer shall be wedged or clipped. Pipes of different diameter,
wall thickness, grade or manufacturer shall be stacked separately, each stack to be
properly marked to the satisfaction of COMPANY.
Coated pipes shall be stacked using rubber or other suitable separator strips ( e.g. PE
ropes)
CONTRACTOR shall verify with COMPANY the acceptable stacking height for
linepipe in storage.
2.3.1.4 Handling of Duplex Linepipe
The handling and storage of duplex linepipe will allow the pipe end caps to remain on
the pipe at all times in order to prevent the ingress of dust and water.
Every precaution shall be taken by the CONTRACTOR to ensure that no carbon steel
comes into contact with the duplex stainless steel.
If pipe hooks are used to handle linepipe, they shall be provided with nylon inserts. The
hooks shall be new and not be used for the handling of carbon steel.
2.3.2 Materials Other than Line Pipe
2.3.2.1 Lifting
Materials shall be lifted by CONTRACTOR using equipment that will not in any way
damage the material. It is prohibited to apply anchor hooks to delicate parts like hand
wheels, nozzles, etc. for lifting of the materials.
Temporary attachments for handling or lifting shall not be welded to any materials.
Fittings shall only be handled by suitable non-abrasive slings.
2.3.2.2 Transport
During transport, materials shall be secured by suitable non-metallic non-abrasive
slings. When volume and weight of material requires adequate lashing and securing,
CONTRACTOR shall either use chain and load binder or webbing strap with ratchet.
It is prohibited to transport fragile materials in more than one layer.
2.3.2.3 Storage
Blinded openings of materials shall be kept closed until installation. The blinds shall be
replaced by CONTRACTOR in case of damage during transport or storage. For
materials which shall be stored cool and/or dry as required by the manufacturer or the
Specifications, CONTRACTOR shall provide suitable storage facilities in accordance
with the requirements of the manufacturer and/or the Specifications.
Stored materials shall be protected from ground surfaces by using timber. Ground
surfaces in storage areas shall be clean and flat. It is prohibited to store fragile materials
in more than one layer.
2.4 Inspection of COMPANY Supplied Materials
2.4.1 General
CONTRACTOR shall visually inspect COMPANY supplied materials immediately
upon receipt to ensure their conformity to specification and suitability for the intended
application. Discrepancies and defects discovered shall be reported within 24 hrs of
such receipt otherwise the material shall be considered conformant and free from
damage and CONTRACTOR shall be considered liable for damage or loss reported at a
later date as well as for any delay of work resulting from CONTRACTOR's failure to
report on time.
2.4.2 Crated Material
In the case of materials delivered to the CONTRACTOR in their original sealed crates,
CONTRACTOR shall open the crates and examine the materials only upon arrival of
these materials at his own storage yard; this examination shall be witnessed by
COMPANY inspector. When crates are damaged, their condition shall be noted and the
contents examined when CONTRACTOR takes receipt at COMPANY's storage yard.
2.5 Reconciliation of COMPANY Supplied Materials
At the end of the project the CONTRACTOR shall submit for COMPANY's approval a
detailed description reconciliation for all COMPANY materials issued, properly
documented and MESC code marked; such reconciliation shall automatically show surplus
materials. Upon approval of reconciliation by COMPANY the CONTRACTOR shall return
all surplus and rejected materials to COMPANY's storage yard or as directed.
3 SURVEY, ROW CLEARING & GRADING
3.1 Survey and Right-of-Way (ROW)

This sub-article covers the minimum requirements for the pipeline route and centreline
survey and mapping.
The following definitions shall apply:
Right-of-Way (ROW): A strip of land 20 meters wide in total, 10 meters on
either side of the centreline of the pipeline.
Public Open Space (POS): A strip of land 15 meters wide on each side of the Right-
of-Way to safeguard the pipeline after construction.
3.1.2 Pipeline Route and Survey

3.1.2.1 General
CONTRACTOR shall be responsible for all survey work prior, during and upon
completion of construction work as well as As Built work. CONTRACTOR shall
perform the survey work specified hereunder using proven equipment and techniques.
COMPANY shall review pre-construction route maps and pipeline centreline alignment
sheets before any pipeline construction works begins
3.1.2.2 Field Survey
CONTRACTOR shall perform a field survey of the pipeline route which includes the
determination of the following:
a) Contour lines of the Pipeline Route.
b) Physical features that may affect the selection of pipeline centreline alignment
and construction.
c) Pipeline centreline alignment.
d) Sloped-distance of alignment to provide the actual pipeline length.
e) Horizontal distance of alignment for ROW acquisition.
f) Property plots
g) Identification of all roads, railways, wadi’s, cables, pipelines, ground beds etc.
which cross the proposed pipeline route.
The field survey shall be tied-up to national geodetic grid and nationally established
geodetic points (bench marks).
3.1.2.3 Profile
The CONTRACTOR shall establish the profile of the survey centreline. Elevations
shall be obtained at all sharp breaks in slope, at high and low points, and at least every
100 meter on gently sloping terrain. Sufficient data on top and sub soil shall be
obtained on active farm land, marsh land, road, railroad, wash, wadi and river crossing
profiles for permits applications and design criteria.
3.1.2.4 Strip Topography, Crossing and Underground Structures
All significant topography and physical structures which might affect pipeline
construction and/or maintenance shall be located and included on the Route Maps and
Alignment Sheets. These features include, but are not limited to, streams, washes,
roads, trails, wadi's, bridges, culverts, buildings, pipelines, power lines, buried cables,
fences, cultivated areas, swamps or wet areas, rock outcrops, railways, archeological
sites, vegetation and soil characteristics, quarries, or any other natural or cultural
features.
CONTRACTOR shall make every attempt to identify underground pipelines, cables,
etc. during the centreline survey. CONTRACTOR shall sweep the full centreline route
of the pipeline with a "pipeline/cable detector". When an underground structure is
encountered, it shall be staked and identified with a description, size, depth and owner
if at all possible.
Existing cables, pipelines, tunnels, etc., if indicated on the Drawings are for
information only. COMPANY does not guarantee that the information shown on the
Drawings is either complete or correct. CONTRACTOR is entirely responsible for
detecting and locating all underground obstacles whether shown on the Drawings or
not. True (Geodetic) bearings shall be used for alignment, permit and property plot
drawings.
3.1.3 Maps and Drawings
3.1.3.1 Route Maps
CONTRACTOR shall draft the survey on a Route Map covering the Pipeline Route,
centreline alignment, ROW, POS as well as all pertinent physical and topographical
features. The map shall also include land ownership within the ROW with ties to
corners and topographic features.
The map scale shall not be smaller than 1/10,000 in length or 1/1000 in width. The map
shall also show the contour line at 1 m. elevation spacing and at a closer spacing on
critical areas.
3.1.3.2 Alignment Sheet
CONTRACTOR shall prepare pipeline Alignment Sheets showing the plan and profile
of the pipeline centreline. The Alignment Sheets shall clearly present all pertinent
information including horizontal distances (partial and cumulative); horizontal angles;
grade, bottom of ditch and centreline elevations; pipeline indicator markers, CP
markers, crossings and all other information as required elsewhere in this Specification.
The horizontal scale shall not be smaller than 1/1000 and the vertical not smaller than
1/200
3.1.3.3 Property Plot Drawings
CONTRACTOR shall prepare a Plot Drawing for each property location and for every
property parcel crossed by the proposed ROW. Plots shall locate surveyed alignment
with respect to title information. Legal descriptions shall be furnished with each plot.
Each plot shall be certified correct by the CONTRACTOR. Scale of plot shall be
approved by COMPANY.
3.1.3.4 Crossing Permit Drawings
CONTRACTOR shall prepare Permit Drawings for all road and railroad crossings, for
river crossings, and crossings of active farm land for the purpose of acquiring permits
and for crossing government lands. All permit drawings shall be in accordance with the
Specifications of the requesting agency.
3.2 Staking, Clearing and Grading
3.2.1 Scope
This Article covers the minimum requirements for staking, clearing and grading along
the Pipeline Route as required for the Work.
3.2.2 Definitions
Clearing: shall mean but shall not be limited to the cutting and
disposal of trees, farm crops, brush and undergrowth.
Grading: shall mean but shall not be limited to removal and
disposal of rocks, sand dunes, tree stumps and roots as
well as filling low points.
Point of Intersection: is a point of intersection in the horizontal plane of the
centrelines of sequential straight sections of the pipeline
route. In general this point will be outside the actual
pipeline centreline because of the bending radius to be
applied.
3.2.3 Staking
3.2.3.1 Pipeline Indicator (PI) Markers
The centreline of the pipeline route shall be staked by CONTRACTOR with (PI)
markers which are inter visible by binoculars or theodolite.
Contractor shall also establish two additional markers at each point of intersection in
such a manner as to enable him to reestablish the said points after completion of
installation work.
3.2.3.2 Construction Reference (CR) Markers
Before the start of the clearing operations, CONTRACTOR shall install two CR
markers, one on each side of the pipeline route at each PI marker location. CR and PI
markers are to be in one line perpendicular to the pipeline route.
3.2.3.3 Establishing Survey Data
All property lines, restrictions, grades, pipe or power lines, levels, and bench marks
shall be established and maintained by CONTRACTOR who shall be responsible for
same.
3.2.3.4 Temporary Markers
Before the start of the clearing operations CONTRACTOR shall install temporary
markers in the centreline of the pipeline route at distances of maximum 100 m.
3.2.3.5 Preservation of Survey Stakes
CONTRACTOR shall offset the centreline stakes as specified herein for clearing,
grading and ditching.
CONTRACTOR shall be held responsible for the preservation of all stakes and marks;
he shall replace, at his own expense, any stakes destroyed or lost and any survey work
required.
3.2.4 Clearing Within the ROW
3.2.4.1 Preconstruction Requirements
CONTRACTOR shall, before starting any clearing operations, familiarize himself with
any requirements by Authorities for work along the Pipeline Route or in connection
with the use of other lands or roads for construction purposes.
3.2.4.2 Crossings
CONTRACTOR shall notify COMPANY 7 days prior to the clearing of all road,
railway, pipeline, cable, stream and wadi crossings and crossings of other existing
structures.
CONTRACTOR shall not commence work on such crossings before having obtained
approval from the Authorities and landowners concerned to the satisfaction of
COMPANY. The crossings shall be installed to meet at all times the requirements and
conditions of the permits, issued by the Authorities concerned.
In the absence of any specific requirements by Authorities, CONTRACTOR shall
comply with COMPANY's instructions.
3.2.4.3 Existing Pipelines and Other Facilities
Where the ROW comes within 25 meters of an existing pipeline, CONTRACTOR shall
propose methods to safeguard the existing pipeline (e.g. a demarcation fence).
CONTRACTOR shall not operate within 25 meters from existing pipe lines without
COMPANY approval.
Equipment may be operated up to 3 m from existing facilities, provided these facilities
are properly located and indicated by CONTRACTOR.
3.2.4.4 Monuments
CONTRACTOR shall protect all shrines and monuments, including border stones. If it
is necessary to remove a number of these items for safekeeping, the CONTRACTOR
shall contact the responsible persons concerned and conform to their requirements.
3.2.4.5 Above-ground Markers
CONTRACTOR shall mark all exposed obstacles to avoid any possible damage
throughout the performance of the Work and restore them to the same state as before if
damage occurs.
3.2.4.6 Underground Obstacles
CONTRACTOR is entirely responsible for protecting all foreign services throughout
the Work. CONTRACTOR shall propose to COMPANY and the relevant Authority for
their approval, methods of temporary and, if necessary, permanent support and back
filling for all foreign services encountered .
Where it is necessary for CONTRACTOR to construct a temporary ROW crossing over
an existing service, CONTRACTOR shall hand-dig a minimum of 2 metres either side
to expose the service and verify cover.
3.2.4.7 Overhead Obstacles
CONTRACTOR shall contact COMPANY and the local Electricity Authority to
determine the minimum safe clearances allowed underneath overhead power lines at
each point where these cross the ROW or access roads.
CONTRACTOR shall then erect goal posts at the agreed height on each side of any
overhead lines which cross the ROW or any access roads to it, which will be used by
CONTRACTOR.
CONTRACTOR shall liase closely with relevant Authorities and give adequate notice
to them of trench excavation, and subsequent back filling, in the vicinity of all
underground services to allow such Authorities to inspect and witness such excavation
and back filling should they require to do so.
CONTRACTOR shall furnish all support and replacement material required at
crossings of underground obstacles.
3.2.4.8 Explosives
In the event CONTRACTOR finds explosives in or along the ROW, CONTRACTOR
shall notify COMPANY and the appropriate Authority or agency without delay.
CONTRACTOR shall be responsible for making all necessary arrangements to have the
explosives removed by a specialist approved by the controlling authorities.
3.2.5 Grading Within the ROW
3.2.5.1 General
CONTRACTOR shall grade off high points and fill low points to allow the pipe to be
bent and laid within the limits set forth herein, and shall drill, blast, and excavate rock
or other material which cannot be graded off with ordinary grading equipment in order
to provide an adequate working space along the pipeline route.
3.2.5.2 Wadis and Water Courses
CONTRACTOR shall perform all necessary grading at wadi crossings and at any other
location, required to permit the passage of construction equipment. In doing so,
CONTRACTOR shall take all necessary precautions so as not to interfere with or cause
pollution of the water flow, and to avoid damage to stream banks.
No ditches, wadis or drains shall be filled, bridged or otherwise obstructed without
written approval of COMPANY and/or Authorities having effective control over such
water courses.
3.2.5.3 Access Roads
In rough or steep terrain CONTRACTOR may wish to grade access roads into the
ROW to facilitate moving in materials, personnel and Construction Equipment.
Where such roads are required by CONTRACTOR he shall be solely responsible for all
violations and for making good all damage caused by the construction and use of such
roads.
4 TRENCHING, LOWERING, CLEAN UP & ACCESS
4.1 Trenching
This Article of the Specifications covers the minimum requirements for trenching as
required for the Work.
The following definitions shall apply to this article:
Depth of Cover: shall mean the measured from the top of the pipe coating
to the top of the undisturbed surface of the soil, or top of
graded ROW which ever is smaller.
Rock: For depth of cover purposes, rock in trench is defined as
the rocky part of the specified trench which cannot be
removed by ditching machine, rock plough, back hoe or
ripper, to be decided after two passes of a D9 Caterpillar
tractor (or one pass of a tandem D9) or equal, equipped
with proper ripping equipment.
4.1.2 Trenching
4.1.2.1 General
The construction over or under all existing structures such as roads, water lines,
telephone lines, and other pipelines shall be the responsibility of CONTRACTOR.
CONTRACTOR shall keep trenching operations at a maximum distance of 10 km
ahead of back filling operations, in order to limit the risk to the public of the open
trench.
The extent of rock encountered during trenching shall be recorded on the as-built route
maps by the CONTRACTOR.
4.1.2.2 Depth of Trench
The trench shall be excavated so as to provide a minimum depth of cover as specified
below and with due consideration to sand padding. Excavated materials shall be placed
at a minimum of 1 m from the edge of the trench.
Trenches having a slope of more than 10% shall be provided with structures or
retaining barrier(s) on the trench sides in order to prevent water from falling into the
trench thus washing out the trench floor or padding thereon.
The minimum depth of cover at crossings of wadis, drainage ditches, tarmac and graded
roads, tracks, and active farm land, shall be 1500 mm. This depth shall be extended a
minimum of 5 m outside the edge of the road, wadi, ditch, etc. measured horizontally
perpendicular to its axis.
Where the pipeline crosses other pipelines, sewers, water lines, cables, conduits or other
underground structures of any kind, CONTRACTOR shall excavate and grade the
trench to a depth and in such a manner that the top of the pipeline will be a minimum of
500 mm below the bottom of the underground structure crossed, except that if a
clearance of more than 500 mm is required by the authorities having jurisdiction,
CONTRACTOR shall provide such increased clearance.
In the event that the pipeline crosses over existing structures, the same clearance as
described above shall be maintained.
For cases other than those specified above, the minimum depth of cover shall be 1000
mm.
Surface of fill material placed to fill low points to accommodate pipe bending
limitations may be used to determine depth of cover subject to approval by
COMPANY.
4.1.2.3 Trench Width
In the case of a single pipeline to be laid in the trench, the trench width shall normally
be equal to the outside diameter of the pipe plus 300 mm (i.e. 150 mm on each side of
the pipe) unless otherwise approved by COMPANY.
In the case of more than one pipeline to be laid in the trench, the trench width shall
normally be the sum of the diameters of the pipes plus 300 mm plus 500 mm clearance
between the outside of adjacent pipes unless otherwise approved by COMPANY.
4.1.2.4 Trench Cleaning and Maintenance
The trench bottom and sides shall be free of all brush, skids, pipe protectors, rocks,
large clods, sticks, projecting rocks and other hard objects which shall be removed, so
the pipe and protective coating shall not be damaged, punctured or abraded. The trench
shall in no way be used for the disposal of construction wastes.
CONTRACTOR shall maintain the trench in good condition and shall provide and use
sheet piles, jacks, pumps, etc., as required to maintain the trench in good condition and
reasonably free of water until the pipe is laid in place and backfilled.
4.1.2.5 Maintenance and Safety of Traffic
In locations where the trench is cut across roads, tracks, paths, walkways, etc.,
CONTRACTOR shall provide temporary bridges or a diversion road of adequate
strength and properly constructed to allow the passage of normal traffic with a
minimum of inconvenience and interruption with COMPANY approval.
Proper warning signals shall be placed and maintained while such crossings are open. If
the crossings are open at night CONTRACTOR shall provide and use warning lights or
lanterns, all as required by the local authorities having jurisdiction and/ or COMPANY.
CONTRACTOR shall arrange to complete the trenching laying and back filling of such
crossings and to remove the temporary bridging before the end of the regular work day
in order to minimize hazard to night traffic.
4.1.2.6 Restoration of Road Surface
Whenever it is permissible to cut open a road to make a road crossing, CONTRACTOR
shall remove and restore the road surface back to its original state in accordance with
the requirements of the local authorities.
4.1.3 Blasting
4.1.3.1 General
All activities including but not limited to storage, transportation and blasting shall be
carried out in accordance with N.F.P.A. No. 495, BS 5607 and the instructions of local
authorities and/or the requirements in this section, whichever is the most stringent.
Blasting shall be carried out prior to stringing the pipes.
4.1.3.2 Classification of Blasted Areas
Areas to be blasted are to be categorized with respect to their distance from existing
pipeline or structures, above or below ground, as follows:
a) More than 50 meters: CONTRACTOR shall submit his proposed blasting
procedure and perform a trial blast for COMPANY approval.
b) Between 20 and 50 meters: CONTRACTOR shall submit a procedure for
controlled blasting, which shall also detail safety precautions to safeguard
existing pipelines or structures. This procedure is to be approved by COMPANY
prior to commencement and execution of trial blast.
c) Less than 20 meters: no blasting is allowed.
4.1.3.3 Vibration Monitoring and Limitation
Ground vibration due to blasting near existing structures shall be continuously
monitored with certified instruments to be provided by CONTRACTOR and approved
by COMPANY.
Peak particles velocities near existing structures (e.g. pipelines running parallel) shall
be kept to a minimum and must be approved by COMPANY as part of the contractor's
proposed blast procedure. In no case shall the peak particle velocity exceed 10 mm/sec.
4.1.3.4 Safety
Blasting will not be permitted in any location where possible danger exists to the
general public, property, existing utilities or other structures. In such locations other
methods of extracting rock shall be proposed by CONTRACTOR for approval by
COMPANY.
Any landowner or tenant that may be affected by the blasting operation shall be notified
far enough in advance by CONTRACTOR so that adequate steps can be taken to
protect livestock or other property.
4.2 Pipe Lowering, Trench Padding, and Back-filling
4.2.1 Scope
This Article covers the minimum requirements for padding, lowering the pipe back-
filling, compacting and stabilizing the trench as required for the work.
4.2.2 Lowering the Pipe
4.2.2.1 General
All pipe shall be lowered in within 96 hours of completion of front-end welding.
4.2.2.2 Holiday Detection
Immediately before the lowering operation commences, the coating shall be holiday
detected and if necessary repaired to the satisfaction of COMPANY. For holiday
detection criteria refer to Article 7 of this Specification.
4.2.2.3 Handling of Pipe
Wide non-abrasive slings or belts shall be used in all lowering operations and care shall
be taken when removing slings from around the coated pipe after it has been lowered
into the trench. Any damage caused to the pipe and coating during lowering operations
shall be repaired before back-filling commences. Lowering in using a COMPANY
approved number of standard pipe cradles will be permitted if CONTRACTOR
demonstrates that pipe coating is not damaged.
4.2.2.4 Lowering of Tie-ins
Unless otherwise agreed by COMPANY, tie-ins shall take place in the trench. For tie-
ins outside the trench, lowering operations shall be undertaken in such a manner as to
minimize induced stresses due to construction procedures. The portion of the pipeline
between trench and bank shall be supported by sidebooms holding the line in a gentle
"S" curve. Due consideration shall be given to the timing of these operations with
reference to minimum and maximum ambient temperatures.
4.2.3 Padding
4.2.3.1 Pre-Padding
All trenches shall be pre-padded with soft sand, screened with 5 mm sieve, before
lowering the pipe in. Compacted pre-padding thickness shall not be less than 150 mm.
No padding shall be placed until COMPANY has inspected and approved the trench
bottoms.
4.2.3.2 Post Padding
Immediately following lowering-in of the pipe and prior to backfilling, sand shall be
placed around and above the pipe, so as to fill the trench to a depth of 300 mm above
the crown of the pipe with the sand padding sloped to its normal angle of repose.
4.2.3.3 Plugging
COMPANY may, at its sole discretion, allow "plugging" as a temporary means of
restraining the pipe in the trench as an alternative to the immediate full post- padding
operation, should such not reasonably be possible. Plugging consists of placing a 2
meter long plug of sand on top and around the pipe at the centre of each pipe length.
4.2.3.4 Padding at Road Crossings
Where the trench has been excavated through or along drive-ways, walks, roads, etc. all
sand padding both prior to and after shall be thoroughly compacted by watering and
utilizing COMPANY approved hand tools.
The CONTRACTOR shall achieve a compacted sand fill around the pipe up to 300 mm
above the crown of the pipe.
4.2.4 Back-filling of the Trench
4.2.4.1 General
The trench shall not be back filled until COMPANY has approved the sand padding
around and above the pipe and has approved starting the back filling operation.
4.2.4.2 Buried Service Crossings
In areas containing buried telephone, telecommunication, or electric cables, back filling
shall not be performed until all tiles have been replaced and protected and/or all cables
have been supported to COMPANY satisfaction.
4.2.4.3 Back Fill Material
Initial back filling shall be performed as soon as possible after padding has been
approved. The material used for initial backfill shall be loose material with no
dimension greater than 100 mm, all subject to COMPANY approval. The fill material
shall be placed in such a manner as to avoid disturbing the sand padding and excessive
penetration (more than 150 mm) of rocks into the sand layer. CONTRACTOR shall
demonstrate that his proposed method of back filling achieves this requirement. The
initial backfill shall be placed in the trench to a level slightly above the surrounding
ground.
After the initial back fill the remaining material excavated shall be neatly crowned over
the trench (the windrow), except in wadi areas. Where rock is excessively large, in
COMPANY's opinion, this shall be removed from the ROW by the CONTRACTOR
and not used as windrow material.
4.2.4.4 Road Crossings
Where the trench has been excavated through or along drive-ways, walks, roads, etc.,
the initial back fill shall be thoroughly compacted by mechanically compacting the
material into place. The road shall be restored to its original condition in accordance
with the requirements of local authorities having jurisdiction or, in the absence of such
requirements, with AFPC Schedule B-CP, Earthwork.
Trenches crossing ditches shall be back filled with the material excavated from the
trench at the location; except that in locations where the excavated material in
COMPANY's opinion is not suitable for back filling, CONTRACTOR shall provide
and use suitable material from another source.
4.2.5 Stabilizing Sand Area
To ensure the retention of sand cover in active sand areas (i.e. where the windrow
consists of sand only), the backfill must be stabilized, preferably with a 150 mm layer
of gravel or other stable material, subject to COMPANY approval.
4.3 Clean-up of the Permanent Right-of-Way
4.3.1 Scope
This Article covers the minimum requirements for clean-up and restoration of the ROW
strip and other construction sites as required for the Work.
4.3.2 Clean up
CONTRACTOR shall clean-up the ROW all working areas, including access roads
used by him during the course of the Work, and shall restore the lands traversed, to the
satisfaction of COMPANY. Light construction debris such as paper and plastic bags
shall not be allowed to blow across and litter landscape.
The excess soil along the ROW strip shall be leveled in a manner satisfactory to
COMPANY.
All loose rock < 200mm diameter exposed by the construction operations which is
scattered over the ROW or adjacent property shall be removed and placed over the back
filled pipe trench.
All loose rock > 200mm diameter exposed by the construction operations which is
scattered over the ROW or adjacent property shall be removed from the ROW by the
CONTRACTOR.
All rubbish/debris left over after removal of camp facilities shall be buried away from
the pipeline ROW. The site shall be leveled to COMPANY's satisfaction.
4.3.3 Restoration
All creeks, water courses, wells, siphons, drains, streams, wadis, ditches and irrigation
channels shall be reinstated by CONTRACTOR to their former condition and their
banks shall, if necessary, be pitched with stone and/or faced with special protection to
prevent washing out or erosion.
All enclosures, walls, gates, etc. shall be restored by CONTRACTOR to at least as
good a condition as they were prior to the commencement of the CONTRACTOR's
operations to approval of COMPANY.
All private roads, bridges and other private structures used by CONTRACTOR for
access or haulage shall be restored by CONTRACTOR to a condition equal to or better
than that which existed prior to the commencement of the CONTRACTOR's
operations.
Construction roads, used at escarpments, may be required by COMPANY to be left as
they are.
4.4 Vehicle Access Strip alongside the Permanent ROW
To ensure permanent access on the pipeline Right-of-Way for COMPANY personnel,
the CONTRACTOR will leave a 4 m wide Vehicle Access Strip along the pipeline.
Where the Vehicle Access Strip crosses the pipeline, a dedicated pipeline crossing
location shall be built and clearly marked.
Irrigation channels crossing the Right-of-Way shall be channeled through a length of
excess pipe or COMPANY approved alternative, in order to maintain a continuous
vehicle access strip.
Areas of soft sand in the continuous vehicles access strip shall be removed and replaced
by approved infill material so as to leave the vehicle access strip in a safe condition for
driving.
5 STRINGING AND BENDING
5.1 Scope
This Article covers the minimum requirements for stringing the line pipe along the trench
and for pipeline bends as required for the Work.
5.2 Stringing
5.2.1 General
CONTRACTOR shall be responsible for the stringing of the pipe.
Pipe shall not be placed directly on the ground but on skids, with proper padding which
are subject to COMPANY approval. Dragging, sliding or dropping of the pipe is not
permitted.
5.2.2 String Location
CONTRACTOR shall string the pipe in such a manner so as to cause no interference
with public roads, footpaths, tracks, etc. Suitable gaps shall be left in the string at
intervals as necessary to permit the passage of live stock and/or equipment.
5.2.3 Handling of Welded Pipe Section
The distance between the trench edge and the pipe string shall be so planned as to allow
convenient work space on one hand and to minimize lowering-in stresses on the other.
A night cap keeping the pipe clean and dry shall be installed at the ends of each welded
section.
5.2.4 Length of Welded Section
The length of the welded pipe section shall take due consideration of thermal expansion
and other expected or accidental movement of the pipe section. Special attention shall
be paid to strings with one or more bends, in view of the inherent increased risk of
failure of skids due to the above movement of the pipe. Length of individual pipe
strings shall generally not exceed 1 km, but in any case be subject to COMPANY
approval.
CONTRACTOR shall lay out and measure the pipes such that the number of pieces cut-
off less than one (1) metre long is kept to a minimum. Pipe lengths 1 to 2 m. shall be
progressively moved forward and incorporated into the string as needed.
5.3 Pipe Bending
5.3.1 Procedure
CONTRACTOR shall, before the start of the Work, submit and demonstrate to
COMPANY a bending procedure, which shall conform with the recommendations of
the manufacturer of the bending machine. This procedure shall be subject to
COMPANY's approval. The procedure shall include amongst others step length,
degrees per pull and method and accuracy of measurement during pulling of the bend.
5.3.2 Design
CONTRACTOR shall make all necessary field bends required for the proper
construction of the pipeline, following a trigonometric survey to establish the number
and degree of bends required, to ensure that the installed pipe shall conform to the
contours of the pre-padded trench.
The radius of Cold Bends shall be not less than 40 times the pipe diameter.
The end tangents of each bend shall be straight over a minimum distance of 2m or
twice the pipe diameter, whichever is greater.
CONTRACTOR shall lay out and measure the pipe for bending such that the length of
cut-off is kept to a minimum.
5.3.3 Fabrication
The Cold Bends shall be made by a smooth stretch bending machine. Bends with
wrinkles or kinks are not permitted, whilst ripples with a depth exceeding 0.5 mm are
unacceptable. CONTRACTOR shall provide a procedure for measuring ripples which
shall be approved by COMPANY.
The pads, dies and rolls of the bending equipment shall have soft surfaces to avoid
damage to the pipe coating. Where applicable, fully retaining bending shoes shall be
used. Roller type bending machines are preferred.
Bends in pipe of diameter 8 in. or greater shall be made using an internal hydraulic or
pneumatic mandrel.
During bending the longitudinal weld shall be located at a position approximately 30
degrees turned away towards the top from the pipe's neutral axis. The correct
combination of the position of the longitudinal weld for successive pipe joints in a bend
shall be chosen such that the longitudinal welds alternate and always occur in the top
half of the pipe.
Bending shall take place before any double jointing.
5.3.4 Examination
All bends shall be tested in the presence of COMPANY with a gauging plate of 97.5%
of the nominal internal diameter of the pipe prior to installation.
5.3.5 Elastic Bends
Elastic bending (cold springing) are forbidden.
6 WELDING AND TESTING OF WELDS
6.1 Introduction
6.1.1 Scope
This Article details the minimum requirements for the fabrication, welding, inspection
and testing of flowlines, pipelines and station pipe work designed for carrying crude oil,
water, oil/water and gas.
It is applicable to all parts of pipeline systems which are subject to ASME B31.3, B31.4
or B31.8.
6.1.2 Applicable Standards, Specifications and Codes
The following codes and standards shall be used as per this Specification.
Unless prescribed by date, the latest version of each publication shall be used together
with any amendments, supplements or revisions to such publications.
American Petroleum Institute
Std 1104 Standard for Welding Pipelines and Related Facilities.
PUB 2201 Procedure for Welding or Hot-tapping on Equipment
Containing Flammables.
API 5L Specification for Line Pipe
ASME Boiler and Pressure Vessel Code
ASME Section II Part A Ferrous Materials.
ASME Section II Part C Welding rods, Electrodes and Filler Metals
ASME Section V Non-Destructive Examination.
ASME Section IX Welding and Brazing Qualifications.
ASME Code for Pressure Piping
B31.3 Chemical Plant and Petroleum Refinery Piping
B31.4 Liquid Petroleum Transportation Piping Systems.
B31.8-Gas Transmission and Distribution Piping Systems.
American National Standard Institute
B1.20.1 Pipe Threads, General Purpose
B16.25 Butt Welding Ends.
B16.5 Pipe Flanges and Flanged Fittings, Steel Nickel Alloy and
Other Special Alloys.
American Society for Testing and Materials
ASTM A 370 Mechanical Testing of Steel Products.
ASTM E 94 Recommended Practice for Radiographic Testing.
ASTM E 586 Definition of Terms Relating to Gamma and X-Ray
Radiography.
National Association of Corrosion Engineers
NACE MR0175 Sulfide Stress Cracking Resistant Metallic Materials for
Oil Field Equipment
Manufacturers Standardization Society
MSS SP-44 Steel Pipe Line Flanges
British Standards
BS 4069 Specification for Magnetic Flaw Detection Inks and
Powders.
BS 5996 Methods of Testing and Quality Grading of Ferritic Steel
Plate by Ultrasonic Methods.
6.1.3 Compliance with Specification

