l01 pipe line construction rev5a

ENGINEER’S STAMP: CONTRACTOR’S STAMP:

5A General update Poelzer Poelzer 19.09.2013

5 General update Kloos/Neumann Poelzer 02.08.2013

4 General update Zhao/Lang Praxmarer 30.05.2013

3 General update Gritsch / Kaim Poelzer 05.08.2010

2 General update Poelzer Neumann 15.12.2006

1 General update Poelzer Neumann 28.04.2006

0 Issue for Tender Documents Poelzer Neumann 30.08.2004

B Issue for Draft Tender Poelzer Neumann August 2004

A For approval Poelzer Neumann August 2003

REV DESCRIPTION PREPARED CHECKED DATE

SALINE WATER CONVERSION CORPORATION KINGDOM OF SAUDI ARABIA

SWCC WATER TRANSMISSION SYSTEMS

ILF CONSULTING ENGINEERS

LOCATION: TITLE:

Specification L01

PIPELINE CONSTRUCTION

SCALE: DOCUMENT No.: REV:

Q C 1 0 - H - 0 2 1 5

SUBCONTRACTOR:

Sheet 1 of 132


Subject: SPECIFICATION L01

Pipeline Construction of 132

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LIST OF CONTENTS

1 SCOPE AND GENERAL REQUIREMENTS 7

1.1 Scope 7

1.2 General Requirements 7

1.3 Conflicting Requirements, Exceptions 8

1.4 Definitions: 8

2 PIPELINE ROUTE AND SURVEY WORKS 9

2.1 Pipeline Route 9

2.2 Survey Works 9

2.3 Survey Work Specifications 10

3 SPREAD CONTROL 11

4 RIGHT-OF-WAY CLEARING, GRADING & FENCING 12

4.1 Right-of-Way, Way Leaves and Facilities 12

4.2 Setting out the Pipeline Route 13

4.3 Location and Protection of existing Services 13

4.4 Timber 14

4.5 Temporary Fencing and Gates 15

4.6 Right-of-Way Clearing 15

4.7 Use of Explosives 16

4.8 Surface Stripping 16

4.9 Grading 17

4.10 Refuse and Debris 17

4.11 Access Roads 17

4.12 Access 18

4.13 Construction Roads 18

5 BLASTING AND EXPLOSIVES 19

5.1 General 19

5.2 Legal Requirements 19

5.3 Procedure 20

5.4 Misfires 21

5.5 Programme 21

5.6 Blast Size, Detonation and Vibration Levels 22

5.7 Records 22

5.8 No Blasting Outside Daylight Hours 22




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5.9 Protective Measures 22

6 HANDLING OF PIPES AND OTHER PERMANENT MATERIALS 23

6.1 Handling of Pipes in the Lining Yard 23

6.2 Transport, Handling and Stringing of CM Lined Pipes 24

6.3 Handling of Other Permanent Material 27

7 TRENCHING 29

7.1 General Excavation 29

7.2 Trench Dimensions and Pipe Cover 29

7.3 Extra Depth 30

7.4 Limitation of Open Trench 30

7.5 Earth Spoil Bank 30

7.6 Rock Trench and Blasting 30

7.7 Access 31

7.8 Timbering and Supports 31

7.9 Excavation in Running Sand and Areas of High Water Table 31

7.10 Disposal of Water 31

7.11 Existing Services 32

7.12 The Obtaining of Bedding/Padding Material 32

8 BENDS 33

8.1 General Requirements for Pipeline Bends 33

8.2 Factory Bends 33

8.3 Miter bends 34

8.4 Field Bends 34

8.5 Segment Bends 35

9 FIELD WELDING AND QUALIFICATION OF WELDING PROCEDURES AND WELDERS 36

9.1 Scope 36

9.2 Codes and Standards 36

9.3 General 37

9.4 Technical Requirements 38

9.5 Inspection, Testing and Certification 50

10 NON-DESTRUCTIVE TESTING (NDT) 51

10.1 Scope 51

10.2 Codes, Standards, Abbreviations 51

10.3 NDT Procedures and Qualification 52

10.4 Qualification of NDT Personnel 52




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10.5 Extent of NDT 53

10.6 NDT Techniques Requirements and Acceptance Criteria 57

10.7 Safety 62

11 COATING OF JOINTS AND REPAIRS 63

11.1 Joint Coating Properties 63

11.2 Coating Application 65

11.3 Inspection and Testing 68

11.4 Repair Procedure 72

11.5 Piping at Line Valve, Vent and Drain Stations 72

12 LINING OF JOINTS AND REPAIRS 73

12.1 General 73

12.2 Lining of Joints 73

12.3 Repair of Defects 73

12.4 Method Statement 74

12.5 Inspection of Internal Lining 74

12.6 Surface Condition 75

12.7 Lining with Fusion Bonded Epoxy (FBE) 75

13 PIPE LAYING 76

13.1 Pipe Trench Preparation 76

13.2 Pipe Internal Cleaning 76

13.3 Pipe laying in the trench 77

13.4 Overhead Sections 78

13.5 Pipe Installation in Casing 80

13.6 Pipe Laying in "Sabkha" Sections 82

14 PADDING AND BACKFILLING 83

14.1 Padding of Pipes 83

14.2 Backfilling of Pipeline Trench 84

14.3 Duration between Welding and Backfilling Works 87

15 HYDROSTATIC TESTING 88

15.1 General 88

15.2 Cleaning and Inspection of the CM Lining 89

15.3 Test Crew Composition 90

15.4 Hydrostatic Test Sections and Test Pressures 90

15.5 Quality of Filling Water 91

15.6 General Set-up of Pipeline Test Sections 91




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15.7 Calibration 92

15.8 Filling 93

15.9 Performance of Hydrostatic Testing 94

15.10 Evaluation of Results and Final Report 96

15.11 De-watering after Hydro test 96

15.12 Safety 97

16 CROSSINGS 99

16.1 General 99

16.2 Railway and Road Crossings 99

16.3 Crossing Below and Running within Water-Course Bed (Wadi) 100

16.4 Crossing of Facilities such as Pipelines, Cables and Channels 102

16.5 Masonry Structure Crossing 105

16.6 General Requirements for SEC Power Transmission Line Crossings 105

16.7 General Requirements for STC Telephone and Telecommunication Cable Crossings 106

16.8 General Requirements of ARAMCO for Crossings with their Facilities 106

17 CONCRETE COATING OF PIPE 110

17.1 General 110

17.2 Responsibility of the Contractor 111

17.3 Materials 111

17.4 Equipment 111

17.5 Weather Protection 112

17.6 Proportions and Properties of Concrete 112

17.7 Fixing of the Reinforcement 113

17.8 Application of the Concrete Coating 113

17.9 Curing of Concrete Coating 114

17.10 Testing and Inspection 114

18 CONCRETE WEIGHTS AND ANCHORS 118

18.1 General 118

18.2 Responsibility of the Contractor 118

18.3 Concrete Weights 118

18.4 Anchors 118

19 SPECIAL INSTALLATIONS 120

19.1 Installation of Pipe Fittings and Special Components 120

19.2 Pipeline Cable Installation 120

19.3 Marker Posts for Pipeline cable and ROW 120




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19.4 Connections for Cathodic Protection 123

20 CIVIL WORKS 124

20.1 Excavation 124

20.2 Hardcore and Chippings 124

20.3 Concrete 124

20.4 Steel Reinforcement 124

20.5 Form Work 125

20.6 Concrete Kerbs and Edgings 125

20.7 Cable ducts and tiles 125

20.8 Requirements for Sheet Piling 126

20.9 Foundation Piles 126

20.10 Roads 126

20.11 Pipeline Maintenance Road 127

20.12 Access Roads 128

20.13 Paved Service Road 128

20.14 Construction Road 129

21 REINSTATEMENT, CLEAN UP AND STABILISATION 130

21.1 General Reinstatement and Clean up 130

21.2 Reinstatement of Cultivated Land and Grassland 130

21.3 Reinstatement of Roads 131

21.4 Reinstatement of Waterways 131

21.5 Renewal of Fences, Walls, Banks and Ditches 131

21.6 Irrigated Land 131

21.7 Stabilizing of Embankments with Stones 132




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1 SCOPE AND GENERAL REQUIREMENTS

1.1 Scope

This Document – Specification for Pipeline Construction – defines the technical requirements for the construction of water transmission pipelines made of steel pipes.

This specification is valid for the works related to the mainline only. For all stations related to the pipeline system such as pumping stations, receiving stations, line valve, vent and drain stations, etc. separate specifications are applicable.

1.2 General Requirements

a) All pipeline construction works shall be performed in such a way that they can be checked at any time by the Employer or his Representative.

b) The Construction Contractor bears the sole responsibility for the correctness of the work and full compliance to the technical requirements defined in this specification.

c) The Employer and the Engineer have the right to inspect the work of the Contractor and give instructions at any time.

The Contractor must afford an insight into all his design documents, records, inspection reports and all other relevant technical documentation related to the pipeline. Such inspection does not relieve the Contractor from his responsibility under the contract.

d) The Contractor must give due consideration in his work approach to all existing facilities whether in possession of the Employer or a third party. This is especially important at areas with parallel routing of the new pipeline to existing lines. Special precautions and safety measures have to be elaborated prior to commencement of the work which will avoid damage of the existing facilities.

e) Before commencement of the works the Contractor shall based on this specification prepare a detailed method statement for each activity considering the actual conditions and the equipment and work force assigned.

f) All work shall be carried out in accordance with the National Health and Safety Regulations applicable at the place of work.

g) Personal protection equipment shall be provided in accordance with the relevant accident prevention regulations.




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h) All personnel shall be instructed on the relevant accident prevention regulations.

i) Sites shall be equipped with appropriate alarm devices and other emergency equipment in order that suitable immediate action can be taken in case of an accident.

j) The degree of maintenance and the reliability of the emergency equipment provided, including utilities and materials, shall be checked regularly. Defective equipment shall be removed from the site and replaced.

k) Prior to the commencement of construction, information (e.g. plans) on all apparatus of other operators located within or crossing the ROW shall be obtained. Safety precautions shall be taken whenever necessary.

l) When laying pipelines and installing components, relevant health and safety regulations shall be observed (e.g. wearing protective clothing and equipment when cutting, welding or otherwise treating materials).

1.3 Conflicting Requirements, Exceptions

The Contractor shall notify the Employer of any conflict between this Specification, the Codes and Standards and any other Specifications included as part of the Contract Documents.

Any exceptions to this Specification and referenced documentation shall be raised by the Contractor and approved by the Employer/Engineer in writing.

1.4 Definitions:

“Employer” means the Saline Water Conversion Corporation.

“Engineer” means the Engineering Company entrusted with the Project Management and Construction Supervision of the Project(s).

“Contractor” or “EPC Contractor” means the Company or Group of Companies entrusted by the Client with the engineering, procurement and construction of the project(s).

“Mainline” shall mean all pipeline segments (with all accessories like cathodic protection facilities, etc.), which connect the Pumping Station outlet with the next Pumping Station inlet or the inlet structure at the endpoint, which together with these stations forms the backbone of the System.

“Final Design” shall mean the design to be performed by the Contractor in accordance with the requirements stipulated in the Contract Documents.




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2 PIPELINE ROUTE AND SURVEY WORKS

2.1 Pipeline Route

The principle route of the pipeline is indicated in the route maps which are an integral part of the tender documents.

The Contractor, based on the principle route as depicted in the tender documents, shall survey and stake out the final route of the pipeline and prepare relevant drawings.

These drawings shall be presented to the Employer and the Engineer for general approval.

Upon general approval the Contractor shall mark the boundary lines of the ROW strip and the centerline of the pipeline on site, to clearly show the route of the line and the land required for the implementation of the pipeline.

If the staked out route is to the satisfaction of the Engineer and the Employer, the Contractor will be granted possession of site.

2.2 Survey Works

The survey works of each mainline section shall start immediately after possession of site has been granted by the Employer. For presentation of Contractor’s survey concept, etc. see Specification C01/1.

It is the Contractor’s obligation to integrate the new project survey data with the national geodetic network through the military survey department. National grid shall be used for elevations, the coordinate system shall be based on WGS 84.

The survey has to be performed by using the polygon-method and under consideration of the up to date survey methods of highest standard, because the construction of a large diameter water pipeline with internal cement mortar lining is not comparable with normal pipeline construction practice.

The survey data shall be handed over to the Employer in a bound and well arranged book.

The exact location, definition and calculation of all levels for grading and trenching, distances, directions, angles, etc. will have to be calculated and shown exactly in the Contractor's detail drawings (pipeline alignment sheets). These drawings have to be prepared at a scale of 1:2,000 for the length and 1:200 for elevation.




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This final design will be of a standard comparable to a road design. Special notice shall be taken, that all construction works will have to be executed in strict compliance with the approved drawings.

The approved alignment sheets and detail crossing drawings shall be on the construction site in time, 14 days prior to commencement of work at relevant section, in order to be able to judge their correctness in view of local requirements.

2.3 Survey Work Specifications

The survey works pertaining to the pre-construction survey and the as built survey are described in detail in the Civil Work Specification C01/1 and C01/2, document no. QC10-H-04 1/1 and QC10-H-04 1/2.




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3 SPREAD CONTROL

The Contractor shall organise his operations so as to keep as tight a spread as is possible and practicable in order to cause the minimum of disruption and inconvenience to Landowners, Farmers, Local Authorities and the General Public and to enable the Engineer to exercise effective supervision of the works.

The requirements as to the permissible distance between front and back operations of a spread and the amount of open trench that will be permitted strongly depends on the project area and soil conditions.

The requirements and limitations will be discussed prior to commencement of the works and mutual agreement shall be reached under consideration of the flexibility the Contractor requires in scheduling work along roads, in rocky areas, the construction of crossings, tie-ins and installation of appurtenances.

The agreed length between activities can only be exceeded with prior written consent of the Engineer. In the event of the length being exceeded without written approval, the Contractor shall cease work on the front of the spread and accelerate respectively complete the work at the back end (i.e. backfilling, etc.).

Special crews shall be utilized in difficult and complicated sections to allow the main spread to maintain the specified limits of construction.




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4 RIGHT-OF-WAY CLEARING, GRADING & FENCING

4.1 Right-of-Way, Way Leaves and Facilities

The Contractor is obliged to apply for all permissions to be given by the authorities and the owners of pipelines and any other installations which will be concerned during the construction of the Pipeline System, before entering the ROW. In principle, the permanent Right-of-Way Contracts with the landowners will be settled by the Employer.

The final route selection has to be performed by the Contractor in consideration of the general route, the soil conditions, the permits of the owners of installations (pipelines, cables, etc.). In difficult areas the Contractor has to pay special attention in his route selection to avoid damages of existing parallel laid pipelines by future utilisation of concerned areas (road or traffic areas, etc.)

Prior to commencement of any ROW activities the Contractor shall install marker posts with sign boards every 500 meters indicating the pipeline kilometre with reference to the survey results.

Marker posts of ROW-line should be erected in concrete monuments accessible and visible during the complete construction time and secured outside the ROW strip to enable re-erection in case of damage.

At all major crossings, such as crossings of foreign lines, wadi crossings, road crossings and cable crossings, etc. where the exact level of the pipeline to be laid is of great importance, the Contractor shall install fixed bench marks with defined altitude. These bench marks will be used for checking the level of the pipeline before backfilling.

Before starting of work, the Contractor is obliged to submit a detailed description of the design and survey method he intends to use, which will be subject to approval by the Engineer.

The right of way (ROW) mentioned in the specification and drawings may be reduced in some areas according to site conditions. The Contractor shall consider those restricted areas during tendering stage.

The provision of the ROW, way leaves and other facilities implies no obligations on the Employer other than that, which may be stated in the Contract. The Contractor shall obtain and be responsible for all other land not provided by the Employer, such as but not limited to any additional access routes and working areas which the Contractor may subsequently require.

The Contractor shall be responsible throughout the contract duration for maintaining the ROW and other land and for their reinstatement, whether or not the land was provided by the Employer.




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4.2 Setting out the Pipeline Route

The Contractor shall demarcate the boundaries of the right-of-way with hardwood pegs or hardwood or metal stakes of sufficient height and at spacing, which ensures visibility. Pegs or stakes shall be firmly driven into the ground at the outer limits of the working width, at all crossings, changes of direction, above-ground structures and at such other places as are necessary.

The Contractor shall peg the pipeline route in accordance with the survey specification.

Construction limits for special sections, including but not limited to, extra working width at crossings, steep gradients, parallel pipelines, overhead and buried utilities and lay down areas shall also be pegged.

The final pipeline alignment shall be subject to Employer approval.

Trench line survey stakes shall be re-established by the Contractor after clearing, grading and topsoil stripping, and shall be maintained in position until the trench is excavated.

4.3 Location and Protection of existing Services

Without prejudice, the Employer shall provide the Contractor with a list of statutory authorities, companies, agencies or other known organisations who may own and/or be responsible for the operation and maintenance of the services and/or equipment that cross or are within close proximity to the pipeline ROW. In conjunction with the Employer, the Contractor shall contact and coordinate with all relevant owners and/or operators prior to locating and identifying the existing services that cross or are in close proximity to the pipeline ROW or those which might be affected by the work.

All services crossed shall be adequately protected by means of laying excavator mats or geo-textile membrane or any other suitable means of protection across the service. The service shall have a fenced barrier erected to each side of the plant crossing location.

Prior to clearing the right-of-way the Contractor shall contact in writing all such relevant authorities, owners and/or operators and shall be responsible for the location of all services within the right-of-way or which might be affected by the works.

The Contractor shall locate the precise position of all existing underground services and apparatus utilizing the latest underground detection equipment and confirm the location by means of trial holes which shall be hand dug well ahead of




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any work which could cause damage. Services located shall be clearly indicated by warning signs, which shall be maintained throughout the construction period indicating the type, size and depth. The location shall be recorded on crossing drawings (plans and sections) to be prepared by the Contractor.

Without prejudice to this obligation, the Engineer and the Employer may issue the Contractor with drawings showing locations of existing underground services. Such information shall be for guidance only and no guarantee is offered or implied as to its completeness or accuracy. The Contractor shall prepare drawings showing his proposals for the support and protection of existing underground services during construction for approval by the Engineer and relevant authority.

Where telephone, power or other overhead utility lines or structures interfere with the Contractor’s access along or to the right-of-way, the Contractor shall if required submit proposals for approval of the Engineer and relevant authority for protecting and maintaining continuous use of such telephone, power or other overhead lines or structures during the Works.

The Contractor shall be responsible for, and shall bear the cost of, any damage caused to existing service, apparatus, overhead lines or structures when locating their position or at any time during the carrying out of the works.

4.4 Timber

Prior to clearing the right-of-way and other lands provided by the Employer the Engineer and the Contractor shall agree which trees are not to be removed. The Contractor shall suitably mark such trees. The Contractor shall ensure that no damage is caused to any such trees.

Saleable timber as directed by the Engineer shall be cut in lengths and stacked in neat piles along the edge of the right-of-way. Such timber shall remain the property of the Employer, who shall be responsible for its disposal in timely manner so that the Contractor’s progress is not delayed.

Protection of trees to be retained within the Working strip will depend on the individual tree location.

One or more of the following measures shall be taken by the Contractor to protect trees from damage as instructed by the Employer.

a) Lopping of limbs from trees to facilitate passage of construction traffic, shall be undertaken by an experienced tree surgeon to the Employer’s approval.

b) Roots of trees shall be protected from construction traffic, typically with sand or wooden excavator mats to the extent of the canopy.




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c) Trees to be retained within the topsoil or subsoil storage areas shall be protected by a temporary fence.

d) Topsoil shall not be stripped from the root zone of the trees to the extent of the canopy.

e) All tree roots severed during construction shall be clean cut with a sharp blade or saw.