In case of contradictions between this Specification and the standards, specifications
and codes listed in 6.1.2, the requirements of this Specification shall govern.
6.2 Terminology and Abbreviations
6.2.1 Terminology
Off-Plot Pipelines within the Scope of ANSI B31.4 and B31.8
On-Plot Pipework within the Scope of ANSI B31.3
6.2.2 Abbreviations
The following abbreviations are used in this Specification:
ASNT American Society for Non-Destructive Testing.
AWS American Welding Society.
CP Cathodic Protection.
CSWIP Certification Scheme for Weld Inspection Personnel.
CV Curriculum Vitae.
DAC Distance Amplitude Correction.
DC Direct Current.
DPI Dye Penetrant Inspection.
DSG Distance Size Gain (Diagram).
FSH Full Screen Height.
GTAW Gas Tungsten Arc Welding.
HAZ Heat Affected Zone.
H&D Hurker-Driffield (method of defining quantitative
blackening of radiographic film)
ISO International Standards Organization.
kV Kilo Volt.
mA Milli-Amp.
MPI Magnetic Particle Inspection.
NDE Non-Destructive Examination (equivalent abbreviation is
NDT).
PWHT Post Weld Heat Treatment.
SAW Submerged Arc Welding.
SFD Source Film Distance.
SKNDO Stichting Kursus Non Destructief Onderzoek.
SMAW Shielded Metal Arc Welding.
SWSI Single Wall Single Image.
WPS Welding Procedure Specifications.
6.3 Materials
6.3.1 Scope
This section of the Specification prescribes the minimum requirements for inspection of
materials on arrival on site and repair of all damaged materials.
6.3.2 Condition and Certification of Material
All materials for permanent incorporation into the Work shall be new, unused and
suitable for the intended application.
Only certified material shall be used in the permanent Work and CONTRACTOR shall
verify that all certificates are available prior to shipment of the materials.
6.3.3 Inspection
Each length of pipe and each fitting shall be thoroughly examined on receipt by the
CONTRACTOR internally and externally to ensure that it is free from visual
defects/damage, laminations, coating damage, defective bevels, incorrect dimensional
tolerances, severe corrosion, dirt, debris, or any other obstruction. Corroded or
damaged pipe and fittings shall be kept separate. CONTRACTOR shall report to
COMPANY the presence of any damaged material and the action proposed by the
CONTRACTOR.
6.3.4 Disposal of Damaged Material
The disposal of damaged material shall be decided solely by the COMPANY. The
COMPANY may either reject the material or allow a repair to be carried out, in which
case the following shall apply.
Acceptability of defects in the pipe or fitting detected during inspection shall be
determined in accordance with code ASME B31.3, B31.4 or B31.8 whichever is
applicable.
Dents which contain a stress concentrator such as a scratch, gouge, arc burn or groove,
and dents located at the longitudinal, spiral or circumferential weld shall be removed by
cutting out the damaged portion of pipe as a cylinder.
If laminations, split ends or inherent manufacturing defects in the pipe are discovered,
the lengths of pipe containing such defects shall be removed from the line to the
satisfaction of the COMPANY.
Repair on line pipe and fittings shall be executed as specified in Code ASME B31.3,
B31.4, B31.8, whichever is applicable. A record of all repairs shall be maintained by
the CONTRACTOR. This record shall be provided with the pipe or fitting
identification number and shall be forwarded to the COMPANY.
If permission for repair is granted, the welding shall be carried out by a qualified
welder to an approved welding procedure.
After completion of welding the repaired area shall be ground flush with the base
material and MPI and Ultrasonic tests carried out on all repaired areas and HAZ as
required by the COMPANY, except that ultrasonic inspection will not be required for
cap repairs.
The bevels shall be thoroughly inspected. If any of the pipe end bevels are damaged to
the extent that, in the opinion of the COMPANY, a satisfactory weld joint cannot be
obtained, and local repair by grinding cannot be successfully done, the damaged ends
shall be cut and beveled to the satisfaction of the COMPANY with an approved
beveling machine. Manual cutting and weld repair of bevels shall not be permitted.
Dents in bevels with a depth of less than 1 mm shall be removed by the
CONTRACTOR during the cleaning and grinding ahead of the welding in the field.
The CONTRACTOR shall re-bevel dented bevel lands with a depth of dent between 1
mm and 3 mm. Dents over 3 mm depth shall be repaired by cutting back and rebelling.
Buttering as a method of reclaiming defective material shall not be employed.
The repair of defective material by heating and hammering or jacking shall not be
permitted.
If due to cutting or repairs the pipe/fitting identification number is removed, it shall be
re-painted immediately in the presence of the COMPANY Site Representative. Pipe
without an identification number shall not be welded into the pipeline.
6.4 Qualification of Welding Procedures
6.4.1 General
The purpose of the Welding Procedure Specification (WPS), and the Procedure
Qualification Record (PQR), is to determine that the weld procedure proposed for
construction is capable of providing the required properties for the intended application.
The WPS is intended to provide direction for the welder and shall be readily available
on Site.
The PQR shall list the parameters used in qualifying the WPS, the NDE results, and the
results of mechanical testing.
Procedures will be qualified in accordance with API 1104 as amended by this
Specification.
Procedure test welds for line welding, welding of fittings on to live lines and tie-in
welding shall be made under fully simulated site conditions. The test shall also
incorporate removal of the line-up clamp and cooling (lapse times) as specified in the
procedure.
Procedure tests will also be developed to cover weld repairs.
All test assembly welding and testing shall be subject to witness and review by a
COMPANY representative.
Previously qualified procedures may be accepted at the discretion of the COMPANY, if
they meet the specified requirements and the testing of the procedures was witnessed by
the COMPANY or a certifying authority.
6.4.2 WPS
6.4.2.1 Essential Variables
Alteration of an essential variable within a WPS will require the requalification of the
WPS. Requalification will be required for changes in:
a) pipe manufacturer, manufacturing process and steel grade
b) bevel design e.g. V groove to U groove
c) pipe diameter outside 0.75 D to 1.5 D
d) wall thickness outside 0.75 t to 1.5 t
e) diameter, manufacturer or SMYS of electrodes
f) shielding gas flowrate or composition
g) electrode polarity
h) heat input outside +/- 10 % of WPS value
i) number of weld beads
j) number of welders
k) time of removal of line up clamp
6.4.2.2 Reporting
The forms used for WPS and PQR shall be similar to those proposed by API 1104.
In addition to the requirements of API 1104, the WPS shall specify the:
a) allowable tolerances on the joint design
b) manufacturer and brand of filler metal
c) number of welders for root and hot passes
d) minimum number of passes before a joint is allowed to cool to ambient
e) stage at which the line up clamp is removed
f) the heat input range for each weld bead, calculated by:
Volts x Amps
Heat input (kJ/mm) = --------------------------------------
Welding Speed (mm/sec) x 1000
The CONTRACTOR shall be responsible for all welding carried out by his organisation
and shall conduct the tests required by API 1104 and this Specification to qualify his
proposed welding procedures entirely at his own cost.
In no way may the responsibility for procedure qualification be transferred to a
subcontracted party. All qualifications carried out by sub-contractor shall be witnessed
and controlled by a CONTRACTOR's representative acceptable to the COMPANY.
The CONTRACTOR shall give the COMPANY a minimum of 48 hours notice prior to
the welding or testing of any qualification test assembly.
Two weeks prior to commencing any procedure qualification the CONTRACTOR shall
submit his proposed WPS to the COMPANY for review. Approval for the WPS will be
given after the NDE and mechanical qualification tests have been made and satisfy the
minimum code requirements.
6.4.4 Welding of the Test Assembly
The welding of the test assembly shall be carried out in Syria under field conditions and
in the presence of the COMPANY.
Test assemblies shall be prepared with pipe material to be installed under this Contract.
The pipes and fittings shall be supplied with API-5L / ANSI B16.25 bevels.
Where contract materials have been supplied in the same dimensions by more than one
manufacturer, a qualification test may be performed using two pipes from different
manufacturers. This may be used to qualify the procedure for use on the pipes from
different manufacturers provided the mechanical tests in the heat affected zone are
taken from both sides of the weld.
On completion of welding (or post weld heat treatment, if required), the weld shall be
left to cool for a minimum of 24 hours.
The root and the cap of the weld shall be visually inspected. Thereafter 100%
examination of the weld by radiography and other NDE method as may be specified by
the COMPANY, using techniques in accordance with ASME V, and Section 6.9 of this
Specification.
The standard of acceptability of welds shall be in accordance with API 1104 Section 6
and as modified in this Specification.
If the NDE examination is acceptable, the test weld shall be sectioned and the
specimens machined for mechanical testing. The mechanical testing shall be in
accordance with API 1104 Section 2.6 and as further required by subsection 6.4.5 of
this Specification.
The mechanical tests shall be carried out in an independent laboratory nominated by the
CONTRACTOR and approved by the COMPANY.
All test specimens shall be submitted to the COMPANY for approval and retention
along with the laboratory report describing all test results, macro interpretation and
including original macro photographs, etc. All testing shall be witnessed by the
COMPANY. The CONTRACTOR shall give 48 hours notice to the COMPANY prior
to commencement of mechanical testing.
6.4.6 Additional Mechanical Testing Requirements to API 1104
In addition to the requirements of API 1104, Macro/Hardness and Charpy Impact Tests
shall be carried out on all procedure qualifications irrespective of whether the NACE
standard is a design requirement or not.
6.4.6.1 Macro/Hardness Testing
The macro specimens shall be removed from the position in the test coupon as shown in
Figure 6.1. It shall be polished, etched and the weld deposit examined. If the macro is
free from defects, a hardness survey shall be carried out 1 mm below the cap and 1 mm
above the root of the weld. The readings shall be taken in the parent metal, heat
affected zone and weld as shown in Figure 6.2. The Macro examination shall conform
to QW-183 of ASME Section IX.
The Macro samples shall be prepared to a 600 grit paper finish, etched in 4% Nital and
shall be examined at X5 magnification. They shall show complete fusion and freedom
from cracks.
A Vickers hardness tester or an equivalent machine with a diamond indenter shall be
used. The test load shall be 20 kgs maximum. The first reading in the HAZ shall be
taken 0.5 mm from the fusion line. The frequency of testing is shown in Appendix 1.
All macros shall be lacquered and returned to the COMPANY. Photomacrographs shall
be presented with the PQR.
6.4.6.2 Charpy V-Notch Impact Testing
Charpy Impact testing shall be carried out in accordance with the procedure described
in ASTM-A370/E-23.
In the case of pipes with a nominal wall thickness of less than 5 mm and/or a nominal
diameter of less than 100 mm, Charpy testing is not required.
The Charpy specimens shall be taken transverse to the weld and the notch shall be
perpendicular to the surface of the weld (see Figure 6.3).
From the samples, groups of three specimens shall be taken at the following locations
(refer to Figure 6.3):
a) Weld metal centre line.
b) Fusion line.
c) Fusion line + 2 mm.
d) Base material.
Charpy samples shall be taken from the 12 o'clock and the 3 o'clock positions of the
weld. Each sample shall consist of three specimens. For each welding procedure to be
qualified , a total of 18 specimens are therefore required for testing; 9 from the 12
o’clock position and 9 from the 3 o’clock position.
Testing shall be carried out at a temperature determined as follows:
Nominal Wall Thickness (t) Test Temperature
(mm) (deg C)
t £ 16 T
25 ³ t >16 T - 10
t > 25 T - 20
where T is the minimum design temperature. If no design temperature is stated, the
impact testing will be carried out at 0 deg. C.
The recorded Charpy values recorded shall meet the following minimum requirements:
Steel Grade Specimen Size Charpy V Requirement
(API Spec 5L) (mm) (Joules)
Min. Average Min. Single
B 10 X 10 27 19
10 X6.7 21 15
10 X 5 18 13
X42 10 X 10 29 22
10 X6.7 23 17
10 X 5 19 15
X46 10 X 10 32 24
10 X6.7 25 19
10 X 5 21 16
X52 10 X 10 36 27
10 X6.7 28 21
10 X 5 24 18
X56 10 X 10 39 29
10 X6.7 30 23
10 X 5 26 20
X60 10 X 10 41 31
10 X6.7 32 24
10 X 5 27 21
X65 10 X 10 45 34
10 X6.7 35 27
10 X 5 30 23
X70 10 X 10 48 36
10 X6.7 37 28
10 X 5 32 24
The mean test value of the three test specimens shall be at least equal to the minimum
requirement, however, one specimen may show a lower value. This lower value shall
not be less than 70% of the minimum average requirement.
Whenever possible, standard specimens shall be used, i.e. 10 mm x 10 mm. In cases
where this is not possible subsize specimens shall be used subject to prior consent by
the COMPANY. The required absolute impact values (scale readings) shall be equal to
the required absolute value of standard size specimens multiplied by the following
factor:-
Specimen Size Factor
10 mm x 10 mm 1.000
10 mm x 7.5 mm 0.833
10 mm x 5 mm 0.667
6.4.7 Re-tests
If any of the mechanical tests fail to meet the minimum requirements then two
additional tests of the type that failed shall be taken. If these two tests are acceptable the
procedure will be accepted.
If either of the retest specimens fail, the procedure qualification shall not be accepted.
The CONTRACTOR shall ascertain the reason for failure and amend his WPS if
necessary before another test assembly is made.
If the results of the welding procedure qualification are unsatisfactory the
CONTRACTOR is allowed to do the following:-
a) two additional tests of the type that failed shall be executed, both of which shall
meet the specified requirements.
b) if one of the impact test specimens gives an unsatisfactory result and is
obviously caused by a local defect, a second test specimen may be taken and
tested; only one such replacement shall be permitted per set. If the test joint fails
to meet the minimum requirements for reasons other than defective preparation
of specimens, a new procedure specification shall be established and the
qualification test repeated.
No retesting shall be carried out without prior consent of the COMPANY.
6.4.8 Qualified Procedures
When all the required tests have been accepted and a procedure has been qualified, the
CONTRACTOR shall submit the WPS and PQR to the COMPANY for approval.
The WPS and PQR shall be cross-referenced since a WPS may require the support of
more than one PQR, while alternatively, one PQR may support more than one WPS.
The CONTRACTOR shall submit two copies of all procedures and test information to
the COMPANY.
6.5 Welder Qualification
6.5.1 Introduction
The Welder Performance qualification tests are intended to determine the ability of
welders and welding operators to make sound welds in accordance with an approved
welding procedure.
6.5.2 Qualified Welders
Only welders who have been qualified by the COMPANY in accordance with API 1104
Section 3 and this Specification shall be used for the welding of pipework and all
attachments to the pipework.
Welders who have executed the welding procedure for qualification purposes, which
has subsequently been tested and accepted for qualification purposes by the
COMPANY, will automatically be qualified for production welding of that procedure.
For each welding process to be used in production the CONTRACTOR shall qualify, at
his cost, each welder or welding operator using that process in accordance with this
Specification.
The Welder Performance qualification weld test shall be carried out in accordance with
one of the CONTRACTOR's qualified Welding Procedure Specifications (WPS).
The welding and radiography tests shall be carried out in Syria in the presence of the
COMPANY.
The CONTRACTOR shall give the COMPANY at least 48 hours notice in writing of
any intended testing in order that the COMPANY may witness the test.
6.5.4 Qualification Tests
All welders shall be qualified in accordance with API 1104 , as required by the WPS,
with the welding progression and other requirements in accordance with the relevant
WPS.
For pipes above 12 inch nominal diameter up to 28 inch nominal diameter, two welders
shall weld simultaneously. Each welder shall complete half (12 to 6 o'clock) of a test
nipple. For pipes 30 inch nominal diameter and above, three welders shall weld
simultaneously. Each welder shall identify the position of each weld on which he has
worked, with his identification number, letter or symbol by marking the pipe adjacent
to the weld with a weather proof crayon. Hard stamping shall not be used.
6.5.5 Termination of Test
If at any time during the qualification test the COMPANY feels that the welder or
welding operator does not have the required skill to produce satisfactory results, the
COMPANY may terminate the test.
The welder may only be re-submitted for another test after a period of training which
must be properly substantiated.
Visual inspection shall be carried out by the COMPANY at setup, completion of root
pass and completion of welding.
The radiographic and mechanical testing acceptance criteria shall be in accordance with
API 1104 as modified by para. 6.11.
6.5.7 Retests
Requalification shall be required when there is a change to any of the essential variables
of API 1104.
A welder or welding operator who fails to meet the requirements of either the
mechanical or the radiographic tests may, at the discretion of the COMPANY, be
allowed an immediate retest.
The welder or welding operator shall make two consecutive test assemblies for each of
the original tests failed.
The retests shall be examined by the original test method and both test coupons shall
meet the requirements. Failure of one retest assembly shall be cause for rejection of the
qualification.
6.5.8 Records
CONTRACTOR shall keep a record of all Welder Performance Qualification tests and
it shall contain as a minimum the information shown in the format suggested in 6.4.3
above.
CONTRACTOR shall also issue the welder with both a unique number, letter or
symbol which shall be recorded on the PQR, and a welder's card. The card shall show
the Welding Procedure Specification for which the welder is qualified. This card shall
be carried by the welders at all times and presented upon request by the COMPANY.
The card shall be valid only in Syria and is the property of, and revocable by, the
COMPANY.
6.5.9 Renewal of Qualifications
The renewal of welders qualifications shall be required when:-
a) The welder has not used the specific process welding procedure qualification
group for more than three months.
b) There is a specific reason to question his ability to produce welds that meet the
required Specification.
The retest shall be carried out in accordance with the original qualification procedure
and shall meet the same specified acceptance criteria.
6.5.10 Positions Qualified
Qualifying of positions shall be in accordance with API 1104
6.5.11 Limits of Qualification
The limits of welder qualification shall be in accordance with API 1104, with the
exception that the selection of wall thickness and diameter of the test specimen require
prior approval of the COMPANY.
6.6 Welding Consumables
6.6.1 Approvals
Welding consumables shall be of a type and brand approved by Controlas, Lloyds
Register, Det Norske Veritas, Bureau Veritas, American Bureau of Shipping or any
other internationally recognized controlling body. The CONTRACTOR shall submit to
the COMPANY Manufacturing, Control and Test Certificates for all welding
consumables proposed for use on the job.
Final approval of welding consumables for a particular job shall be given only when the
testing requirements of the Welding Procedure Specification have been met and
approved by the COMPANY.
6.6.2 Identification and Traceability
All consumables shall be clearly identified. In the case of SMAW electrodes at least
one legible imprint of the applicable AWS or other recognized classification shall be
marked on the flux as near as practical to the grip end of the core wire.
CONTRACTOR shall maintain a system of traceability whereby the batch number of
the weld consumables are related to the weld numbers welded with that particular
batch.
6.6.3 Deposited Weld Metal
Welding consumables (i.e. wire, electrodes, fluxes and shielding gas) shall be the same
as used in the WPS.
Alternative, equivalent consumables, may be accepted at the discretion of the
COMPANY, subject to requalification if deemed necessary in the opinion of
COMPANY.
6.6.4 Storage of Welding Consumables
Welding consumables shall be stored under clean, dry conditions in accordance with the
manufacturers recommendation, where possible in their original unopened containers
until required.
6.6.5 Drying of Welding Consumables
Welding consumables shall be handled prior to their use as specified by the
manufacturer.
In particular, basic coated electrodes and some SAW fluxes may require baking to
reduce moisture levels. The baking shall be carried out in accordance with the
manufacturer's specifications.
When baking, electrodes shall be placed in temperature controlled ovens in such a
manner as to prevent damage to the flux. They shall not be stored more than 50 mm
high on each shelf of the drying oven.
If there is a possibility that Basic or Rutile electrodes have picked up moisture, then
they may be rebaked in accordance with the manufacturers specification to restore them
to a usable condition. Number of bakes shall not however exceed two.
Cellulose electrodes shall not be baked since these electrodes contain 3-7% moisture
and baking may adversely affect their performance.
Basic electrodes shall be transported to and stored at the work Site in heated quivers.
At the end of a working day, unused electrodes shall be returned to store.
6.6.6 Electrode Handling and Control
Prior to commencement of production welding, the CONTRACTOR shall submit in
writing, for approval by the COMPANY, the proposed method of storage, baking,
holding, handling and issue of welding consumables.
The proposal, once approved, shall be implemented and maintained throughout the
duration of the Contract.
The method shall elaborate on the measures to be taken by CONTRACTOR in order to
avoid mixing of rods returned at the end of a working day.
Tungsten electrodes shall be carefully preserved to prevent tungsten contamination.
Electrodes with partially used, rusted or damaged flux shall be discarded.
6.6.7 Filler Metal
Welding electrodes used shall conform to the requirements of the AWS specifications
e.g. E6010, E7010, E8010, E7016, E7018, E8016, E8018.
The COMPANY reserves the right to request the CONTRACTOR to re-qualify the
PQR if electrodes are used from a different production batch to that used for the
original PQR.
The root pass of the production butt welds for all pipeline material grades shall be
deposited using E6010 or E7010 electrodes.
6.7 Fabrication and Erection
6.7.1 Outline
The basis for the fabrication of piping shall be "Approved For Construction" drawings,
WPS and other additional information. The type and grade of pipe, flanges, fittings,
connections, and the extent to which welded joints are applied shall be indicated on the
drawings.
6.7.2 Cutting and Preparation
The cutting of pipes may be done either by mechanical means or by flame or plasma
cutting, when the following is taken into account:
a) For carbon steel, flame cutting and beveling is acceptable only if the cut is
reasonably smooth, consistent, and free from gouges.
b) For low and intermediate alloys, flame cut bevels are acceptable only when
machine cutting is not feasible. After flame cutting, approximately 2 mm shall
be removed from the bevel by grinding.
c) Arc air gouging, flame gouging and chipping shall not be permitted.
Pipe ends when prepared for welding shall be square and beveled to the correct angle in
accordance with the WPS. If cut by automatic torch they shall be dressed smooth by
filing or grinding. If grinding is applicable it shall be accomplished using a guided
profile grinder clamped to the pipe by a bracket. Mitered joints shall not be permitted.
Manual cutting shall not be permitted.
When welding pipes of different wall thickness or different grades, a weld preparation
in accordance with the ANSI B31.3, 31.4 and 31.8 shall be made.
The maximum number of circumferential welds shall be three welds in any 10 m of
pipeline. The minimum distance between two circumferential welds shall be twice the
diameter of the pipe or as approved by COMPANY.
The minimum distance between the toes of attachment welds and any other weld shall
be 50 mm.
6.7.3 Installation and Erection
6.7.3.1 General
Prior to installation, all spools, pipes and fittings shall be visually inspected for damage
and cleaned of all foreign matter.
The welding of temporary attachments to pipework during installation or erection shall
not be permitted. Pipework shall be lined up with the use of internal or external pipe
clamps.
6.7.3.2 Line-up Clamps
An internal line-up clamp shall be used for all line circumferential welds except at tie-
ins and other points where it would be impractical; in such instances an external clamp
shall be used. The CONTRACTOR shall ensure that the internal clamps used on lined
pipe do not in any way damage the lining. The use of internal line-up clamps for all
nominal pipe sizes of 4 inches and larger is mandatory. The internal line-up clamp shall
not be removed until the root bead is 100% completed.
Tack welds shall only be used where it would be impracticable to use an internal or
external line-up clamp. In this case, the tack welds shall be evenly spaced around the
circumference and shall have a minimum length of 25 mm.
The external clamp shall not be removed until the root bead has been completed in all
clamp quadrants with an absolute minimum of 50% complete, spread evenly around the
circumference.
6.7.3.3 Pipe Orientation
Seam orientation of welded pipe shall be selected to ensure that at the circumferential
welds, the longitudinal welds shall be staggered over the top half of the pipeline by a
minimum angle of 90 degree. or 250 mm, whichever is the lesser.
6.7.3.4 Transition Pieces
Line pipe for transition pieces as indicated on the drawings shall be specially supplied
by CONTRACTOR. All bevels shall be prepared by the CONTRACTOR to match the
wall thickness of mating pipe, valve, fittings, etc.
6.7.3.5 Fit-up and Alignment
All bevels and material adjacent to the bevel shall be cleaned and free from dirt, oil,
rust, paint, scale, temporary varnish, coating, or any other contaminant, for not less than
25 mm from welding edge, on both the inside and outside of the pipe.
All pipes and fittings shall be supported in such a manner that there is no undue stress
on the joints during welding.
Immediately prior to line-up the CONTRACTOR shall inspect the pipe ends inside and
outside for damage, dents, laminations, etc. Pipe for welding shall be set up and
correctly spaced, allowing for temperature changes during welding and any incorrect
alignment, and shall in no circumstance be sprung into position. Welds joining sections
of pipeline, valve installations or similar welds classed as tie-in welds may be made in
the trench. In all other cases the alignment and pipeline welding shall be made
alongside the ditch with the pipe supported on skids and pack pads or other suitable
means in accordance with 6.7.3.6 to a height of at least 500 mm above the ground.
Misalignment to the centreline of the string shall not exceed 50 mm per 12 metres.
Every effort shall be made to reduce misalignment by the use of the clamp and rotation
of the pipes to the best fit. On pipe diameters up to and including 12 in. the maximum
mismatch allowed shall be 1.5 mm. On pipe diameters over 12 in. the maximum
mismatch allowed shall be 2 mm at any one point. Any branch connection, sleeve, etc.,
shall be at least 150 mm from any other circumferential weld. The welds for fittings
shall be so located that the toe of the weld shall not come within 50 mm of any other
weld. Cold dressing is permissible only in cases of slight misalignment and may only be
carried out with a bronze-headed hammer.
Hot dressing shall not be permitted.
Subject to the instructions of the COMPANY, the pipeline shall be continuously
constructed in accordance with the approved programme for the Work. When breaks
are left for the purpose of testing, road crossings, etc. The minimum length of matching
pieces ("pups") shall be twice the outside diameter of the pipe, but in no case less than
1000 mm unless otherwise approved by the COMPANY.
6.7.3.6 Pipe Lifting and Skidding
When lifting pipe, care shall be taken not to kink or overstress it. Proper pipe slings and
hooks of a type approved by the COMPANY shall be used.
The CONTRACTOR shall submit his method of skidding and skid spacing for
COMPANY approval.
Soft material shall be placed in between skid and pipe to protect the factory applied
coating. The material shall be approved by the COMPANY. The pipe shall be properly
cradled on the skids or pads.
Skids shall be at least 1.20 metre long. For pipe with a nominal diameter of 12 in. and
larger the skids in contact with the pipe shall have a width of a least 150 mm. For pipe
with a nominal diameter of less than 12 in. the skids in contact with the pipe shall have
a width of at least 100 mm.
Where possible the skid elevations shall be planned such that minor differences
between grade profile and bottom of trench profile (e.g. at locations where an increased
trench depth is required) can be accommodated without requiring an additional tie-in
weld.
Pipe supports shall be stable, so that pipe movement will not cause the supports to
move. Skids shall not be removed from under a welded section until welding has been
completed (the welded pipe shall be maintained on skids at the minimum specified
distance above the ground).
6.7.3.7 Threaded Connections
The screw threads of threaded pipework shall conform to the requirements of ANSI
B1.20.1.
Jointing material shall only be used when specified by the drawings. Jointing materials
shall not be substituted unless approved by the COMPANY.
Seal welding of thread connections shall be carried out in accordance with paragraph 2
of subsection 6.8.9 except where specified otherwise on the Drawings.
6.7.3.8 Cleaning Pipe and Fittings
The CONTRACTOR shall clean the inside of each fitting and pipe length immediately
prior to welding and shall clean all fittings and pipe lengths to remove all dirt, sand or
other foreign matter.
The pipeline shall at all times be kept free of extraneous material, and when work is not
in progress the open ends of the pipeline sections shall be securely plugged with an
approved watertight plug or stopper firmly fixed to resist spontaneous dislodgment.
Claw type plugs or any type liable to damage the pipe shall not be used.
6.7.3.9 Flanged and Bolted Connections
The maximum deviation between flange facings measured in any direction shall not
exceed half a degree. When branches are in the same plane and their flanges are also
positioned in the one plane, the flange facings shall not deviate by more than 1 mm
from the latter plane in the same direction.
Unless otherwise indicated, the bolt holes of all flanges shall straddle the vertical centre
line of the pipe. Alignment of welding neck flanges shall be in accordance with ANSI
B31.4.
The maximum deviation of bolt holes permitted from the required position, measured
along the bolt circle shall be 1.5 mm.
Only jointing materials specified on the drawings shall be used.
Stud bolts 1.5 in. dia and larger shall be tightened by means of hydraulic tensioner only.
The threads of bolts and nuts shall be protected by a suitable compound such as
graphite based or as approved by the COMPANY.
No underground flange connections will be allowed other than those flanges required
for the installation of HDPE lining in pipelines.
6.8 Production Welding
6.8.1 Scope
The following requirements shall apply to the shop and field welding of pipelines and
station work designed for carrying crude oil, water, oil/water and/or gas.
This section also prescribes the minimum requirements for pre-weld and post weld heat
treatment.
Where piping is designed for sour service the requirements of NACE Standard MR0175
shall apply for materials and welding procedures.
6.8.2 Qualifications
All welding shall be carried out in accordance with a COMPANY prequalified
procedures and by qualified and COMPANY approved welders. The CONTRACTOR
shall ensure that all welding is carried out under competent and skilled supervision.
Under no circumstances shall a welder do any production welding other than using
those procedures for which he is tested and qualified.
6.8.3 Welding Technique
6.8.3.1 Welding Process
Welding of pipelines of 3 inches nominal diameter and above shall be with the SMAW
process using covered electrodes. The GTAW process shall be used for pipe nominal
diameter less than 3 inch nominal diameter.
However, other processes such as "fully automatic gas shielded metal arc welding" and
"fully automatic submerged arc welding" may be considered, provided the COMPANY
is convinced of the previous experience of the CONTRACTOR in these processes. In
such an event, the COMPANY will specify an extensive series of tests to be
successfully completed by CONTRACTOR before final approval is given.
6.8.3.2 Position of Welding
All welding shall be done in Fixed Position. Roll welding shall be permitted provided
alignment is maintained by use of skids or structural framework having an adequate
number of roller dollies to prevent sag in the supported lengths of pipes. Separate
WPS's shall be submitted for each welding position used.
6.8.3.3 Direction of Welding
All normal pipeline production welding shall be carried out by vertical down method,
except as below:-
The vertical up method of welding shall be used for the root pass of tie-ins, fittings,
fillet welds, repairs and when an external line-up clamp or temporary tack weld is being
used. Longitudinal welding on to the pipe, e.g. for attachment of sleeves, CP plates,
etc., shall not be permitted. Longitudinal welding (of for example saddles) shall only be
carried out using a 3 mm backing strip of similar material between the pipe and the
saddle.
Procedures for vertical down and vertical up shall be separately qualified.
6.8.3.4 Number of Welders
For pipe of nominal diameter 12 inch to 28 inch inclusive, all welding passes shall be
deposited by a minimum of two welders working simultaneously, one on each side of
the pipe. For pipe less than 12 inch nominal diameter, a single welder shall suffice.
Three welders minimum shall be used for the root and second pass on all pipe with a
nominal diameter of 30 inch and above, and a minimum of two welders shall be used
on all subsequent passes.
6.8.3.5 Welding
Internal welding of any kind shall not be permitted. During welding, all slag, spatter,
and excessive weld buildup, shall be removed from the weld and adjacent area using
power tools prior to the deposition of the next weld pass. CONTRACTOR shall, as
directed by COMPANY, use edge-weighted shields (minimum 50 cm wide) on each
side of the coating cut-back, to protect it from burn-through by hot weld spatter on the
top quadrant of the pipe.
The root pass shall be ground. Each weld pass shall be completed before commencing
the next weld pass. Weld craters shall be ground and feathered to ensure that all
porosity and defects have been removed. On completion, the finished weld and adjacent
area shall be thoroughly cleaned of all slag and weld spatter.
The stop/starts of weld beads on each pass shall be staggered by 25 mm from the
preceding pass. The stop/starts on a multi-pass cap shall also be staggered in a similar
manner.
The use of permanent backing rings shall not be permitted.
The maximum width of weaving shall be limited to 2.5 times the electrode diameter.
6.8.3.6 Time Lapse between Passes and Interruption of Welding
The hot or second pass shall follow as soon as possible after completion of the root
bead, and should whenever possible start within 3 minutes of root weld completion. A
first fill pass shall be deposited as soon as possible after deposition of the hot pass, and
should also whenever possible, start within 3 minutes after hot pass completion.
Welds shall not be allowed to cool until at least three weld runs are complete. Any
interpass cooling due to a discontinuation of the welding process shall be slow and
under insulation. The insulation shall be COMPANY approved and shall have
waterproof backing. A reheat shall be established before welding is again resumed
when the interpass temperature has dropped below the minimum temperature specified
in Section 6.8.10.
The welding of fittings, tie-ins and fillet welds should be completed in one heat cycle
whenever possible, but in all cases interpass temperatures shall be in accordance with
Section 6.8.10. Repair welding shall always be completed in one heat cycle.
Should a section of the line containing uncompleted welds fall from the skids, the
CONTRACTOR shall immediately inform the COMPANY, and cut out all
uncompleted welds.
6.8.3.7 Electrical Characteristics
Electrode polarity and amperage shall be within the range qualified by the WPS.
6.8.4 Earthing Cables
All earthing cables shall be connected directly to the work piece and secured by means
of mechanical clamp, or approved system, to avoid arcing.
Under no circumstances shall earthing cables be welded to the pipework.
CONTRACTOR shall take all necessary precautions to prevent arc burns or strikes;
should however they occur, CONTRACTOR may be allowed a repair by completely
removing the notch by grinding, provided the remaining wall thickness is not less than
the nominal W.T. A repaired arc burn or strike shall be inspected by CONTRACTOR
in the presence of COMPANY by an ammonium persulfate test, ultrasonic thickness
measurement and any other suitable method to satisfy COMPANY of the acceptability
of the repair. If a notch is not repairable by grinding it shall be cut out.
The CONTRACTOR shall periodically check all of his welding cables to ensure that
the insulation is not damaged and all connections are in good condition.
6.8.5 Weather Protection
Prior to welding, the CONTRACTOR shall ensure that the working areas are suitably
protected from any adverse weather conditions.
When windy conditions prevail the CONTRACTOR shall ensure that the wind breaks
are adequate, and that the open ends of pipeline sections are blocked to prevent any
through draught.
Special precautions shall be taken if any field welds have to be made using the GTAW
method. As far as possible all welds by this method should be made under shop
conditions.
COMPANY shall have the final decision concerning the conditions under which
welding is carried out e.g. suitability of weather, the need for weather protectors,
adequacy of protection measures etc.
6.8.6 Tack Welding
Tack welds shall always be temporary and shall be completely removed by grinding as
the welding progresses. The method of grinding shall cause only minimum damage to
the bevel profile.
Tack welds for pipework 4 inch and over shall be at least 50 mm long with a minimum
of four tacks per butt equally spaced round the circumference. Tack welds shall not
encroach on the root of the bevel.
6.8.7 Weld Cleaning
Interpass cleaning shall be carried out by grinding and power brushing to remove all
slag, before the deposition of the succeeding passes. Removal of weld irregularities by
chipping shall not be permitted.
Upon completion of the weld, all slag and spatter shall be removed by wire brushing
and grinding if necessary. Final acceptance of a weld shall be by the COMPANY
Welding Inspector.
The removal of excessive reinforcement, undercut or cold lap by grinding shall not be
carried out unless approved by the COMPANY.
6.8.8 GTAW
The scratch start method of igniting the arc shall not be used. All power sources shall
have a superimposed high frequency mode for igniting the arc.
A post purge of approximately 5-10 seconds shall be maintained upon completion of
welding to allow the weld bead and the tungsten electrode to cool sufficiently.
The weld joint shall be thoroughly cleaned and be free from contaminants.
6.8.9 Socket and Fillet Welds
All socket welds shall have a 1.6 mm gap between the pipe and the bottom of the socket
to prevent any undue stress on the root of the fillet weld during welding.
All fillet welds shall have a flat or convex profile.
Fillet welds used as a sealing run on threaded connections, shall not be permitted unless
the threads are fully engaged or the visible thread has been removed by grinding or
other means. No seal welding shall be permitted on soft seated valves.
Fillet welds shall be multipass using basic coated low- hydrogen electrodes (e.g. for
saddles, sleeves, CP attachments, etc.). See also Section 6.8.3.3 above.
6.8.10 Preheat, Interpass, Cap Pass and Reheat Temperatures
Preheating shall be in accordance with the approved WPS and the following
requirements.
The minimum preheat and reheat temperatures required shall be as listed in Table 1
below. Reheat shall always be applied when the interpass temperature drops below the
minimum value specified in Table 1.
Table 1 - Minimum Preheat & Reheat Temperatures
Application Minimum Temperature

(Deg C)
Main line welding with carbon steels up 60

to and including Grade X60. 1, 2
Repair Welding 150
Welding of fittings, tie-ins and fillet 150

welds
Notes
1 For grades greater than X60, or when the carbon equivalent is greater than
0.39%, temperature requirements shall be reviewed on an individual basis
2 Only required if ambient temperature is below 20 deg.C or when pipe is wet.
Depending upon factors such as chemical composition, wall thickness of material,
weld-end geometry, type of welding technique, ambient and/or material temperature,
etc., pre-heating or higher preheat/reheat levels than stated above may be required in
order to produce an acceptable weld quality. This requirement shall be subject to
agreement by the COMPANY before welding procedure testing commences.
Unless the minimum preheat or reheat temperature specified in the Welding Procedure
Specification has been obtained, welding, including tack welding, shall not be carried
out.
Preheating and reheating shall be around the entire circumference and over a width of
150 mm on either side of the weld. For repair welding, preheating shall be effective
over an area of 150 mm from either end and 150 mm on either side of the repair area.
Actual temperature measurement shall be within 10 mm of the outer edge of the bevels.
Preheating shall be carried out by a method which provides the required metal
temperature, temperature uniformity and temperature control. Acceptable methods are
electric resistance, electric induction or local fuel fired heating. Preheating shall not be
carried out using cutting torch nozzles; a rosebud or similar arrangement shall be used.
Care shall be taken not to damage the coating.
The maximum preheat, reheat, interpass temperature shall not exceed 300 Deg C.
The temperature shall be checked around the whole of the joint at least 15 seconds after
removal of the heaters, immediately prior to commencement of welding and also while
welding is taking place.
Temperature measurement shall be by thermocouples, digital thermometer, templestick,
or other COMPANY approved methods.
6.8.11 Post Weld Heat Treatment
Postweld heat treatment for carbon steel shall be carried out as required by ANSI
B.31.3, 31.4, 31.8, and the approved welding procedure as applicable.
PWHT shall be carried out by a fully controllable method which ensures uniformity of
heat distribution.
Temperature shall be measured by thermocouples that monitor temperature and control
the rate of heat input.
At all stages during heat treatment the pipe shall be adequately supported.
When local heat treatment is employed using electrical resistance pads the temperature
shall be measured by at least 3 thermocouples. They shall be placed 25 mm away from
the weld toe to ensure that the width of the heated circumferential band will extend at
least 25 mm beyond the weld on either side.
A temperature recording chart shall be supplied for each heat treatment cycle by the
CONTRACTOR. The COMPANY shall have the option of signing the chart on and off.
The area being heat treated shall be wrapped in an insulating blanket at all times; open
ended pipes shall be blocked to prevent a through draught.
Temperature shall be raised and controlled not to exceed 300 deg.C per hour.
The soaking temperature shall be 580 to 620 degree C and be maintained for a
minimum period of one hour per inch (25 mm) of nominal wall thickness. The
minimum soak time shall be 1 hour.
After the completion of the soak period the weld shall be cooled at the maximum rate
of 300 deg.C per hour until a temperature of 300 deg.C is reached; thereafter the
heating elements shall be switched off and the weld shall cool under the blankets.
6.9 Quality Control
6.9.1 Scope
This section prescribes the COMPANY's minimum requirements to ensure that the
CONTRACTOR has conformed with all the relevant codes and specifications as
defined by the Contract and this Specification. It details the extent of inspection
required, the methods used, and the acceptance criteria. It also defines the
CONTRACTOR's responsibility for documenting and maintaining records of all
production welding and welders performance.
6.9.2 Documentation
6.9.2.1 Quality Control Manual
Prior to commencing any welding the CONTRACTOR shall submit to the COMPANY
a copy of his Quality Control and Quality Assurance Manual. This shall detail but not
be limited to, the CONTRACTOR's inspection system, reporting procedures
organization and responsibilities, and documentation of work.
6.9.2.2 Procedures
Before starting the Work, the CONTRACTOR shall submit the following written
information in detail to the COMPANY for approval:
a) Radiographic Examination Procedures.
b) Magnetic Particle and Dye Penetrant Examination Procedures.
c) Ultrasonic Testing Procedures.
d) Site Hardness Testing Procedures.
e) Separate (blank) reporting sheets for visual, radiography, ultrasonic, magnetic
particle and production hardness test results.
f) Certificates (original) of the qualifications, including experience records, of all
inspection personnel.
g) Manufacturers Certificates for all proposed X-ray films.
h) A document detailing the Contractors quality control schemes, organization
structure, reporting systems, inspection facilities, etc.
j) Batch numbers of welding consumables.
6.9.2.3 Records and Certificates
The CONTRACTOR shall prepare and maintain a record system which shall identify
each weld with a unique number for traceability and record the history of each weld.
The weld history sheets shall detail the following:
a) Weld number and location.
b) Isometric/line number.
c) Welders identification mark.
d) Date welded.
e) Visual inspection.
f) NDE inspection report number and result.
g) NDE inspection report and result of repair.
h) Hardness test if applicable.
i) PWHT if applicable.
j) Batch number of weld consumables used.
CONTRACTOR's records shall be kept in such a way that pipe mill identification
numbers of the pipe, bend, or fittings, on each side of the joint can be determined.
The CONTRACTOR shall also record the performance of each of the welders used
during construction.
The CONTRACTOR, through a COMPANY approved NDE subcontractor, shall be
responsible for all non destructive examination and shall visually examine, radiograph,
MPI, ultrasonic and hardness test welds in accordance with this Specification. The
CONTRACTOR shall be responsible for the interpretation of all NDT results and for
the integrity of all welds. Notwithstanding the foregoing, the COMPANY shall have the
right of rejection of any welding.
The CONTRACTOR shall supply all labour, equipment, and materials necessary to
carry out his obligations with regard to non-destructive examination and inspection.
This shall be done through a COMPANY approved NDT Subcontractor. The NDE
subcontractor shall be a completely independent COMPANY having no business
connection with the CONTRACTOR.
The COMPANY has the right to require that nominees for radiographic interpretation
and ultrasonic examination pass a test by a third party in Europe at CONTRACTOR's
account before agreeing to mobilization of such nominees to Syria.
In addition, CONTRACTOR shall supply such materials and equipment that are
necessary for the interpretation of radiographs and all other modes of inspection. The
materials and equipment shall include, but not be limited to, radiographic equipment,
films, dark-rooms, chemicals, viewing equipment, dye penetrant materials, ultrasonic
and magnetic crack detection equipment, site hardness testing equipment, and all
internal inspection equipment.
The CONTRACTOR shall hold in store an approved quantity of spares for all
equipment. The CONTRACTOR shall provide separate viewing rooms for his and
COMPANY use, together with all equipment necessary for viewing and interpreting
radiographic films.
All equipment supplied by the CONTRACTOR shall be maintained by him in
satisfactory working order, and the CONTRACTOR shall also be responsible for
maintaining the supply of all consumable materials.
Acceptance by the COMPANY does not relieve the CONTRACTOR of his
responsibility for ensuring that the Work has been carried out in accordance with the
Contract requirements, and to an acceptable standard of workmanship.
6.9.4 Standards of Acceptability
The standards of acceptability shall be in accordance with API 1104 and as further
defined by this Specification.
6.9.5 Extent of Inspection
The extent of inspection for any material per service per rating shall be as defined in
Figure 16.4. Under no circumstances shall these requirements be altered, unless written
permission is obtained from the COMPANY.
The COMPANY reserves the right to request ultrasonic or MPI inspection of the weld,
if this is considered necessary to assist radiographic interpretation.
The COMPANY shall have the right to order the removal of any weld for the purpose
of carrying out destructive tests.
The following definition shall apply to the extent of examination for all methods:
100% NDE: - is defined as the Non-Destructive Examination of the complete
circumference of all welds in a designated lot by the specified method.
Spot examination or random NDE shall not be used.
6.9.6 Visual and Radiography Inspection
6.9.6.1 Safety
When radiography is carried out, the CONTRACTOR shall ensure that all regulations
as detailed in the Contract relating to the use and handling of radioactive isotopes are
implemented.
The recommendations of the International Commission on Radiological Protection shall
be observed. In particular, attention is drawn to the necessity for visual warning
arrangements, and for regular monitoring of radiation levels. Radiographic protection
shall be the responsibility of the CONTRACTOR.
The CONTRACTOR shall supply COMPANY with a list and CV of their appointed
competent persons. Such competent persons shall be completely familiar with the
regulations in regards to ionizing sources and shall assist in the enforcing and
observance of them.
All Contractors NDE personnel engaged in work for the COMPANY shall be qualified
to CSWIP, ASNT Level II, SKNDO or equivalent, in the appropriate method.
6.9.6.2 Visual Examination
A visual examination shall be made prior to welding, to ensure that there are no
apparent material defects, and that the bevel faces are smooth and free from oxides,
dirt, paint, oil, etc.
The joint fit-up shall also be checked to ensure that the parameters are in accordance
with the welding procedure, seam orientation and misalignment is within Specification.
All completed welds shall be visually examined. A daily report of all completed and
visually examined welds shall be compiled by CONTRACTOR and submitted to
COMPANY representative for review and approval.
Visual examination shall essentially be carried out during welding and while the weld is
still above the minimum interpass temperature recorded in the welding procedure, so
that remedial work necessary to the capping pass can be carried out before non-
destructive examination.
Only when the weld is visually acceptable shall any further NDE be carried out.
6.9.6.3 Radiography
All radiography shall be carried out using X-ray or Gamma ray (see Appendix 1 for
applicability of X- ray/ Gamma ray). If gamma rays are used the source shall be Iridium
192. Cobalt 60 shall not be used. Gamma Ray techniques shall only be used when prior
approval from the COMPANY is obtained.
The radiographic technique shall be in accordance with API 1104 and ASME V Article
2 as applicable and the acceptance criteria shall be in accordance with API 1104 and
para. 6.11.
The following exposure techniques shall be used:-
a) For 1 in. diameter and below, double-wall superimposed image with a minimum
of three exposures 60 deg. C. to each other.
b) For diameters greater than 1 in. through 3.5 in. double-wall elliptical exposures
shall be taken with a minimum of two exposures at 90 deg. to each other.
c) In Gamma radiography, for diameters greater than 3 inch, the double-wall-
single-image technique shall be used with at least three exposures at 120 deg. C.
to each other. Where possible, panoramic exposure may be used in place of
double-wall-single-image. A lead screen of minimum thickness 7 mm shall be
used behind the film.
d) In X-ray radiography, for pipe sizes 8 in. nominal diameter and above, an
internal X-ray crawler giving 360 degrees exposure (SWSI) shall be used. For
smaller diameter pipes and tie-ins, the double wall / single image technique may
be used.
e) Branches, Forged Set-in Type.
Panoramic type technique where the complete weld is examined in one exposure shall
not be permitted. The weld shall be examined in separate exposures with the X-ray
focal spot positioned at normal incidence to the area being examined to within 50 mm.
Either single wall single image, or double wall single image techniques shall be
permitted.
When the single wall single image technique is used, the film shall be placed against
the inner pipe/fitting surface and the X-ray focal spot outside. The focal spot to film
distance shall not be less than 690 mm. Where access and/or other fittings prevent
correct alignment of the beam, the double wall / single image technique shall be used.
Branches up to 150 mm nominal bore require a minimum of four exposures equidistant
around the weld circumference. Branches of 200 mm nominal bore require a minimum
of six exposures, equidistant around the weld circumference. Exposure of larger
branches shall be subject to agreement by the COMPANY.
6.9.6.4 Film
Fine, or very fine grain, high contrast, direct type film conforming to ASTM E-94 latest
edition, film type 1 or 2 shall be used in conjunction with lead screens. (Only film type
1 shall be used for pipe of nominal diameter 4 inch or less)
The type of film shall be COMPANY approved and shall be suitable for dusty, desert
environment, high temperatures and the travelling distances involved. The use of roll
pack film shall be permitted.
6.9.6.5 X-Ray Equipment
X-ray radiography shall be carried out using 200, 250 and 300 kV equipment with
generators for power supply.
The CONTRACTOR shall ensure that all equipment is suitable for working in the
environmental and climatic conditions to be expected at Site.
The CONTRACTOR shall have available a complete spare crawler plus sufficient
spares to make up a complete crawler with the exception of the chassis.
The CONTRACTOR shall use such equipment as necessary to allow for a 2000 meters
welded section between the open ends of the pipe.
6.9.6.6 Film Density
The H and D film density required for gamma radiography shall be between 2.0 and 3.5
measured in the weld. When X-ray is used then the density shall be between 1.8 and 3.5
according to ASTM E94 and ASTM E586, latest edition.
With some types of fitting there may be substantial differences in wall thickness
between the pipe and the fitting. If the film density range within the aforementioned
values cannot be obtained in one exposure, then either two separate exposures shall be
made, or alternatively, a sandwich technique using a fine grain film and an ultra fine
grain film shall be used.
6.9.6.7 Penetrameter Sensitivity
The image quality obtained by X-ray/Gamma-ray inspection shall be at least that given
in Table 2: All radiographs shall exhibit a sensitivity of 2% or better.
Table 2 - Image Quality Indicator - Wire Selection
Pipe Wall Thickness ISO Wire 2 % Sensitivity
mm Inches Wire No. Wire Diameter
0-6 0-1/4 16 0.10
6-8 1/4-1/3 15 0.12
8-10 1/3-3/8 14 0.16
10.0-12.7 3/8-1/2 13 0.20