4.5 Temporary Fencing and Gates

The Contractor shall provide, erect and maintain temporary fencing along the right-of-way wherever it passes through land used by livestock. The Contractor shall also provide temporary fencing in order to permit reasonable fenced access across the right-of-way for the passage of people, vehicles, farm equipment and livestock. Should temporary fencing prevent livestock from getting to water, then the Contractor shall ensure that an adequate temporary supply of drinking water is provided.

Before any existing fence crossing the right-of-way is cut it shall be adequately braced.

The Contractor shall install gates to all enclosures where necessary. These gates shall be kept closed at all times, except during the passage of Contractor’s Equipment and for other reasons necessary for the Works. He shall prevent livestock from entering such enclosures and, if so required by the Engineer, provide watchmen to ensure compliance with this requirement.

The Contractor shall provide safe temporary access at all existing road and track crossings and temporary fencing shall also be provided as necessary at the boundaries of public roads and tracks wherever they intersect and cross the ROW.

4.6 Right-of-Way Clearing

Prior to any clearing operations, the Contractor shall be fully conversant with all conditions and provisions detailed in the Contract and the agreements with land owners. The Contractor shall comply fully with all such provisions and avoid damage to property, other pipelines and utility services on or adjacent to the ROW.

Before clearing and grading work will be commenced, the Contractor shall take photographs of the ROW for record of the original condition.




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The Contractor shall clear the full width of the right-of-way (except trees identified in accordance with Clause 4.4), all hedges, fences, walls, brush, vegetation, non-saleable timber, stumps, tree roots, boulders, debris and other obstructions.

The Contractor shall, whenever possible, avoid causing damage to irrigation installations and shall install temporary arrangements to maintain the flow of water across the right-of-way.

The Contractor shall install temporary culverts in all drainage ditches and watercourses, which would otherwise be obstructed during construction operations.

4.7 Use of Explosives

Blasting in connection with clearing operations shall be carried out only with the written approval of SWCC and the Engineer and shall be in accordance with Section 5 of this Specification.

4.8 Surface Stripping

On agricultural land and grassland the topsoil shall be stripped over the full working width, except for the area to be utilized for stacking topsoil or areas designated for special treatment as may be shown on the Drawings. The topsoil shall be stripped to its full depth and care shall be taken to avoid mixing topsoil and subsoil.

The Contractor may apply for modification to these requirements in rocky ground and semi-desert terrain taking into consideration the local conditions and the need to satisfactorily reinstate the pipeline route. Stripped topsoil shall be stacked on one side of the right-of-way and kept free from the passage of vehicles and plant. Topsoil and subsoil stacks shall be placed to ensure that they are free draining. Gaps shall be left in the topsoil stack to permit reasonable access across the right-of-way and at low areas where surface water may be held against the stack.

Over made up roads and paved footpaths surface materials shall be removed only over the width of the pipe trench and shall be kept separate from the other stripped or excavated materials.




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4.9 Grading

The right-of-way shall be prepared and graded to suit the terrain encountered, to facilitate subsequent operations and to permit pipe laying to the specified profile while not exceeding permissible bending.

The graded width of the ROW shall be in accordance with the Contract Drawings for the ROW. The Contractor shall select which side of the pipeline is to be the working side for the construction of each pipeline section subject to site conditions and third parties. Any existing ROW shall not be used without prior approval from the relevant authority.

Where the construction ROW follows or crosses roads, tracks, overhead power lines, plantations or any other improved or confined areas, the Contractor shall only grade the width of the ROW necessary for excavation of the pipeline trench. In areas where construction activities require greater width, the Contractor shall obtain prior approval from the Employer before commencing clearing operations.

The Contractor shall maintain and preserve all survey control points already staked, such as benchmarks and intersection points, until construction operations are completed. The Contractor shall reinstate missing benchmarks; to allow accurate levels to be taken during pipe laying or “as built” surveys of the pipeline.

4.10 Refuse and Debris

All refuse and debris shall be collected from the right-of-way and hauled away from the Site to tipping areas to be provided by the Contractor.

4.11 Access Roads

The Contractor shall, prior to use for access of any road or track, obtain written permission from the owner or appropriate authority and shall make due allowance for restrictions placed by authorities on movement of vehicles on such accesses.

The Contractor shall prepare a record of the condition of all such accesses prior to their use. Such records shall take the form of a written report supplemented by photographs to be submitted to the Engineer.

The Contractor shall maintain such accesses in a usable condition and shall on completion of construction, reinstate the accesses to a condition at least equal to that existing before commencement of the works.




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4.12 Access

Grading of the ROW shall be carried out in conjunction with construction of access roads. The Contractor shall grade the ROW and construct access roads to allow the safe movement of loaded trucks and equipment without causing undue wear and tear to the graded surface. Where necessary, the Contractor shall form cuts through hilly terrain to allow vehicle access.

The Contractor shall install all necessary drains and culverts as required to ensure adequate and safe drainage of all works, temporary and permanent.

Contractor shall construct all temporary accesses such as ramps, temporary bridges, etc., to enable plant, equipment and personnel to cross obstructions safely and efficiently. The temporary accesses shall permit continuous use of vehicles and construction traffic and shall preserve banks and structure of crossings. Existing crossings shall not be filled or otherwise obstructed without approval of the Employer or Authority having effective control or ownership of the crossing. Prior to commencement of the work, the Contractor shall provide the Employer with the originals of the respective approval notices. The Contractor shall maintain such accesses in a usable condition and shall upon completion of construction activities, reinstate such access to a condition equal or better to that existing before the commencement of the work.

4.13 Construction Roads

Grading of ROW shall be carried out in conjunction with implementation of a construction road within the working strip along the route. This road construction shall be an integral part of the ROW preparation. The construction road shall be fully operational and maintained during the whole project period to allow safe movement for all types of construction equipment. The road shall be capable to withstand all loads acting during pipeline construction and transport of materials, equipment, etc.

After the construction phase this road shall be upgraded to the maintenance road as described in this specification.

No construction road is required where the pipeline is laid parallel to an existing road which is suitable for construction purposes and written approval of the owner has been obtained for use of the road.




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5 BLASTING AND EXPLOSIVES

5.1 General

Where the pipeline to be constructed is located in built up areas and in close proximity to highways or runs parallel to SWCC existing pipelines, other pipelines or underground facilities within the same right of way or close to it, blasting is not permitted. Rocky zones will have to be trenched by mechanical means only.

Blasting shall only be carried out with the written approval of the Engineer; where possible mechanical methods of excavation of rock should be used in preference to blasting.

Any landowners or tenants who may be affected shall be notified far enough in advance so that adequate steps can be taken to protect livestock or other property.

The Contractor shall comply with relevant safety and security procedures of the explosives manufacturer and the authorities.

Extreme care shall be exercised to avoid damage to underground structures, cables, conduits, pipelines and the like, and to underground watercourses of springs. Trial blasts shall be undertaken to establish the minimum quantity of explosives required. In addition to shot holes being fully stemmed, blasting mats or other effective means shall be used if necessary to prevent rock being scattered over the right of way and adjacent property.

The Contractor shall take every precaution of protect persons and the Permanent Materials from any injury or damage, which might arise from the use of explosives.

The Contractor shall be fully responsible for any injury or damage arising from the blasting operations. Compliance with this specification and approval of procedures by the Engineer shall not relieve the Contractor of this obligation.

The Contractor shall use only authorized and suitably certified personnel or subcontractors.

5.2 Legal Requirements

The acquisition and storage of explosives and detonators and all blasting work undertaken shall be in accordance with statutory regulations. The Contractor shall at his own expense obtain any permits required and shall comply with the provisions of such permits.




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5.3 Procedure

In general blasting work shall be performed according to the guidelines as stipulated in the code ASME A 10.7.

The Contractor shall comply with all good blasting practice and shall submit to the Employer and the Engineer his detailed procedures for approval prior to any blasting taking place. Any proposed revision on procedure arising during blasting shall be submitted to the Employer and the Engineer for approval.

The information to be provided shall include:

(a) Details of all permits and licenses, issuing authority and validity period.

(b) The location and length of the proposed area of blasting

(c) The charge pattern

(d) The number of charges

(e) The type of explosive

(f) The sizes of charges

(g) The depths of drill holes

(h) The delays to be used

(i) What notifications have been issued

(j) Name of shot firer

The Contractor shall comply with the following:

(1) All shot firing shall be undertaken by a shot firer duly appointed by the Contractor in writing. Only workmen thoroughly experienced in handling explosives shall be permitted to supervise, handle, haul, load and fire explosives.

(2) The shot firer shall supervise the transportation and storage of all explosives. Explosives shall be carried and stored in approved containers. Detonators shall be carried in a separate vehicle form that of explosives and shall be stored separately on Site.

(3) Before shot firing commences the shot firer shall give clear and adequate warning to all persons within, near or approaching the danger zone. In addition, audible warnings shall be given as follows: One note on a siren 5 minutes before basting. Two notes on a siren 2 minutes before blasting. Continuous note or three notes to indicate the all clear. Visible displays or




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notices shall be posted on the perimeter of the danger zone indicating clearly the sequence of audible warnings.

(4) The Contractor shall be responsible for ensuring that all persons within, near or approaching the danger zone remove themselves to a safe place.

(5) The shot firer shall post sentries and, where necessary, suitable notices, on the perimeter of the danger zone.

(6) On completion of blasting the shot firer shall examine the area for misfires and if it is safe, shall signal the “all clear”.

(7) All shot firing activity shall be suspended in the event of a thunderstorm.

5.4 Misfires

(1) In the event of a miss-fire, the shot firer shall duly inform all the sentries and instruct them to warn all persons likely to approach the shot hole.

(2) The shot firer shall not approach the hole until he has disconnected the shot firing cable from the exploder and not before 5 minutes have elapsed from the last attempt to fire the shot.

(3) The shot firer shall then examine the cable and connections and remedy any fault found. He shall then re-connect and make a further attempt to fire the shot if this is practicable.

(4) All persons within the danger zone shall remain under cover until a miss-fire has been cleared.

(5) In the event of a further miss-fire, the shot firer shall take steps to ensure that no person enters the danger zone until the hole has been inspected.

(6) Any unexploded charges shall be detonated by placing and priming an adjacent charge.

(7) Following blasting, the shot firer shall search the debris for unexploded charges after the clearance of the miss-fires.

(8) The shot firer shall accurately record all miss-fires in a report to be presented by the Contractor to the Engineer.

5.5 Programme

The Contractor shall submit his blasting programme to the Engineer at least 5 days in advance of each 7-day period or as required by the Engineer.




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5.6 Blast Size, Detonation and Vibration Levels

The proposed blasting pattern shall be fired on an individual short delay electric detonator using a system, such as Magnadet, that minimizes current leakage. Detonating cord shall not be used outside holes and any used within drill holes shall be kept to the absolute minimum that is necessary for safety. Good stemming material shall be used in all holes.

The maximum vibration levels as defined in DIN 4150-3 shall not be exceeded.

5.7 Records

The Contractor shall provide the Engineer with comprehensive records of the locations of blasting, the charges used, the timing of the blasting operations, and any other specified information such as may be required by the Engineer or as specified in the procedure.

5.8 No Blasting Outside Daylight Hours

The Contractor shall only undertake the detonation of explosives during the hours of daylight.

5.9 Protective Measures

The Contractor shall ensure compliance with all protective measures and permitted distances as stipulated by the owners/operators of any underground plant, equipment, aquifer spring etc. and also overhead structures.

The Contractor shall give adequate notice to all members of the public, resident owners, tenants, nearby residents and local authorities and any landowners or tenants who may be affected in order that adequate steps can be taken to protect livestock or other property.




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6 HANDLING OF PIPES AND OTHER PERMANENT MATERIALS

6.1 Handling of Pipes in the Lining Yard

This chapter defines the minimum technical requirements and necessary precautions to be taken during the handling of steel pipes in the Lining Yard.

6.1.1 Loading and Unloading

Loading and unloading of pipes shall be performed by cranes equipped with a spreader bar and wide strong textile or leather belt slings, to avoid damage of the coating and lining of pipes. Vacuum lifts of appropriate capacity may also be used for pipe handling. Chains, metal hooks, etc. shall not be used to lift the coated and/or lined pipes.

During the loading/unloading operations, pipes and bends shall be handled according to modalities and suitably to avoid dents, cuts, cracks and other damages especially at beveled ends. If the pipes are damaged during handling in the yard, the damages shall be marked and damaged pipes shall be stored separately from the rest of the pipes until repair work is carried out.

6.1.2 Pipe Handling and Stacking

Handling and stacking of cement mortar lined pipes and unlined pipes shall be carried out in a manner at all times that will prevent damage to the cement mortar lining, to the external coating, and distortion of the pipe.

Pipe handling, shall be carried out by experienced personnel under the supervision of the yard foreman. Pipes shall be lifted using a crane of suitable capacity with a lifting beam attached to textile or leather belt slings. The slings shall be positioned at one fifth of the pipe length from each end of the pipe.

Cement mortar lined pipes and unlined pipes shall be always stacked on suitable bearing supports (sand berms) in the storage area. Bearing supports shall be free from any objects, which may damage the pipe external coating or damage the steel pipe end. The bearing supports shall be covered with PE sheets of suitable thickness.

The bearing supports shall provide a minimum ground clearance and be spaced approximately one fifth of the pipe length from each end of the pipe.

CM lined pipes and pipes which are ready for lining application shall not be stacked in more than one layer, to avoid ovalization.




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Unlined pipes of diameter 1000 mm and below may be stacked in three (3) layers.

Unlined pipes of diameter 1000 mm and above may be stacked in two (2) layers. For pipes of diameter 1500 mm and above, proper stiffeners will have to be inserted to avoid ovality.

Particular care is required for handling of FBE coated or liquid epoxy coated pipes to avoid coating damage. Epoxy coated pipes shall not be stacked in more than one (1) layer, independent of pipe diameter.

6.2 Transport, Handling and Stringing of CM Lined Pipes

This chapter of the specification defines the minimum technical requirements and necessary precautions to be taken for transportation, handling and stringing of the line pipes after their coating and CM lining are completed. The requirements start from taking over of the pipes from the CM lining yard after they are ready for transportation, describes the transportation methods and measures up to the site where they are to be strung along the right of way. This section also enumerates the guidelines for handling of the pipes to avoid negative impact on the integrity of the cement mortar lining.

6.2.1 General requirements

The pipes shall be properly protected for transportation to the destination, as detailed in clause 6.2.3 below, so as to prevent damage to coating and CM lining. All relevant regulations concerning transport of pipes (height and weight of trucks) on the roads or highways within the Kingdom of Saudi Arabia (K.S.A.) shall be strictly observed.

Transportation of CM lined pipes shall not commence until the required value of strength of the lining is achieved. The required min. value of compressive strength is 55 N/mm²; bending strength value shall be 6 N/mm². The pipes shall not be transported to the site before the curing period as defined in the CM lining specification is completed.

As and when the pipes are ready for transport from the pipe yard to the pipeline construction site for stringing, measures are to be taken to make certain that the pipes are so prepared that the CM lining cannot dry out.

For this purpose the pipes must be fitted with end caps of sufficient strength to withstand the forces acting on the end caps during road transportation.

The end caps shall be bound to the pipes with steel bands or bands of equal strength. The steel bands shall not come in contact with the coating.




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A small volume of water (minimum of 50 l) is to be maintained inside the pipe itself during transport.

The pipes will be transported only upon clearance from the Engineer upon final inspection.

6.2.2 Loading and Unloading

Loading and unloading shall be performed by cranes or pipe layers (side booms) equipped with a spreader bar and wide strong textile or leather belt slings, to avoid damage of the coating and lining of pipes. Vacuum lifts of appropriate capacity may also be used for pipe handling. Chains, metal hooks, etc. shall not be used to lift the coated and lined pipes.

During the loading/unloading operations, pipes and bends shall be handled according to modalities and suitably to avoid dents, cuts, cracks and other damages especially at beveled ends. If the pipes are damaged during transportation, the damages shall be marked upon delivery and stored separately from the rest of the pipes at the stringing areas.

During loading, all necessary precautions shall be taken to prevent pipes, their ends, coatings, and linings from being damaged. Care shall be taken to ensure the integrity of the coating and the canvas covers at the end of the pipes as well as the curing water contained inside the pipes. If any damage or leaks on the end covers are observed, they shall be immediately repaired/replaced upon delivery. If the water quantities inside the pipes are not sufficient, they shall be increased before transportation.

Before a loaded truck leaves the loading area the trailer shall be checked carefully to make sure that it is safe and properly loaded. For this final inspection, qualified responsible representatives shall be provided to supervise the loading operation. Respective records shall be completed at load-out.

The pipe trucks shall provide supporting by suitable cradles that fit the curvature of the pipe and having sufficient area and padding to prevent damages in case of oscillation of the pipe.

For the transport by truck all necessary precautions to prevent coatings and linings from damage and breaking shall be adopted.

Loading arrangements of different size pipes shall be worked out by the Contractor and provided for approval by the Engineer. In case two (2) layers of CM lined pipes will be transported by trucks, proper saddles supported by goal posts shall be provided.




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6.2.3 Transportation of CM lined Pipes to the Construction Site

Suitable trailers shall be used for transporting of the lined pipes. Dollies shall not be used for this job.

All relevant regulations concerning transport of pipes (height and weight of trucks) on the roads or highways within the K.S.A. shall be strictly observed.

Before the transportation commences the route shall be analyzed carefully not to interrupt the transportation activity.

The truck drivers shall take maximum care and drive defensively not to cause any trouble or problems.

All drivers shall have a valid license and be familiar with local traffic regulations and rules.

The transportation vehicles shall not be over loaded.

The Contractor shall provide enough number of supervisors at site to unload the pipes safely and properly.

At delivery to site, the pipes shall be inspected and delivery records shall be filled-out.

6.2.4 Stringing of Pipes to the Pipeline Route

Prior to pipe stringing all clearing and grading operations of the right of way shall be completed. Stringing shall be done after trench excavation. Pipes may be strung directly from the truck into the pipeline trench or be strung along the working strip.

During stringing along the right of way the line of strung pipes shall be interrupted at intervals suitably spaced and at passages, roads and water course crossings.

The aforesaid shall be carried out as far as necessary to avoid damages and mishandling to pipes and not to stop traffic, passage of herds, if any, and the natural water flow during the interval of time elapsing between the stringing period and the beginning of the subsequent stage of work.

During the stringing, direct contact between pipe and ground shall be prevented to avoid damages to the pipe ends, to lining and coating.

Stringing shall be done safely and properly to protect the cement mortar lining of the pipes. Contractor’s supervisors shall make a visual check of the pipes coating and CM lining.

All adequate protective measures and proper spacing of the pipes shall be provided.




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The lengths of the pipes shall be adequately spaced in order to facilitate subsequent handling. Pipes shall be laid on bags filled with sand and in appropriate position to avoid the impact of vehicles in transit or the danger of being damaged due to surface flow of rainwater.

6.2.5 Special Precautions for Cement Mortar Lined Pipes

If not properly maintained the cement mortar lining will develop cracks. To avoid any negative impact on the lining the below listed precautions shall be observed:

The condition of all end caps of pipes strung along the pipeline route is to be monitored daily by a special team of workers designated for this purpose.

Defective pipe end caps shall be immediately replaced. Reduced water in individual pipes is likewise to be restored immediately to suitable levels. The progress of the stringing interval may precede the welding interval by 5 days at the maximum.

The end caps may be removed from the ends of the pipe only just before beveling and welding of the pipe is undertaken. In case of longer construction breaks, e.g. overnight, weekend, etc. all uncapped pipes are to be refitted with end caps.

6.3 Handling of Other Permanent Material

Materials other than pipes and which are susceptible of dispersing, deteriorating or suffering from damages, especially from humidity, exposure to high temperature or other adverse weather conditions shall be suitably stored and protected. In particular, materials for protective coatings and wrappings, concrete, cement mortar mixture, paints, etc. are falling within this category.

The materials mentioned above shall always be handled so as to prevent any damage, alteration and dispersion. When supplied in containers and envelopes, they shall not be dropped or thrown, or removed by hooks which might damage the material during the unloading and during the following handling operations till their use.