12.7-15.9 1/2-5/8 12 0.25
15.9-19.0 5/8-3/4 11 0.32
19.0-22.2 3/4-7/8 10 0.40
22.2-25.4 7/8-1.0 9 0.50

6.9.6.8 Film Processing
Chemicals used for processing films shall be of a manufacture approved by the
COMPANY, and shall be used in strict accordance with the manufacturer's
recommendations, including efficient replenishment of developer. Films shall be
developed in approved solutions for not less than 4 minutes or more than 5 minutes at a
temperature of 20 deg.C + 1 deg.C. Radiographs shall be processed to allow storage of
film without deterioration, for a period of at least five years, and this shall be verified
by the THIODET or equivalent test. The radiographs shall be free from imperfections
due to processing or other defects which could interfere with satisfactory interpretation.
The CONTRACTOR may be required at any time to demonstrate that the film can be
processed, using the site facilities, to have a fog level of not more than 0.3. Approved
automatic processing may be permitted at the discretion of the COMPANY.
6.9.6.9 Film Viewing
Film viewers shall be suitable for films with densities up to 3.5. In no circumstances
shall films be interpreted whilst viewed wet or through wet or broken glass.
6.9.6.10 Radiographic Procedure Specification
The CONTRACTOR shall submit the proposed radiographic procedure to the
COMPANY for approval.
The radiographic procedure shall include the following details:-
- Material quality and dimensions, welding process, and joint design.
- Type of X-ray equipment, kV ranges to be used, (external or internal).
- Type of film, trade name, and designation.
- Type of intensifying screens
- front and/or back material thickness.
- Arrangements for shielding against scatter (if any).
- Geometric relationships, focal spot size, generating voltage, focus to film
distance, object to film distance, beam angle, and tolerances on location of X-
ray head.
- Film coverage.
- Exposure (mA minutes).
- Material thickness range.
- Processing, developing time/temperature, stop bath, fixation, washing, drying,
etc.
The CONTRACTOR shall make and process, in the presence of the COMPANY, three
radiographs of a weld, preferably the procedure test weld, to establish consistency of
the radiographic procedure. Radiographically similar material to that which will be used
for production welding shall be employed. The test radiographs shall be submitted to
the COMPANY, who shall decide whether the procedure is satisfactory. The
COMPANY shall retain the test radiographs for future comparison purposes. Operators
shall be required to perform a qualification test using the qualified radiographic
procedure.
Image quality indicators of the wire type and of the correct number are to be placed on
both the film side and on the source side (See also 6.9.6.12). The sensitivity of the
source side indicator is to be equal to or better than the requirements of 6.9.6.7. The
COMPANY shall require requalification of the procedure should any change be made
to any of the above variables.
6.9.6.11 Radiography Identification
All radiographs shall exhibit permanent identification to ensure traceability. This shall
include the COMPANY contract number, the line number, the weld number, the
isometric drawing, the diameter, and the date radiographed. Handwritten corrections on
the films shall not be tolerated.
In order to identify any specific area of a weld on a radiograph, the following
techniques shall be used:-
a) On diameters of 3 in. and over, a tape measure with lead numbers every 100 mm
shall be placed adjacent to the weld. The zero point shall be on the top of the
pipe and the divisions shall run clockwise in the ascending order, viewed in the
direction of the flow.
b) On diameters of less than 3 inch, each shot shall be designated by a lead letter
placed on the pipe i.e. A,B,C.
c) Where the weld is dressed, markers in a form to be approved by the COMPANY
shall be placed alongside, but just clear of, the weld zone edges of the weld to
identify its position.
d) All radiographs shall be adequately identified to the welds they represent. All
measurements used for defect location shall be metric.
e) Every radiograph shall be identified in an approved manner. If sufficient space
is available, the pipe reference weld number, section number, and root welder(s)
involved shall be included in the radiograph identification.
f) Each weld shall be marked using indelible material, to provide reference points
for the accurate relocation of the position of each radiograph.
6.9.6.12 Image Quality Indicator
The sensitivity of the radiograph shall be determined by the use of IQI (Image Quality
Indicator). For all pipework, wire type IQI's shall be used i.e. DIN type or equivalent.
Film side indicators shall be used for double wall single image and elliptical exposures.
Film side or source side may be used for panoramic exposures, except as below:
When a complete circumferential weld is radiographed in a single exposure from the
inside of the pipe, four Image Quality Indicators (penetrameters) shall be placed outside
the pipe at each quadrant.
The number of IQIs used shall be as follows:-
a) A panoramic exposure shall require four IQIs, spaced one in each quadrant.
b) An elliptical or superimposed exposure shall require one IQI per film.
c) Double wall, single image shall require one IQI at either end of the film for each
exposure.
d) When a circumferential weld is radiographed using a multiple exposure
procedure, the exposed films shall overlap by 25 mm and an IQI shall be located
within 25 mm of each end of the applicable limits of film coverage.
e) When double wall single image exposure is used, and the diagnostic film length
requirements as detailed in API 1104 can be achieved in four shots, these shall
be centred on the 3, 6, 9 and 12 o'clock positions.
In all cases the IQI shall be placed across the weld.
6.9.6.13 Radiography Procedures and Interpretation
Only approved radiographic procedures shall be used. Radiography shall not be carried
out until the weld has reached ambient temperature.
As soon as the radiographs have been taken by the CONTRACTOR, and this shall be
within 24 hours of weld completion, they shall be developed and interpreted by the
CONTRACTOR. Thereafter all radiographs shall be submitted to the COMPANY for
examination. The radiographs shall be submitted separately for each weld.
With each batch of radiographs submitted for examination to the COMPANY in any
one day, the CONTRACTOR shall give a list in triplicate of these radiographs. The list
shall convey such information as:
- weld NO. and location
- welder identification
- line diameter and thickness
- film type, density and sensitivity
- isotopes sizes and strength
- SFD
- IQI
- Report number and date
This list shall contain also CONTRACTOR's interpretation of each radiograph, and
shall be submitted to the COMPANY for approval. The COMPANY will state on this
list their conclusions, as to the acceptability or otherwise, of the weld.
These conclusions will state whether the weld is passed, has to be repaired, has to be
cut out, or requires additional NDE. The conclusions will be contained on the copy of
the welding list returned to the CONTRACTOR, not more than 24 hours after the
CONTRACTOR's submission of the list. The CONTRACTOR shall forthwith repair or
cut out and reweld the welds, or carry out additional NDE in accordance with the
instructions on the list returned to him. The daily radiography list shall be clearly
marked to show that such welds are repairs or rewelds.
The COMPANY has the right to require the CONTRACTOR, as a daily check, to
reshoot and process one film of a weld (and position) selected by the COMPANY from
the previous day's batch of radiographed welds. The reshoot radiography can be carried
out externally or internally to suit the CONTRACTOR's construction schedule.
6.9.6.14 Film Identification/Storage
On-site administration, storing and records for radiographic films prior to, and after,
exposure shall be the CONTRACTOR's responsibility.
Conditions of storage, temperature and humidity shall comply with the
recommendations of the film manufacturer.
All unexposed films shall be stored in a clean dry place where the surrounding
conditions will not detrimentally affect the emulsion. If there is any question regarding
the condition of the unexposed film, sheets from the front and back of each package (or
a 900 mm length from the front of each roll) shall be processed in the normal manner
without exposure to light or radiation, to satisfy the inherent fog requirements of
6.9.6.8.
On completion of the Contract, all exposed film shall be handed over to the
COMPANY, indexed, catalogued and boxed up in accordance with COMPANY's
requirements.
6.9.6.15 Rejection of Radiographs
The COMPANY shall reject any radiograph that does not fully comply with the
approved radiographic procedure or which, in it's opinion, is for any reason unsuitable
for viewing and judging the acceptability of the weld it portrays. The CONTRACTOR
shall reshoot and process any radiograph so rejected.
6.9.7 Ultrasonic Inspection
6.9.7.1 General
The technique shall be in accordance with ASME V Article 5. The acceptance criteria
shall be as specified in para. 6.11.
Prior to any examination the CONTRACTOR shall submit a written procedure to cover
the weld configuration under examination. The procedure shall be in accordance with
ASME V Article 5 T-523 and shall include all the relevant information required by that
section.
Ultrasonic operators shall be qualified to a minimum level of ASNT Level II, or
equivalent.
A spare ultrasonic test set shall be available on Site.
All equipment shall be calibrated prior to use and as required by ASME V, Article 5,
Para T-534. The calibration shall be carried out in accordance with section T-544 of
ASME V.
Before ultrasonic testing, it is necessary to thoroughly clean a zone not less than 50 mm
wide on each side of the weld. Spatter shall be removed, and the weld zone allowed to
cool to ambient.
6.9.7.2 Ultrasonic Testing Procedure
1) Welds
Calibration of the probes for beam angles is required on the IIW (International
Institute of Welding) test block, or suitable approved alternative (for example the
V2 block), at least daily. Calibration of the flaw detector time base and
amplification shall be carried out before examining each weld.
A probe of 65 deg. to 70 deg. refraction angle, 4 MHz frequency, and
approximately 50 x 10 mm shall be used. Welds shall be scanned in a zigzag
manner, the probe being moved between the weld reinforcement and one skip
distance. The beam shall be pointed such that it is normal to the weld length. The
weld shall be scanned from both sides. Amplification shall be set so that the echo
from the reflector hole in the V2 block is 75% FSH. The reflector hole size shall be
5 mm diameter. Either liquid detergent, or paste and water, shall be used as
couplant.
Defects shall be identified primarily by accurate positioning of the source of the
echo in the weld cross section, and their approximate orientation determined by
comparing the echoes received from each side of the weld. Identification of defects
by the shape of the echo on the CRO (cathode ray oscilloscope) screens alone shall
not be permitted.
2) Testing Pipe Material
Ultrasonic testing practice shall be in accordance with BS 5996 using technique 2
(flaw echo/bottom echo ratio for sizing the lamination), or technique 3 (multiple
echo pattern), depending on wall thickness and type of lamination (if any)
encountered. The probe shall be scanned in a zigzag fashion in a zone 100 mm wide
around planned cut-outs for nozzles, and back from the new end of pipes which
have been cut. Laminar defects shall not be accepted if they exceed 6 mm in any
dimension. Any lamination not parallel to the pipe surface shall be deemed
unacceptable.
3) Levels of Investigation
When the examination shows indications of a defect the following shall apply:-
a) All reflectors giving an indication in excess of 20% DAC shall be
investigated to the extent that they can be evaluated in terms of the
acceptance standard.
b) All reflectors giving an indication in excess of 50% DAC should be
investigated, evaluated and recorded on the report.
c) All reflectors in excess of 100% DAC shall be cause for rejection.
4) Test Report
A test report shall be issued for each weld with all the relevant data, including but
not limited to:-
- Report number.
- Weld number.
- Isometric/line number.
- Material thickness.
- Couplant.
- Probes used, size and frequency.
- Calibration technique.
- Surface condition.
- Name of operator.
- Acceptance code.
- Reportable defects and disposition and sketch.
- DSG Probe Calibration Chart.
6.9.8 Magnetic Particle and Dye Penetrant Inspection
DPI and MPI shall be carried out in accordance with ASME V Articles 6 and 7
respectively. The acceptance criteria shall be to para.. 6.11 of this Specification. The
frequency of inspection shall be in accordance with Appendix 1 of this Specification.
Prior to any examination the CONTRACTOR shall ensure that the welds are free from
slag or spatter which may interfere with the examination.
All testing materials shall be approved brands, and the material bases shall be non-
flammable, i.e. a suspension of particles in kerosene shall not be used. Wet methods
only shall be used. Either water-based fluorescent inks viewed with ultraviolet light, or
black ink on white background paint may be used. The inks shall conform to BS 4069.
For fluorescent inks the concentration of suspended magnetic materials shall be within
the range 0.1% to 0.3% by volume, whilst for black inks the concentration shall be
within the range 0.8% to 3.5%. The spray dispenser or aerosol containers shall be
shaken frequently to ensure consistent concentrations. The concentration shall be
checked regularly and at any time at the discretion of the COMPANY. When white
background paint is used it shall be applied as thinly as possible, consistent with
satisfactory viewing.
A "U" section permanent magnet shall be used for magnetization. Its shape and size
shall be such that the weld area being examined can be viewed whilst the magnet is still
in position. The magnet shall be fitted with pole pieces shaped to the profile of the pipe
being examined. The magnet shall be of sufficient strength to ensure detection of
relevant defects. Convenient methods of measuring strength in engineering terms are
not available at present, but as a guideline, a magnet with pole pieces 12.5 mm x 50
mm in area and which is able to lift a piece of mild steel weighing 11 kg would be
suitable.
Initially the magnet shall be set to straddle the weld at the 6 o'clock position, the fluid
applied, and the weld viewed whilst the magnet is still in position. Thereafter, the
magnet shall be transferred to the 12 o'clock position; the examination shall proceed
progressively towards the 6 o'clock position clockwise and anti-clockwise to cover the
full pipe circumference.
The test report shall contain as a minimum the following information:
- Report number.
- Weld number.
- Isometric/line number.
- Material.
- Method DPI/MPI.
- Type of consumables.
- Type of magnetization source.
- Defect size and location if applicable.
- Acceptance standard.
- Name of Operator.
6.9.9 Hardness Testing
When the pipework is intended for sour service and the NACE standard MR0175 is a
design requirement then hardness testing shall be carried out as a quality control check.
Checking frequency shall be as required by COMPANY representative.
In order to carry out the testing, 25 mm length of weld cap shall be ground flush with
the base material. The area shall then be polished with emery cloth until smooth.
A 5% solution of Nital or other suitable etchant shall be used to etch the polished area.
A hardness survey shall be carried out in the parent metal HAZ, weld metal, HAZ and
parent metal, for each specimen sample using a portable Vickers hardness tester or an
equivalent tester with a diamond indentor. Hardness testing with a ball type indentor
shall only be accepted if carried out with a portable EQUITIP type tester.
One reading shall be taken in each zone with the HAZ reading taken 0.5 mm from the
fusion line.
The maximum allowable hardness shall be 248 HV20 for pipe in sour service and
300 VPN for pipe in non sour service.
If a hardness figure greater than that allowed is recorded, three additional readings shall
be taken in that area. If any of these are above the maximum allowable hardness, the
COMPANY shall be informed and advise whether the weld requires to be cut out.
Corrective action, if required, shall be specified by the COMPANY.
A report shall be submitted for the hardness testing and the results shall also be
recorded on the weld history sheet.
6.9.10 NDE Requirements for Joints other than Butts
The requirements for the inspection of joints other than butt welded joints shall be as
detailed below.
The frequency of inspection shall be as specified for butt welds which fall under the
same material/service/class category.
Full penetration welds, i.e. weldolets, etc., shall be inspected by ultrasonic testing if
they cannot be radiographed because of their geometric configuration.
If due to their size or orientation, welds can neither be radiographed nor ultrasonically
tested, they shall be inspected by MPI or DPI.
Fillet welds, i.e. slip-on flanges, socket welds, etc. shall be inspected by MPI or DPI at
the discretion of the COMPANY.
6.9.11 Reports
All reports shall be completed as required and submitted to the COMPANY for
approval; they shall be concise, legible, and identified by a unique number.
The reports shall be filed in a suitable manner and handed over to the COMPANY upon
the completion of the Contract.
6.10 Weld Repair Procedures
6.10.1 Scope
This Section specifies the minimum requirements for carrying out repairs to welds with
defects unacceptable to this Specification.
6.10.2 Approvals
With the prior permission of the COMPANY, welds which do not comply with the
standards of acceptability shall be repaired, or the joint cut out and rewelded. Repairs
shall not be made before full non-destructive testing has been made in accordance with
the Specification.
A separate Welding Procedure Specification sheet shall be formulated and qualified by
the CONTRACTOR for repair welds. Welders shall be qualified in advance for repairs.
The root pass, for repairs opening the root, shall be replaced by the vertical up
technique. The procedure shall be proven by satisfactory procedure tests to API 1104,
and shall also be subjected to metallographic examination, hardness surveys and Charpy
tests, to determine the effects of repair welding on the associated structure (see Figures
6.3 and 6.4). Arc-air gouging, chipping, or flame gouging shall not be permitted for
defect removal.
The preheat for repair, including carbon and low alloy steel, shall be 150 deg. C.
6.10.3 Sequence of Repair
The NDE technician shall mark the defective area on the pipe with a wax crayon. The
minimum length of a local repair shall be 100mm and the maximum shall be 30% of
the circumference. If the pipe diameter is less than 4 inch the entire butt shall be cut-
out.
The defect shall be removed by grinding. However, when the repair of a planar defect
is to be effected, then additional precautions shall be taken to prevent propagation of
the defect. These precautions shall include a written repair procedure and an MPI or
DPI test to ensure complete removal of the defect.
If the defect is in the root of the metal the bulk of the defective weld may be removed
by grinding. The removal of the root shall be by grinding with a slitting disc so that a
configuration as near as possible to the original weld bevel can be obtained.
Root sealing or single pass repair deposits shall not be permitted. Internal root repair
deposits shall not be permitted.
The excavated area shall then be welded using the parameters of the repair procedure
with a preheat temperature of 150 deg.C.
After the repair has been completed the weld shall be visually inspected to ensure that
there is a smooth transition between the original weld and the repair area. Post weld
heat treatment of repair welds, in a manner approved by the COMPANY, shall be
carried out where applicable.
The repair shall be subjected to the same testing and inspection requirements as the
original weld. The repaired area shall be radiographed over a distance of 50 mm on
either side of the repaired weldment. A 100% visual, a 100% MPI and a 100%
ultrasonic test (where practicable) shall be done externally at the repaired area. Any
repaired area that is wide, irregular or rough shall be rejected and a full cutout shall be
done.
Welds not meeting the Specification after one repair shall be cut out. A report of all
repairs shall be maintained by the CONTRACTOR. All repairs shall be carried out the
day after initial radiography or earlier.
6.10.4 Limitation of Repairs
Only one attempt at repair of any region, in a pipe- to-pipe butt weld shall be permitted.
Repairs shall be limited to a maximum 30% of the weld length, with the exception of
cap repairs, for which there shall be no limit. For repairs which open the weld root, the
repairs shall be limited to 20% of the weld length. For pipes smaller than 3 inch NPS
no open-root weld repair shall be permitted. Repairs opening the root shall only be
carried out in the presence of the COMPANY. Welds exceeding the above maximum
limits or containing cracks shall be cut out.
6.10.5 Weld Rejected by Accumulation of Defects
Where a weld is rejected by the accumulation of defects clause, as defined by API 1104
and this Specification, repairs within these limitations are permitted. Defects in the
filling and capping passes shall be repaired preferentially.
6.10.6 Repair Rates
If high welding repair rates occur, then the COMPANY shall have the right to stop all
welding and request that a detailed investigation is made into the cause of the problem.
For this purpose the following acceptance criteria shall apply:
- daily butt repair rate shall not exceed 8%
- weekly butt repair rate shall not exceed 5%
- cumulative repair rate (after two weeks production) shall not exceed 3% of the
total number of circumferential welds completed during the corresponding
period, excluding cap repairs.
6.11 Welding and Inspection of Duplex Stainless Steel

6.11.1 General
The welding of duplex stainless steel shall be executed in a clean environment.
Particular care shall be taken to ensure no contact between carbon steel and the duplex
stainless steel linepipe. Consequently, all wire brushes and tools shall use stainless steel
parts. The wire brushes, grinders and other tools shall be dedicated for use on the
duplex stainless steel linepipe and not used on any carbon steel.
6.11.2 Welding
6.11.2.1 Process
All welding shall be executed by the Gas Tungsten Arc Welding (GTAW) process.
6.11.2.2 Backing Gas
An inert backing gas (minimum 99.9 % Argon) will be applied to the weld from the
inside of the pipe during the running of the root and a minimum of one subsequent
pass.
6.11.2.3 Bevel Preparation
The bevel preparation will be a J-bevel with a 22.5 degree bevel angle from the
vertical.
6.11.3 Inspection
6.11.3.1 Radiography
Radiographic inspection will be performed with X-ray equipment in order to achieve a
high quality weld inspection. Gamma ray radiography is unacceptable.
6.11.3.2 Ferrite Content
The ferrite content in the weld shall be between 30 and 70 percent EFN (Extended
Ferrite Number). The ferrite content shall be checked with a magna gauge apparatus,
calibrated with the base material.
6.12 Standard of Weld Acceptability
6.12.1 General
These standards of acceptability are applicable to the determination of the size and the
type of defects located by non- destructive testing methods and visual examination.
6.12.2 Right of Rejection
Since radiography gives two dimensional results only, welds may be rejected even
though they appear to meet the standards of acceptability, if there are reasonable
grounds to anticipate that the depth of a defect might in any way prejudice the integrity
of the weld.
6.12.3 Visual Examination Acceptance
Completed welds shall be free of porosity, cracks, lack of fusion and other defects and
shall have a smooth uniform appearance. The external weld reinforcement shall be
fused and shall merge smoothly into the component surfaces and the weld shall not
extend or overlap the outside of the groove by more than 1.6 mm on each side. The
thickness of the external weld reinforcement and internal weld protrusion shall not
exceed the following:-
Wall Thickness External Weld reinforcement or Internal
(mm) Weld Protrusion
(mm)
6.4 and under 1.6

over 6.4 through 12.7 3.2
over 12.7 through 25.4 4.0
over 25.4 4.8
Cap and root undercut shall not exceed the limits of API 1104.
For welds applied to live pipelines, the maximum depth of line fusion zone shall be 2
mm. This shall be confirmed by macrographical examination of cross-sections taken
from the test coupons produced during the weld procedure qualification tests. The
number and position of such cross-sections shall be approved by the COMPANY.
6.12.4 Magnetic Particle and Dye Penetrant Inspection Acceptance
Any weld with cracks shall be deemed unacceptable.
6.12.5 Site Hardness Checks Acceptance
The maximum hardness of the weld, HAZ or parent metal shall not exceed 248HV.
6.12.6 Radiographic and Ultrasonic Acceptance
Any weld, which as a result of radiographic and/or ultrasonic examination, and which
in the opinion of COMPANY exhibits imperfections greater than the limits stated in
API-1104 latest edition or as superseded in this article, shall be considered defective
and shall so be marked with an identification paint marker.
In addition to the API-1104 requirements any welds containing cracks, including crater
cracks regardless of size or location, shall be deemed unacceptable.
For sour service gas/oil lines, in addition to the API-1104 requirements the following
shall apply:-
- Any amount of inadequate penetration of the root shall be unacceptable in the
bottom part of the line between the four and eight o'clock positions.
- Unrepaired burn through areas shall be unacceptable in the bottom part of the
line between the four and eight o'clock positions.
FIGURE 6.1 - POSITIONS OF MACRO SPECIMENS REMOVAL
FIGURE 6.2 - POSITION AND FREQUENCY OF HARDNESS TEST
1 mm 0.5 mm
x x x x x x x x x x x x x
x x x x x xxx x x x x x
1 mm TYPICAL LOCATION OF
INDENTATIONS
NOTES
1. In the weld metal at least 6 indentations equally spaced shall be made
2. In the heat affected zone the distance between indentations shall be as

short as possible, and the checks shall be from base metal to weld metal
3. Samples extracted from 3,6,9,12 o,clock positions shall be used
4. 20 Kg Load
FIG 6.3 - POSITIONS AND MINIMUM VALUES OF CHARPY SPECIMENS
(SPECIMENS AND NOTCH DETAIL AS PER ASTM A370, E23).
Test samples shall be extracted from the 12 o’clock and 3 o’clock position.
Each sample consists of three specimens. For each welding procedure to be
qualified, a total of 18 specimens are required for testing; 9 from the 12
o’clock position and 9 from the 3 o’clock position.
2 mm
10 mm x 10 mm SPECIMEN NOTCH CENTRED IN WELD METAL
2 mm
10 mm x 10 mm SPECIMEN NOTCH CENTRED ON FUSION LINE
2 mm
10 mm x 10 mm SPECIMEN NOTCH CENTRED AT 2 mm

2 mm
FROM FUSION LINE
Figure 6.4 - Extent of Inspection
ANSI VISUAL RADIOGRAPHY MPI UT HARDNESS
SERVICE/ TYPE OF WELD CLASS % TYPE % EQUIPMENT % % % *
1. Main Oil/ Gas Lines
1.1 Field Butt Joints All 100 X-Ray 100 Crawler for NPS > 12 As As As
Static for smaller Req'd Req'd Req'd
1.2 Field tie-ins " " " " " " 100 "
1.3 Repaired Butt Welds " " " " " 100 100 "
1.4 Auto Gas Shielded " " " " " Req'd 100 "
Metal Arc
2. Transition joints where

nominal wall thicknesses As
differ by > 50% All 100 X-Ray 100 As applicable Req'd 100 "
3. Welds on Fittings All 100 NA 100 100 "
4. All Fillet/ Lap Welds All 100 NA NA 100 100 "
5. All field cut backs on

pipes for laminations All 100 " " NA 100 NA
6. All field bevels All 100 NA NA 100 NA NA

7. Golden Welds All 100 X-Ray 100 100 100 NA
* Applicable for sour service only. 5%
for weldments subject to PWHT.
Note: Use of Gamma Ray is subject to Company approval.

7 PIPE LINE ANTI-CORROSION COATING
7.1 Scope
This article covers the minimum requirements for the external field coating of pipeline weld
joints and fittings for underground installation and repair of damaged coating.
7.2 General
Line pipe shall be supplied with plant applied corrosion coating, unless specifically stated
to the contrary in the Contract.
CONTRACTOR shall supply COMPANY approved materials required for the field coating
and coating repairs. Only material supplied by prequalified manufacturers shall be used
for the Work. Other types of coating may be proposed by CONTRACTOR; their use shall
be subject to COMPANY’s approval.
CONTRACTOR shall as a minimum follow manufacturers recommendations regarding
material storage, application methods, equipment, spares and tools.
The type of field joint coating to be applied shall be compatible with and have good
adhesion to the plant applied corrosion coating.
For Fusion Bonded Epoxy (FBE) coated line pipe the field joint coating shall be by high
temperature shrink sleeve.
For Polyethylene (PE) coated line pipe the field joint coating shall be by low temperature
shrink sleeve.
7.3 Material and Equipment

7.3.1 Scope of Supply
CONTRACTOR shall supply all field joint coating and coating repair material, all
equipment including spares and skilled manpower required for adequate pipe cleaning,
application of coating, coating repair in the field and inspection and testing of same in
accordance with this Specification.
7.3.2 Condition of Supplied Material
CONTRACTOR shall ensure that supplied materials meet the manufacturers
specifications as approved by the COMPANY. Certificates and data sheets certifying
the quality of the coating materials shall be provided
CONTRACTOR shall ensure that the coating materials supplied are properly packed
and clearly marked with:
- The manufacturer's name
- Material qualification and identification
- Batch number
- Date of manufacture
- Test certificates and test data
- Storage temperatures.
7.3.3 Handling and Storage

Coating materials shall be kept dry and stored as long as possible in the Manufacturer's
original packaging, and in accordance with Manufacturer's instructions.
7.4 Field Joints
7.4.1 General
The materials, at time of application by CONTRACTOR, shall not be older than the
shelf life stated by the manufacturers. If no shelf life is stated, materials shall not be
older than 6 months.
7.4.2 Shrink Sleeve Method
7.4.2.1 Material Specification
The wraparound shrink sleeves for the field joints shall be of a high density radiation
cross-linked polyethylene with an adhesive having a melt point suitable for the pipeline
service temperature and the pipe ambient temperatures foreseen during construction.
Shrink sleeve coating materials shall as a minimum be in accordance with DIN 30672
(latest issue). The adhesive shall have a minimum thickness of 2 mm.
7.4.2.2 Coating Application Procedure
CONTRACTOR shall propose the Coating Application Procedure (CAP) for
COMPANY approval. The CAP shall be in accordance with manufacturer's instructions
and the minimum requirements specified below, and shall be presented to COMPANY
prior to field application.
The procedure shall include as minimum the following information:
- Manufacturer
- Type identification of sleeve material and adhesive
- Pipe nominal diameter
- Surface preparation and inspection criteria thereof
- Surface preheating temperature
- Heating equipment type and number, and number of skilled labour involved.
- Surface temperature measuring device
- A sketch showing the orientation of shrink sleeve and closure patch with respect
to pipe position.
- Description of shrinking process
- Curing time
- Coating inspection and tests
The submitted procedure shall also include manufacturers application instructions.
Upon approval by COMPANY the CAP shall be qualified. CONTRACTOR shall
demonstrate the effectiveness of the approved procedure by applying it, in the presence
of COMPANY's representative, onto a test specimen and subject it to inspections and
tests specified in the approved CAP. The inspection and tests shall be witnessed by
COMPANY and the results shall be submitted for final approval before any field
coating is effected.
The qualification of previously qualified CAP could be waived at COMPANY's
discretion.
7.4.2.3 Surface Preparation for Coating

After any field weld is completed and non- destructively tested and accepted, the
surface shall be prepared for the application of the sleeve in accordance with the
following provisions:
- All burr edges of the plant applied coating, weld spatter and other sharp points/
edges shall be removed by filing or grinding, prior to cleaning and blasting
- Polyethylene pipe coating shall be cut back and chamfered if corrosion is visible
underneath the coating.
- The surface shall be solvent cleaned using a suitable solvent.
- The surface shall be grit blasted to obtain a surface cleanliness of Sa 2.5.
- The surface profile shall be 40 - 75 microns (peak to trough).
- General checks at random shall be carried out such as monitoring of particle size
of copper slag, grit/shot used for blast cleaning, cleanliness of materials used for
blast cleaning and coating, and temperature control of the pipe surface.
- Any field joint not coated within 4 hours after grit blasting shall be re-blasted
before the shrink sleeve is applied.
All blast cleaning operations, equipment and personnel protection shall comply with the
Specification and Safety requirements
7.4.2.4 Application of Coating
The pipe joint shall be heated up to the temperature indicated by the procedure.
induction heaters, ring burners or propane torches of a suitable type could be used for
pipe diameters smaller than 16". Induction heaters should be used for the pipe line
welds for pipe diameters of 16" and larger, however torches could be used for tie-in
welds at COMPANY's discretion. As an alternative CONTRACTOR could propose the
use of torches for the application of heat shrink sleeves on production welds on pipe
diameters of 16" and larger, provided that the application procedure and number of
personnel working on the joint at any one time are such that speed, efficiency and
quality assurance are equivalent to the use of induction heaters.
To check that the required preheat temperatures have been achieved, a digital contact
thermometer shall be used.
The sleeve shall be wrapped entirely around the joint. The closure patch shall be
positioned off the one side of the pipe in a 10 or 2 o'clock position, with the edge of the
undergoing layer facing upward.
The CAP shrinking method shall be applied to shrink the sleeve in such a manner that
all entrapped air is forced out at either end using gloved hands and hand rollers. Special
attention shall be given to the closure patch and overlapping areas.
The installed sleeve shall be left undisturbed until the adhesive has been solidified.
7.4.2.5 Inspection of Coating
Inspection and testing shall be carried out in accordance with the approved CAP and
section 7.6 below.
7.4.3 Other Methods
Should other methods of field coating be used, such as FBE powder or coal tar epoxy,
CONTRACTOR shall submit for COMPANY approval and shall qualify a suitable
CAP similar to that detailed in 7.4.2.2 above.
7.5 Coating Repair Procedures

7.5.1 General
Coating repairs shall be executed on all coating damages and imperfections detected
visually or by holiday detector.
7.5.2 Repair Procedure
The coating (shrink sleeve or other) repair method and the required materials for this
including the installation of repair sleeves shall be in accordance with a procedure
submitted by CONTRACTOR and approved by COMPANY.
The repair procedure for polyethylene coatings shall be selected based on the criterion
of magnitude of the damaged area, i.e.:
a) for pinholes and damages with a diameter or width of 10 mm maximum a
thermoplastic repair stick or PE powder shall be used.
b) for damages from 10 mm width to 100 mm diameter a patch of thermoplastic
heat shrink material shall be used.
c) for damages with a greater diameter than 100 mm a thermoplastic wrap-around
shrink sleeve shall be used.
d) minor flaws of polyethylene coating may be smoothed down using a torch and a
hot iron.
Polyethylene repair coating materials shall as a minimum be in accordance with DIN
30670 (latest issue).
7.6 Testing, Inspection and Acceptance
7.6.1 General
The testing and inspection for acceptance of the coating system shall be carried out and
recorded by CONTRACTOR as specified in the CAP and as further specified hereunder
and witnessed by COMPANY's representative. The frequency of testing as specified
herein could be altered by COMPANY at COMPANY's sole discretion.
7.6.2 Surface Inspection
The surface preparation shall be inspected immediately prior to the application of the
shrink sleeve, in accordance with the approved CAP.
The cleanliness of the blast cleaned surfaces for every field joint shall be inspected by
comparing the cleaned surface with the relevant prints in the Swedish Standard SIS 05
5900.
After the surface has been blast cleaned and dusted off, a strip of transparent cellotape
shall be applied to the surface, and subsequently removed and examined for particle
contamination. This shall be done on every first joint each day, plus two more times
during the day and when a new batch of grit is being used. If in the opinion of
COMPANY the test has failed, CONTRACTOR shall undertake to perform additional
cleaning to the specified standard.
The profile of the blast cleaned surfaces shall be tested by means of Testex tape (type
X-course) replicas, produced at least twice a day and additionally the first few joints
and at each change or replenishment of abrasive. Before applying the tape the surface
shall be free of rust or residual abrasive. The surface profile shall be evaluated from the
replicas in accordance with manufacturers instructions, using a recently calibrated
micrometer. The replicas shall be included in the as built documentation. As an

alternative to the above COMPANY could allow the surface profile to be tested on site
by a suitable profile gauge.
7.6.3 Shrink Sleeves
7.6.3.1 Visual Inspection
Shrink sleeves shall be visually inspected for adhesion and bonding. Adhesive extruded
from the ends of the sleeve indicates proper application. The ends of the sleeve shall be
firmly bonded to the surface of the coated pipe.
There shall be no sign of punctures or pinholes. The external appearance of the sleeves
shall be smooth and without dimples or ripples.
7.6.3.2 Destructive Testing
The following destructive testing on shrink sleeves shall be executed along with the
acceptance/rejection criteria.
Sleeves for testing shall be chosen by COMPANY.
From each test sleeve one or more strips 2.5 cm wide and 20 cm long shall be cut
perpendicular to the pipe axis and slowly peeled off, using an approved peel strength
gauge.
The temperature of sleeve and pipe during such a peel test shall be 50 degrees C
minimum. The required peel strength for the above strip shall be 5 kg minimum. Repair
shall be carried out as per article 7.5.
Following the peel tests COMPANY could request CONTRACTOR to remove the
entire sleeve to check the overall degree of adhesion and absence of bare metal voids
achieved.
After removal of the shrink sleeve the bulk of the adhesive layer which remains on the
pipe surface shall be essentially free from voids, although a certain amount of voids
could be allowed at the discretion of COMPANY, up to a maximum of 6 mm x 6 mm.
Voids exposing bare metal shall not be acceptable and fail the shrink sleeve.
In case the test has failed it shall be repeated on the two sleeves adjacent to the tested
sleeve. Tests will continue until the sleeves which are inspected are acceptable.
COMPANY shall have the right to test one out of every hundred shrink sleeves applied
or one sleeve out of every days production if less than one hundred sleeve are applied in
any day.
7.6.4 Epoxy Coating Inspection
7.6.4.1 Thickness
The dry film thickness of epoxy coatings shall be measured at each joint or application
by means of a COMPANY approved type of coating thickness gauge, which is
calibrated at regular intervals.
7.6.4.2 Adhesion
Every day at least one representative epoxy coated field joint shall be subjected to an
adhesion test. With a Stanley knife, two cuts are made through the coating to the
substrate to form a "V" with an intersection at about 30 degrees. Starting at the top of
the "V", CONTRACTOR shall attempt to force the coating from the substrate with the
Stanley knife. Peel off of coating exposing bare metal constitutes as failure. This test is
carried out on the same day that the coating is applied. In the event of failure the joint
on either side shall also be tested. The test area of the joints passed, shall be repaired
with the liquid epoxy system. Failed joints and other joints rejected on the basis of the
test results shall be stripped and re-coated to the original specification at no extra
expense to COMPANY.
7.6.4.3 Cure test
CONTRACTOR shall provide a fully cured laboratory prepared sample.
Every day at least one representative epoxy coated field joint shall be subjected to a
cure test. This is done by rubbing a smooth coated area, free from overspray and
surface powder contamination, with a suitable solvent and judge the amount of
coloration as compared with the previously carried out tests on a laboratory prepared
and cured panel. No softening of the coating shall be noticeable by comparing the
rubbed area with the adjacent non rubbed area of the joint. This can be checked by
pushing a finger nail in the rubbed area and the adjacent untreated area and judge the
difference between the two impressions.
The solvent to be used shall be either MEK (Methyl Ethyl Ketone), MIBK (Methyl Iso
Butyl Ketone), or other dependent on the powder manufacturers recommendation and
the outcome of the laboratory test.
During the test the coated substrate must be cooled down to ambient temperature. The
test shall be carried out on the same day that the coating is applied. In the event of
failure the joints on either side shall also be subjected to a cure test. Failed joints and
other joints rejected on the basis of the test results shall be stripped and re-coated to the
original specification at no extra cost to COMPANY.
7.6.5 Holiday Detection
Holiday detection of 100% of the surface area of all coated main pipe shall be carried
out immediately prior to lowering in the ditch.
The holiday detection equipment which shall be COMPANY approved shall be set at
2000 volts DC for Fusion Bonded Epoxy and 22000 Volts DC for PE coated pipes.
However, the voltage setting for holiday detection may be lowered slightly at
COMPANY discretion if coating damage results. The electrode shall be conductive
rubber or be a spiral metal ring. A brush type electrode shall not be used. The voltage
applied by the holiday detection equipment shall be measured by means of a voltage
read out. Alternatively, a means of calibration of the applied voltage of holiday
detection equipment shall be provided to enable daily calibration of each piece of
equipment.
All holidays, imperfections and damaged areas shall be identified with a waterproof
marker at sufficient distance from the defect to allow surface preparation and patching
to take place without detriment to the adhesion of the coating.
8 CATHODIC PROTECTION
8.1 Scope
This Article covers the minimum requirements for the installation of an impressed current
cathodic protection system as required for the Work. The specific requirements for design
and materials are detailed in AFPC Schedule FF "Cathodic Protection Systems for Buried
Pipelines" and shall form an integral part of this specification.
CONTRACTOR's scope shall include but is not necessarily limited to the supply and
installation of all pipe to cable connections, test stations, bonding stations, current
measurement stations, grounding facilities, drain point facilities with reference cells (if
required), all inclusive with junction boxes, etc. complete with interconnecting cabling up
to the CP stations, all in accordance with the COMPANY approved design produced by the
CONTRACTOR's CP design consultant in accordance with Schedule FF.
8.2 Materials
Specifications of materials to be supplied and installed by CONTRACTOR shall be in
accordance with the COMPANY approved design produced by the CONTRACTOR's CP
design consultant in accordance with Schedule FF.
8.3 Installation
The installation of all pipe to cable connections, test stations, bonding stations, current
measurement stations grounding facilities, drainpoint facilities, cables, junction boxes and
reference cells shall be carried out concurrently with the construction of the pipeline by the
CONTRACTOR.
To facilitate the installation of test stations, cable connection pads shall be welded on the
top of the pipe at minimum 2 km intervals and at all locations indicated in the COMPANY
approved design prepared in accordance with Schedule FF and the Standard Drawings.
Welds on to the pipe shall be in the pipe's circumferential direction only.
Where looplines are to be laid parallel to existing pipelines, the new bonding stations at 10
km intervals are to bonded to the test stations on the existing pipeline. This is to be done by
erecting the bonding station on the loopline opposite to the test station on the existing line,
and laying a cable between them in a trench 600 mm deep x 500 mm wide incorporating
sand bed and sand cover and cable warning tape.
8.4 Insulating Couplings/Insulating Flanges

All Insulating couplings or flanges shall be tested in accordance with the requirements of
Schedule FF. Installed insulating couplings and flanges shall be finished with two coats of
red enamel.
8.5 Cables
All cables shall be in accordance with the COMPANY approved design prepared in
accordance with Schedule FF. The cabling shall be installed prior to hydrostatic testing.
Where cables rise above grade, for connection at junction boxes, they shall be run through a
galvanized steel conduit.
9 PIPELINE CONCRETE COATING
9.1 Scope
This article of the Specifications covers the minimum requirements for concrete coating of
the corrosion coated line at dredged river crossings and wadi crossings type "B" and "C", as
required for the Work. The application of concrete to both line pipe and field joints is
covered by this article.
9.2 General
The concrete coating of line pipe shall be applied either in the factory or in the field at
Contractors option. Field application shall be by the dry mix gunite technique and the
coating yard shall be COMPANY approved. CONTRACTOR may propose to COMPANY
for approval an alternative method for the field application of the continuous concrete
coating of uniform quality and thickness, provided that as a minimum all requirements as
per this specification are met.
CONTRACTOR shall be responsible for the supply and installation of all concrete coatings,
including all associated handling and transport.
The identity of each line pipe shall be preserved and records kept during and after the
coating process. Pipe number shall be painted on concrete in resistant white paint.
9.3 Concrete Specification

The concrete shall have a minimum density of 22.6 kN/m3. For wadi crossings the
minimum thickness shall depend on the pipe outside diameter D as specified below:
For D up to 6.625" : 40 mm
For D over 6.625" and up to 12.75" : 50 mm
For D over 12.75" : 60 mm
For dredged river crossings the thickness and concrete density shall be determined by
negative buoyancy calculations employing a safety factor of 1.2 and accounting for both
drag and lift forces induced by the currents in the river. Also the type of reinforcement shall
be by caged rebars rather than the galvanised steel mesh fabric specified for concrete
coatings at wadi crossings. Both the design basis and the calculations shall be subject to
COMPANY approval.
The concrete shall be Grade 30 to BS 8110 with a characteristic crushing strength of 21
N/mm2 at 28 days.
9.4 Concrete Materials