Wood or glass felt or tape for outer protective coating and cement mortar mixture shall be permanently stored, hoisted from the ground in a dry and weather protected location and transported to the point of utilization only at the moment and in the quantity necessary for immediate use.

In any case, material supplied in rolls (e.g. geo-textile, glass felt, isolation tape, etc.) shall be kept in a place protected from dust, humidity and heat sources,




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piled up in layers to a height not exceeding 1.50 m. Moreover the rolls core shall always be kept up-right.

During unloading, transport and utilization any contact with water, mud, earth, dust, crushed stone and any other foreign material shall be carefully avoided.

Primer or mastic containers shall be kept at ambient temperature perfectly tight in order to prevent solvent from evaporating and being polluted with dust, water or other foreign materials.

In any case the Contractor shall strictly conform to supplier’s instructions regarding storage temperature and modalities of volatile materials which are susceptible of modification in properties and primary characteristics due to unsuitable storage.

Therefore, if necessary, for some materials the Contractor shall provide for a proper thermal conditioning.

Materials with machined surfaces such as flanges, fittings, equipment, wire net etc. shall be piled and handled so as to avoid the contact of the machined surfaces with the ground or with substances which may damage them.




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7 TRENCHING

7.1 General Excavation

The pipe trench shall be carefully excavated and the trench bottom graded so that the pipeline is evenly supported throughout its length. The trench bottom contour shall be such as to obtain a smooth profile for the pipeline and to minimize field bending.

The pipe trench shall be excavated along the staked alignment but where there is a change in direction, the trench shall be cut so as to accommodate the specified minimum radius of pipe bend. A clearance shall be maintained between the bend and the trench walls to conform to the trench dimension requirements set out on the Drawings.

In cases where excavation by the use of mechanical excavation equipment is unsuitable or hazardous in the existing ground conditions, or may cause damage to other property or existing facilities, the Engineer may require the pipe trench to be excavated by hand.

The finished trench shall be free from roots, stones, rocks or other hard objects, which may damage the pipe or pipe coating. Provision shall be made for dewatering if required.

Where the trench has been over-excavated to a depth significantly greater than that shown in the alignment sheets or required for obtaining a smooth profile, the Contractor shall re-fill the trench to such a depth and with such materials and degree of compaction as instructed by the Engineer.

7.2 Trench Dimensions and Pipe Cover

The pipe trench shall be excavated to sufficient depth to provide the specified cover, allowing extra depth for any soft bedding required beneath the pipe. The trench width shall be at least 600 mm greater than the outside diameter of coated pipe. At points where work on the installed pipe is to be performed, such as welding, coating, etc. sufficient extra excavation shall be made so that the work can be performed satisfactorily around the pipe in the trench.

Cover shall not be less than depicted in the relevant drawings for the type of construction, or as stated in this Specification.

The trench walls shall be excavated to the slope that corresponds to the actual soil type (actual geological situation) of the given location. In general the angle of walls should correspond with the angle of internal friction of the soil and hence the requirements for the sloping of the trench walls are different in different soil




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conditions. Man shall be admitted to the trench only after verifying that the trench walls are stable.

Special care shall be taken for proper and adequate barricading the trenches in order to prevent fall of personnel and animals inside the excavations.

7.3 Extra Depth

Extra depth cover shall be provided as required at various locations. These shall include, but not be limited to, road, rail, waterway crossings, and crossings of existing services, as shown on the Drawings. Such crossings are dealt with more particularly in Section 16 of this specification. Trenching around existing services is dealt with in Clause 7.11 of this Section. Approvals for construction of crossings by statutory authorities may include provisions regarding the depth of cover.

Where there is extra depth all additional safety precautions shall be taken to ensure adequate access and egress and the trench shall be supported with close supports or battered back to a safe angle.

7.4 Limitation of Open Trench

In order to reduce the hazard of long lengths of open trench excavation and to avoid the risk of problems and additional work caused by earth slips and falls in rainy weather, the Contractor shall plan his construction program and excavating operations so that the trench remains open for a period as short as practicable.

7.5 Earth Spoil Bank

The bank of earth spoil produced by pipe trench excavation shall not be contaminated by organic and other foreign materials that would produce an unsatisfactory backfill. The Contractor shall make gaps in the spoil bank so that rainfall will not cause water to accumulate and flood adjacent cultivated fields.

7.6 Rock Trench and Blasting

The term “rock” shall be deemed to include any hard compact material (other than concreted or paved surfaces of roadways) which in the opinion of the Engineer cannot be removed by heavy mechanical excavators, rippers or manual means and therefore requires the use of pneumatic drills or rock breakers, rock cutting machines or blasting.




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The trench depth in rock shall be such that the cover is not less than depicted in the relevant drawings for the type of location, or as stated in the Specification.

Where the bottom of the pipe trench is in rock, or has hard protrusions capable of damaging the pipe coating, the bottom of the trench shall be excavated for a further 300 mm across the full width, so as to accommodate the necessary thickness of soft bedding material. The trench shall be of sufficient depth to accommodate the soft bedding, pipe and specified cover.

Blasting in connection with trenching operations shall be in accordance with Section 5, Blasting and Explosives.

7.7 Access

Where fenced access is provided across the right-of-way under Clause 4.5, the Contractor shall provide safe access across the trench. Such access shall be provided at reasonable intervals where required by landowners or tenants.

7.8 Timbering and Supports

When ground conditions are such that the sides of the trench do not remain stable for the period of time between trenching operations and laying of the pipe, the Contractor shall provide trench support units, piling or timbering and supports to retain the trench sidewalls.

7.9 Excavation in Running Sand and Areas of High Water Table

The Contractor shall submit to the Engineer his proposed method of excavation in running sand and in areas of high water table, also details of the ground dewatering equipment to be used. Inlet filters shall be fitted and used on all pumps used for dewatering.

7.10 Disposal of Water

Water shall not be pumped onto the right-of-way or adjacent land, but shall be disposed by means of hoses or pipes to a suitable watercourse.

The deposition of silt in ditches or water courses due to disposal of water from the Works shall as far as possible be avoided, but if so caused, shall be cleared out by the Contractor.




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7.11 Existing Services

The Contractor shall follow the approved proposals for support and protection of existing underground services (see Clause 4.3).

Excavation around existing service shall be carried out by hand with such care as is necessary to avoid damage to the services.

The trench shall be excavated so that the clearance between a buried pipeline and any other underground service or structure is not less than specified in the relevant code, or as stated in the Particular Specifications.

All major underground services shall be located using hand dug trial holes, operating to agreed procedures, Permit to Work and supervision as required by the owners/operators of the apparatus.

7.12 The Obtaining of Bedding/Padding Material

Suitable fine soft material free from sharp stones or flints, perishable matter or other materials which could damage the pipe coating, shall be selected from the excavated material other than top soil, and sieved if necessary for use as bedding or initial backfill. Where excavated material is unsuitable for use as bedding underneath the pipeline in rock or stony conditions, or for initial backfill (padding), the Contractor shall import sand or other suitable material.

The use of “rock shields” in replacement of the soft sand layer for the further diminution of the trench will not be permitted.




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8 BENDS

8.1 General Requirements for Pipeline Bends

For horizontal and vertical change of direction in general four (4) types of bends may be used:

Type 1:

Factory bends with a center-line radius of 5 x outside diameter. These bends shall be furnished with cement mortar lining and PE-coating analogously to the pipes.

Type 2:

Bends fabricated on site by cutting the pipe end with a bevel machine (Miter bends).

Type 3:

Field bends, made of standard line pipe. The following requirements are valid for this type of bend:

only pipes without lining may be bent

bending shall be performed in accordance with the applicable API and ASME regulations

bending is only permitted at the yard and under “yard-conditions”

cement lining must be performed after bending at the yard and under “yard-conditions”

Type 4:

Elbows according to AWWA M11 (segment bends) with combined radius of 5D.

8.2 Factory Bends

Factory-made, hot-formed bends shall be used where indicated on the Drawings or specified in the Particular Specifications. The bends generally up to 48” shall be produced by induction bending of prefabricated steel pipes. The Contractor shall not use a field bend where a hot-formed bend is shown on the Drawings. Requirements pertaining to factory bends are defined in specification M04 Factory Made Bends for Mainlines, Doc. No. QC10-H-044.




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8.3 Miter bends

These bends are only permitted up to an angle of max. 3° per joint (cutting of the two pipe ends in an angle of 1 ½° each). Minimum pipe length between cuts is approx. 6m (half of minimum length of pipe piece). Detailed requirements for cutting and pipe end preparation are described in Section 9.4.5 c.

8.4 Field Bends

Field bends shall be cold formed on an approved bending machine of the correct size with an internal mandrel. The pipe shall be bent to a radius to be defined by the Contractor based on applicable code and diameter respectively wall thickness of the pipe. All bends shall have a tangential straight of adequate length on each end. On seam welded pipe the seam shall be aligned along the neutral axis prior to bending.

All field bends shall be of constant radius, uniformly circular in section and free from buckling, wrinkling, flattening, cracking or any other defect or damage. The pipe diameter shall not be reduced at any point by more than 2 per cent.

If the pipe has a longitudinal seam, the seam shall be located on the neutral axis. Longitudinal seams in adjacent joints shall be offset by at least 250 mm at the pipe circumference. The difference between the maximum and minimum diameters of the bent pipe due to ovality shall not exceed 2.5 % of the nominal diameter. All bends shall have a tangential straight no less than 2 meter on each end.

Prior to the start of field bending, the Contractor shall carry out a bending procedure on each and every pipe size and wall thickness in the presence of the Engineer. The completed bend shall be ultrasonically checked before and after the test to ensure that any reduction in the wall thickness does not exceed the maximum under thickness tolerance as specified in API 5L.

Before they are incorporated in the pipeline, all bends shall be proved with a gauging device fitted with two sizing plates of the min. permitted pipe internal diameter held apart by a distance of approximately 1 pipe diameter.

Where bends have been formed from coated pipe, the coating shall be inspected. Where damage has occurred, the coating shall be repaired or replaced.

Contractor shall be required to maintain a bend register, which shall indicate the following types of information

The date when the cold bend was pulled

The bend angle




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Pipe Number

KP Location

8.5 Segment Bends

Generally for pipeline size above 48” the segment bends can be used. The layout of the bend shall comply with AWWA M11. The total angle will be divided into several segments welds, up to a maximum of 15 degrees per weld.

The method for wall thickness determination according to AWWA M11 shall be considered including a safety factor of 2.0 for internal pressure design.

If applicable for the pipeline system piggability of the elbow for all types of pigs including “intelligent” ones shall be proven.

Segment bends shall be manufactured from PE coated pipe with no internal lining. After testing (NDT) of the bends CM lining with steel mesh reinforcement shall be applied in the lining yard. Specification M03 shall be observed. The lined segment bends shall remain in the lining yard for the full curing period of the CM lining.




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9 FIELD WELDING AND QUALIFICATION OF WELDING PROCEDURES AND WELDERS

9.1 Scope

This chapter defines the minimum technical requirements for all field welding operations and relevant qualifications of welding procedures and welders for cross country pipelines designed in accordance with ASME B31.4. This includes large size pipelines with butt welded joints and smaller size pipelines where slip joints are used.

Further in this document field welds or field welding will be referenced as production welds or production welding, to use the equivalent terms of API 1104.

Welding requirements of ASME B31.4 and API 1104 in their latest revisions shall apply unless amended by this specification.

The detailed technical requirements, the extent and the acceptance criteria for non-destructive testing (NDT) are contained in chapter 10 of this specification.

9.2 Codes and Standards

The latest edition of the following codes and standards shall establish the minimum standards for the work.

ASME B31.4 Pipeline Transportation Systems for Liquid and Slurries

API 1104 Welding of Pipelines and Related Facilities

EN ISO 9001 Quality management systems – Requirements

EN 10204 Metallic products - Types of inspection documents

ASTM A370 Standard Test Methods and Definitions for Mechanical Testing of Steel Products

ASTM E92 Standard Test Method for Vickers Hardness of Metallic Materials

ISO 148 Steel; Charpy impact test (V-notch)




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9.3 General

9.3.1 Environmental Conditions

The environmental conditions, operating conditions, water quality data, etc. under which the pipeline shall operate are defined in the specification G-02.

9.3.2 Definitions

The terms Contractor and Company are used as per definition of API 1104, further definitions are as follows:

Welding Procedure Specification (WPS)

A written procedure, based on applicable codes, standards and good engineering practice, listing the materials, detailed method and parameters to be employed during welding of a joint

Procedure Qualification (PQ)

A demonstration of welding a joint (qualification weld) by using approved equipment and methods, utilizing the parameters outlined in the proposed WPS to demonstrate that the given weld will have suitable mechanical properties and soundness. The qualification weld has to be subjected to non-destructive and destructive testing.

Procedure Qualification Record (PQR)

A document containing all information concerning the welding of the qualification joint (as run parameters, detailed methods and conditions) as well as the results of the subsequent tests, material certificates, calibration certificates etc.

Welder Qualification

Demonstration of the abilities of the welder to produce a weld that meets the requirements of the applicable qualified WPS. The qualification weld has to be subjected to non-destructive testing.

9.3.3 Abbreviations

ANSI American National Standards Institute

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASTM American Society for Testing and Materials




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CE Carbon equivalent

HV Vickers Hardness

ISO International Organisation for Standardisation

NPS Nominal Pipe Size

MPI Magnetic Particle Inspection

RT Radiographic Testing

UT Ultrasonic Testing

9.4 Technical Requirements

9.4.1 Qualification of Welding Procedure Specifications (WPS’s)

a) General

All testing equipment and facilities shall be supplied and/or at least one accredited and experienced test laboratory hast to be nominated to perform all necessary destructive and non-destructive testing as per requirements of this specification and other referenced standards and specifications.

The equipment and facilities shall be subject to approval.

Sufficient notice shall be given before commencement of any procedure qualification and related testing.

The use of pre-qualified procedures may be permitted based on specific approval.

b) Preliminary Welding Procedure Specification (pWPS)

Preliminary WPS`s shall be submitted for review and approval at least two weeks prior to the beginning of the welding procedure qualifications.

The preliminary WPS`s shall be in accordance with the requirements of API 1104 and this Specification for the entire scope of work, including procedures for repair welding.

The pWPS shall briefly contain the information as required in the relevant standards.

c) Essential Variables

Unless otherwise specified Essential Variables shall be as per the requirements of the applicable standards. If a change in the welding conditions will affect the notch-toughness properties of a weld than also the Supplementary Essential




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Variables for the relevant welding process as indicated in API 1104 shall be qualified.

For changes outside the range of the Essential and Supplementary Essential Variables a new WPS/PQR shall be qualified in accordance with the applicable standards and this specification.

d) Grouping of Materials

The applicable welding standards API 1104 and ASME Section IX allow a wide range of materials to be grouped for the qualification of welding procedures. This can be considered sufficient for most applications in pipeline construction.

However, taking the project specific parameters like operating pressure, stress levels etc., in case of pipeline failure into consideration a qualified, separate procedure shall be prepared for cases where materials of considerable different strength, chemical properties, heat treatment conditions etc. shall be welded together.

e) Welding Procedure Qualification (WPQ’s)

All WPQ’s shall be performed in accordance to the previously approved pWPS’s, which have to be stamped and signed as “APPROVED FOR QUALIFICATION”.

The qualification test welds shall be performed simulating production welding and reflecting the specific conditions, like clamping, lifting and lowering etc.

All welding parameters and conditions influencing the essential variables shall be recorded using calibrated equipment. All welding for procedure qualification and for production shall be done using calibrated welding machines.

The quality of the qualification welds shall be determined by non-destructive testing (NDT) and destructive testing as per the applicable standards unless amended by this chapter and the separate NDT chapter.

f) Testing of Qualifications Welds

Preparation of test samples and testing shall be performed at an approved test laboratory.

All Qualification Welds shall be subjected to NDT after the completion of welding. Where post-weld heat treatment is necessary, this shall be performed prior to NDT.

NDT shall consist of the following:

• Visual examination

• Radiographic testing and/or

• Ultrasonic testing and/or




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• Magnetic Particle Examination

as applicable to the joint design and the specific requirements.

NDT shall only be performed using the approved equipment and procedures that will be employed for production. NDT of a Qualification weld may serve as a qualification test for NDT procedures.

The NDT acceptance criteria are defined in the applicable standards, unless amended by chapter 10 of this specification. Any welds failing to meet the acceptance criteria shall not be subjected to destructive testing.

For destructive testing as a minimum all Qualification Welds shall be subjected to Macro Examination, Hardness Test and Fracture Toughness Test as described below, supplemented by further tests required in the applicable standards.

MACRO EXAMINATION AND HARDNESS TEST

Specimens of the cross section from suitable locations covering the weld and the heat-affected zone shall be prepared for macro examination. The prepared surfaces shall be etched using a suitable enchant to reveal the grain structure. The sections of the weld taken for macroscopic examination shall be used for hardness testing.

The hardness shall be measured in accordance with ASTM E92 or equivalent standards using a 10 Kg load. The hardness indentations shall be evenly distributed across the base material, the heat affected zone and the weld metal.

The macro sections shall be examined at a magnification of x3 and the macro-photographs of the same magnification showing the hardness indentations included in the PQR.

CHARPY IMPACT TESTING

Charpy Impact testing in general accordance with ASTM A370, ISO 148 or equivalent standards shall be carried out for butt welds when the nominal pipe wall thickness exceeds 5 millimetres.

One set of three specimens shall be taken, with the notch location at each of the following positions:

• Root weld centre line

• Root fusion line

• Root fusion line + 3 millimetres

When the wall thickness exceeds 20 millimetres, an additional set of three specimens shall be taken at each of the following positions:

• Cap weld centre line




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• Cap fusion line

• Cap fusion line + 2 and 5 millimetres

Specimens shall, wherever possible, be 10 x 10 millimetres full size. Where these dimensions are not possible, sub-size specimen shall be extracted. The test temperature shall be minimum 0°C or below if specified in the base material standards.

The acceptance criteria of Charpy V-Notch test shall as minimum fulfil the requirements of the base material standard unless otherwise specified.

g) Qualification of Repair Welding Procedures

All repair welding shall be performed in accordance with an approved repair welding WPS and shall be executed by qualified welders. The repair welding WPS is separate from the original welding procedure with the addition of the following:

• Method of defect removal

• NDT requirements to determine complete removal of defect

To qualify a repair welding procedure, a production weld shall be produced in accordance with the approved WPS and shall be non destructive tested after completion. If acceptable, a section within the allowable limits has to be removed and re-welded in accordance with the proposed repair procedure. Finally this repair weld has to pass all required tests described in the relevant sections of the applicable standards and this specification.

h) Re-Tests

GENERAL

If the mechanical tests fail for whatever reason, the Contractor shall immediately investigate the causes of the failure, and take all necessary actions including but not limited to retest and/or re-evaluation of PQR parameters.

If after re-testing as described below the qualification weld finally fails to meet the minimum requirements, a new WPS proposal shall be established and qualification welding and testing repeated.

TENSILE AND BEND TESTS

If one tensile test or bend specimen does not meet the acceptance criteria, two additional specimens shall be tested and both have to meet the acceptance criteria.




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CHARPY V-NOTCH IMPACT TESTS

If either the specified minimum average value has not been achieved or one specimen is below the specified minimum single value, a re-test of three further specimens shall be made. The location of the re-test specimen shall be as close as possible to the location of the original specimens.

HARDNESS TESTS

If only one hardness result exceeds the specified maximum then three further impressions shall be made in close proximity to that which failed such that they do not mutually interfere. If all of the further tests are below the specified maximum then the test shall be accepted.

If the test joint finally fails to meet the minimum requirements, a new WPS proposal shall be established and qualification welding and testing repeated.

i) Procedure Qualification Records (PQR’s) and final approval of WPS’s

During procedure qualification all the parameters used shall be recorded. After completion of the welding procedure qualification a procedure qualification record shall be compiled, containing the following information:

• Revised WPS based on “as-run” parameters

• Printout or datasheet of the “as-run” parameters and welding details

• Summary of the welding parameters including heat input calculation

• Certificates of base materials

• Certificates of filler materials and other welding consumables

• Calibration certificates of equipment

• Pre-heat treatment Records (as applicable)

• PWHT records (as applicable).

• Visual inspection report

• Results of NDT

• Results of destructive testing

The final WPS, accompanied by the PQR, shall be submitted for review and approval. Based on satisfactory results the WPS will be stamped and signed as “APPROVED FOR CONSTRUCTION”.




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9.4.2 Qualification of Welders

a) General

Each welder shall be qualified in accordance with the welding procedure qualification requirements for each WPS according to which he will perform welding works on site.

Welders and/or operators who welded the procedure qualification test welds, which have been satisfactory non-destructive tested, shall be deemed as being qualified.

The limits of welder qualification are the essential variables of the WPS. The use of pre-qualified welders, obtaining qualification, which is covering the range of the qualified WPS’s, shall be subject to approval.

The welds shall be subjected to non-destructive testing as per applicable standards and specifications. NDT procedures shall be identical to those used for the welding procedure tests.

Qualification shall be valid for a period of six months unless otherwise stated in the applicable standards. This period may be extended by a further six months when it can be shown by NDT from production welding that the welder has produced satisfactory welds. Therefore a “Welder Performance Record” shall be maintained, showing the number of welds and NDT results for each welder and/or operator.

The Contractor shall perform re-training and re-qualification of welders, if the individual weld repair rate exceeds 5%.

b) Welder Identification

A unique identification number shall be assigned to each welder and a welder identification card with the welder's name, photograph, identification number, and WPS’s for which the qualification is valid shall be issued for each qualified welder.

Each welder shall have the card or a copy available at work location and shall produce the card to the welding inspector if asked for. Welders performing work without identification card shall be suspended from production welding until such time as the card can be produced and shown. In case a welder terminates his work, the identification number shall not be reassigned to another welder.

9.4.3 Welding Processes

Applicable manual welding processes are shielded metal arc welding (SMAW), and gas tungsten arc welding (GTAW) or a combination of those. Other welding processes shall be subject to approval.




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As automatic or semi-automatic welding processes submerged-arc welding (SAW), gas tungsten arc welding (GTAW), gas metal arc welding (GMAW) and flux cored arc welding with external shielding (FCAW) or a combination of those may be used.

For the eighty and seventy inch pipelines the automatic welding process shall be used.

During the automatic welding sequence, the operator shall monitor the electrical and mechanical procedure parameters of the welding machine on an appropriate strip-chart recorder. If any of the welding parameters deviate beyond the toler-ances specified in the procedure specification, the weld shall be unacceptable. If the strip chart is found to be unacceptable after welding has been completed, the joint shall be rejected and removed from the line.

9.4.4 Welding Consumables

Filler metal identification, trade name and batch certificates shall be kept and maintained during the entire welding operation.

All batches of welding consumables shall be ordered including Manufacturer’s Certification according to EN 10204 type 3.1 or similar to demonstrate that they meet the requirements of classification as per ASME Section II Part C or other applicable standards.

The chemical composition of the deposited weld metal shall be compatible with the used base materials, and shall be selected such that the deposited weld metal exhibits mechanical properties equal to or in excess of the base material, as demonstrated in the welding procedure qualifications. As a guideline for the selection of welding consumables ASME Section II Part C or other applicable standards shall be used.

All welding consumables shall be stored and handled in accordance with a written procedure and with the manufacturer’s recommendations. The written procedure has to be submitted for approval prior commencement of welding activities.

Any consumables that cannot be properly identified or are damaged or contaminated in any way shall be segregated and removed from the job site.

9.4.5 Production Welding

a) Pipe Receipt

All pipes shall be inspected upon receipt by the Contractor’s QC inspector as per the requirements of applicable codes, standards and specifications.




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The Client/Engineer shall be advised of all defective pipes that are designated for repair work prior to any repair being undertaken.

Pipe body repair by welding shall not be permitted.

b) Pipe Body Repair

A minimum length of cut out shall guarantee the complete removal of the defective area, plus 75 mm on either side of the defect. Preheat before cutting is not required when automatic bevelling machines are used and/or the heat affected area will be removed by other mechanical methods.

If the ovality of the new pipe end is within the requirements for ovality as per the line pipe specification, and acceptable alignment for welding can be demonstrated the pipe may be re-used.

c) Pipe End Preparation and Inspection

If the supplied pipe shows any bevel damage or it is required to be repaired as stated in the clause “pipe body repair then the bevel ends of the cut pipe shall be prepared and inspected as stated below. This also applies to pipes, which have been cut to shorter length.

Pipes are to be supplied with bevel design in accordance with the approved welding procedure specification (WPS).

If necessary pipe ends shall be bevelled by machining, grinding or machine thermal cutting.

Fusion faces and the surrounding surfaces within 25 mm of the joints shall be free from heavy scale, moisture, oil, or any other substance that may have a detrimental effect on the weld quality.

If machine gas cut is used, the edges shall be free of slag and the cut surface shall be machined or ground back removing any defects having a negative impact on the subsequent welding process. After grinding the bevelled edges shall be visually and MT examined to ensure freedom from defects.

If the pipe is cut back more than 25 mm from the factory bevel, the pipe end shall also be ultrasonic tested in accordance with original mill standard to ensure that no laminations are present.

d) Alignment and Fit-Up

As a minimum, the pipe shall be visually inspected for the following, immediately prior to line-up for welding:

• Pipe ends are uniform and circular with no indication of flatting or denting

• Pipe bevels are free of nicks and gouges




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• The joint design conforms to the welding procedure specification (WPS)

• Cleanliness, the bevel and surrounding area shall be free from contaminants such as oil, grease, oxides etc.

For mainline welding internal line up clamps shall be used. For tie-in welds or situations where welding with internal clamp is not applicable (on steep slopes in mountainous areas etc.) external clamps may be used in accordance with the qualified WPS.

Internal line up clamps shall not be removed until completion of root and hot pass and after lowering the pipe on to supports or trench bottom.

External clamps shall not be removed until as much as feasible but a minimum of 50 % circumference of root pass has been deposited in the uphill direction.

In case of longitudinally or spirally welded pipes, a minimum distance of 10 inches (254 mm) between each longitudinal or spiral weld shall be maintained in lining-up pipes and these weld seams shall be located in the top half of the pipe (120º). Particular relaxations in case of welding pipe to bend or bend-to-bend shall be subject to approval.

All fit up conditions like bevel angle, root gap and misalignment shall be checked by using gauges of recognized commercial quality, such as TWI etc.

The maximum allowable misalignment (high/low) measured at the outside diameter shall be as per API 1104. Offsets greater than this limit, which are due to variations in wall thickness may be either corrected by rotating the pipe or machining or grinding to give a 1:4 taper at the transition, providing the minimum wall thickness is maintained. This applies to both mainline and tie-in welds.

Correction of misalignment should normally be corrected by rotating the pipe.

Heating and strong backs shall not be used for correction of misalignment. Hammering is not permitted except by means of a tool with non-ferrous, soft contact surface, for example bronze.

e) Weather Conditions

Contractor shall supply welding shelters when using a gas shielded welding process.

No welding shall be performed on wet parts. Therefore, in case ambient conditions should cause condensation on the joints and especially in case the joints are wet, the edges shall be dried by heating with a torch on min. 100 mm at each side of the weld. In case of wind, rain, low ambient temperature (lower than +10°C), welding operations shall not be carried out without having taken all necessary precautions.




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Especially in case of rain, or wind (particularly in presence of sand) special shelters shall be erected to protect welders and joints.

Preheating of min. 50°C is required if the ambient temperature of the pipe is below 10°C. If the ambient temperature goes below 0°C a preheating of 100°C shall be performed.

f) Preheating and Preheat and Interpass Temperature Control

Preheating, if necessary, shall be carried out using induction heaters or propane torches.

The preheat temperature shall be checked immediately prior to the start of welding, it shall be measured 75 mm from the weld preparation at one point (minimum) in each quadrant. The interpass temperature shall be stated in the WPS and shall not exceed that recorded during procedure qualification.

Preheat and interpass temperature measurements are to be performed on the external pipe surface using calibrated digital thermometers or temperature measuring crayons.

The minimum preheating temperature for weld repair shall be as stated in the relevant WPS

The minimum preheating temperature for tie-in welds shall be as stated in the relevant WPS.

g) Welding Operations

Welding shall be performed by qualified welders using qualified welding procedures (WPS`s) previously approved by the Engineer.

The approved WPS`s shall be available at the construction site with the welder and the welding supervisor or the welding inspector. During the welding operations the Contractors welding inspector shall be present at each welding work location or area. He is also responsible for 100% visual inspection of Contractors welding work and has to stamp and sign the visual inspection report on a daily basis.

Inspection and Testing shall be done by the Contractor as specified API 1104, and as amended by this or other relevant specifications.

All welding shall be limited to the weld joint. Insulated ground leads shall be attached by mechanical pressure or magnetic type clamps only. Contractor shall take necessary precautions to prevent arc burns between the ground clamp and the pipe. All arc burns beside the weld bevel or ground clamp arc burns shall be removed by grinding. Defective area shall be examined by MPI to guarantee the complete removal of defect and by UT to guarantee the compliance with the




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minimum pipe thickness requirement. Where thickness is below the specified minimum, the section of pipe shall be removed.

A minimum of two welders shall be working on opposite sides of the pipe if pipe dia D≥ 323.9 mm. Number of welders should be as per approved WPS.

The hot pass shall be commenced immediately after root pass welding within the time limit established in the WPS.

Interrupted welding shall be part of the mainline welding qualification. Any field weld started shall be completed by the CONTRACTOR on the same day. If for any reason the weld could not be finished it shall be completed 70 %. The weld shall be wrapped for slow cooling and protected from weather conditions that may impair the quality of the completed weld. Preheat in accordance with the approved WPS, but as a minimum 100°C, shall be applied to complete the weld.

The minimum spacing between any two-girth welds shall not be less than 2 meters unless agreed otherwise by the Engineer. There shall be not more than three girth welds on any 8 m of pipeline. This shall not apply to the welding of valves and fittings into the mainline.

Where air draughts may develop in the piping during welding operations this shall be avoided by properly plugging one end.

h) Repair Welding

For pipeline welds all repairs shall be performed in accordance with an approved repair welding procedure (WPS`s) and shall be executed by qualified welders.

A weld with unacceptable defects shall be repaired only once, a repair of a repair is thus not permitted. If the repair is unacceptable the complete weld and HAZ shall be removed.

Defects necessitating repair shall be removed by grinding to sound metal and repair weld grooves shall be visually and magnetic particle inspected prior to re-welding. Repaired areas shall be NDT examined as per original weld with extension of 50 mm beyond both ends.

The maximum length of a single repair portion shall be:

• 30 % of the total weld length, for partial penetration repairs

• 20 % of the total weld length, for full penetration repairs

No repair weld shall be shorter than 50mm. The total repair length shall not exceed 30 % of the total weld length.

Repair welding shall be carried out by matching electrodes with vertical up progression and shall be a minimum of 150 °C preheated as stated in the relevant WPS.




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i) Tie in Welding

Definitions

This section covers the welding operation to be carried out on line pipes in the following cases:

• Connection of long pipeline sections inside or outside of the trench

• Connection of prefabricated river, railway and road crossings to the mainline

• Connections to or into the mainline, where free welding shrinkage is restricted (Closing joint on pup pieces etc.)

PERFORMANCE OF TIE IN WELDING

All tie in welds shall be carried out in accordance with an approved tie in welding procedure and shall be executed by qualified welders.

For the alignment and fit up of tie in joints an external clamp shall be used.

The root pass shall be performed in uphill progression. Both welding ends have to be machined or have to have an equivalent preparation in accordance with the tolerances of the WPS. The root pass shall be completed and the hot pass shall follow immediately after. The welding shall not be interrupted until the joint has been completed as per the relevant WPS.

The filling and capping passes may be performed using uphill or downhill progression

TRANSITIONS

Transitions details for welding of pipe or components having different wall thickness shall be in accordance with the regulations of the design code and good engineering practice.

If pup pieces are used for transitions they shall have a minimum length of 2 meters and shall be welded to the end of sections.

When Automatic Ultrasonic Testing (AUT) is to be used on welds connecting material of unequal wall thickness (i.e. at crossings) special considerations for transitions are necessary in accordance with the type of equipment to be used.

j) Traceability of Welds

Contractor has to ensure full traceability of any welding work. The identification number of the welder for each pass has to be marked on the pipe adjacent to the joint with weatherproof chalk or paint marker. This information shall not be removed until the welds have been visually inspected and non-destructive tested




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and found acceptable. Contractor has to submit a written procedure for weld traceability, along with a sample form of the pipe book/pipe tracking system for approval.

A Pipe & Weld Book (software-based) shall be maintained, whereby, each pipe and weld shall be uniquely identified to its final position in the pipeline, this includes all works such as double joint, mainline, fabrications, crossings, tie-ins, etc.

Data shall include, but not be limited to, consecutive pipe and weld numbers as-laid, date welded, repaired, or cut-out, NDT type and report numbers, weld accepted dates, and agreed survey locations.

9.5 Inspection, Testing and Certification

The Contractor shall operate a Quality Management System in compliance with requirements of ISO 9000 Series.

All project materials and welding work shall be inspected and tested in accordance with the requirements of the applicable design codes and as described in detail in this specification.

All welding work shall meet the acceptance criteria for non-destructive testing (NDT) as defined in chapter 10.

All procedures for testing and inspection shall be subject to the approval of the Engineer prior to commencement of work.

Measuring and test equipment, as well as qualification, inspection and test personnel, shall be in accordance with the requirements of the applicable Codes and Standards.

The project material and the welding consumables shall be furnished with material test certificates according to the requirements of the applicable Codes and Standards and the relevant Project Specifications.




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10 NON-DESTRUCTIVE TESTING (NDT)

10.1 Scope

This chapter defines the minimum technical requirements for the non-destructive testing for pipelines which are designed and constructed in accordance with the requirements of ASME B31.4, covering welds on pipelines (field joints), fittings, valves and other accessories.

The non-destructive testing (NDT) requirements of ASME B31.4 and API 1104 in their latest revisions shall apply unless amended by this specification.

10.2 Codes, Standards, Abbreviations

The latest edition of the following codes and standards shall establish the minimum standards for the NDT work.

ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons

API 1104 Welding of Pipelines and Related Facilities

ASME Section V Non Destructive Examination

EN ISO 9001 Quality management systems – Requirements

The abbreviations used in this chapter have the following meaning:

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASTM American Society for Testing and Materials

ISO International Organisation for Standardisation

NDE Non destructive Examination

MT Magnetic Particle Examination

RT Radiographic Examination

UT Ultrasonic Examination

PT Liquid Penetrant Examination

AUT Automated Ultrasonic Examination




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10.3 NDT Procedures and Qualification

Written NDT procedures for

Liquid Penetrant Examination (PT)

Magnetic Particle Examination (MT)

Ultrasonic Examination (UT)

Radiographic Examination (RT)

Automated Ultrasonic Examination (AUT)

shall be submitted to the Engineer for approval before commencement of any NDT activities.

These procedures shall contain detailed information about the processes and materials to be used and shall cover as well safety and emergency aspects.

Final approval shall be based on a qualification test either to be performed during qualification of welding procedures or on separate produced welds in case pre-qualified welding procedures will be used. This shall confirm the quality of the NDT methods and materials to be used.

Along with this procedures Contractor has to submit the CV’s and valid qualification certificates of the personnel to be used for approval.

The Contractor shall give a minimum of 48 hours notice before commencement of any procedure qualification and related testing.

10.4 Qualification of NDT Personnel

Non-destructive testing personnel shall hold a valid qualification in one of the following schemes at the level shown as a minimum:

ASNT Level II for the relevant technique

CSWIP/PCN Tester/Practitioner/Interpreter (Welds) Level 2 for the relevant technique.

For the visual inspection of any welds the qualification as certified welding inspector (CSWIP or equivalent) is acceptable.

Contractor’s personnel for the interpretation of radiography results shall have a minimum of 2 years working experience.




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Contractor’s personnel for the interpretation of automatic ultrasonic examination results shall have a minimum of 2 years working experience on the relevant system.

Contractor shall employ or appoint at least one Level III qualified NDT operator/interpreter to establish and control Contractor’s NDT procedures and to be available to interpret doubtful indications.

10.5 Extent of NDT

10.5.1 Main Examination Method

Depending on the specific conditions of the project, the availability of the NDT equipment and personnel, the welding process and technology to be used as well as depending on economic considerations, either radiographic examination or automatic ultrasonic examination shall be used as the main examination method for pipeline girth welds.

As a minimum the extent of examination for pipeline girth welds shall be as per the requirements of the applicable design and welding standards as outlined in the NDT summary table. In case of unsatisfactory weld quality the amount of non-destructive examination will be increased accordingly.

In addition to the main examination method performed on the pipeline girth welds additional and/or supplementary examinations shall be performed as outlined in the following paragraphs.

10.5.2 Visual Inspection

All welds and weld repairs shall be subjected to 100% visual inspection by the Contractor’s welding inspector in accordance with API 1104 Section 9 as applicable to external surfaces. Internal surfaces should also be inspected when safe access permits.

The internal surfaces of branches and/or o’lets shall be visually inspected following fit-up and root pass, prior to connecting pipe run, or fitting.

To perform his task he shall be equipped with all necessary gauges, mirror, digital thermometer, etc. Only equipment of recognised commercial quality shall be used.

The acceptance or rejection of any weld shall be mentioned in the visual inspection report. The format of the report has to be approved in advance.




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10.5.3 Radiographic Examination of Girth Welds

All tie-in welds, repair welds, welds to be enclosed in casings or concrete weighting, welds between pipes of different thickness and welds for joining special parts as bends, tees, reducers, valves, etc. shall be subject to 100% radiographic examination by the Contractor’s qualified NDT personnel.

At the start of production welding the first 100 joints shall be subjected to 100% RT. In case welders/operators will be changed the first 50 joints of the new welder’s production shall be subjected to 100% RT.

If AUT is used as the main examination method the first 100 joints shall be additionally subjected to 100% radiographic examination for verification purpose.

Manual ultrasonic examination and/or magnetic particle examination may supplement radiography and shall be used to interpret doubtful indications in the radiographs. Subject to approval, liquid penetrant examination may be substitute for magnetic particle examination in exceptional circumstances or on stainless steel pipelines.

The acceptance or rejection of any weld shall be mentioned in the radiographic inspection report. The format of the report has to be approved by the Engineer in advance.

10.5.4 Ultrasonic Examination

All tie-in welds and repair welds shall be subject to 100 % automatic or manual ultrasonic examination.

For automatic welding (narrow gap) automatic ultrasonic examination shall be used.

If branch connections or o’lets are welded to a run pipe, the respective area of the run pipe shall be subjected to UT to ensure that no laminations are present.

If thermal cutting is used on pipe ends, the new bevel shall be prepared in accordance with the approved procedures. If the pipe is cut back more than 25 mm from the factory bevel, the pipe end shall also UT examined to ensure that no laminations are present.

After removal of arc burns by grinding the defective area shall be examined by UT to guarantee the compliance with the minimum pipe thickness requirement.

The acceptance or rejection of any weld shall be mentioned in the ultrasonic inspection report. The format of the report has to be approved in advance.




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10.5.5 Magnetic Particle Examination

Magnetic particle testing shall be used on all repair welds (to ensure complete removal of defects prior to welding), branch connections, fillet welds, cut back pipe ends, field bevels (produced by thermal cutting) and after removal of arc strikes to ensure freedom of cracks and shall be performed by the Contractors qualified NDT personnel.

Magnetic particle examination may supplement radiography and shall be used to interpret doubtful indications in the radiographs. Subject to approval, liquid penetrant examination may be substitute for magnetic particle examination in exceptional circumstances or on stainless steel materials.