9.4.1 Cement
The cement shall be sulfide-resistant Portland cement conforming to BS 4027. Cement
which is held in stock for longer than three months, or any cement which shows signs
of deterioration, partial setting or other defects or which fails when tested, shall be
rejected.
9.4.2 Aggregates
Aggregates shall be naturally occurring washed sand and shall be hard, dense, durable,
clean sharp and graded evenly from fine to coarse as per the grading limits specified
below, and be in compliance with BS 882. If in the opinion of COMPANY the
aggregate contains an undesirable proportion of chemicals, dust, clay, organic matter or
other undesirable constituents, the consignment shall be rejected. The grading of
aggregate when plotted against sieve size shall be within the limits tabulated below:
BS 410 Sieve Size Percent by Weight
passing a 3/8 inch 100
passing a no. 4 95-100
Stockpiles of aggregates shall be covered by tarpaulins.
9.4.3 Water
Water for use in concrete shall be clean and free from all substances which may be
injurious to concrete or steel. It shall satisfy the requirements of BS 3148 and contain
no staining colouring. The moisture contained in the aggregate shall comply with the
same requirements.
9.4.4 Reinforcement
Reinforcement of concrete coating shall be by one layer of electrically welded
galvanized steel mesh fabric reinforcement to BS 4483. Minimum mesh dimensions
shall be 25 x 25 mm x 2mm wire diameter. The minimum overlap between two
consecutive rolls of mesh shall be 50 mm except at field joints where no overlap is
required. The reinforcement shall be placed at the centre of the concrete coating layer
by using PVC spacer blocks or a COMPANY approved equivalent. The reinforcement
shall be clean and free from scale, mud, grease, hardened rebound or anything likely to
destroy adhesion or promote corrosion.
9.5 Performance
9.5.1 Barrier Coat
Prior to concrete coating CONTRACTOR shall apply a protective layer or "barrier
coat" to epoxy coated pipe. The type of barrier coat to be used shall be a two
component fibre reinforced cementitious coating such as FEB brush crete, Fosroc's
H.I.M. Epoxytar, Rezex water based epoxy coating ES 2 or equivalent.
CONTRACTOR shall demonstrate to the satisfaction of COMPANY that the proposed
barrier coat serves its purpose, its primary purpose being to prevent holidays in the
epoxy coating due to the concrete application process, and the secondary purpose being
to promote a good bond between the epoxy and concrete coating.
To this end one or more sections of a test joint shall each be coated with a proposed
barrier coat, in accordance with manufacturers recommendations. The number of
applications, film thickness and curing time shall be representative for the application
in the production process. The test joint shall be concrete coated, whereupon the
concrete shall be immediately washed off and each test section subjected to a holiday
test in accordance with article 7. Also CONTRACTOR shall demonstrate to and satisfy
COMPANY by destructive testing that good adhesion is achieved.
9.5.2 Concrete Mixing
Batching, proportioning and mixing of the materials shall be such that a concrete
coating is provided with the minimum specified strength and density. No batch of
cement and aggregate shall be used in the work if it has stood for more than one hour
after mixing. No rebound shall be mixed into any batch.
CONTRACTOR shall pay attention to the moisture content of the sand used for
guniting. If the sand is too wet the hose will block and a mortar layer will build up
inside the gun. If the sand is too dry the cement will not adhere to the sand grains on
mixing and excessive separation will occur in the hose. In case the moisture content
falls outside the critical range of 5 to 8%, CONTRACTOR shall make the sand suitably
damp either by spraying too dry sand with water or mixing too wet sand with specially
supplied dry sand.
The mixing equipment shall be capable of providing a uniform mix. The dry mix used
for gunniting shall be screened to prevent inclusion of stone, flakes from the mixer
drum, pieces of cement bag, etc.
9.5.3 Surface Condition
Concrete shall not be placed until:
a) The line pipe corrosion coating has been approved by COMPANY.
b) The barrier coat (if required) has been applied and sufficiently cured.
c) Reinforcement has been adequately secured in the correct position with use of
spacer blocks, to prevent displacement during concrete application.
d) Shading has been installed to prevent the line temperature to exceed 35 degrees
C.
Concrete shall not be placed when the temperature of the concrete mix exceeds 32
degrees C.
9.5.4 Application
Since the technique of gunniting centres almost entirely round the skill of the
nozzleman, he shall have at least 3 years experience in work of similar nature. Other
operators of the gunniting crew shall have a minimum of one year experience. Written
evidence of such experience shall be furnished to COMPANY. CONTRACTOR shall
have a minimum of five years experience in gunniting or alternatively shall subcontract
the gunniting work to a specialist subcontractor with similar minimum experience level.
Before directing the gunniting nozzle onto the pipe surface the nozzleman shall ensure
that the proportioning of water and dry mix is correct. Further regulating of the water
supply shall be kept to a minimum to ensure uniform concrete quality. The nozzle shall
be held in the optimum position for placement at all times i.e. 0.6 to 1.2 m from, and at
right angles, to the receiving surface.
The outer surface of the concrete coating shall be smooth, without corrugations and
concentric with the steel pipe. Both ends of each joint for a distance of approx. 300 mm
from the end of each joint shall be completely free of concrete to facilitate field joints.
The concrete shall taper back from these points at a two-to-one slope until the required
thickness of coating is reached.
9.5.5 Curing
The finished concrete coating shall be completely protected from wind, draught, rain,
spray, etc. for a minimum period of 7 days by wrapping with polythene sheeting. Also
for this period the pipe shall not be exposed to direct sunlight and/or temperature below
freezing point.
After a period of 8 hours from placement and for the 7 days curing period the concrete
surface shall be kept wet.
The concrete coated pipe shall not be transported from the curing area during the 7 day
curing period. The CONTRACTOR shall take precautions to prevent detrimental
movement of line pipe after concrete coating to minimize handling stresses whilst
concrete is hardening and curing.
9.6 Inspection and Testing
Every length of concrete coated pipe shall be inspected visually and by spiral ring holiday
detector (not less than 3 days after concrete application). If faulty concrete is indicated
CONTRACTOR shall remove an entire ring of a minimum 10 cm width of the coating at
the indicated location of the fault.
CONTRACTOR shall remove cores from the test pipe for crushing test. If the crushing
strength tests of the cores fail CONTRACTOR shall remove the defective coating by
COMPANY approved method, inspect and where necessary repair the corrosion coating
and reapply the concrete coating. CONTRACTOR may elect not to await the test results
and immediately initiate the stripping and subsequent coating repair work.
On a regular basis cores shall be taken as follows:
a) for factory applied concrete one core sample from the coated line pipe per 15 coated
joints.
b) for field applied concrete one core sample from each test panel. Test panels shall be
made every day one at the start of work and one in the course of the day. The test
panel formers, made from mild steel, shall be positioned alongside the work and in a
position similar to the work (horizontal, vertical or overhead). Before the cores are
taken the test panels shall be cured in a similar manner as to the coated pipe.
Core samples shall be obtained using a diamond core cutter set to ensure that the cut is
perpendicular to the surface and fitted with a positive depth of cut limit to ensure that the
core barrel will not penetrate closer than 6 mm to the corrosion coat of the line pipe, where
applicable.
The minimum diameter of the core shall be at least three times the nominal maximum
aggregate size. The length to diameter ratio of the core when trimmed for testing shall not
be less than one-to-one. Sampling, storing, testing and calculation shall be in accordance
with the provisions of BS 1881. Cores shall be cut four days after concreting and stored in a
curing tank until tested.
Samples shall be tested as specified in BS 1881. The compressive strength of each
specimen shall be calculated using the computed cross-sectional area based on the average
diameter of the specimen. For acceptance each core shall have the minimum density and
compressive strength as specified in article 9.3.
The thickness of applied concrete coating shall be measured on every joint to check
compliance with the minimum requirements as per article 9.3. Concrete coatings not in
accordance with the dimensional requirements shall be repaired or stripped and recoated at
the discretion of COMPANY.
10 PERMANENT PIPELINE MARKERS
10.1 Scope
This article of the Specifications covers the minimum requirement for the supply and
installation of permanent pipeline markers, as required for the Work.
10.2 General
CONTRACTOR shall supply and install permanent pipeline markers along the pipeline
route for pipeline inspection and warning as close as possible to the windrow. Except when
specified by COMPANY, permanent pipeline markers shall not be required for flowlines.
Construction details of all types of markers shall be shown on the drawings.
Each marker consists of a post, mounted with two marker plates as per the drawings.
Marker plate no.1 shows general information about the pipeline involved, whereas marker
plate no. 2 shows relevant information for each location. The different types of pipeline
markers are listed below. Chainages shall be indicated on the marker plates with an
accuracy of one meter. The posts shall be of sturdy design to minimize the chance of
pilferage. CONTRACTOR may propose alternative (concrete) designs for COMPANY
approval to satisfy this requirement. The markers shall be properly founded in a concrete
foundation of sufficient size.
Colour coding of the background of the pipeline markers shall be as follows:
Crude : red
Gas : blue
Water : green
Markers can be combined as per 10.3. Separate markers are required on parallel lines.
Aerial markers are not required.
10.3 Chainage Markers

Chainage markers shall be installed along the pipeline at each full one (1) kilometre
chainage station. A chainage marker is not required if the distance between its location and
any other type of pipeline marker, as mentioned hereafter in this Article is less than 200
metres.
10.4 Block Valve Markers

Block valve markers shall be installed along the pipeline at each block valve station.
Chainages of all block valve stations shall be given on the pipeline route maps.
10.5 Road Crossing Markers

Road crossing markers shall be installed at both sides of each paved or graded road
crossing. Location to be 5 metres from the borders of the road. Chainages of all paved and
graded road crossings shall be given on the pipeline route maps.
10.6 Wadi Crossing Markers

Wadi crossing markers shall be installed at both sides of each wadi crossing. Type, number
and chainage of wadi crossings shall be given on the pipeline route maps. Location to be 5
metres from the borders of the wadi.
10.7 Pipeline Crossing Markers

Pipeline crossing markers shall be installed at each crossing with an existing underground
or above ground pipeline.
10.8 Cable Crossing Markers

Cable crossing markers shall be installed at each crossing with an existing underground
cable.
10.9 Markers at Horizontal Bends

Markers shall be installed at the tangent points of each horizontal bend.
10.10 Cathodic Protection Markers

At all test stations, bonding stations and negative connection stations a pipeline marker shall
be installed. Locations to be preferably combined with chainage markers.
11 STATION PIPEWORK
11.1 Scope
This article of the Specifications covers the minimum requirements for the installation of all
above and below ground station pipe work, such as pig launchers and receivers, block valve
stations, etc., required for the Work.
11.2 Performance
11.2.1 General
Valve Internals and cavity shall be protected from damage and ingress of dirt. Valves
shall, as long as possible, be left in a fully open position during delivery, construction,
hydrotesting and pre-commissioning activities.
Indicators of pig passage shall be installed as per drawings. The nipple (pressurized
part of the indicator during operation) shall be installed separately prior to hydrostatic
testing. Upon acceptance by COMPANY of the hydrostatic testing the indicators shall
be completely assembled.
The corrosion monitoring fitting shall be welded onto the line, tapped and fitted prior
to the hydrostatic testing.
When temporary vents are required (location to be approved by COMPANY) during
hydrostatic testing these shall be 1 inch size, consisting of a weldolet, a nipple and a
valve, all welded. After the line is emptied the nipples (partly) and valves are to be
removed and the nipples capped by welding. This final weld shall be 100%
radiographed. After providing caps to the nipples, coating shall be applied as per these
Specifications. The exact locations of the capped nipples shall be indicated on the "as-
built" drawings.
Anchors shall be installed at locations as indicated on the drawings. Before the civil
work may start, the anchor flange shall be installed completely. The anchor flange to be
embedded in the concrete shall be coated in accordance with Article 7. Pipe coating
shall be tested with the holiday detector prior to embedding in concrete.
The concrete work shall be back filled and left to cure a minimum of three weeks
before further joints are allowed to be welded to the anchor flange assembly.
COMPANY will allow a shorter curing time provided that CONTRACTOR
demonstrates to COMPANY that 80% of the specified compressive strength of the
concrete has been reached at that time.
11.2.2 Fabrication
CONTRACTOR shall perform all fabrication work in accordance with the following
documents and order of precedence in case of conflict:
- Requirements below
- Article 6.8 of this specification
- Other relevant AFPC Specification Schedules and - ANSI B31.3
CONTRACTOR shall weld all bars in COMPANY supplied tees whenever this is
indicated on the drawings. Such bars shall not intrude into the bore of the pipeline.
11.2.3 Construction
It shall be CONTRACTOR's responsibility to maintain elevations, shown on the
drawings and to carry out any pipe work adjustment necessary for this purpose.
Care shall be taken to avoid entry of sand particles etc. to parts of equipment, during
installation.
11.2.4 Valve Actuators
The following guidelines shall apply for valve actuators at remote block valve stations:
Valves, 16 inch and larger shall be provided with a hydraulic actuator in addition to a
handwheel or handpump. Valves, 6 inch up to and including 14 inch shall be provided
with a manual gear actuator only. Valves 4 inch and smaller shall be lever operated. All
valve actuators shall be sighted above grade.
11.2.5 Buried Valves
Unless agreed otherwise all buried valves shall be installed with welded ends, and they
shall be provided with extended spindle and body connections. All above ground valves
shall be flanged.
11.2.6 Block Valve Station
The location of block valve stations shall be carefully selected with due consideration
of the following:
Accessibility: The location preferably should be near a road or track, but
positioned such that it will not be liable to damage from
traffic. Low lying areas, prone to seasonal flooding, shall
be avoided since access to the BVS must be available at
all times.
Hazard: Block valve stations shall where possible be located away
from populated areas to minimize the possibility of third
party interference.
The selected location shall be subject to COMPANY approval.
11.3 Cast-in Materials
Anchor bolts, etc. shall be properly protected against damage and corrosion. Threaded parts
shall be greased and securely wrapped with wire before pouring of concrete. Anchor bolts
shall be as shown on the drawings. All embedded parts shall be free from oil, loose scale,
rust, paint, grease or other harmful matter.
12 QUALITY AND TREATMENT OF FLUSHING AND HYDROTESTING WATER
12.1 Scope
This article of the Specifications covers the minimum requirements for the flushing and
hydrostatic testing water as required for the Work.
12.2 CONTRACTOR Responsibilities

12.2.1 Water Source
CONTRACTOR shall allocate one or more sources of water sufficient for meeting
flushing and hydrostatic testing requirement.
Where water is to be supplied from wells, CONTRACTOR shall install submersible
pumps, lines, generators, etc. sufficient to obtain water in the desired quantities.
CONTRACTOR shall also supply, install and later remove all temporary facilities, e.g.
filters, pumps, break tanks, desert pits, fill lines, etc., as required to execute the flushing
and testing of all pipelines under this Contract.
For gas lines the water shall be filtered through 50 micron filters, whereas for flow
lines, oil lines and oil/water lines 1 mm strainers shall be used.
CONTRACTOR shall be cognizant of the fact that it may be necessary to share water
obtained from wells from time to time with others on a priority basis.
12.2.2 Water Testing
CONTRACTOR shall test the quality of the water supply for flushing and hydrostatic
testing; he shall carry out all water sampling and analysis that may be necessary for the
COMPANY to approve the water source and quality.
12.2.3 Water Treatment
CONTRACTOR shall procure such inhibitors and oxygen scavengers as are necessary
to render the water suitable for introduction into the pipelines.
The CONTRACTOR shall provide for approval by the COMPANY all details of his
water treatment proposals necessary to bring the water to the required quality for both
flushing and hydrotest use.
12.3 Water Quality
12.3.1 Introduction of Air after Hydrotest
If air is introduced after the hydrotest the water used shall be of the minimum quality
below:-
pH : 6.5 to 10.5
Total dissolved solids : less than 1.5 kg/m3
H2S : Nil
Suspended Solids : 0.002 kg/m3
Appearance : Clear with no visible sediment.
If the maximum period of contact of this water with the pipeline is 7 days or less
chemical treatment shall not be required. If the period of contact is or could be in
excess of 7 days, chemical treatment as specified in 12.4 shall be provided.
12.3.2 Exclusion of Air after Hydrotest

If air is excluded from the system by leaving the system full of water and continuously
pressurised between 30 and 150 kPa, the quality of the water may be relaxed as below:
pH : 6.5 to 10.5
Total dissolved solids : less than 30 kg/m3
H2S : Max. 0.001 kg/m3
Suspended Solids : Less than 0.005 kg/m3
Appearance : Clear with no visible sediment.
Black or red water shall be rejected. Irrespective of the period of contact the above
water shall be chemically treated as specified in 12.4.
12.4 Chemical Treatment
Advice on approved chemicals and treatment rates may be obtained from COMPANY.
The type of treatment to be used will depend on the period of time that the water remains in
the system after the hydrostatic test. For contact periods up to 3 months either the cocktail
treatment or individual chemical treatment could be used. For contact periods exceeding 3
months individual chemical treatment shall be employed.
Every time test water is transferred from one test section to another the quality of water i.e.
the amount of treatment remaining, shall be checked and additional chemicals added as
required to bring it back up to Specification. Also when reusing test water, the water shall
be filtered, to reduce the amount of debris to a COMPANY acceptable standard. These tests
and activities shall be properly documented and immediately reported to COMPANY.
Two basically different types of treatment are currently approved by the COMPANY i.e.
cocktail treatment and individual chemical treatment:
12.4.1 Cocktail Treatment

A single-chemical blend comprising two or more components of oxygen scavenger,
corrosion inhibitor, scale inhibitor or biocide.
12.4.2 Individual Chemical Treatment
Injection of oxygen scavenger, biocide and corrosion inhibitor separately. When using
this treatment the oxygen scavenger shall be added first, and as far upstream in the
system as practical to allow complete reaction prior to adding the other chemicals. The
biocide shall follow and finally the corrosion inhibitor.
12.4.3 Special Treatment
In locations where no water of suitable quality is available, alternative treatments are
possible e.g. for seawater or sour water (containing H2S). Approval for the use of such
method of treatment shall be obtained from COMPANY.
12.5 Approved Cocktail Treatments
Supplier Chemical Concentration (ppm)
CECA Norust 471 400

NALCO Unitreat 3900 400
NL Treating Chemicals Coat RD-1766 800
OILEX Oilex 3760 350

PETROLITE Fludex WF-2020 400
TR Oil Services Tros 650 400
12.6 Approved Individual Chemical Treatments
Supplier Type Chemical Concentration

(ppm)
ESSOCHEM OS Corexit 8381 100
B Corexit 7672 200
CI Corexit 7730 50
NALCO OS Visco 3656 100
B Visco 1153 300
CI Visco 936 25
NL Treating OS Coat - 777 100
B Coat - 122 150
CI Surflo - B17 100
OILEX OS Oilex - 302 100
B Oilex -2668 200
CI Oilex -3760 50
PETROLITE OS Kontol K-490 100
B X-Cide XC-102 500
CI Kontol KW-32 100
SERVO OS MCA-602 100
B CK-492 150
CI CK-341 100
TR Oil Services OS TC-1000 100
B Troskil-1 200
CI Tros C-70 300
13 HYDROSTATIC TESTING
13.1 Scope
This article covers the minimum requirements for cleaning, gauging, hydrostatic testing and
bulk dewatering of pipeline test sections, as required for the Work.
13.1.1 General Provisions

Each pipeline system installed by CONTRACTOR shall be hydrostatically tested in its
entirety or in sections. Recommendations of API RP 1110 "Pressure Testing of Liquid
Petroleum Pipeline" shall apply. Due consideration shall further be given to the
following:
a) the sensitivity of the test instruments and the length of the temperature
stabilization period shall be such as to enable the tracing of pinhole leaks in
relatively long and large volume test sections.
b) due account shall be taken of possible restrictions in the availability of water in
determining the length of test sections.
c) the incorporation of station pipework (i.e. block valve stations and scraper traps)
shall be determined by the possible detrimental effect the debris in the test water
can have on the ball valve seats.
d) CONTRACTOR shall propose for COMPANY approval a fully defined split of
each pipeline system into test sections. Contractors proposal shall be in
accordance with the provisions of the Contract.
e) At COMPANY's option, the removal of some or all temporary pipework and/or
facilities shall be delayed until after commissioning, at no extra cost to
COMPANY.
13.1.2 Sequence of Operations
13.1.2.1 Pipeline
Generally the sequence of operations for each pipeline test section shall be as follows:
- water cleaning (max 10 km sections)
- gauging
- water filling
- pressurisation (entrapped air test)
- temperature stabilization
- strength test
- leak test
- depressurization
- bulk dewatering (if required)
- removal of temporary pipework and facilities.
13.1.2.2 Station Piping
Generally the sequence of operations for testing the station pipework as a separate unit,
shall be as follows:
- Water or air cleaning
- filling
- pressurization (entrapped air test)

- combined strength and leak test
- depressurization
- dewatering
- final tie-in work and removal of temporary pipework and facilities.
13.2 CONTRACTOR's Responsibilities

CONTRACTOR shall supply a weather proof, properly lit and air-conditioned test-van in
which the test equipment can be operated comfortably and safely.
CONTRACTOR shall furnish all materials, equipment, instruments, temporary works,
spare parts, consumables, supervision, personnel and inspection personnel, arrange
transport and bear the cost of all expenses incidental to and necessary for the successful
performance of the work covered under this article in a manner satisfactory to COMPANY.
CONTRACTOR's key personnel involved in cleaning and hydrostatic testing work shall
have proven capabilities and adequate past experience for the operations to be performed. A
specialist test engineer, to be approved by COMPANY, shall control and supervise all
operations. He shall be resident on Site from the date of commencing the preparation of the
procedures until the complete test results have been approved by COMPANY.
In case the Contract includes the requirement for pretesting of specified parts of the pipeline
system, for example tarmac or heavily used graded road crossings, such testing shall be
carried out after installation in the trench but before placement of backfill. A 2 hour
combined strength and leak test shall be required, producing a hoop stress of 95% of
SMYS.
The local situation may preclude the performance of the pre-test in situ, in which case
CONTRACTOR shall inform COMPANY representative, in writing, giving complete
details of the obstacles preventing him from discharging the contractual requirements and
requesting the waiver of same. COMPANY representative shall consider CONTRACTOR's
request and shall inform CONTRACTOR of his decision.
13.3 Safety
13.3.1 General
During testing operations CONTRACTOR shall ensure that adequate measures are
taken to safeguard all personnel involved in the operations and to safeguard the general
public and environment. These measures must be approved by COMPANY.
13.3.2 Personnel
The safety of personnel during the tests is of paramount importance and no procedure
shall be allowed which would violate this concept. All safety precautions shall be
The CONTRACTOR shall certify in writing that he has instructed all employees
engaged in testing work, or work associated with testing, on the possible consequences
of a pipe or fitting failure under pressure test conditions. Warning of the hazards
associated with the energy stored within a pipe under test and in particular the energy
stored within a pipe containing water and air shall be given to employees.
The CONTRACTOR shall take all necessary measures to ensure that all personnel are
adequately protected during the course of the test and in particular to ensure that no
works are permitted on the pressurised sections during the period of the test and during
subsequent pressure reducing operations.
13.3.3 The Public
When testing takes place in inhabited areas patrols shall be provided to watch special
points of hazard during the test, in particular road crossings and points of public access.
When deemed necessary by COMPANY protection walls constructed of sand bags, or
other methods approved by COMPANY shall be placed in locations of blanked or
capped ends of pipes and any above ground pipework under test.
During the test, all construction within 50 m of the test section shall cease.
Warning notices reading 'Warning Pipeline Under Test' in English and Arabic, shall be
placed at appropriate locations for the duration of the test. The COMPANY approved
boundaries of the test equipment locations shall be defined by marker tapes or a fence
and by lights at night.
Before pressurizing the test section and during the test, the Specialist Test Engineer
shall ensure that no person approaches within 30 m of the test end manifold on the pipe.
If it is necessary because of site restrictions for any one to approach nearer than this, a
suitable protective wall shall be constructed. The pressurising pump, pressure release
valve and instrument caravan shall be located in a safe area to be approved by the
Engineer, but at least 30 m from the test end.
13.3.4 Work Performed on Test Section
Pressure shall be reduced to a safe level of static head plus 100 kPa before any work
directly on the section under test or associated connections is permitted.
13.4 Procedures
CONTRACTOR shall prepare a detailed procedure for the cleaning, gauging, hydrostatic
testing and leak detection of the pipeline and shall submit this procedure to COMPANY for
approval not less than 2 months before the planned commencement of hydrostatic testing.
The procedure shall be approved in writing by COMPANY before any cleaning and/or
testing commences.
The procedure shall be sub-divided into sections to suit the various activities as per 13.1.2
and shall include, but not be limited to, the following:
a) Section on safety and safe working practices including safety precautions, warning
signs, notice to personnel, defined test area, handling of chemicals etc.
b) Location, identification of the test section(s).
c) Hydrostatic test diagram for each test section incorporating a schematic lay out of
the pipework under test, the as built route profile and the diameter, wall thickness,
grade, design pressure (to be indicated whether limited by valves or fittings), design
code, strength test pressure and stress and leak test pressure and stress along the line
and for each branch incorporated in the test section.
d) If applicable the additional loading on other structures due to the mass of the test
liquid in the test section.
e) Volume of test section(s) including test heads and temporary receivers/launchers.
f) Theoretical volume required to raise to test pressure, i.e. the theoretical slope of the
P/V plot.
g) Formulae for calculating change in pressure related to temperature stating assumed
coefficients.
h) Schematic drawing of each test section, showing all temporary pipework, indicating
all filling and pressurizing points, test connections, with all hooked-up equipment
and instruments, vent and drain points, etc.
i) Sources of water and method for water disposal.
j) Fully detailed programme giving proposed dates of tests and cleaning activities.
k) List of nominated supervising personnel and times of duty.
l) samples of proforma's to be used during cleaning and testing, such as:
- Air inclusion plot at 3500 kPa showing air content.
- Pressure volume plot for the whole range of the test showing liquid added and/or
subtracted.
- Forms on which readings will be recorded from the deadweight tester, and
volume added, together with frequency of readings.
- Pressure/time graph to determine the stabilisation period.
m) a description of the operational aspects showing:
- Pig tracking devices and procedures.
- Rate of increase of pressure, showing hold periods, reduction in rates at top end
of pressurization.
- Points and periods at which visual inspection will be made during pressurization
and method of inspection.
- Definition of a minor or major leak.
- Pressure to which the line will be reduced to rectify minor leaks.
- Maximum and minimum pressure deviations before adding water / bleeding off
pressure.
- Method of calibration of test pressure pumps and chemical injection pumps.
- Rate of depressurization after testing.
The following general details are also to be included in CONTRACTOR's documentation:
- Full description and calibration certificates of all cleaning and test equipment to
be used including compressor rates, pump rates, capacities, pressure, pump
curves, pigging speeds.
- Description of test cabin and its contents. Flexible piping shall not be allowed
within the test cabin.
- Rating of all temporary piping, hoses and fittings accompanied by material
certificate prior to testing/use.
- Contingency plans including back-up equipment to be used in the event of
equipment failure.
- Drawing showing layout of equipment, piping and hoses.
- Drawings and details of test heads, pig traps, temporary filling and emptying
lines.
- Method of communication.
- Documentation to be signed prior to cleaning and/or test commencing, at end of

test and to be handed over at the end of the activities.
- Produce a check list for actions to be carried out preparing the system for
cleaning and pressure test, for inspection during cleaning and/or pressurization
and inspection during the test if unaccountable pressure loss takes place.
- Detailed emergency procedures to cover a rupture of the test sections, temporary
piping/hoses and/or stuck pig(s).
All measurements and calculations shall be agreed with COMPANY and submitted to
COMPANY for assessment.
13.5 Testing Materials and Equipment