The acceptance or rejection of any weld or bevel shall be mentioned in the magnetic particle inspection report. The format of the report has to be approved by the Engineer in advance.

10.5.6 Liquid Penetrant Examination

Liquid penetrant examination shall be used if required for the detection and evaluation of surface flaws in materials and weldments of pipelines using solvent cleaner, penetrant (solvent removable), developer and lint free cloth or equivalent.

Only consumables of a recognized commercial quality shall be used.

Each examination shall be reported together with interpretation of flaws/defects encountered; where necessary a diagrammatic sketch shall be made to show locations of defects. The format of the report has to be approved by the Engineer in advance.




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10.5.7 Summary

The extent of NDT is summarised in the table below:

Inspected Item NDT Requirement

Visual UT RT MT/PT

Field butt welds (general) 100% 10% (1) (2)

First 100 joints at the start of production (8)

100% 100% (3) (2)

In case of change of welders up to the first 50 joints of the new welder

100% 100% (1) (2)

Field tie-in welds 100% 100% 100% (2)

Welds for connecting pipes of different wall-thickness

100% (2) 100% (2)

Welds enclosed in casings or to be concrete weighted

100% (2) 100% (2)

Welds for joining special parts such as bends (mitre bends), tees, reducers, valves, etc.

100% (2) 100% (2)

Repaired areas in any welds. 100% 100% 100% 100% (4)

Joint after and before defected joint weld

100 % (2) 100 % (2)

Branch connections and fillet welds

100% (5) -- 100 %

Pipe-cut back area and lamination checks prior to welding attachments or fittings

100% 100 % -- --

Field bevels 100% -- -- 100% (6)

Following removal of arc strikes and crater cracks

100% 100 % (7)

-- 100%

Notes: (1) examination with either automatic ultrasonic or radiographic inspection according to the selected main examination method. For automatic welding (narrow gap) AUT shall be used.

(2) to interpret doubtful indications if required

(3) if AUT is the main examination method, than additional 100% RT will be used for verification/validation purposes of the AUT results. If RT is the main examination method, than only 100% RT will be used for the first 100 joints

(4) to ensure defect removal prior re-welding




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(5) if practical

(6) if hot-cutting has been used

(7) to verify remaining wall-thickness after grinding

(8) if a defect will be detected within the first 100 joints at the start of production, the next 100 joints (counted from the defect joint) are subject to NDT

10.6 NDT Techniques Requirements and Acceptance Criteria

10.6.1 Visual Inspection

a) General

All visual inspection shall be performed under acceptable conditions with regard to light, access to the weld, etc. The weld surface and the adjacent pipe surface shall be clean and dry.

To perform his task the operator/interpreter shall be equipped with all necessary gauges, mirror, digital thermometer, etc. Only equipment of recognised commercial quality shall be used.

b) Acceptance Criteria

Cracks, craters, pinholes, weld spatter, residual slag or arc strikes shall not be acceptable. Undercuts shall be acceptable to the criteria given in API 1104.

If cracks have been found, the reason/cause of the crack shall be thoroughly investigated and the WPS immediately reviewed or modified such that they do not reoccur. This may result in halt of welding until resolved.

The external weld reinforcement shall merge smoothly with the adjacent surfaces of the parent material. The thickness of the external weld reinforcement shall not exceed the limits of API 1104.

10.6.2 Magnetic Particle Examination

a) General

Magnetic Particle Examination shall be in accordance with ASME V Article 7 with acceptance criteria according to API 1104. The use of magnetic particle inspection and the frequency of its use shall be as stated in the relevant section of this specification.




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b) Equipment

Electromagnets (electromagnetic Yokes) operated by direct current (DC) or alternating current (AC) shall be used for MT, either fixed or adjustable pole and shall be demonstrated as capable of a lifting power of at least 18 kg for DC Yokes and 4.5 kg for AC Yokes in accordance with ASME Section V, Paragraph T-762 (b) and (c) on a test weight.

AC Yokes shall be considered superior to DC Yokes for the detection of surface discontinuities on wall thickness greater 6 mm.

The use of permanent magnets shall be subject to approval.

Only consumables of a recognised commercial quality shall be used. It shall be identified by the manufacturer. Batch certificates shall be available for Company approval.

c) Acceptance Criteria

The criteria of API 1104 shall apply. Indications evaluated as cracks are not acceptable.


10.6.3 Liquid Penetrant Examination

a) Equipment

Liquid penetrant inspection shall be performed using:

- Solvent cleaner

- Penetrant (solvent removable)

- Developer

- Lint free cloth or equivalent.

Only consumables of a recognised commercial quality shall be used. It shall be identified by the manufacturer. For the purpose of this procedure consumable in aerosol can form shall be used. Batch certificates shall be available for review.




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The criteria of API 1104 shall apply. Indications evaluated as cracks are not acceptable.


10.6.4 Radiographic Examination

a) General

The use of radiographic examination and the frequency of its use shall be as stated in the relevant sections of this specification. All radiographic techniques and quality of film shall comply with the requirements of API 1104 and ASME V Article 2.

b) Equipment

Radiographic examination shall be performed by means of X-ray. On the Contractor’s request beside X-rays also gamma rays are allowed, provided that Iridium isotope is used and the required film quality, including density and sensitivity, is achieved.

Internal sources, (crawler units), shall be employed for the radiography of all field butt joints in pipe of 8 inch NPS or over, including repair welds where accessible. In cases where the sources cannot be placed inside the pipe the double-wall/single-image technique shall be applied for diameters over 3 ½ inch (89 mm) and double-wall/double-image technique for diameters of 3 ½ inches (89 mm) and below.

Pre-packed films in the form of roll pack and rigid or flexible cassettes may be used.

The selection of radiographic film suitable for the specific material and thickness conditions as well as for the radiographic equipment (X-ray, gamma-ray) to be used shall be in accordance with ASTM E94-00 Standard Guide for Radiographic Examination or similar codes and standards,

For gamma radiography (Ir 192 isotopes) of welds in steel materials the recommended minimum material thickness shall be 0.75 Inch (19 mm). This thickness may be reduced when the radiographic techniques used demonstrate that the required sensitivity can be obtained.




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Wire type penetrameters (image quality indicators, IQI’s) in accordance with EN-462, BS 3971 or ASTM E 747 shall be used and selected in accordance to the wall thickness. The radiographic sensitivity shall be 2% or better in the weld area and meet the requirements of API 1104.

The density measured by means of a densitometer must be 1.8 to 3.5.

c) Film Marking

On pipe diameters over 3 ½ inches (89 mm), 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 ascending order, viewed in the direction of pipeline chainage. On diameters less than 3 ½ inches (89 mm), each shot shall be designated by a lead letter placed on the pipe, i.e. A, B, C.

The zero position on the weld shall be indicated, without any mistakes, by means of convenient markings. All measurements used for defect location shall be stated in metric units. The pipeline reference weld number, contract number, date of radiography and repair reference shall be as a minimum included in the radiograph identification. Corrections in identification by scraping the film surface to change film numbers, etc., are prohibited.

The joint position of all joints shall be indicated in the pipe book with reference to the above-mentioned numbering system. The conformity between joint locations in the pipe book shall be ensured by the Contractor.

On completion of the Contract, all radiographs shall be indexed, catalogued, boxed up and handed over as part of the as built document package.

d) Acceptance Criteria

As a minimum the acceptance standards for non destructive examination of API 1104 and/or as indicated in the relevant design codes shall apply.

10.6.5 Ultrasonic Examination

MANUAL ULTRASONIC EXAMINATION

a) Equipment

The ultrasonic equipment in use shall be capable of generating and receiving frequencies between 2 MHz and 5 MHz as a minimum.




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The ultrasonic instrument, flaw detector, shall be calibrated on annual basis, or following repair or damage, to manufacturer’s specification. Contractor shall produce valid calibration certificate for each flaw detector on request.

Probes or transducers shall be electrically matching to the flaw detector and shall not exceed the size of 600 mm² for either single or twin crystal types.

Probe angles shall be accurate to +/- 2 degrees of the nominal 45, 60 or 70 degrees for individual probes. Probes with worn faces, which affect the testing angles, shall not be used.

The technician shall have access to calibration and/or test blocks such as IIW-V1 or V2, etc. which are required to ensure compliance with regard to calibration of flaw detector and accuracy of probe characteristics etc.


All indications that produce a response greater than 20 percent of the reference level shall be investigated to determine the location, shape, extent and type of reflectors. All indications that produce a response greater than 50 percent of DAC/TCG screen height (in accordance with API 1104) shall be as a minimum evaluated according to the acceptance criteria of API 1104 and/or the applicable design standards.

AUTOMATED ULTRASONIC EXAMINATION (AUT)

If the Contractor proposes to use AUT, in place of (as the main examination method), or together with a reduced level of radiography, for instance on welds produced by automatic welding processes, the Contractor shall employ a specialised AUT Sub-Contractor and submit full details of the proposed Sub-Contractor and the proposed system for approval at an early stage following award of Contract.

This shall include the work history to-date, and any past or current Client or Owner recommendations/reports, where available.

The AUT equipment shall be capable of providing a reproducible examination and a permanent record of the examination, and be capable of discriminating between defects according to the categories specified in API 1104, excluding near surface defects such as cap undercut.

Detailed AUT procedures for each pipe type, thickness, and weld geometry, including calibration, shall be established and submitted for approval.




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Details of the training and certification of AUT operators and interpreters shall be agreed and approved.

10.7 Safety

The Contractor shall have detailed written procedures and work instructions in place, covering all aspects of health, safety and environmental impacts due to the use of NDT equipment, especially radiation protection. Same have to be approved by the Engineer prior to commencement of work.




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11 COATING OF JOINTS AND REPAIRS

The Contractor shall apply the protective coating on welded joints, special parts and fittings and other metallic installations according to the type and sequence defined in the final design.

Coating of buried joints, fittings, etc. shall be performed with Heat Shrinkable Sleeves. Above ground pipeline joints and components shall be coated with liquid epoxy in compliance to the specification M22.

11.1 Joint Coating Properties

11.1.1 Epoxy and Sleeve Properties

The corrosion coating shall consist of a high build epoxy applied to the steel surface, followed by a wrap-around heat shrinkable sleeve, and shall be suitable for an operating temperature not exceeding 80° C in wet conditions.

As one of the requirements for Quality Control of proper shrinking of sleeve, the shrink sleeve backing shall have a built-in permanent change indicator. This shall be in the form of a special pattern on the backing. Prior to shrinking the pattern shall be clearly visible and feelable to the touch. Once the sleeve has been shrunk down properly, the pattern shall disappear and the sleeve surface shall become completely smooth.

11.1.2 Epoxy and Sleeve Thickness

The first layer of the joint coating system shall be a 100 % solids two component epoxy of a minimum dry-film thickness of 150 microns when applied on the steel surface. The epoxy layer shall be the primary anti-corrosion barrier and shall be capable of corrosion protecting the steel surface on a standalone basis.

The heat shrink sleeve shall provide mechanical protection to the epoxy layer and shall seal onto the epoxy layer and the adjacent line coating. It shall have the following minimum thickness:

Backing: > 1.4 mm

Adhesive: > 1.6 mm

Total sleeve (Backing + Adhesive): > 3.4 mm

Once installed the sleeve system shall have an average minimum thickness of 3.25 mm.




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11.1.3 Sleeve Width

The sleeves on the weld joint shall be wide enough so as to overlap onto the mainline coating by a minimum of 50 mm on each side of the weld joint once installed. The installed sleeve width shall be considered as the edge-to-edge width of the backing of the sleeve once fully shrunk down.

The sleeves on field bends may be wider and shall overlap onto each other by a minimum of 50 mm once installed.

11.1.4 Coating Performance Requirements

Contractor shall ensure that all material proposed for field joint coating has been tested and meet the requirements for physical, chemical and electrical properties as detailed in the table below.

The Shrink sleeves Materials to be supplied shall have a track record of satisfactory performance for a period of at least ten years worldwide on projects of equal or larger size than this project.

Contractor shall provide test certificates for all accepted materials, detailing the information as required in this Specification.

The self-adhesive layer of the coating shall be homogeneous, free from flaws, defects, pinholes, bubbles, cracks and inclusions.

The corrosion coat shall be resistant to bacterial attack and shall not deteriorate during the design life of the pipeline.

The sleeve shall be resistant to the high Ultra Violet light of the Saudi summer without requiring any sort of painting or covering. To confirm suitability, the sleeve shall be tested for UV resistance as per EN 12068 standard. An independent lab test report shall be provided to confirm compliance.

To ensure that the sleeve is applicable in the high ambient temperature and Black Body temperatures of Saudi Arabia in the summer, the backing and adhesive shall be of a high enough temperature rating such that it shall be fully installable without damage. It shall not be necessary, nor will it be allowed, to paint or cover the installed shrink sleeve with any protective cover during the peak of the summer. At this time, under the direct sun in the summer and without any protective coating, the sleeve and adhesive shall not become soft and the adhesive shall not flow. Any sleeve which exhibits such softness or flow of adhesive when directly exposed to the sun shall be considered unsuitable and rejected.




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The requirements for the physical, chemical and electrical properties have to be proven by the test methods shown in the below table.

Performance Parameter Test method Required Result

Ring and Ball Softening Point of adhesive

ASTM E-28 > 120°C

Lap Shear Strength of adhesive ASTM D-1002 > 0.35 MPa (50 psi) @ 80°C

Peel Strength of installed sleeve at 80°C (pull rate of 10 mm/min) to pipe surface (steel) to factory coating (PE coating)

EN 12068 > 2 N/cm > 2 N/cm

Penetration resistance @ 80°C for 24 hours

ASTM G-17 No holiday at 10 kV

Impact Resistance at 23°C EN 12068 Class C Pass

Ultraviolet resistance EN 12068 – Annex F Pass

Moisture Vapor Transmission of sleeve at 38°C, 90 % RH

ASTM E-398 <0.08 gm/ 24 hrs/100 sq.in

Cathodic disbondment of installed sleeve at 80°C after 30 days

ASTM G-42 < 15 mm

Soil Stress Creep Resistance of installed sleeve at 80°C

TP-206 < 0.1 inch after 24 hours

Hot Water Immersion resistance of installed sleeve at 80°C for 120 days

ASTM D-870 No blisters or determination. No water under sleeves.

Holidays Detection Pass at 5kV/mm + 5kV

11.2 Coating Application

Installation of shrinkable sleeves must be done according to regulations and usual safety precautions.

Joint coating shall be carried out only by qualified staff that have been trained and certified by the manufacturer of the shrink sleeves.




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11.2.1 Joint Coating Applicator and Procedure Qualification

The Contractor in presence of the Engineer shall prequalify the application procedure and each member of the joint coating application crew. Each member of the application crew shall apply coating to a minimum of three joints in the presence of the manufacturer who will certify the procedure and the applicator as acceptable for carrying out the coating application. Any joint coating or mainline coating repair applied by a team or team member that has not been qualified shall be completely removed and re-applied by a qualified team.

11.2.2 Joint Coating Procedure

The coating application sequence should be as follows:

The exposed steel area and adjacent pipe coating shall be cleaned of all dust dirt, moisture, salts, grease or other contaminants, if necessary using a non-contaminant solvent, Xylene or equal.

Weld area shall be thoroughly abraded to a near white metal finish, SIS SA 2 ½ to yield an anchor pattern of 50-100 microns. Anchor pattern shall be checked using Testex Press-o-film tape. Blasting material shall be either industrial grade grit or copper slag, approved by the Engineer prior to its use at site. Sand shall not be used for blast cleaning of joints. No blasting shall be carried out if Relative Humidity is above 80 %. The line coating adjacent to the weld area shall also be sweep blasted and should be bevelled to less than a 30° angle. The exposed steel and coated areas should be wiped clear of all foreign materials. Grit/slag used shall be free of any slat contaminants and shall be sieved to give the required anchor pattern.

Adjacent line coating over which the shrink sleeve shall be shrunk, shall be sweep blasted to give it a rough finish. The sweep blasting shall extend 25 mm beyond the edge of the shrink sleeve.

Just prior to sleeve shrinking, the surface of the blast cleaned joint steel area shall be tested for salt contamination using an Elcometer Salt contamination test instrument. The level of salt contamination on the joint steel shall not exceed 4 microgram/sq.cm. If the contamination level exceeds this value, the joint shall be cleaned with clean stilled water and reblasted. Contamination of the blasting medium may also have to check to ensure that the 4 microgram/sq.cm level is not exceeded.

After blasting and as soon as possible (within ½ hour of blasting), joint area shall be pre-heated to the manufacturer’s recommended minimum temperature. A pyrometer shall be used to ensure that correct temperature is




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reached on steel and the line coating. As a minimum, Pre-heating of the steel surface 5 deg above dew points is required.

The total elapsed time between the start of blasting of any pipe bend or fitting and the heating of that pipe to the specified temperature shall not exceed the following time-humidity table:

Percent Relative Humidity (Elapsed Time Hours)

85 0.5

80 1.0

70 1.5

60 1.75

50 2.0

Any pipe surface not processed within the above time-humidity table shall be completely re cleaned and reblasted before coating.

The two component epoxy shall be mixed together thoroughly in the ratio recommended by the manufacturer and brush, pad, roller or airless spray applied to the bare steel surface to yield a Dry Film Thickness of minimum 150 microns. Runs, sags, or other application defects shall be removed and coating reapplied.

The heat shrink sleeve shall be wrapped loosely around the pipe, centering it over the epoxied weld area and evenly overlapping the adjacent pipe coating by 50 mm or more.

Using a torch the flame length shall be adjusted to approximately 500 mm to produce a yellow flame at the end. Using the yellow portion of the flame, the closure shall be heated evenly until the pattern of the fabric reinforcement is visible. The closure shall then be put down with gloved hand and any wrinkles shall be smoothened by gently working them outward from the center of the closure.

A small hand roller shall be run over the closure to push out any trapped air.

Using a torch heating shall start at the center of the sleeve and move circumferentially around the pipe, using a constant paintbrush motion.

Heating shall be continued toward one end of the sleeve, followed by the other, starting at the shrunk down weld bead area and continue to the other end of the sleeve.




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Alternatively, shrinking may be started from one end and continued to the other end of the sleeve.

During shrink-down, adhesive flow shall be occasionally checked with finger. Wrinkles should disappear automatically.

When the sleeve has been shrunk onto the joint area and is still hot and soft, a small hand roller may be run over the sleeve to push out any trapped air. Particular attention shall be paid to the weld and cutback area. If necessary, areas may be reheated to roll out air.

Sleeve shall be fully recovered when all of the following have occurred:

a) The QC permanent change indicator has disappeared completely and the sleeve is smooth to the touch.

b) The sleeve has fully conformed to the pipe and adjacent coating.

c) There are no cold spots or dimples on the sleeve surface.

d) Weld bead profile can be seen through the sleeve.

e) After sleeve is cooled, adhesive flow shall be evident on both edges.

All coating material containers shall be kept in suitable cabins/rooms so as to avoid to be submitted to hot temperatures. After drawing the necessary quantities the containers shall be immediately closed in order to avoid contamination of dirt, dust or water and solvent leaks due to evaporation. Containers shall never be opened in the presence of open flames.

11.3 Inspection and Testing

11.3.1 General

The Engineer shall have the right to inspect at all times, any tools, instruments, materials or equipment used or to be used in the manufacturing process.

The Engineer shall have the right to reject any or all tools, instruments, materials, equipment or work which does not conform to this Specification.

Any rejected material not conforming to this Specification shall be replaced/rectified by the Contractor at no expense to the Owner. Any rejected tools, instruments, materials or equipment shall be replaced or rectified.




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11.3.2 Test and Inspection Requirements

Factory Testing

Contractor shall provide factory test procedures prior to purchasing of shrink sleeve materials. In addition test results of factory testing shall be provided for each batch of material.

Field Installation Inspection and Testing Procedures

The Engineers inspectors at site shall spot check the application procedure without any limitation. Any non compliance with the agreed procedure shall constitute reason for rejection of heat shrink sleeves and their replacement by Contractor at no cost.

Installation shall be subjected to the tests detailed below which shall also be the basis of the format of the filed record to be kept of the joint coating.

a) Visual

The inspection of the joint shall only be done after the cool down of the sleeve and the substrate to ambient temperature. The sleeve shall be visually inspected for the following points:

The QC permanent change indicator shall have disappeared completely and the sleeve shall be completely smooth to the touch.

The weld bead profile contour shall be visible through the sleeve.

The ends of the sleeve shall be firmly bonded to the mainline coating.

There shall be no upstanding edges.

Adhesive flow shall be evident at both edges of sleeve.

The sleeve shall be smooth; there shall not be any dimples, cold spots, bubbles, punctures, burn holes or any signs of holidays.

There shall be no signs of entrapment of foreign materials in the underlaying adhesive.

The sleeve shall overlap the adjacent mill coating for at least 50 mm each side.




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b) Coating Thickness

The thickness of the cooled, field joint coating shall be checked using an approved Elecometer ultrasonic or electro-magnetic type thickness gauge. Measurements shall be made as follows:

4 readings of the installed sleeve thickness shall be taken, 1 each at the 12, 3, 6 and 9 o’clock positions of the installed shrink sleeves on the main body of the pipe away from the girth weld and the closure patch.

4 readings of the installed sleeve thickness shall be taken, 1 each at the 12, 3, 6 and 9 o’clock, over the weld bead but not on the closure patch.

The average of each of the four readings shall result in an average min. thickness of 3.25 mm and no individual reading shall be less than 3.0 mm.

If required, a weld bead filler tape may be used to achieve the required coating thickness on the weld bead.

A sleeve which does not meet the above thickness requirements shall be rejected and replaced.

c) Holiday inspection

After complete cooling down, holiday inspection shall be done.

Holiday inspection shall be done using a voltage setting of minimum 5 kV/mm + 5 kV with a full encirclement contact electrode for every joint.

d) Adhesion (Peel) Test

One out of every 50 sleeves or alternatively one out of a two day’s production (whichever is lower) shall be subjected to a manual peel test.

Peel strength inspection shall be done at a sleeve temperature of up to 40° C; both the substrate and the sleeve shall be at this temperature.

Strips of 25 mm x 200 mm shall be cut perpendicular to the pipe axis either at 9 or 3 o’clock positions as per DIN 30672 halfway between the circumferential weld bead and the mill coating.

Manually remove the first 30-40 mm of the leading edge of the strip by using a screwdriver, make sure that the initial adhesive bond line cut is essentially centered within the adhesive layer.

Attach the peel strength test gauge to the leading edge of the test strip and fasten clamp.




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Holding the test gauge with both hands exert a steady force with a slow pulling speed of 100 mm/min., and at an angle of 90° to the circumference of the pipe.

At this point the peel strength shall be greater than 30 N/cm, and the bulk of the adhesive shall remain on the epoxied pipe.

e) Air voids

Window testing can be carried out on one sleeve out of 100

Window testing shall be done at a sleeve temperature of 23° C; both sleeve and substrate shall be at this temperature.

On each sleeve tested, at least one window each shall be cut in the patch overlap area, across the field girth weld, and in the body of the sleeve.

There shall be no evidence either of voids extending to bare metal or areas of no adhesive wetting.

If any defects are found, their extent shall be determined, if necessary by removing the entire sleeve backing.

The sleeve installation shall be acceptable if both of the following requirements are met:

(a) The maximum dimension of voids extending to bare metal does not exceed 50 mm.

(b) At least 99 % of the metal surface is free of voids extending to bare metal.

(c) The maximum dimension of voids extending to bare epoxy does not exceed 10 cm².

(d) At least 97 % of the adhesive layer is free of voids and/or lack of adhesive wetting.

Defective areas shall be repaired in accordance with the manufacturer recommended installation procedure.

If the sleeve does not meet the acceptance criteria above, the adjacent sleeves shall be tested until acceptable installations are found on both sides of the defective installation.

Normal testing frequency can then be re-established.




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11.4 Repair Procedure

Damaged PE line coating or shrink sleeves damaged during destructive testing shall be repaired with repair materials that meet the following criteria:

a) Small Damages Extending up to 1.0 cm²

Small damages to 3 LPE line coating or sleeve shall be repaired using PE melt sticks; with epoxy primer if bare metal is visible.

b) Damages Extending up to 300 mm or 100 cm²

Polyethylene repair patches precoated with hotmelt adhesive, shall be used in conjunction with a hotmelt filler adhesive and epoxy primer (if bare steel visible) as per manufacturer’s recommendations. Repair patches when installed should overlap the damaged area by minimum 50 mm all round.

c) Damages Extending Over 300 mm or 100 cm²

Full encirclement heat shrink sleeves with epoxy primer shall be used.

Following repair, the repaired section shall be tested for any Holidays at minimum 5kV/mm + 5kV.

11.5 Piping at Line Valve, Vent and Drain Stations

The coating of piping and joints at line valve, vent and drain stations which is located above ground or in shafts shall be made with epoxy in full compliance to Specification M22.




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12 LINING OF JOINTS AND REPAIRS

12.1 General

For lining of joints and repairs, the requirements of Specification M03 Cement Mortar Lining have to be observed.

The lining of the butt welding joints has to be performed within the first ten days after welding. Prior to application of the joint lining the backfilling of pipeline trench has to be completed.

For handling of the cement mortar mixture in general reference is made to specification M03.

12.2 Lining of Joints

Only cement mortar mixture, manufactured as per the Specifications for the internal cement mortar lining of the pipes shall be used. The quality of the cement mortar mixture shall be exactly the same as that used for "Repair of Defects" (see Spec. M03).

All stipulations of specification M03 pertaining to the cement mortar mixture have to be fully observed. This includes but is not limited to quantity of additives, quantity of water, max. allowable time for using the mixture, climatic conditions, curing, etc.

The use of plastic additives is not permitted.

Before lining the joints the metal surface will have to be cleaned according to relevant stipulations in specification M-03 (Surface Preparation/Cleaning).

The cement mortar mixture shall be applied mechanically in one layer and the surface shall be smoothened with proper tools in an adequate quality.

Special care must be taken to achieve a good connection between the factory-lining and the joint lining.

During the curing period of the cement mortar of the joints any movement; vibration etc. of the pipes must be avoided.

12.3 Repair of Defects

Repair of minor defects of the factory-applied lining are permitted and shall be done by removing a strip of the lining which covers approx. half of the circumference of the pipe. The minimum width of the strip shall include the whole extension of the defective area. If defective areas of the lining are large or




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distributed in excess of half of the circumference, the whole lining ring has to be removed.

The cement mortar mixture shall be applied according to the Specification M03.

12.4 Method Statement

The Contractor shall prepare a detailed description of the method to be used for applying the cement mortar lining, for curing and the inspection of the completed lining.

The method shall be demonstrated in practical use before starting of work and will be subject to approval by the Engineer.

Special note shall be taken of the requirement, that the lining of joints and repairs will have a quality comparable to the quality of the factory lining.

12.5 Inspection of Internal Lining

Prior to commencement of hydrostatic testing the completed lining has to be inspected.

For the inspection of the internal lining the Specification M03 as well as the below stipulations have to be observed. It is the obligation of the Contractor to provide adequate equipment and qualified personnel. Following two methods for the inspection are acceptable:

visual inspection for large diameter pipes of 36” and over

TV-inspection for small pipe diameter below 36”

The equipment and methods used will be subject to approval by the Engineer.

Visual inspection has to be done before hydrostatic testing of the pipeline sections by independent "third party" inspectors to be approved by the Engineer.

For TV-inspection, the inspection device shall consist of several heads (each of them adjustable) to get an overview over the whole circumference.

The TV-inspection has to be done continuously with respect to the progress of joint lining and curing of the laid pipe sections.




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12.6 Surface Condition

The surface of the cement mortar lining of the joints and repairs has to have the same appearance and shall be as smooth and even as the lining of the pipes.

For detailed requirements reference is made to specification M03.

12.7 Lining with Fusion Bonded Epoxy (FBE)

At his discretion, the Client may decide to change the lining material from cement mortar to FBE. In this case the joint lining must also be performed by the FBE process according to requirements as laid down in Specification M20. The joint lining shall be performed by the same applicator as for the factory lining in order to ensure system integrity.




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13 PIPE LAYING

13.1 Pipe Trench Preparation

13.1.1 General

All timber, sticks, stones, hard clods of earth, projecting rocks and other hard objects, which might damage the pipe or pipe coating shall be removed from the bottom of the trench.

Before lowering the pipe into the trench, the trench depth shall be checked to ensure that the specified cover on the pipe can be maintained, taking account of any soft bedding that may be required.

13.1.2 Rock Trenches

Wherever the bottom of the trench comprises hard rock or hard material, which might damage the pipe coating, the bottom of the trench shall be covered with sand or other approved bedding material. A layer of at least 300 mm thick soft bedding shall be placed in the bottom of the trench so as to cover all projections in the trench bottom. See Clause 7.12 for provision of suitable bedding material.

Protective shields shall be placed along the trench walls to prevent damage to the coating during lowering-in if necessary. The shields shall be removed only after the pipe is in place and subject to no further movement.

13.2 Pipe Internal Cleaning

The Contractor shall take all necessary precautions to keep the internal surface of pipes free of dirt, waste and other foreign matter. Before laying and welding, each single length of pipe or bend shall be visually inspected and, if necessary, cleaned inside by appropriate tools such as brushes or swabs.

Special care has to be taken to avoid contamination or damage of the internal lining. All tools used for cleaning shall be adequate for the special use paying due consideration to the internal lining.

A plate cover of a type approved by the Engineer shall be placed at each open end of a section of pipes already connected every time the pipe laying or welding work is interrupted, so as to prevent dirt, water, animals and any other foreign substance from entering the pipe.

Covers shall be in place for the whole period of interruption of the Work; therefore, at crossings and at other points of interruption of each section, they shall be removed only when the tie-ins are carried out.




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The Contractor has to take special care to avoid under all circumstances that any substance which might cause deterioration to the quality of the drinking water, will be in contact with the internal surface of the pipeline at any stage of the construction work.

13.3 Pipe laying in the trench

13.3.1 General

Other than for normal pipeline construction practice a different method of pipe laying shall be used for a large diameter pipeline with internal cement mortar lining.

Pipe installation shall be performed by laying pipe by pipe into the trench and welding in the trench (single laying method).

Special care shall be taken to ensure that the deformation of the pipes is within small limits which will not cause any damage of the lining.

During pipe laying the pipe must not be lifted in excess in order to protect the lining. The pipe must not be moved during welding on any of the passes.

At the position of the welding joints the trench must be prepared in an adequate width and depth to allow the welding and coating operation in a proper manner. This trench preparation has to be performed before pipe laying.

In any case before starting the laying of pipes the Contractor shall have terminated all checks and tests pertaining to coatings, linings and cleaning of the pipes.

13.3.2 Particular Requirements

a) The laying bed shall be sufficiently wide, in any case not less than the dimensions defined during the final design, so that the swaying of the pipe during laying does not cause rubbings between pipe and trench walls. When necessary, trenching shall be touched up, in order to get the pipeline resting continuously on the bottom of the trench.

b) The pipes shall be lifted and laid using flat bands or belts, of non abrasive material of a width adequate to the fragility of the coating.

The type of the lifting equipment used for pipe laying shall prevent temporary stresses and deformations capable to cause damages to the internal lining.

c) The pipes shall be laid in such a way that they rest over the entire length on the trench bottom. For the welding and external coating, bell holes shall be excavated.




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For welding in rock sections where bell hole excavation is not practical the pipes may rest on temporary supports within the pipe trench. These supports have to be removed as soon as the joint coating is complete. The permanent laying of pipes on sand bags is not permitted.

d) Where coating comes into contact with welding supports or lifting equipment during the laying operation, thorough inspection has to be performed to discover possible damages or dents or other defects which shall, when found, be completely repaired.

Before laying the pipe into the trench the coating of the complete pipe shall be inspected.

If after inspecting and repairing the coating, the pipe has to be put again on supports on the trench bottom, these supports shall be suitably padded in order not to damage the coating, thus avoiding to carry out more repairs when the pipe is finally lifted and laid.

e) In case of presence of water in the trench, the Contractor, before commencing pipe laying, shall dewater the trench as much and as long as necessary to inspect the laying bed visually. The trench must be kept free of water until completion of backfilling. This requirement is particularly valid for laying of pipes in trench mode at sabkhat sections.

f) At some areas it will be required to install pipes in trench mode within sabkhat sections. At these areas the Contractor has to perform comprehensive soil investigation works including determination of the ground water table. If the bearing capacity of the native soil is found to be inadequate soil replacement works have to be undertaken. It also has to be ensured that the pipes are protected against uplift. Contractor has to provide all respective design for approval by the Engineer and Owner and implement countermeasures to the satisfaction of the Engineer.

13.3.3 Tolerance of Pipeline actual vertical Alignment

The tolerance of pipeline actual vertical alignment to be design shall be in the magnitude of +/- 10 cm.

13.4 Overhead Sections

13.4.1 General

Before assembling and laying overhead pipelines the Contractor and/or the third parties shall have terminated the following works:




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painting and/or coating of the pipeline, according to the requirements stipulated in the project design

construction of the pipe supporting structures or of the structures on which the supports will rest

13.4.2 Particular Requirements

a) The Contractor shall first of all erect the supports taking care that they are properly aligned in plan and elevation, according to the indications of the design documents and drawings. When the supports consist of steel structures, Contractor shall carry out the prefabrication and/or erection taking into account the clear spans provided and avoiding to have the supports to coincide with the pipe field welds. The prescription indicated in the following para b) shall be complied with, especially when the supports consist of rollers.

b) Rollers shall be lubricated and checked for free turning. In case of seizure, the defect shall be repaired or the roller shall be replaced. In case of overhead sections with inclined risers, the alignment of the end supports shall be temporary before the pipe laying. Final alignment shall be carried out after the pipe laying has been terminated. At this point all the rollers shall be perfectly centered, by acting on the seat of the support plates. The centering operations shall be carried out before connecting the overhead pipeline with the ends of the buried sections.

c) For modalities of lifting, moving and laying of the pipeline, contents of the foregoing stipulations shall apply.

Any reinforcing plate for the pipeline shall be centered on the support and its ends shall not be at a distance less than 12 inches from the support. The Contractor shall take into account the above requirements in case the pipeline is prefabricated and erected away from the supports.

If the pipeline sections are pre-assembled away from the rollers, the sections may be laid by pulling them on the rollers.

The pull may be helped by pushing the pre-assembled section, but pipeline sliding on rollers by pushing action only is not allowed.

The progress speed of the pipeline being pulled shall be limited in order to avoid collision with the rollers, especially when it passes on the welds and reinforcing plates.

During the pulling operation, the cantilevered end of the pipeline section in progress shall be kept at a level slightly higher than that at which the pipe rests on rollers, in order to avoid shocks and jerks.




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d) In overhead and buried sections with risers, the latter shall be assembled starting from the top if the final position is vertical, starting from the bottom if the final position is inclined.

For tie-in between riser and pipeline under normal laying conditions, the jointing procedures shall be regular and such not to cause deformations in the riser itself. Moreover, at the end part of the buried section, the laying bed shall be suitably compacted in order to prevent movements in the riser due to settlement of the first section of the buried pipeline.

13.5 Pipe Installation in Casing

At major road and highway as well as railway crossings the open cut method will not be allowed, therefore the product pipes will have to be installed into casing pipes made of reinforced concrete or GRP material.

Design calculations for casing pipes must be handed over to the Engineer for approval prior to commencement of pipe jacking.

13.5.1 Preparatory Works

The pipe jacking operation and casing pipe installation shall be completed and checked before the preparatory works can start. The tunnel provided by the casing pipes shall be as straight as to allow safe installation of the carrier pipe.

Before starting the operation, one side of the crossing is decided to be the launching side and the other, the receiving side. At both sides the trench shall be prepared. At the launching side, depending on the availability of working space, a welding and launching platform is to be prepared.

Product pipes shall be welded triple, double or single joints at the launching platform. All weld joints shall be 100 % radiographed, repairs completed and certified. The joints shall be coated as per the applicable procedures. The pipes shall be holiday detected and repairs made if required.

A pulling head with a lug shall be welded to the front of the first length of welded pipe(s) to attach a pulling cable.

After a welded length of pipe(s) is ready, insulator rings of adequate design shall be installed. The insulator rings shall be spaced at approx. 1.5 m intervals according to the manufacturer’s recommendation.

The purpose of installation of the insulator rings is electrical insulation between the casing and the carrier pipes and providing a sliding support as well as to protect the coating of the pipe during pulling.




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After the insulator rings are installed, protection sleeves for the fibre optic cable conduit shall be fixed to the insulator rings. Also cathodic protection reference cells and cables shall be fixed according to the design.

After the pipe length is ready for installation, is shall be checked for a last time before pulling operation will start.

13.5.2 Pipe Installation

The casing pipe assembly shall be checked and cleaned from any debris before start of pulling. Some soft soap may be applied at bottom of the casing to decrease the friction factor.

A pulling cable shall be attached to the pulling head and pulling equipment (a tractor or a ground winch) shall be prepared on the receiving side.

First length of pipe(s) shall be lifted by the pipe layer and led to the casing as the tractor at the receiving side pulls.

Sling position shall be changed after the pipe layer progresses until the beginning of the casing. During sling position change, the pipe shall be supported on wooden skids and/or sand bags.

When the first welded pipe length is almost completely inserted, sling shall be released and the pipe left on skids.

Second length of the pipe shall be aligned and welded to the first. Joint shall be 100 % radiographed, coated and holiday detected.

Insulator rings shall be fitted to the second pipe length, final checks done and pulling continued. The insulator rings shall be of heavy duty so as to withstand the friction developed when threading the carrier pipe into the casing.

When the carrier pipe is in its final position, the pulling cable shall be removed, the pulling head shall be cut off.

Tie in to the rest of the pipeline can be done after pulling is completed, or can be left to another operation.

After pipe installation is complete, the ends of the casing shall be sealed and provision for the insertion of the grout inlet pipes and other conduits required shall be made at both ends at suitable intervals. The annular void between the carrier pipe and the casing shall be filled with grout. In high water table areas, this operation should be done before the dewatering installations are removed.




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13.6 Pipe Laying in "Sabkha" Sections

Pipe laying in "Sabkha" sections shall be performed in full compliance with the requirements laid down in contract documents (drawings etc.). The material, necessary for the construction of the embankment and the backfilling after pipe laying shall be delivered and transported to the site by the Contractor.

The height of the embankment for the pipe pad shall not be less than 60 cm above Sabkha level.

The minimum distance between pipes laid parallel shall be 1.00 m.

The compaction of the material for the pipe pad shall be performed in layers of 25 cm each with minimum 95 % proctor density including the 30 cm pipe bedding. The accessibility of the construction strip is the Contractor's responsibility. For the maintenance road, the fill material (subgrade) has to be compacted with proctor density of 95 %.

Backfilling of the pipeline berm can be performed without compaction.

The embankment of the pipeline and maintenance road must be prevented from erosion by spraying of weathered crude oil or non-toxic chemicals called "Sandstills", the material proposed by the Contractor is subject to approval by the Engineer.

The compaction of backfill in trench at crossings with foreign facilities shall be performed with a proctor density of at least 95 % as stipulated in item 14.2.2 of this Specification.

The road for construction vehicles and for pipe stringing shall be performed by the Contractor before commencement of pipe transport. It is the obligation of the Contractor to use appropriate material for the construction of this road.

The Contractor has to pour concrete ducts under the pipeline embankment in sufficient size and number to allow rising and falling water levels unhindered discharging conditions. Related calculations and drawings are subject to approval by the Engineer. In case of existing culverts, they have to be extended accordingly.

All other regulations for pipe laying will be valid analogously.