13.5.1 Materials
All pressure carrying materials shall be supplied with mill certificates.
Contractor shall test all equipment to match the specification to the satisfaction of
COMPANY prior to mobilization. COMPANY shall approve the equipment and be
notified to provide the opportunity to witness the tests.
All equipment and cables shall be suitable for either non-hazardous or hazardous areas
as specified in the drawings. All instrument cables shall be shielded against the
influence of external currents and signals.
All temporary connections fitted to enable the hydrostatic test to be performed shall
preferably be of rigid construction.
Flexible hose shall be of the armoured type and shall only be used if it is manufactured
to standards applicable to permanent hydraulic installations and has a safe working
pressure at least equal to the test pressure. CONTRACTOR shall provide evidence (test
certificate) that each hose has been hydrostatically tested to a pressure level approved
by COMPANY. Such hose shall only be used in short lengths as required for the
pressurizing line to the test end and for instrumentation, and must be anchored to
prevent "whip" in the event of failure. Flexible hose must not be used inside the test
cabin.
13.5.2 Test Instruments
Test instruments shall be of a suitable range and as a minimum requirement shall
include:
- A deadweight tester (Budenburg Fig. 80 or equivalent), capable of reading the
pressure to an accuracy of + 0.5 kPa.
- A recording manometer with 24 hours dial. Maximum reading 1.5 times test
pressure. Dial division 50 kPa. Accuracy 50 kPa.
- A recording thermometer. Dial division 0.5 deg. C. Accuracy 0.5 deg. C.
Maximum reading 100 deg. C.
- A recording thermometer and barometer for the weather conditions with dial of
24 hours or more.
- Thermocouple type recording thermometers to indicate the line pipe and soil
temperature. Dial divisions 0.1 deg. C. Accuracy 0.01 deg. C.
- Bourdon pressure gauges. Maximum reading approximate 1.5 times the test
pressure. Accuracy 100 kPa.
- Water flow meter of suitable capacity and range not to exceed 1.5 times the
contract filling rate. The flow meter shall be fitted with a totalizer which shall be
accurate to 5 percent.
Each manometer, and thermometer shall have a calibration certificate not older than 3
months at start of testing. The dead weight tester shall have a calibration certificate
supplied by the manufacturer upon purchase. The dead weight tester shall be "re-
certified" for accuracy every year or for each new Contract, whichever is sooner. This
recertification shall be carried out by a COMPANY approved third party. A copy of
each calibration certificate shall be handed to COMPANY and the original certificates
shall be shown to COMPANY and included in the Hydrotest Report. If COMPANY has
reasonable doubts about the calibration of any instrument to be used for the test,
CONTRACTOR shall at COMPANY's request, have the instruments in question
recalibrated in the presence of COMPANY.
Bourdon pressure gauges shall be checked for accuracy on Site, in the presence of the
COMPANY, before the commencement of the pressure test of any section of pipeline
or station works. This shall be carried out by comparison with the dead weight tester.
The accuracy of the pressurizing flow meter shall be demonstrated to the COMPANY
at least every three months. A calibrated tank shall be retained to enable spot checks to
be made of the volume rating of the pressure pump or flow meter. Flow meters of the
turbine or vortex type shall have a flow straightener installed upstream of the meter.
Certificate of accuracy shall be made up by the CONTRACTOR for the pressure
gauges and flowmeters and included in the Hydrostatic Test report.
13.6 Pre-test and Test Requirements
13.6.1 Pre-test Requirements
When above-ground piping are pressure tested, they shall be sheltered in order to
minimize the effects of ambient temperature variations.
Pressure indicating and recording instruments shall be connected to the test section
before pumping commences.
All screwed connections which form a permanent part of the installation shall be
included in the tests and shall not be used as temporary pressurizing connections.
A relief valve of full charging pump capacity and set at the local test pressure, which
shall be indicated on the Hydrostatic Test Diagram, shall be installed on the test head
piping assembly. A pressure recorder shall record continuously the pressure at the test
manifold.
Test ends shall be numbered and a record kept by the CONTRACTOR showing the
results of non-destructive tests on each fabrication weld, the number of times each test
end is used and the test pressure attained on each test. Entries in the record shall be
signed by a competent person. Test ends which do not have a complete record of use
from the new condition, shall not be used.
Prior to each re-use, each temporary test end shall be cut back to remove all weld metal
and the heat affected zone. To achieve this at least 12 mm of pipe shall be removed.
Dimensional and ultrasonic examination of the new weld end preparation shall be
carried out. If, after dismantling and re-using, further welding of test end assemblies is
required, these shall be subject each time to full non-destructive testing procedures.
Each test end manifold shall incorporate a device to establish that pigs or spheres have
arrived at the receiving end. Radioactive indicators shall not be used.
13.6.2 Test requirements
During the running of pigs, the CONTRACTOR shall operate pressure indicating and
recording apparatus and shall supply pig detectors and arrange for tracking the run of
each pig, as required by this Specification and where considered necessary by
COMPANY. The pressure downstream of the pig shall be carefully monitored and
controlled at a pressure of not less than 2 bar.
During the test, any variation in the rate of pressure increase with volume shall be
immediately reported to the Specialist Test Engineer who shall decide such action as
necessary.
Pipe and soil temperatures shall be measured at each end of the test section and at every
5 km throughout the length of the pipeline using temperature recorders firmly attached
to bare metal of the pipe, and the back of the probe shall be well covered with
insulating material. The points of measurement at each end of the test section shall be
such that there is at least 100 m of pipeline buried to specified depth between that point
and the test head. For short lines a minimum of three locations shall be used to measure
pipe and soil temperatures.
13.7 Pipeline Cleaning
13.7.1 Air Blowing
Prior to filling the pipeline section with water, the CONTRACTOR shall pass air
through the pipeline for a minimum period of 3 hours at a minimum speed of 3m/s in
order to blow out all loose welding slag, sand and debris from the pipeline.
The CONTRACTOR will install an impingement plate at the receiving end to ensure
that the pipeline debris carried by the air is deflected to the ground.
All personnel at the receiving end will wear eye protection goggles.
The air blowing procedure will be approved by the COMPANY representative.
13.7.2 Brush Pig Cleaning
The CONTRACTOR shall inform the COMPANY before any pigging operation is
carried out. A pig register shall be prepared for the purpose of logging pigs into and out
of the pipeline and for noting details of their "as received" condition.
CONTRACTOR shall run new stiff wire brush cleaning pigs of a type and in a
condition to be approved by COMPANY, through each segment of the test section, by
using water at a flow rate sufficient to induce a minimum liquid velocity of 1.5 m/sec.
The maximum length of pipeline to be cleaned and gauged shall be 10 km.
A minimum of two brush pigs will be run.
CONTRACTOR shall at all times ensure that suitable temporary pig launchers and
receivers are welded in position during propelled pig runs.
Upon arrival of each pig at the receiving end, the discharge flow shall be such that the
pig velocity becomes almost zero when entering the receiver.
Should a gauging pig get stuck in the pipeline, CONTRACTOR shall not employ
pressures greater than the pipeline design pressure to dislodge it. If the specified
pressure is insufficient to dislodge the pig, the pig must be located and removed from
the pipeline by back flushing (applying pressure at the receiver end) or by cutting or
other method to be approved by COMPANY.
Brush pigs will be run until visual inspection of water and debris collected at the
receiving end after the running of a new brush pig reveals debris of less than 10g per
km of pipeline section.
13.7.4 Pigging with Air
If water supply is insufficient for propelling the pig, or other circumstances exist that
prevent using water for pig propelling, CONTRACTOR shall inform the COMPANY's
representative stating the circumstances that preclude the use of water and requesting
permission to use air propelling as alternative. CONTRACTOR shall also in his request
describe all the safety precautions and measures he plans to take in order to alleviate the
hazards of using compressed air as pig propellant. At the COMPANY’s sole discretion,
the COMPANY may approve the CONTRACTOR to use compressed air instead of
water for propelling the pig.
Upon COMPANY's Representative approval CONTRACTOR will use compressed air
for pig propelling subject to the following specifications:
a) The air pressure shall not exceed 700 kPa.
b) CONTRACTOR shall install a 1000 kPa pressure recorder and a 1000 kPa
pressure gauge at the launching end of all test sections or segments of test
section to record pressure during all air propelled pig runs (i.e. cleaning &
gauging runs).
c) CONTRACTOR shall use compressors suitably rated to ensure a pig travelling
speed controllable between 1.2 and 1.7 m/sec. Each compressor shall be fitted
with a non-return valve at the compressor outlet. A pressure regulating device
and a pressure relief valve set at 750 kPa shall be installed at the inlet to the
pipeline. CONTRACTOR shall take all measures for safe disposal of debris
containing air at an acceptable noise level.
d) Should any cleaning or gauging pig get stuck in the pipeline, CONTRACTOR
shall not employ pressures greater than 700 kPa differential to dislodge it. If a
differential pressure of 700 kPa is insufficient to dislodge the pig, the pig must
be located and removed from the pipeline as described in 13.7.3 above.
e) Other requirements as specified above shall remain applicable.
13.8 Gauging
A pig fitted with an aluminium gauging plate shall be run through each fully welded test
section propelled by water to confirm the geometric integrity of each pipeline section.
The minimum diameter of the gauging plate shall be such that there is a clearance of 6 mm
around the circumference between the plate and the smallest pipeline internal diameter. The
gauging plate dimensions are to be approved by the COMPANY. The aluminium plate will
be a minimum of 10 mm thick. The plate edge will be machined with a 4 mm shoulder and
a 45 degree bevel.
The gauging plate shall be run on a stiff pig (i.e. disc pig or 4 cup pig) in order to maintain
the gauging plate in the centre of the pipeline during the run.
The following activities shall be undertaken in the presence of the INSPECTOR:
- measurement and recording of the cup/disc and gauge plate dimensions,

immediately prior to gauge pig installation
- installation in and removal of the gauging pig from the pipeline
- measurement and recording of the gauge plate dimensions immediately after gauge
pig removal.
All recovered pigs shall be carefully examined to establish the degree of wear or damage to
the cups or discs. Measurements of the cup/disc dimensions shall be taken and the results
recorded. The results of the pig runs shall be analysed and the evaluation submitted to
COMPANY within 24 hours.
CONTRACTOR shall determine the cause and make all necessary repairs to the pipeline if
the gauging plate shows any damage. CONTRACTOR shall not proceed with the testing
procedure before the rerun gauging plate has been accepted by COMPANY.
Should a gauging pig get stuck in the pipeline, CONTRACTOR shall not employ pressures
greater than the pipeline design pressure to dislodge it. If the specified pressure is
insufficient to dislodge the pig, the pig must be located and removed from the pipeline by
back flushing (applying pressure at the receiver end) or by cutting or other method to be
13.9 Filling
13.9.1 Material and Equipment
CONTRACTOR shall provide and make operational suitable filling pumps and test
pumps, each fitted with suction filters as specified in Article 12. The pumps shall be
suitable for the required filling rate.
CONTRACTOR shall install and operate a water meter, a recording pressure gauge,
and pressure gauge at the fill point to aid in determining the location of the filling pig,
and a pressure gauge at the receiving end to facilitate checking of the back pressure.
The pressure range of gauges shall meet the anticipated pressure requirements.
Pigs selected for use during the filling operations must be capable of passing all side
connections and valves without the by-passing of fill water.
13.9.2 Execution
Inhibited water shall be injected in front of, between and behind a minimum of two
suitable filling pigs into the section to be filled.
During filling all line valves if any, shall be fully opened.
All necessary measures shall be taken to remove the air from the line during the filling
operation. Such measures shall include, but shall not necessarily be limited to:
a) Controlling the filling rate. (maximum velocity of pig to be 2 m/sec).
b) Use of filling pigs of the 4 cup type of the proper size and in first class
condition, to preclude the possibility of air and/or water by-passing them.
c) Limitation or elimination of fill pump shutdowns.
d) Use of a break tank between the water supply source and the fill pump.
e) Maintaining a suitable back pressure against the fill pigs, dependent on pipeline
elevations.
13.10 Stabilization, Entrapped Air Test and Pressurisation

13.10.1 Stabilization
Prior to commencing testing there shall be a stabilization period in which the
temperature of the water in the line shall increase or decrease to within 5 deg.C of the
soil temperature. During the stabilization period the following measurements shall be
taken and recorded every 1 hour:
- line pressure (deadweight tester).
- pipe temperature.
- soil temperature.
- air temperature.
13.10.2 Volume of Entrapped Air
During pressurization, CONTRACTOR shall adhere to the following procedure to
determine the volume of air trapped within the section under test. CONTRACTOR
shall record pressure and cumulative volume readings of water added at 100 kPa
intervals during pressurization up to 3500 kPa and construct a pressure vs. volume plot.
To determine the percentage air entrapment, recording of pressure and volume shall
commence at static head pressure. The linear section shall be extrapolated back to the
volume axis. The volume of entrapped air can then be read from the volume axis and
the percentage entrapped air calculated, thus:
Volume of air x 100
% entrapped air = ----------------------------------
Volume of line at static head
The rate of pressurization shall not exceed 100 kPa/min. The P/V plot shall be
continued up to test pressure and should the volume added be greater than predicted,
the cause shall be identified.
If the measured volume of entrapped air, reduced to atmospheric pressure, is less than
0.2 percent of the test section volume, then the filling of the line shall be deemed
acceptable for proceeding with the hydrostatic test. If the volume of entrapped air
exceeds 0.2 percent then CONTRACTOR shall take measures to reduce the quantity of
air in the test section, either by venting or by refilling the line. In any case the line shall
be fully depressurised and another air entrapment test carried out to determine
acceptability of the filling operation.
13.10.3 Pressurization Requirements
During pressurization, CONTRACTOR shall carry out leak checks.
At 90% test pressure the rate of pressurization shall be reduced to max. 50 kPa/min. and
at 95% to a rate as slow as practicable.
During pressurization, actual hydrostatic test and bleeding operations, all globe, gate
and ball valves shall be fully opened.
13.11 Strength Test
13.11.1 General
All pressure containing components of the pipeline shall be subject to the strength test.
Any repairs after the strength test shall be made in accordance with Article 6 of these
Specifications and to the satisfaction of COMPANY. After any repair the subject
section shall be re-tested commencing with the entrapped air test as per the contents of
this Article.
During pressurization and at 3500 kPa, 80% and 95% of the test pressure, a leak check
shall be carried out. The duration of the leak checks is determined by the time it takes
to check all above ground pipework, flange connections, etc. for leaks.
13.11.2 Strength Test Pressure
The strength test pressure in each test section shall be limited such that the hoop stress
induced by the strength test falls within the range of 90 to 95% of the pipe Specified
Minimum Yield Stress (SMYS). Note that the maximum pressure induced stress, as
indicated above, shall be reduced, as approved by COMPANY in case the drawings
indicate that one or more components in the test section have a pressure rating lower
than the pipeline itself.
13.11.3 Execution
An experienced operator shall be at the test pump controls during the entire period of
the 24 hours strength test. He must be advised by CONTRACTOR of the required
pressure at the pump corresponding to the strength test pressure of the section. Pressure
is to be maintained at the required levels within + 100 kPa by bleeding or filling as
required. All quantities of water drained off or added to the line shall be measured and
recorded by CONTRACTOR.
During the strength test the following measurements shall be taken every 30 minutes:
- line pressure (deadweight tester)
- pipe temperature
- soil temperature
- air temperature
If any leak is found during the strength test then the test shall be discontinued and the
necessary repairs made. CONTRACTOR shall supply, install and tighten gland packing
on those valves that leak during the hydrotest.
13.12 Leak Test
13.12.1 General
All pressure containing components of the pipeline shall be subject to the leak test.
After any repair the subject pipeline shall be re- tested commencing with the entrapped
air test.
13.12.2 Leak Test Pressure
When the test section has reached a stable condition and the strength test has been
satisfactorily concluded, it shall then be subject to a leak test of 24 hours duration
starting at the pressure level causing a stress of 90% of SMYS or at a reduced pressure
level, as approved by COMPANY, in case the drawings indicate that one or more
components in the test section have a pressure rating which is lower than that of the
pipeline itself.
13.12.3 Execution
No water may be added or removed nor shall the section be vented for the duration of
the test.
A responsible operator shall be at the bleed off and test pump controls while the test
section reaches the test pressure and until the leak test is complete. He must be advised
by CONTRACTOR of the required pressure at the pump which corresponds to the leak
test pressure of the section.
The pressure recorder shall record continuously the pressure at the test manifold.
During the leak test the following measurements shall be taken and recorded:
- line pressure (deadweight tester) Every 1/2 hour
- line temperature
- soil temperature
- air temperature Every 3 hours
- barometric pressure
13.13 Assessment of Strength and Leak Tests

On the basis of pressure and temperature measurements made during the 24 hours leak test
and measurements recorded during the entrapped air tests, and taking into account possible
inaccuracies in measured or assumed parameters, CONTRACTOR shall demonstrate to
COMPANY's satisfaction that the section under test has not leaked during the leak test
period.
If COMPANY suspects that a leak has occurred, then COMPANY may reject the section
involved or decide to extend the test for a further period of time.
If during the strength test, no water has been added or removed, and the CONTRACTOR
can show that any small pressure difference (i.e. less than 100 kPa) between the start and
finish, is due only to temperature effects, then the strength test may, at COMPANY's
discretion, be accepted as a leak test as well as a strength test.
13.14 Depressurization and Bulk Dewatering

13.14.1 Depressurization
Following satisfactory completion and acceptance of the strength and leak tests the test
section shall be depressurised to a pressure level approved by COMPANY.
In case the test section requires to be dewatered, and unless otherwise approved by
COMPANY, the bulk of the water from the section shall be displaced with oil in one
continuous operation. A sealing pig shall be used to separate oil from water. The
displaced water shall be led either to processing equipment or to a drain pit as directed
by COMPANY.
13.14.2 Bulk Dewatering
The need for dewatering a pipeline test section shall be determined according to the
following guidelines, which shall only be overruled when specific requirements to the
contrary are incorporated in the Scope of Work.
a) The pipeline system shall be left full of inhibited water in case the entire system
is left full of water on completion of the hydrostatic testing and the system is
built for the transportation of crude oil and/or water.
b) Bulk dewatering of the pipeline system shall be required for making final tie-ins
and when the system is already partly dewatered on completion of the
hydrostatic testing for example due to tie- ins and/or the system is built for the
transportation of gas.
The condition of all pigs shall be subject to COMPANY approval before they are
entered into the line.
CONTRACTOR’s programme of work shall be such that the period between bulk
dewatering and drying is as short as possible, in order to allow COMPANY to delete
the requirement of running the corrosion inhibitor (dosed) slug.
13.15 Station Works Testing
13.15.1 General
For station work, pigging is not required, and the 24 hour strength test and 24 hour leak
test can be combined into one test at strength test pressure.
Before filling the pipework to be tested, the Specialist Test Engineer shall ensure that
all pipework is secure and any tie-in points have suitably welded test caps/ends.
CONTRACTOR shall make sure that all high points are vented to assure complete
water fill.
During the test, a pressure gauge and recorder shall be used.
Following completion of test, the inhibited water shall be drained/ removed as soon as
possible, to a location approved by COMPANY.
13.15.2 Performance
When the test pressure has reached 30% of the test level, the pressure shall be held
briefly while the Test Engineer carries out a preliminary inspection of the pipework to
ensure there are no major leaks. (e.g. flanged connections, valve glands etc.)
The pipework shall then be pressurized to the level at which the induced hoop stress is
95% of SMYS maximum or COMPANY approved lower value in case any component
in the station work has a lower pressure rating than the pipework. The pressure shall be
held for 3 hours, meanwhile system may be bled if necessary in order to maintain the
test pressure.
After the test is completed the pressure shall be reduced to "design pressure", and the
Test Engineer together with the COMPANY Site Representative will do a visual check
of all welds and connections for leaks.
13.16 Reporting
CONTRACTOR shall prepare and fill out complete "Test Data Sheets" indicating:
- Project No.
- Date.
- Section under pressure.
- Test pressure kPa (Strength/Leak test).
- The pressure readings of the deadweight tester.
- The temperature readings of the pipe.
- The temperature readings of the soil.
- The temperature readings of the air.
- The barometer reading.
- The water quantities added and/or drained for test and/or readings.
CONTRACTOR shall submit for each completed test:
- The applicable Test Data Sheets.
- Pressure, temperature and water volume measurements for each of the entrapped air
tests.
- A plot of Leak Test pressure versus time with the pressure variations converted to
equivalent changes in pipe temperature superimposed upon plots of the actual pipe,
soil and air temperature versus time.
- Type and concentration of inhibitors and oxygen scavengers used.
Test Charts and Data Sheets shall be signed by CONTRACTOR and COMPANY.
The above test charts and Data Sheets shall be submitted to COMPANY with a Hydrostatic
Test Report within two weeks of completion. This report shall include a short summary of
the test, describing the location, pipe size, wall thickness and section length, and any
difficulties/abnormalities encountered during the test.
Acceptance by COMPANY of any hydrostatic test shall only be based on a clean and
logical presentation of all the results by CONTRACTOR.
14 AS-BUILT RECORDS
14.1 Scope
This Article covers the minimum requirements for providing as-built records in compliance
with AFPC Schedule PEA.
14.2 As-Built Drawings

14.2.1 CONTRACTOR's Commitments
CONTRACTOR shall submit to COMPANY one reproducible copy of each drawing,
updated with as-built information for all of the Work. These as-built drawings shall be
supplied for approval to COMPANY within 2 weeks of the Completion Date and shall
be approved by COMPANY before Acceptance of Work.
14.2.2 Scope of Submittal
The required as-built information shall include all drawings related to pipeline and
station piping as specified in Article 3 of this specification.
14.2.3 Performance
CONTRACTOR shall provide an experienced, full-time "As-Built" surveyor
throughout the duration of the Contract. He shall maintain Construction Record Sheets
in a format that shall be approved by COMPANY and shall collect and maintain all
data required for the "As-Built" drawings. He shall also prepare the "As-Built"
drawings during the progress of the Construction Work. The "as-built" surveyor shall
be based on Site and CONTRACTOR shall provide a drawing office and all necessary
equipment and other facilities to the approval of COMPANY.
Preliminary "As-Built" drawings shall be submitted to COMPANY for approval on a
weekly basis within 2 weeks of the completion of back filling of the trench on that part
of the pipeline route contained on the drawing concerned.
15 PRECOMMISSIONING OF GAS LINES
15.1 Scope
This Article covers the minimum requirements for the precommissioning of gas lines
including but not limited to final dewatering, cleaning, drying and where necessary
conditioning of the gas lines as required for the Work.
CONTRACTOR shall, after COMPANY acceptance of the hydrostatic pressure test and
bulk dewatering activities, clean and dry each gas line to the standards of cleanliness and
dryness as specified in this article.
For final drying CONTRACTOR shall use either Air Drying or Vacuum Drying.
15.2 General
CONTRACTOR shall supply all materials, consumables, equipment, spares, labour,
supervision and other services incidental to and necessary for the successful performance of
the precommissioning work covered under this article in a manner satisfactory to
COMPANY.
CONTRACTOR shall make detailed proposals, for COMPANY approval, for the
precommissioning work including but not limited to detailed procedures, programme and
schedule for the Work. Contractors proposals shall include complete information regarding
the following aspects:
- the tie-in work to be carried out after hydrostatic testing.
- precise definition of the sections to be precommissioned.
- the method or combination of methods to be employed.
- a summary and lay out of the temporary pipework, equipment and facilities
(including spares) for each section to be precommissioned.
- the method(s) to be employed to preserve the dryness and cleanliness of the line.
- the tie-in work to be carried out after precommissioning.
- the precommissioning of valves, branch off takes, etc.
- the tests to verify the success of the operation.
- a summary of the material, consumables and number and qualifications of
personnel, to be used for the precommissioning work.
- test/calibration procedures for all main equipment and instrumentation.
15.3 Final Dewatering

15.3.1 General
Dewatering of the pipeline by gravity alone is not permitted.
Final water cleaning may be combined with the first dewatering run.
Only high sealing disc pigs with at least two guiding and four sealing discs shall be
used.
15.3.2 Dewatering Pig Runs
After bulk dewatering has been completed, the CONTRACTOR shall perform pig runs
propelled by oil free air dehydrated to a relative humidity lower than 80% at the
pipeline temperature and operational pressure. Air for propelling pigs shall be made oil-
free and dry by means of oil filter units and air drying or desiccant units downstream of
the air compressors. The capacity and pressure rating of the air compressor, oil filter,
and air drying system shall be sufficient to achieve the requirements of this article.
Only one pig (or pig train) shall be sent through the line at any one time. The pig runs
shall preferably be executed in a downhill direction and in one continuous operation.
The pig velocity shall be kept constant and within the range of 0.5 to 1 m/sec. The
internal pipeline pressure shall be kept at least 1 bar above the ambient pressure at any
point along the pipeline by back pressure control at the discharge end.
CONTRACTOR shall perform dewatering runs with sealing pigs until no more water is
removed from the pipeline in front of the pig train.
15.3.4 Dewatering Records
The CONTRACTOR shall measure and record for each dewatering run the details of
the pig train, flowrate, pressure, temperature and quantity of water received at the
discharge end.
15.4 Cleaning and Initial Drying
15.4.1 General
Following the satisfactory removal of free water from the line, pig runs with water
absorbing soft foam pigs to soak up the water adhering to the inner pipe wall and with
power brush hard foam pigs for cleaning the line are required to clean and start drying
of the pipeline.
Effective cleaning can only be achieved in combination with drying the line
Prior to the start of cleaning, all in line pipeline valves will be removed in order to
maintain their cleanliness. The valves will be reinstalled after acceptance by
COMPANY of the cleanliness of the pipeline.
If Air Drying is to be employed for Final Drying, the Cleaning and Initial Pig runs shall
be propelled by compressed air as specified in 15.5.1.
15.4.2 Cleaning and Initial Drying Pig Runs
Per pipeline section, a minimum of 50 soft foam swabbing pigs (density between 30
and 50 kg/m3) shall be run for drying in combination with a minimum of 35 power
brush hard foam pig runs for cleaning. Foam pig speed shall not exceed 1.2 m/s.
Final cleaning shall be carried out by cupped brush pigs with bypass plugs open, to
create a swirling motion and to blow the loose dust ahead of the pig.
Pigs shall be propelled with dehydrated oil-free compressed air dehydrated to a relative
humidity lower than 80% at the pipeline temperature and operational pressure.
Initial drying shall be deemed complete when a new soft foam pigs is retrieved from the
line in a dry condition.
The line is considered clean when the amount of solids displaced from the line by a new
brush pig is not greater than 10 grams per 10 km section of 18 inch pipeline as
quantified and witnessed by the COMPANY's Site Representative.
15.4.4 Cleaning and Initial Drying Records

The CONTRACTOR shall measure and record for each pig run:
- pipeline pressure, temperature, flowrate and pig train details
- air dewpoint at pipeline inlet and discharge
- description and quantity of media received at discharge end
- initial and final condition of pig train
15.5 Final Drying by Air Drying