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14 PADDING AND BACKFILLING

14.1 Padding of Pipes

14.1.1 Preparatory Activities

Before starting padding works the trench relevant to the section of pipeline to be buried shall be inspected to make sure that there is no foreign matter. All temporary pipe supports, tree roots or branches, stubs, pebbles, or other construction debris shall be removed.

Coating which may have been damaged during construction activities shall be tested by a holiday detector. In case of holidays being detected, these shall be repaired by applicable coating repair procedure before backfill. Finally the pipe shall be inspected visually for its integrity, perfect surface and general condition.

When the pipeline is at its final position and prior to commencement of padding, the as-built survey crew shall record as-built survey measurements on weld joints as per the pertinent requirements.

Before any padding is started the pipeline shall be adequately supported along its entire length to avoid undue stresses.

14.1.2 Padding of Pipes

Material used for padding of pipes shall be of selected nature with properties which will not have any negative impact on the coating. If no such selected material can be recovered directly from the excavation material, suitable material may be produced by sieving of excavation material or otherwise has to be imported. The padding material shall be placed between the pipes, in case of a twin line, and around them such that each pipe is embedded in an annulus of selected material not less than 200 mm in thickness.

In principle the same material as specified for pipe bed preparation shall also be used for padding.

In the upper part of the padding, the conduit for the fibre optic cable system shall be installed.

The padding material shall be carefully placed around and between the pipes and adequately compacted until the level of 200 mm above the crown on the pipe across the full width of the trench. Padding material for pipes installed within the ROW of existing or future road areas (MOT/ Municipality) shall be compacted to 95% proctor density:

For padding material at wadi sections especially for the lower part (up to pipe centre line) same requirements as for the bedding material are applicable. For the




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upper part material the grain size may be increased to max. 50 mm provided natural wadi deposit (round corn) is available.

At steep slopes, the padding material for the upper part of the pipes may consist of excavation material with grain size of < 50 mm. In both cases rock shield material of adequate quality shall be placed between pipes and padding material to avoid damage to the coating.

14.2 Backfilling of Pipeline Trench

14.2.1 Backfill Material

Large rocks or stones, rubbish, vegetable growth or other material which is unsuitable for backfill, shall not be put back into the trench but shall be collected and disposed of. Any consequent deficiency in material shall be made good with suitable imported material.

The remaining excavated material of suitable quality together with any imported material shall be returned to the trench. The backfill material shall be heaped up along the trench line to leave a crown of approximately 500 mm above adjacent natural ground level to ensure a minimum of 1.50 m total pipe cover, unless otherwise specified or required by the Employer.

Surplus excavated subsoil, if any, shall be removed from Site or spread over the right-of-way on exposed subsoil. Surplus subsoil shall not be spread on topsoil.

14.2.2 Compaction of Backfill

Compaction of backfill material is only required at special sections as detailed below. For the remaining trench sections no compaction is foreseen or required.

In the sections defined during detailed design the material put back into the trench up to natural ground (and above) shall be duly compacted with Proctor density of 95 % according to DIN 18127, or as required by the respective authority.

at inhabited areas

at road areas, the crossings of roads or at areas involved by transit loads (trail crossings in desert areas, etc.)

at the crossings of pipelines and cables

at the areas where the pipeline is laid within the ROW of an existing or future roads.




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Compaction at above mentioned locations shall be done according to the following procedure:

Backfill materials up to a level 500 mm below the final ROW level shall be very gently and carefully compacted to avoid damage to the pipeline coating, internal lining and not to cause out of roundness to the pipe. Only small compactors shall be allowed within this range.

For the remaining backfill, medium size roller compactors may be used, however, operation of vibration shall not be allowed.

Backfilling works shall be carried out as soon as possible after coating of joints and padding is complete in order to give the pipe a natural anchorage, avoiding harmful actions of adverse weather conditions and caving in of the trench walls.

Backfilling of trenches opened at crossings of roadways, pavements or other public areas shall be carried out immediately after laying the pipeline in conformity with the request of the proponent authority, and all temporary and permanent surface restorations shall quickly be completed.

Sections of ground with significant slope in which the upper part of the backfilling is likely to be eroded by rains, efficient drain ditches or other works suitable to prevent scouring shall be implemented. Moreover, dams consisting of earth bags or sand sacks, properly spaced, shall be bound and connected to the natural ground of the trench wall by adequate supports, where necessary. Diversionary furrows shall also be provided if necessary to direct the flow of water into natural drainage courses and away from the pipeline trench. Movement of fine graded particles within the trench shall be avoided by provision of geotextile on the back side of the sand bag barriers.

During backfilling temporary markers, suitable for locating the axis of the pipeline shall be installed. These temporary markers shall later be replaced by final markers.

14.2.3 Precautions to be observed during backfilling

In order to avoid damage of the CM-lining and to prevent ovality of pipes the following precautions to be observed for placement of padding and backfilling materials into the trench.

a. Only excavators shall be used for backfilling. The use of shovels and or dozers is not allowed.

b. Padding and backfilling materials shall be placed at the required locations of the trench to avoid movement of material within the trench.




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c. Padding material and first layer of backfilling material shall not be dropped on the pipes from a height exceeding 500 mm from pipe top elevation. For upper layers of backfill the dropping height shall in no instance exceed 800 mm.

d. Only track bound equipment of moderate size shall be used for levelling of backfill material above ROW elevation and clean up works within the pipe trench zone.

14.2.4 Pipe Protection within Wadis

The pipe protection at wadi crossings and wadi sections will depend on the type of wadi.

In flat and wide wadis it shall consist of additional cover only or a combination of additional cover and gabions or riprap.

In narrow wadis the pipes shall to the greatest possible extent be positioned on the wadi banks and safeguarded against wash out and erosion by adequate protection measures. Wadi bank protection shall be achieved by gabions, concrete retaining walls or heavy rip rap.

If the ground conditions consist of solid rock the pipes shall be laid into the rock trench and shall be encased with concrete. The concrete encasement will serve as mechanical protection. In such situations reduced cover can be considered.

Concrete encasement must always consider the requirement of adequate CP measurements (i.e. installation of sufficient reference electrodes etc.).

At typical wadi crossings the pipe has to be protected against wash out by installation of gabions or riprap. The gabions and/or riprap have to be placed downstream of the pipe in flow direction of the wadi. With this provision erosion at the pipe area will be avoided.

In extreme cases it will be required to protect the pipes by check dams of adequate dimension and material. This will be required at very narrow wadis with high flow velocity.

The type of pipe protection within wadis shall be approved by SWCC and the Engineer.

14.2.5 Crossings with Wadis

Classification of Wadis shall be prepared by the Contractor prior preparing detailed alignment sheets, so the wadi bed has not been yet interrupted by the construction activities. Wadis Classification Report shall be submitted for review/approval, before opening the ROW. After approval during common site




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visit, the categories of the wadis shall be depicted in Alignment Sheets. For each type of wadi respective typical drawings with proposed protection measures shall be worked out which shall be the basis for detailed wadi crossing and protection design.

14.3 Duration between Welding and Backfilling Works

Backfilling must be performed within 6 days of the welding interval at the latest in order to assure that the pipeline is no longer exposed to direct solar radiation or floatation during rain storm. Within a maximum of 12 days of the welding interval, sufficient quantity of water is to be introduced into the pipeline in order to allow the reproduction of ideal curing conditions within the welded pipeline section (by making it possible to keep the water level and atmospheric humidity within the given section properly adjusted).

Each deviation from the above mentioned time intervals requires specific, case to case permission from the Engineer.




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15 HYDROSTATIC TESTING

15.1 General

Hydrostatic testing shall be performed on the basis of VdTUEV Leaflet 1051.

Contractor shall schedule the high pressure test sufficiently in advance and shall develop the following for approval to the Engineer:

a detailed method statement, with particular reference to sectioning of line sections with which every single test is concerned, including a hydrostatic test profile and a hydrostatic test section map,

the complete list of envisaged equipment, material and installations, safety measures

list of personnel charged with carrying out testing operations, including names and CV’s of the responsible personnel

filling and testing record forms, structure of final hydrostatic testing report.

Besides personnel, Contractor shall supply all equipment, materials, instruments and necessary installations to perform the tests including but not limited to the following:

prescribed test heads

provisional scraper launching and receiving traps

cleaning scrapers and calibration scraper which must be equipped with an acoustic source for detection of location. Due to the drinking water to be transported by the pipeline system, the use of scrapers with radioactive source is not permitted.

all valves, test flanges, head, pipe fittings etc.

pumps for filling, capable to produce high flow rate and low pressure

calibrated tanks

test pumps, capable to produce a pressure approx. 20% higher than that of test, with small flow rate

flow meter

dial gauges, recorder gauges and temperature measuring devices with high class accuracy capable to record values higher than specified test values

dead weight tester with adequately prepared hardware and evaluation software

high accuracy manometric scale for pressure gauge calibration




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communication along the pipeline routes

means of transport for working, observation and supervision personnel

erection, installation and checking of above mentioned materials, equipment and instruments

every other installation, supply or temporary work connected with testing operations

compressor and foam scrapers for drainage of tested pipeline.

Any pressure testing activity shall only be allowed after completed civil works, welding, coating, lining and backfilling along the pipeline section to be tested.

The accuracy of measuring devices shall be in accordance with VdTUEV 1051.

In addition all safety measures defined by the manufacturer of the internal cement mortar lining shall be observed, that means for instance:

time between filling the line and pressure test

suitability of scraper disc material

speed of pressure rising

speed of pressure reducing

period of line to remain filled between pressure test and emptying.

15.2 Cleaning and Inspection of the CM Lining

15.2.1 Pipeline Sections 36” and above

Before commencement of test water filling, the pipeline sections shall be pre-cleaned from any construction debris.

Cleaning shall be carried out before the automatic vent valves are installed. Pipe line shall be cleaned manually in sections between each automatic vent

station. All drain and automatic and manual vents valves of the section to be cleaned will be opened one or two days in advance of cleaning day to drain any remaining CM lining curing water and to aerate the pipeline interior to prepare for personnel entry. Fresh air shall be blown into the pipeline by fans and large flexible hoses, before and during the period when cleaning crews are working inside the pipeline.

Internal cleaning crews shall carry emergency breathing apparatus with them. Spare breathing apparatus units shall be kept at site, and regular safety precautions shall be observed.




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The pipeline interior surface shall be cleaned by using water, brooms and squeegees. The cleaning crew shall be trained and be fully aware that they are working to drinking water cleanliness standards, wear hygienic clothing and shall not take any foreign material into the pipeline.

After cleaning the final inspection of the pipeline including the CM lining shall take place. Inspection is visual and is done by inspectors walking through the entire length of the pipeline interior in accordance with 12.5 above.

15.2.2 Sections below 36”

Where due to its size it is not possible to enter a pipeline section for broom cleaning, the cleaning shall be carried out during filling operation by means of suitable cleaning pigs.

Also visual inspection of the CM lining is not possible and for this reason other means have to be applied, such as video recording of the pipeline internal surface. The video recordings are to be taken during construction on suitable section lengths which allow for pulling an appropriate device through the pipeline. The video recordings will afterwards be visually checked by an inspector. See also 12.5 above.

15.3 Test Crew Composition

Contractor shall provide at least one experienced Test Engineer to head the hydrostatic testing, assisted by one foreman. The crew shall comprise of fitters, riggers, helpers and other skilled workers to guarantee an optimal performance of the test and a high safety level.

15.4 Hydrostatic Test Sections and Test Pressures

The test pressure at the lowest point of a test section shall correspond to 1.25 times the design pressure. The design pressure is depicted in the Hydraulic Profile Drawing. The minimum test pressure shall be not less than 5 bar above maximum water level of a reservoir, if this reservoir is located at a highpoint of the pipeline. No pressure may occur (e.g. developed due to a temperature increase during testing) which exceeds 95% of the specified minimum yield strength.

The maximum length of a test section shall be 50 km.

Adjacent test sections shall be constructed so that they overlap to permit a single tie-in weld after hydrostatic testing.

The following sections may be individually tested:




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major road crossings

main wadi crossings

15.5 Quality of Filling Water

Water shall be fresh, clear and clean and shall be comparable to drinking

water quality according to WHO standard.

Filling water for testing shall be chlorinated to a level of approximately 5 ppm. Disinfection shall be performed during start up and line fill activities and shall be based on the guidelines of AWWA C 651 “Disinfecting Water Mains”.

Corrosion inhibitors, additives or other substances which might cause a danger for the drinking water which will be transported through the pipeline may not be used in any case.

15.6 General Set-up of Pipeline Test Sections

Test water shall be filled into the pipeline in sections.

The filling and cleaning operations shall be performed through the test heads (launcher and receiver) on each test section. Test heads shall be prefabricated and welded to the test sections as per approved welding procedures. Fittings and valves used in test headers shall be of required pressure rating.

Adjacent to the stations which are not included in the pipeline hydro test (pumping stations, receiving stations, etc.) it has to be ensured that there is sufficient space for installation of the temporary test equipment like test heads, pumps, temporary scraper traps, etc., at both sides.

The test heads shall be designed to accommodate the required number of scrapers. A sufficient number of scrapers shall run through the section for cleaning (smaller pipe sizes which cannot be otherwise cleaned) and filling,

followed by the calibration pig (see next subchapter). One scraper shall remain in the launcher of each section for de-watering/cleaning after hydrostatic testing if so required.

Scraper discs shall be made of urethane or of other suitable material. Blades and brushes shall not be used as they may damage the CM lining.

The final type of cleaning and the system set-up shall be agreed between the Contractor and the Engineer as a part of Contractor’s hydrostatic test procedure.




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Pressure gauges and pressure recorders shall be installed to the test heads. All instruments shall have valid calibration certificates issued by an accredited testing laboratory.

Thermocouples shall be installed for measurement of pipe and soil temperatures. They shall be installed due time (approx. 1 week) before the start of the pressure test in order to attain temperature compensation.

The thermocouples for the pipe temperature readings must be well insulated

against the filling material. Soil thermocouples shall be buried at pipe centre line depth on the surface of the pipe. Thermocouples shall be installed at 100 meters from the end of the buried section and every 4 km. In short test sections a minimum of 4 thermocouples shall be installed.

15.7 Calibration

Calibration is the geometrical proof that at no location or point along the pipeline the internal diameter deviates by more than 3% from the pipe diameter as recommended by AWWA M11.

Hence the minimum internal diameter at any point shall be

IDmin = 0.97 x [ODn – 2 x (tn pipe + ttol pipe+ tnCM + ttolCM)]

with

IDmin Minimum internal diameter

ODn Nominal outside diameter

tn pipe Nominal pipe wall thickness

ttol pipe Pipe wall thickness plus-tolerance

tnCM Nominal cement mortar lining thickness

ttolCM Cement mortar lining thickness plus-tolerance

For pipelines with a size up to and including 48” calibration shall be done by running electronic calibration (caliper) tools.

The recording of the calibration pig shall be interpreted by the specialised company which supplies the services and the equipment.

For pipelines larger than 48” calibration may be carried out using a chart mounted gauging plate with a diameter of not less than than IDmin as defined above.




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If there are dents and/or ovalities detected on the calibration survey the location of the defective points shall be found and proper repair shall be carried out.

Dents with depths beyond the allowable range shall generally be cut out as a cylinder and replaced by a pipe section as described in clause 451.6.2.9 of ASME B31.4.

15.8 Filling

Filling shall be performed according to the procedures described below. These directions shall not be applicable in the case of tests for short pipeline sections for which a final test is provided together with the main section to which they belong.

Establish communication with receiver end

A quantity of water corresponding to the capacity of 300 to 5,000 linear meters of line shall be introduced into the pipeline and then the first scraper, the cleaning scraper, shall be launched into the line. When determining the front water quantity, it shall be observed that no scraper is allowed to run on dry CM surface. A scraper speed between 500 and 1000 linear m/h shall be maintained.

A quantity of water sufficient to flush and clean the line, but not less than corresponding to a capacity of 100 linear meters of pipeline shall be introduced in order to move the cleaning scraper away from the launching trap. In case major siphons are expected in the test section, the water quantity between first and second scraper shall be as long as the longest siphon length (e.g. major valleys or similar). Next the second scraper shall be launched into the line.

After this the calibration scraper shall be launched at an appropriate distance.

Filling operation shall proceed without interruption. The above instructions aim to produce inside the pipeline the movement of a full cross section liquid mass to remove air. Movement of scrapers, flow rates, volume of water introduced, temperatures etc., shall be recorded on a special graph at the test point.

The drains along the pipeline shall be opened prior to passing of the scrapers and shall be closed after the last scraper has passed. In this way it is ensured that dirt and debris is flushed out and clean water is in the drainage pipes.




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The vents installed at each highpoint shall be used to release the air from the pipeline.

Filling shall continue until all scrapers have run the whole length of the line and been recovered at the temporary receiver. After completion of the hydro test the temporary test ends shall be cut out of the test sections. The recovered scrapers shall be carefully examined in order to ascertain the degree and regularity of wear of cups. The crew at the filling end has to be

informed and filling shall be stopped. Blocking of one or more scrapers at any point of line shall entail suspension of filling operations. In this case Contractor shall locate the position of the blocked scraper, recover it, ascertain causes which stopped its course and make necessary substitutions and repairs to restore the line to testing condition. These works shall be carried out in complete accordance with directions contained in the preceding paragraphs. After this, Contractor shall start filling the line again.

The dirty water which comes out in front of the filling scrapers shall be drained as per approved procedures and in accordance with local legislation and authority requirements.

Evaluation of the calibration scraper readings shall be carried out.

15.9 Performance of Hydrostatic Testing

Once filling has been completed, Contractor shall isolate the line from any parts which are not to be tested, and shall connect the test pump for raising the internal pressure. Moreover, he shall check conditions of pressure and temperature measuring instruments, and make sure that all preparatory operations and other installations required have been completed. In particular, dial and recording gauges shall be calibrated.

Tests shall commence not earlier than 96 hours from completion of filling so that thermal equilibrium is established between filled pipeline and soil temperature and to provide enough time for soaking of the CM lining. During this period all parameters shall be recorded continuously. Temperature equilibrium shall be deemed to be achieved when the average pipe temperature and the average soil temperature of the section is within 1 degree Celsius. For soaking purposes a pressure of around 50% of the test pressure shall be applied.

During pressurisation, the pressure and volume readings shall be recorded at an interval of 100 kPa. Dead-weight-tester shall be used as the primary pressure measurement device and shall be connected continuously to the test section.




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After the soaking period the pressure shall be increased continuously and checked by means of two gauges of which one shall be a recorder. The rate of pressurisation shall be in accordance with the cement mortar lining manufacturer’s requirements but shall not exceed 100 KPa per minute. At this stage the air content shall be checked in accordance with VdTUEV-leaflet 1051.

If the air content does not meet the criteria set out in VdTUEV 1051 the

pressure shall be brought down to 100 kPa above static head. Air shall be vented from all available points. After repetition of pressurisation the air content shall be checked again. This shall be repeated until the criteria are met. If there is no improvement, after various attempts the line might be filled again.

If the air content is less than specified in VdTUEV 1051 pressurisation shall continue up to the specified test pressure at a rate of max. 50 kPa/min. and held for four hours to identify any significant pressure losses.

If no pressure drop occurs during this interval, pressure shall be lowered to 50% of test value. Then another interval of two hours shall elapse, after which the pressure shall be set again at test value and maintained constantly for a period of 24 hours. Should pressure drops occur during the above intervals the aforesaid operations shall be repeated not more than twice, after which the line shall not be considered fit for testing until Contractor has established and eliminated the cause of tightness failure.

The 24h test shall be carried out in accordance with and applying the acceptance criteria of VdTUEV 1051.

Throughout testing, pressure and temperatures are to be systematically recorded for the various schedule times (generally every 30 minutes).

In case of pipeline internal pressure is exceeding, as a result of significant thermal variations, the maximum value specified above, Contractor shall partially bleed the line so as to bring pressure back to initial test values. In such case the test shall be started again after bleeding.