15.5.1 Air Specification
CONTRACTOR shall dry the line with oil free air dehydrated to a relative humidity of
2% or less at the pipeline temperature and operational pressure. The relative humidity
of the air shall be as low as possible to maximize the absorption of water throughout the
line.
The air drying units shall be sufficiently sized to dry the line to the required dewpoint
within 7 days.
The sizing of the drying equipment and calculations of the time required for drying
shall be based on a film thickness of the residual water of not less than 0.1 mm. Lower
values may be assumed if the Contractor can demonstrate, to the COMPANY's
satisfaction, their validity from previous experience.
CONTRACTOR's equipment specification shall include, but not be limited to, the
following:
15.5.2.1 Compressor
Air compressors of suitable capacity and pressure complete with after coolers,
condensers, separators and dehydration unit required for the operational conditions. The
type and required number ( of each type ) shall be subject to COMPANY approval.
15.5.2.2 Air Manifold
Manifold to suit the air flow into the pipeline consisting of:
- non-return valve in each compressor outlet;
- instrument spool piece with fittings for instruments detailed below;
- pressure regulating device and water separator at the inlet to the pipe line which
takes care of condensation due to adiabatic expansion.
Instruments will be provided as specified below to monitor and record the flow,
pressure, temperature, and dew point at the inlet and discharge of the pipeline:
- airflow recording with an inaccuracy of less than 5%. Flow meters of the turbine
or vortex type shall have a flow straightener installed upstream of the meter.
- pressure gauges, transmitter and recorder. The instruments are to record in the
range of 40 to 75 per cent of their maximum indication with an inaccuracy of
less than 2%.
- temperature recording with an inaccuracy of less than 0.5 degrees C.
- dew point recording in the range from +50 deg. C to -40 deg. C with an
inaccuracy of less than 0.4 deg. C. Dewpoint meters shall be of the cooled
mirror type, with the manufacturer to be approved by COMPANY. One spare

dew point meter shall be available on Site. All dew point meters shall be
calibrated on Site once per day during the precommissioning operations.
15.5.2.4 Air Disposal Equipment
Piping and equipment for safe disposal of air to a location and at a noise level subject to
COMPANY approval.
15.5.3 Execution
CONTRACTOR's operational procedures shall include, but not be limited to pressure,
flow and dew point monitoring at both the inlet and outlet of the line.
The pipeline should be purged with air achieving a minimum velocity of 3 m/s in the
pipeline at the discharge end. Air purging shall continue until the dewpoint at the
discharge end remains below the specified dewpoint whilst replacing twice the content
of the pipeline at purge pressure.
15.5.4 Acceptance Criteria for Air Drying
Upon completion of air purging, the pipeline shall be blocked-in for a period of at least
12 hours at a pressure of 0.5 bar above the ambient pressure at all points along the
pipeline. After this period the pipeline content shall be replaced at the lowest possible
pressure and the dewpoint continuously measured at the pipeline inlet and discharge.
Drying is complete when the dewpoint of the air flowing into the pipeline and the air
leaving the pipeline at the other end has a minimum dewpoint of 0 deg. C at
atmospheric pressure.
If the acceptance criteria is not met, purging for drying shall recommence and the
acceptance test shall be repeated until this requirement has been met.
After acceptance by COMPANY of drying and cleaning, the pipe shall be blocked in at
a pressure of 0.5 Barg above the ambient pressure at any point along the pipeline.
Ingress of atmospheric air into the pipeline shall be avoided.
All temporary installations/connections etc. shall be dismantled and the pipeline shall
be brought into its permanent state.
15.6 Final Drying by Vacuum Drying
15.6.1 Vacuum Specification
CONTRACTOR shall perform the drying operation by vapourisation of water in the
pipeline and the evacuation of the water vapour from the pipeline. The vapourisation
shall be effected by lowering the pressure in the pipeline to slightly lower than water
vapour pressure at the temperature of the soil surrounding the pipeline.
The vacuum drying units shall be sufficiently sized to dry the line to the required
dewpoint within 7 days.
The sizing of the drying equipment and calculations of the time required for drying
shall be based on a film thickness of the residual water of not less than 0.1 mm. Lower
values may be assumed if the Contractor can demonstrate, to the COMPANY's
satisfaction, their validity from previous experience.
CONTRACTOR's equipment specification shall include, but not be limited to the
following:
15.6.2.1 Compressors
Compressors, ejectors and/or vacuum blowers of types and number suitable to enable
the evacuation of the pipeline in such a span of time that the boil off level will be
reached within 36 hours after completion of the dewatering operation. This is in order
to limit puddling of water.
15.6.2.2 Vacuum Pumps
Vacuum pumps of types and numbers suitable to pull the pipeline down to the required
vacuum level. The vacuum pump should be able to drawdown, under operating
conditions, to a minimum pressure level corresponding to 0.5 times the required water
vapour pressure.
15.6.2.3 Manifolds
Suction manifold to suit the operation consisting of:
- emergency shutdown device in the vacuum suction unit close to the pipe line.
- suction line with filter.
All transducers and probes shall be suitable for vacuum and so located that the readings
will give a true indication of the pipeline condition, at pre-determined locations.
Furthermore the instruments shall not be influenced by climatic conditions or by
vibrations of running equipment.
The following instrumentation complete with recorders will be provided by the
CONTRACTOR:
- dew point meters with a dew point sensor ranging from +50 to -40 deg. C; the
accuracy shall be better than 0.4 deg. C.
- Pressure gauges covering the following absolute pressure ranges:
I 0-1000 mbar
II 0- 100 mbar
III 0- 10 mbar
The inaccuracy of the pressure measuring/ reading shall be less than 2%.
- Temperature recording with an inaccuracy less than 0.5 deg. C.
The following equipment will be calibrated on Site:

- dew point meters;
- pressure transducers;
- vacuum equipment (for capacity).
15.6.3 Vacuum Drying Procedure
The CONTRACTOR shall submit to the COMPANY a detailed procedure with
calculations explaining the proposed vacuum drying procedure.
This shall include calculations of the pressure/time curves for the evacuation of water,
saturated air and water vapour during first draw-down and the boil-off phases as well
for the evacuation of dry air from a theoretically dry line.
Additional calculations and/or test procedures are required when the pipeline system
friction loss affects the pump mass flow capacity. This is in order to determine the
theoretical pressure drop at various flow rates during boil-off.
15.6.4 Execution
Vacuum drying shall consist of the following stages:
- pre-drying checks;
- leak test;
- pump-down;
- evaporation/evacuation, including vacuum purging;
- soak test/acceptance test;
15.6.4.1 Pre-drying checks
Before commencement of vacuum drying the Contractor shall verify that:
- the pipeline has been isolated from other pipelines and pipework;
- valves are designed for vacuum drying and have been placed in to the half open
position;
- valve body bleeder parts are vacuum tight;
- temporary connections, pig trap valves and pig trap end closure have vacuum
tight seals.
15.6.4.2 Leak test
The pipework connecting the vacuum unit with the pipeline, including pig trap(s) and
vacuum unit(s), shall be isolated from the pipeline and the pressure in the isolated
pipeline lowered to slightly above the theoretical evaporation pressure.
The vacuum unit shall be switched off and the isolated pipework checked for leaks by
visual and audio inspection. Leaks shall be cured by either flange tightening, taping
flange circumferences, taping grease nipples and applying plasticine or equivalent to
valve stems.
The pipeline shall then be opened to the vacuum unit(s) and the pressure in the entire
system reduced to a pressure of 50 to 100 mbara for the final leak test. The pressure
shall be maintained at this level and all other piping, such as at inline block valve
stations and the pig trap system of the other end of the pipeline if vacuum drying is
carried out from one end only, shall be checked for leaks.
After all leaks have been cured, where possible, the vacuum unit shall be turned off and
isolated from the pipeline and the pressure in the pipeline and the associated pipework
monitored for at least one hour. Pressure increases shall be recorded and plotted on a
pressure/time chart. From the measured pressure increase, the total leak rate shall
calculated. Curing of leaks shall be continue until the calculated total leak rate is less
then 10% of evacuation capacity of the vacuum units at the initial leak test pressure.
15.6.4.3 Pump-down
The pressure in the pipeline shall then be reduced to the level predicted for the
evaporation of the residual water. The pressure shall be kept at this level and pig traps
and piping inspected for vacuum tightness and leaks cured.
15.6.4.4 Evaporation/evacuation
The vaporisation pressure shall be maintained and water vapour evacuated by pumping
until all residual water has evaporated.
The vacuum rate will be controlled to ensure that the suction pressure in the pipeline
section where evaporation is taking place does not fall below 6 mbar in order to avoid
ice formation in the pipeline.
CONTRACTOR's operational procedures shall include, but not be limited to, the
following:
- Monitoring of the pipeline pressure and dew point at a location close to each
vacuum suction unit connection on the pipeline and at any other location
selected for meaningful monitoring.
- Estimating the position of the drying front by comparing the theoretical water
distribution per unit length with actual amounts of water removed from the
pipeline per unit length derived from the vacuum unit capacity, the total pressure
and the dew point.
- Determination of end of boil-off phase both by comparing pressure differences
in pumping and non-pumping conditions and by comparing theoretical pressure
drops per unit of time with actual pressure drops per unit of time. In both cases
dew point behaviour shall correspond with the pressure changes.
Vaporisation and evacuation by pumping shall continue until the vapour pressure has
reached the required dewpoint specification. This pressure shall be maintained for at
least 3 hours to confirm that a stable balanced vacuum pressure is established
throughout the pipeline. Evacuation shall then be stopped and a soak test carried out.
15.6.4.5 Soak test/acceptance test
The pipeline shall be blocked in and isolated from all equipment other than that
required for pressure monitoring for a period of at least 24 hours
15.6.5 Acceptance Criteria for Vacuum Drying

A minimum dewpoint of 0 deg. C at atmospheric pressure shall be achieved in the
pipeline.
Vacuum Drying is complete when the observed pressure increases during the soak test
can be accounted for from the leaks measured during the pipeline leak test.
This shall be confirmed by monitoring the moisture content of a suitable purge gas (i.e.
nitrogen) in a pumping condition.
15.6.6 Filling Phase
Upon acceptance by COMPANY of the soak test, the pipeline shall be conditioned with
nitrogen to a pressure just above atmospheric, and the line closed in to prevent ingress
of atmospheric air.
All temporary installations/connections etc. shall be dismantled and the pipeline shall
be brought into its permanent state.
15.7 Detailed Procedure for Drying on-Plot Piping
15.7.1 Dewatering
Compressed oil-free dehydrated air of same quality as used for the final dewatering of
the main line shall be blown through the lines. All existing drains shall be opened.
15.7.2 Cleaning and Drying
The same dew point meters shall be installed as were used for the main line. The
blowing of compressed oil-free dehydrated air shall continue to the dewpoint of the air
that enters the pipe is equal to the dewpoint of the air that leaves the pipe.
15.7.3 Completion
Completion of on-plot piping shall be carried out as part of the completion of the main
line (ref. Art. 5.1.5 and 5.2.6 in this Annex).
16 ROAD, RAILWAY, WADI & RIVER CROSSINGS
16.1 Scope
This Article covers the minimum requirements for the installation of a pipeline crossings of
roads, railways, wadi’s and rivers.
16.2 Road and Railway Crossings

16.2.1 General
The installation of road and railway crossings shall meet the requirements as laid down
in the latest revision of API RP 1102 Recommended Practice for Liquid Petroleum
Pipelines Crossing Railroads and highways.
The construction of the crossing will be optimised to minimize the interference of the
construction work on the road and railway traffic. Generally, and unless otherwise
instructed by COMPANY, all road crossings shall be made by open cut.
Unless otherwise instructed by COMPANY, railway crossings shall be cased.
16.2.2 Cased Crossings
16.2.2.1 Design
Cased crossings shall be constructed in accordance with Figure 16.1. Any deviations
from this figure shall be approved by COMPANY in writing.
A stress analysis shall be undertaken for each crossing to confirm that the maximum
installation and operational loadings are within the limits defined within ANSI B 31.8.
Design calculations shall be submitted to the COMPANY for approval justifying the
selection of the steel grade and thichness of the casing proposed.
The spacer blocks shall be of a frequency so as to avoid the risk of contact between the
casing pipe and the mainline.
The casing pipe shall be sealed at each end, purged and filled with Nitrogen to a
pressure of 5 Barg.
CP test leads shall be attached to both the casing pipe and mainline shall be connected
to a CP test point near the crossing point.
16.2.2.2 Materials
Those materials to be utilised for the construction of the crossings shall be suitable for
the environmental conditions and the load conditions imposed. The material utilised for
the casing pipe shall be fully traceable.
The material used for the spacers between the main pipeline and the casing pipe shall be
of suitable material so as to fully maintain the electrical isolation of the mainline and
hence the cathodic protection system.
16.2.2.3 Construction
The casing shall be cleaned by the pull-through of suitable objects, prior to incursion of
the main pipeline.
Unless otherwise permitted by COMPANY, all welded sections of pipeline used in
crossings under installed roads and at such other locations as may be shown on the
Drawings shall be hydrostatically tested prior to installation for 2 hours.
Reinstatement of roads must be to the same standard as existing.
16.2.2.4 Inspection
The completed construction shall be visually inspected for workmanship and
compliance with the drawing.
CONTRACTOR shall undertake tests of the mainline Cathodic protection system in
order to confirm the electrical isolation of the mainline pipeline.
16.2.3 Diversion Roads
CONTRACTOR shall install and operate a diversion road, when specifically permitted
or required to do so by COMPANY and/or responsible authorities and provide adequate
maintenance. The diversion road shall not cross the pipeline where it has already been
installed.
Diversion roads must be constructed with compacted materials, which must not
degenerate into dust during use.
CONTRACTOR shall at all times and at every unfinished road crossing furnish
adequate and proper traffic aids, such as warning signs/lights, and other safeguards to
ensure the safety of the public by day and by night. All warning signs shall be in both
the Arabic and English language.
16.2.4 CONTRACTOR's Proposal
CONTRACTOR shall submit details of all proposed diversions, methods of crossings,
reinstatement and standards of construction to COMPANY and the Authorities having
jurisdiction for approval before commencing work on Site.
16.3 Wadi and Escarpment Crossings
16.3.1 Definitions
Wadi: shall mean dry river bed which could be temporarily filled
with water following rain.
16.3.2 Wadi Crossing Classification
The wadis shall be classified by CONTRACTOR for COMPANY approval as Wadi
type "A", Wadi type "B" or Wadi type "C" as defined below. The route map shall
clearly indicate each type.
a) Wadis Type "A" are minor wadis where rather low velocity flow is expected
during heavy rains.
b) Wadis Type "B" are wadis where erosion due to rather high velocity flow is
expected after heavy rains.
c) Wadis type "C" are wadis where heavy erosion due to very high velocity flow
is expected after heavy rains.
16.3.3 Construction
Wadi crossings shall be installed to meet at all times the requirements and conditions
issued by the authorities having jurisdiction in the area.
Pipeline crossings of wadis type "A" are made without concrete protection, and with a
minimum cover of 1500 m.
Pipeline crossings of wadis type "B" are made with continuous concrete coating
protection, and shall be installed with a minimum cover of 1500 mm.
Crossings of wadis type "C" are the same as type "B" above but additionally the pipe is
protected with gabions placed on top of the concrete protection up to grade level.
The type of wire mesh to be used for gabions shall be suitable for the purpose required.
Type of wire mesh shall be submitted to COMPANY for approval.
All concrete coated pipes shall be electrically tested on site prior to installation in order
to demonstrate that there is no contact between the reinforcing steel and the pipe steel.
The concrete for wadi "B" and "C" type crossings shall be applied in accordance with
Section 9 of this specification.
At locations where concrete protection has been applied, the trench shall be back filled
with coarse gravel and rock with a minimum dimension of 50 mm, up to a level of 500
mm below grade level. For type "C" wadi crossings, gabions consisting of packages of
boulders with dimensions between 100 and 200 mm contained in galvanized, coated
steel wire mesh, shall be placed on top, up to grade level over the full width of the
trench.
A windrow is not required for any type of wadi crossing.
Ditches with lined or otherwise improved surfaces shall be resurfaced in a manner
satisfactory to and approved by COMPANY and the responsible authorities. Backfill in
or on the banks of ditches, wadis, etc. shall be compacted as necessary to prevent soil
erosion or other damage which might be caused by the construction of the pipeline.
Where wadis or roads are graded, trenched or otherwise disturbed, CONTRACTOR
shall restore these to their original contour and condition even to the extent of hauling
in and placing new fill materials, gravel and stabilizing materials or compounds, or by
using special compaction methods, as necessary to obtain the approval of COMPANY
and the responsible authorities.
16.4 River Crossings
16.4.1 Design & Engineering
16.4.1.1 Design
The river crossing will be installed by either the Excavate & Pull or the Directional
Drilling method.
The pipeline will be installed such that the distance from the original firm consolidated
riverbed bottom to the top of the pipeline concrete coating shall be a minimum of 1500
mm.
The river crossing will be designed in accordance with ASME 31.4 or ASME 31.8. The
pipeline river crossing W.T. will be determined using a Safety Factor of 0.5.
For an excavated river crossing, the pipeline will be concrete coated to provide both
mechanical protection during the pull and to provide a weight coating. The concrete
coating will be done in accordance with Article 10 of this specification to provide a
weight in water safety factor of at least 1.2. (This safety factor will be increased if the
river crossing survey reveals a soft and/or silty unconsolidated river bed.)
16.4.1.2 Block Valve Stations
The river crossing will be designed with a Block Valve Station on both sides of the
river in order to facilitate the isolation of the river crossing from the main pipeline.
Block Valve stations shall be installed complete with isolating block valves and
pipeline isolating joints. The Block Valve station shall be installed in a suitably
designed concrete pit surrounded by a locked fence
16.4.1.3 Engineering Study

The Engineering study will perform all the calculations in support of the installation
method. These include, but are not limited by, the following calculations:
- theoretical pipe trajectory
- design pipe start and end location
- pipe buoyancy
- pipe friction (static and dynamic)
- pipe trench cross section
- calculation of spoil volumes
- pulling head design
- fixed anchor designs
- pull cable safe working load specification
- effect of river bottom currents during pull
- pull layout
- river bank consolidation
16.4.1.4 Execution Plan
The Execution plan will document the detailed river crossing procedure. It will include,
but not be limited, by details of :
- Organisation
- CV’s of key personnel
- Detailed Construction Plan
- Detailed Survey methods and Equipment
- Methods of river bank consolidation after the pull
- Project Safety Plan identifying project hazards e.g. man overboard
- Location of deposition of spoil
- Layouts and positions of equipment and personnel proposed for the pull
- Pipe string lift points
- Responsibilities during the pull (and other critical) operations
- Communications during the pull (and other critical) operations
- Equipment specifications
- Excavation equipment positioning technique
- Method for avoiding damage to installed pipe during backfill operations
16.4.2 Survey Requirements for the Excavate & Pull Method
The CONTRACTOR will perform the following survey work:
16.4.2.1 PRELIMINARY Survey
A preliminary survey of the proposed river crossing area will be conducted by the
CONTRACTOR in order to identify the optimum pipeline crossing route. The survey
will establish an elevation datum on both sides of the river and then survey the river
bed depth profile. Further, soil sample cores of the river bottom will be taken every 50
metres to a minimum depth of 2 metres. The results of this survey will be used to
finalise the pipeline crossing route.
16.4.2.2 River Level

Throughout the river crossing installation construction, the CONTRACTOR will keep a
daily record of the river level. This will be correlated with the natural river backfill
rate.
16.4.2.3 River Bank Survey
The purpose of this survey is to establish the original river bank position 100 m
upstream and 500 m downstream of the proposed river crossing route in order to
confirm that the river crossing work has not altered the rivers flowing characteristic.
Upon completion of the pipeline river crossing, a second survey will confirm that the
river banks have been restored to their original position.
16.4.2.4 IN Survey
The purpose of this survey is to establish the original river depth along the agreed river
crossing centre line and 10 metres either side. This survey will form the benchmark
against which subsequent survey results will be compared.
The IN survey will be witnessed by an AFPC survey representative
16.4.2.5 POST TRENCH Survey
The purpose of this survey is to confirm that the CONTRACTOR has excavated a
trench along the river crossing route centreline which exceeds the minimum trench
depth required to install the pipeline in conformance with AFPC’s specification.
This survey will be executed a maximum of 24 hours before the pipeline pull.
The POST TRENCH survey will be witnessed by an AFPC survey representative
16.4.2.6 POST PULL Survey
The purpose of this survey is to confirm that the CONTRACTOR has installed the
pipeline at the bottom of the excavated trench in order to meet AFPC’s depth of burial
specification. The POST PULL survey will be witnessed by an AFPC survey
representative.
16.4.2.7 POST BACKFILL Survey
The purpose of this survey is to confirm that the CONTRACTOR has backfilled the
trench back up to the original river bed level.
The POST BACKFILL survey will be witnessed by an AFPC survey representative.
16.4.3 Survey Equipment
The CONTRACTOR will provide surveying systems for both the above water and
underwater survey work.
The underwater survey system will provide for the simultaneous acquisition of survey
position (i.e. Easting and Northing) to 0.5 metre accuracy and water depth data to 0.1
metre accuracy. The acquired data will be interfaced to a computer which will be able
to assimilate the acquired survey data into contoured profiles of the river bed for
comparison with the original undisturbed river bottom profiles and required depth
profiles.
16.4.4 Execution Requirements
The following details of the pull will be compiled in the execution plan.
16.4.4.1 Pull Requirements

The pipestring will be pulled using either a winch or bulldozers. A continuous reading
of the pull force will be recorded during the pull. Backup equipment will be available
during the pull in the event that a failure occurs with the primary equipment.
The pulling head will be ballasted such that it is buoyant and lifts clear of the river bed
when submerged.
16.4.4.2 Communications
Communication between the two river banks will be by radio. A complete back up
communication system will be available on site prior to the start of the pull to be used
in the event that the first communication system fails.
16.4.4.3 Transportation across the River
Transport between river banks will be by motorised launch. A backup launch and motor
will be available during the pull in the event that the first launch fails.
16.4.4.4 Pre pull meeting
Immediately prior to the pull, the CONTRACTOR will arrange a meeting to review the
pull execution plan to ensure that the pull operation is fully understood by all involved
parties.
16.4.5 River Bank Consolidation
Upon completion of the pull, the river banks will be reinstated. Gabions will be placed
to prevent future erosion of the river banks at the pipeline crossing.
16.4.6 Safety
The CONTRACTOR will prepare a job specific HSE plan for the river crossing work.
It will specifically address the restricted access around the cable during the pulling
operations as well as the danger of drowning.
1.5 m mi n.
Vent Pi pe
Casi ng pi pe
0.4 m
15.0 m 1.5 m
Figure 16.1 Cased Crossing Design

APPENDIX "A" - TECHNICAL SCHEDULE USER FEEDBACK PAGE
Any user who identifies an inaccuracy, error, ambiguity or omission in this Technical
Schedule is requested to notify the chairman of the "Discipline Standards Committee"
whose reference indicator is shown below, so that appropriate action can be taken.
The user is requested to return this page fully completed, indicating precisely the
amendment(s) proposed.
From :
To : TES/5
Date :
Subject : AFPC Technical Specification PL-CP
: Para

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Engineering Schedule

Technical Specification for

Controlled Document Ref.: Custodian: TES/5

Reason for Revision: Reformatting

1 SCOPE AND DEFINITIONS

2 MATERIAL HANDLING & CONTROL

3 SURVEY, ROW CLEARING & GRADING

Page 3 of 118 February 1997

3.2.4 Clearing Within the ROW

4 TRENCHING, LOWERING, CLEAN UP & ACCESS

4.4 Vehicle Access Strip alongside the Permanent ROW

5 STRINGING AND BENDING

6 WELDING AND TESTING OF WELDS

6.5.2 Qualified Welders

6.8.10 Preheat, Interpass, Cap Pass and Reheat Temperatures

6.12 Standard of Weld Acceptability

7 PIPE LINE ANTI-CORROSION COATING

9 PIPELINE CONCRETE COATING

10 PERMANENT PIPELINE MARKERS

12 QUALITY AND TREATMENT OF FLUSHING AND HYDROTESTING WATER

15 PRECOMMISSIONING OF GAS LINES

15.5 Final Drying by Air Drying

16 ROAD, RAILWAY, WADI & RIVER CROSSINGS

16.4.1.3 Engineering Study

APPENDIX "A" - TECHNICAL SCHEDULE USER FEEDBACK PAGE

AL FURAT PETROLEUM COMPANY

1 SCOPE AND DEFINITIONS

2.3 Handling of Materials

3.1 Survey and Right-of-Way (ROW)

3.1.2 Pipeline Route and Survey

6.1.3 Compliance with Specification

Application Minimum Temperature

Main line welding with carbon steels up 60

Repair Welding 150

Welding of fittings, tie-ins and fillet 150

Pipe Wall Thickness ISO Wire 2 % Sensitivity

mm Inches Wire No. Wire Diameter

0-6 0-1/4 16 0.10

6-8 1/4-1/3 15 0.12

8-10 1/3-3/8 14 0.16

10.0-12.7 3/8-1/2 13 0.20

15.9-19.0 5/8-3/4 11 0.32

19.0-22.2 3/4-7/8 10 0.40

22.2-25.4 7/8-1.0 9 0.50

6.11 Welding and Inspection of Duplex Stainless Steel

6.4 and under 1.6

FIGURE 6.2 - POSITION AND FREQUENCY OF HARDNESS TEST

1. In the weld metal at least 6 indentations equally spaced shall be made

2. In the heat affected zone the distance between indentations shall be as

3. Samples extracted from 3,6,9,12 o,clock positions shall be used

(SPECIMENS AND NOTCH DETAIL AS PER ASTM A370, E23).

10 mm x 10 mm SPECIMEN NOTCH CENTRED IN WELD METAL

10 mm x 10 mm SPECIMEN NOTCH CENTRED ON FUSION LINE

10 mm x 10 mm SPECIMEN NOTCH CENTRED AT 2 mm

2. Transition joints where

3. Welds on Fittings All 100 NA 100 100 "

4. All Fillet/ Lap Welds All 100 NA NA 100 100 "

5. All field cut backs on

6. All field bevels All 100 NA NA 100 NA NA

Note: Use of Gamma Ray is subject to Company approval.

7 PIPE LINE ANTI-CORROSION COATING

7.3 Material and Equipment

7.3.3 Handling and Storage

7.4.2.3 Surface Preparation for Coating