Filling of water into the test section will only be allowed after interruption of the test.

The hydrostatic testing is considered successful if the pressure has remained constant during the test period with the exception of variations due to temperature differences on test water and steel pipes, compression of test water under pressure and expansion of steel pipes under pressure.

The impact of above listed variables shall be calculated based on formulae listed in VdTUEV 1051. The test shall be considered accepted if the actual final




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pressure at the end of the 24 hour test does not deviate from the calculated final pressure by 0.2 bar.

15.10 Evaluation of Results and Final Report

Should test finally fail, Contractor will seek the cause, and in case of pipeline leakage, he will locate the defective point. The Contractor shall then effect

complete repair in accordance with approved procedures and perform the necessary works in accordance with the clauses contained in this specification. On completion of repair the Contractor shall repeat the entire hydrostatic test according to the procedures described previously.

Contractor shall prepare a report at the end of the test including the following:

Contractor’s responsible engineer for the test

denomination and location of tested line

characteristics of pipeline (diameter, wall-thickness, type of pipe and grade of steel)

test point, installed apparatus and equipment

data and times of each operation

all information, and any necessary descriptions, concerning execution of each operation

characteristic data regarding filling fluid, pressures, temperatures

details of any accidents which may have occurred

any other information considered significant.

This report shall be signed by the Engineer, by relevant Authorities (if any), and by the Contractor.

15.11 De-watering after Hydro test

Contractor's detailed program shall include whether the pipeline sections will be emptied or not. If the Contractor intends to leave the test water in the section of pipeline after the hydro test, he has to prepare adequate proposals for avoiding chemical reactions or changes in water quality which might cause danger to the drinking water.

If the pipeline section after hydro test will be emptied and/or the water used for the hydro test of the next section, the pipeline may have to be completely




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emptied. Where all sections of pipe are laid at a convenient altimetry, drainage may be achieved by gravity.

During drainage operations, Contractor shall take the necessary arrangements for the drained water to be suitably disposed, in order to avoid pollution, damage to crops and/or land, to existing works and obstruction to traffic. Contractor shall therefore bear in mind provisions of this point during scheduling stage of hydro tests.

If a pipeline section will be emptied, the Contractor has to ensure that cement mortar lining will not be negatively affected. Some water shall remain in the pipe to maintain humidity to avoid cracks in the cement mortar lining. The quantity of water shall be as per Contractor’s detailed program, which shall be approved by SWCC and the Engineer.

At the end of testing operations, Contractor shall also remove provisional test heads as well as other temporary installations connected with the test. He shall also effect the tie-in of the pipe section to the previously tested line in accordance with the approved procedures.

15.12 Safety

Contractor will make sure that all safety measures are implemented during testing activities. He shall provide the necessary safety equipment, communication equipment, access barriers, etc.

All local and statutory authorities, residents in the vicinity of the pipeline and all personnel shall be notified of the proposed dates of testing and shall be advised of any extension

Contractor shall issue a statement to all persons connected with testing, warning of the hazards of failure under pressure.

Safety signboards both in English and Arabic language shall be posted at appropriate locations during testing. The display shall be as follows:

“PIPELINE UNDER PRESSURE – KEEP AWAY”.

Areas where test equipment is being used shall be clearly marked and entry of unauthorized persons shall not be permitted.

Before pressurisation the Contractor shall put in place appropriate measures to avoid danger to personnel resulting from pipe failure under test, and any damage, disruption or pollution to land, roads, railways, waterways and any other service or installation along or close to the pipeline route.

No work shall be permitted on sections under test.




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The Contractor shall provide patrols to watch special points of hazard during test, in particular road, rail and water crossings and points of public access.

All safety measures shall be described in detail in Contractor’s written method statement.




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16 CROSSINGS

16.1 General

This chapter has to be considered as a general specification describing all types of crossings which may be encountered during construction of the pipeline.

For all crossings of railways, roads, wadis, pipelines, cables, etc. the Contractor has to prepare in addition to the alignment sheets adequate construction drawings, including all levels and design features.

The drawings are subject to approval by the owner of the road, railway, pipeline etc. and by the Engineer.

The methods of crossing and the use of casing pipes described in this Specification are the requirements of the Engineer. However, the Contractor is obliged to comply with any other and/or additional requirements of the owner of the facilities to be crossed and has to include also these requirements in his Contract Price.

Work may not be executed unless the drawing has been approved by the owner of the facility and by the Engineer and the Contractor has obtained the work permit form the owner of the facility.

For crossings with important traffic areas or other special sections, the Engineer may request the Contractor to install pipes with stronger wall thickness and/or to perform a separate hydrostatic pressure test for the mentioned pipeline section.

The list of these special sections and crossings will be agreed during final design stage.

16.2 Railway and Road Crossings

16.2.1 General

Railway and road crossings shall be carried out in strict compliance with the approved drawings.

Casing pipes shall be used when crossing railways and major roads. In case of minor road crossings, the casing shall be used according to design requirements or as requested by the Engineer.

For all railway and road crossings the Contractor shall give the Engineer adequate notice on the date the work is planned. The Contractor is obliged to make all necessary agreements with the competent Authority prior to starting of work.




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In any case the Contractor shall examine the permit conditions issued by the competent Authority and shall be responsible for the compliance with all the clauses contained in them, together with the necessary safety regulations and rules in force. In particular he shall care for the necessary installation of day and night signals, the temporary discipline and/or deviation of traffic, the restorations and repairs, both temporary and permanent, which shall be carried out without delay.

In crossings with casings, the Contractor shall carry out the installation and laying works in compliance with the requirements of the specification.

In road crossings without casing, the Contractor shall open the trench only after the pipeline section relevant to the crossing is prepared.

Before opening the excavation, the Contractor shall weld the straight pipeline section having a length exceeding by about 2 - 3 meters on each side the overall dimensions of the road, shall carry out the radiographic test on 100 % of welded joints and shall coat them according to the type and system provided in the design.

In all road crossings for which no individual construction drawing is provided and/or for which no casing is provided, the pipeline shall be laid with a single gradient and alignment for a length exceeding the overall dimensions of the road. Anyway, the crossing shall be made in strict compliance with the standard drawings and design specifications, especially with regard to minimum depth at which the line must be buried.

16.2.2 Major Road Crossings

All major road crossings are defined as follows and have to be crossed by means of casing pipes and the thrust boring or pipe jacking method.

All crossings with highways and expressways

All crossings with ramps to highway or expressway interchanges

16.2.3 Railway Crossings

At all railway crossings casing pipes shall be installed.

16.3 Crossing Below and Running within Water-Course Bed (Wadi)

Wadi crossings and Wadi sections shall be carried out in strict compliance with the standard drawings and design specification. However the minimum cover




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over the top of the pipe shall be two meters plus the estimated scouring depth. In addition Municipality requirements for minimum cover shall be met.

The pipes for wadi crossings and Wadi sections, when not otherwise specified in the individual design drawings, or not required by the Engineer during final design stage, shall have the same wall thickness as the line.

When pipes having a greater wall thickness are required, the Contractor, while stringing, shall store thicker pipes near the crossing/section in sufficient quantity.

The pipes shall be prepared in the most suitable position for their subsequent laying. 100 % of the welded joints shall be radiographed and shall then be coated externally according to the type and system of coating provided.

The pipe weighting, when required, shall be executed according to the specification and to the type mentioned in the design; moreover, it shall be extended, unless otherwise indicated in the individual drawing, over the whole section up to the upper bends (excluded) of the bent section.

In crossings of ditches, or embanked canals dug by drilling, the pipe shall be prepared and laid according to requirements of previous paragraph.

In underground crossings the excavation shall be carried out in such a way to comply with the pipe bottom elevation as provided in approved drawings. Particularly, the minimum cover shall be strictly complied with.

In crossings for which no individual construction drawings are required, the minimum laying depth shall not be less than indicated in the design standard drawing for the type of crossing involved.

For the crossing between the two bends of the pipe section, a straight pipeline with a single gradient of horizontal excavation shall be provided. The elevation of the gradient shall be determined by the minimum burying depth required, referred to the lowest level of the natural bed.

The excavations shall by no means affect the embankments without the previous authorization of the Engineer.

Before starting the Works, the Contractor, in order to comply with the elevations described above, shall prepare near the crossing one or more benchmarks, having elevation referred or referable to that of the natural bed.

For crossings of all wadis a pipe construction according to the project design shall be provided.

The bends of the bent section, unless otherwise indicated in design specification or drawing, shall be of the mill-fabricated bend type.




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When crossings are rather long and require particular laying methods, the Contractor shall submit to the Engineer's approval an organization/ working program.

Backfilling shall be carried out by bringing the bed and the banks back to the conditions existing before starting the Works. Particular care shall be taken for the compaction of the banks, the restoration of the existing protective works or the execution of protection works of masonry, gabions, rip-raps, sand bags or concrete. The type of protection shall be designed in such a way that they form continuous structures connected to each other over a certain distance.

The design shall be subject to the approval of the Engineer.

If gabions should be proposed for the structures the Contractor shall lay a filter-mat (Geotextile) under or on the back-side, where necessary, in order to protect the fine material from being washed out. The construction and filling shall be in strict accordance to the specifications of the manufacturer.

In particular, all residual deposits of material shall be removed. The bed shall be brought to the original condition. Moreover all necessary restorations, especially of temporary excavations, shall be carried out to avoid water stagnation or seepage areas.

The crossing of embankments shall be carried out strictly complying with the approved drawings. No earth moving/drilling on embankments shall be permitted, without first obtaining the authorization of the Engineer.

A separate high pressure test shall be performed for the crossings for which it is expressly required in the design.

16.4 Crossing of Facilities such as Pipelines, Cables and Channels

16.4.1 General

Crossing of buried facilities and above-ground facilities shall be carried out in accordance with this specification and the pertinent drawings. However, the Contractor has to prepare detailed design for each crossing of foreign facilities with regard to pipeline, maintenance road and construction road and has to obtain the individual approval therefore.

In principle, there are the following crossing possibilities:

thrust boring/pipe jacking (tunnelling)

open construction (trench)

overhead construction (bridge)




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berming/embankment

All above-ground facilities such as pipelines shall be under passed. The maintenance road and the construction road shall be led over the foreign line with a minimum cover of 1.20 m.

16.4.2 Crossing of Buried Facilities

As far as possible and if not otherwise ordered by the owner of the foreign facility, all existing buried facilities such as pipelines and cables of any kind, type and size, shall be crossed underneath by the pipeline under construction. At crossings with existing pipelines of bell and spigot design casing pipes shall be installed. The type of crossing --boring or trenching-- shall be determined in such a way that a minimum burying depth equal to that indicated in the design and in the drawings will be guaranteed under consideration of the route characteristics at the crossing point.

This condition shall be provided by maintaining the minimum distance between the external surface of the pipeline under construction and the existing pipes and cables, as provided in the Contract Documents.

When the boring or pipe jacking method is to be used, these methods shall be executed with casing pipes. Boring in normal ground may be executed in two different ways

a) boring or pipe jacking by means of concrete or steel casing, or

b) by a method without material transport through the CM-lined pipes (horizontal drilling). This method requires the express permission of the Engineer.

The mechanical protection of the coating of the pipeline to be laid is to be considered.

In the event steel casing pipes are used, special emphasis has to be assigned to the design of the cathodic protection system. In any case the annular space between casing pipe and product pipe has to be filled by bentonite or special grout. To ensure that there is no void in the grouting material, special mixing equipment and pumps have to be used in order to ensure complete filling of the annular space.

During the period in which the buried facility is uncovered, the Contractor shall install the necessary supports or protections in order to avoid stresses of any kind and nature which may cause damages or breakings in the existing pipe or cable.




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The uncovering of the buried facility, especially of pipelines and electric or telephone cables shall be carried out by hand excavation, unless otherwise indicated by the owner of the foreign line or cable.

16.4.3 Overhead Crossings

The overhead crossings shall be carried out by the Contractor in strict compliance with the design drawings and the requirements of the owner respectively of the Engineer.

Unless otherwise indicated in the design, 100 % of the welded joints shall be checked by radiographic inspection.

The laying of the pipeline and the supports shall be carried out in compliance with the clauses described in the specification. Moreover, the clauses described in the specification shall be strictly complied with for the tie-ins with the upstream and downstream sections of buried pipe.

The pipeline overhead sections shall, in addition to the approved corrosion protection, be coated with adequate durable heat insulation.

During and after construction the foreign line owner shall have free vehicular access to all his facilities. The Contractor has to maintain the access roads at all times.

The construction and maintenance road shall have a maximum slope of 10 % over foreign lines.

16.4.4 Sabkha Crossings

At crossings in Sabkha and in all Sabkha areas where the line is to be laid under the soil surface, the line shall be concrete-coated if safety against uplift cannot be achieved otherwise. Dewatering of the pipe trench is a must to avoid laying of pipes into a trench which contains water.

The concrete coating shall be applied up to that length until the line is a minimum of 0.5 m above the Sabkha surface.

For boring in Sabkha three alternative methods are allowed:

a) Boring by means of concrete casing; the pipe must be heavy enough to prevent uplift.

b) Boring by means of GRP casing, whereby the intermediate space between the casing and the pipe shall be injected. The casing shall have the necessary dimension for injection to avoid up-lift of the pipe.




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c) Boring by a method without material transport through the CM-lined pipe. The pipe must be secured against up-lift.

All crossing alternatives for Sabkha are analogously valid for other soil conditions, considering no concrete coating of the line.

16.5 Masonry Structure Crossing

At the crossing of brick or stone masonry and when no movement due to thermal expansion is expected the pipeline section corresponding to the thickness of the structure crossed shall be completely protected by neoprene bands at least 1/4" thickness or by other protective means giving the same result.

At the crossing of reinforced concrete masonry structures or when movements due to thermal expansion are expected the pipeline shall be passed through casing stubs, the installation shall be made according to the typical drawings for casing installation.

16.6 General Requirements for SEC Power Transmission Line Crossings

At crossings of power transmission lines all relevant requirements for “SEC Activities and Facilities" must be strictly observed.

It belongs to the Contractor's duty to coordinate all related provisions directly with the electricity authority.

Modifications on existing facilities are only allowed with the owners approval, the works can be performed only by approved companies.

THE FOLLOWING GUIDELINES SHALL BE OBSERVED:

a) For overhead transmission lines, Contractor shall satisfy any of the conditions specified in SEC General Guidelines for facilities located in proximity of SEC transmission lines.

b) For underground transmission power cables:

For pipeline crossing on top of SEC power cables, the pipeline must be installed 150 mm above the yellow warning terratape.

For pipeline crossing below the SEC power cables, the pipeline must have a minimum vertical separation of 500 mm.

For pipeline paralleling the SEC power cables, the pipeline must have a minimum horizontal separation of 1000 mm.

c) Work permit requirements




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The work permit requirements of SEC are to be followed. Close coordination with respective department is to be emphasized when working in the vicinity of all overhead and underground transmission lines.

d) Traffic on the route of the pipeline

If the proposed pipeline is passing SEC property, it must pass below grade level and must NOT obstruct traffic inside the SEC site, vehicle access going to site, or vehicle access leaving the site. Also the pipeline must NOT interfere with the site drainage system and its surroundings and must meet SEC requirements. The design of the underground water pipeline should allow for heavy traffic passage over the pipeline areas, of heavy duty vehicles, trailers with earth moving equipment/bulldozers and heavy transformers.

e) Valves

No valves, vents or drains shall be installed in the SEC property.

16.7 General Requirements for STC Telephone and Telecommunication Cable Crossings

For crossings with STC telephone and telecommunication cables all necessary provisions and works concerning the protection of the cables must be performed only by a company approved by STC.

16.8 General Requirements of ARAMCO for Crossings with their Facilities

Non-Saudi Aramco piping crossing pipeline corridors shall pass under the pipelines in a manner such that the minimum vertical distance between the bottom of any Saudi Aramco pipeline and the top of the non-Saudi Aramco piping is 1.0 m. The non-Saudi Aramco piping shall have no servicing points within pipeline corridors.

As a general rule for crossings between Aramco facilities and SWCC pipelines Aramco will prepare their facilities.

It is the responsibility of the Contractor to obtain the detailed requirements from Aramco and follow all related instructions precisely.

All relevant details such as construction time schedule, description of construction works, equipment used during different stages of the work etc. shall be coordinated with Aramco.

The documents to be prepared for each crossing shall contain at least the following information:




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detailed route survey from the crossing point

horizontal and vertical position of Aramco facilities related to the pipe to be installed

elevation of all facilities related to Aramco reference points

crossing method (boring, open construction, bridge construction etc.)

cathodic protection cross bonding

working program and all other relevant information

The design documents shall be approved by the Engineer and by Aramco. Since Aramco will also supervise the work at the crossing point the Contractor must obtain the approval of Aramco prior to commencement of any field activity.

Aramco safety requirements dictate that no work shall be executed in the vicinity of their pipelines without first obtaining a work permit from the appropriate Aramco operation agency. Work permits can be received only by persons certified by Aramco as qualified to receive the permit. Certification procedure includes a short training session and a test, which are administered by Aramco at designated intervals. In the interest of smooth operation, and to avoid delay, it is desirable that the Contractor gets a sufficient number of his work force certified early in time. Arrangements to do this should be made through the Contractor Liaison Division GAO, at least 6-10 weeks in advance of the time anticipated need for work permits.

Detail: ARAMCO Crossing Requirements:

a) The Contractor has to provide Saudi ARAMCO with the detail project drawings of the SWCC pipeline(s), UTM coordinates of the waterline route and proposed crossing with Saudi Aramco facilities. These drawings should be submitted for Saudi Aramco review six months before the start of construction.

b) Saudi Aramco Engineering Standards (SAES) and General Instructions (GI) should be adhered to. These include, but not limited to the following:

SAES-X-400 Requirements for Cathodic Protection of buried pipelines

SAES-L064 Crossing and spacing requirements for pipelines and flowlines.

SAES-L-046 Requirements for Road Crossings

SAES-B-055 Spacing requirements for Saudi Aramco facilities

GI-2.100 Work Permits requirements




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GI-1021.000 Street/Road Closures requirements

GI-434.000 Pipeline repair and maintenance requirements

GI-475.001 Blasting requirements in the vicinity of Company pipelines

Saudi Aramco Construction safety Manual shall be observed during construction.

c) The proposed pipe shall have no servicing points within any of the Aramco pipeline corridors.

d) If not expressly permitted SWCC pipeline route shall not run parallel to any Saudi Aramco pipeline inside Saudi Aramco pipeline corridor.

e) Access to the pipeline corridor for pipeline operation, maintenance and inspection shall be maintained during construction of the proposed pipeline.

f) Heavy equipment and trucks shall cross the pipelines (if required) only through an approved road crossing across the corridor to be designated by Saudi Aramco.

g) Saudi Aramco will not be responsible for any claim associated with any utilization, crossing or proximity use of non Saudi Aramco properties.

h) Excavation must only be done by hands inside the pipeline corridors.

i) Pipe markers shall be installed on either side of the crossing and at 20-meter interval along the corridor.

j) The proposed pipe that will cross Saudi Aramco pipeline corridors shall pass under the pipelines in a manner such that the minimum vertical distance between the bottom of any of Aramco’s pipeline and the top of the non Saudi Aramco pipelines is one (1) meter.

k) If blasting is required within 1500 meters of existing pipelines, then the requirements of GI-457.001 must be followed.

l) Cathodic protection bonding and test stations should be installed between the proposed and existing pipelines.

m) The affected construction area, including fences inside the pipelines corridors shall be cleaned and restored to original conditions.

n) Any new Saudi Aramco pipeline that will be constructed and will cross the new waterlines of SWCC will cross above the SWCC lines.

o) Extreme care shall be taken during construction to avoid any damage to Saudi Aramco pipelines. The Contractor shall be held accountable for any damage to any of Aramco pipeline facilities, including flow interruption impact.




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Moreover, work permits shall be obtained through the pipelines Area Foreman. The Contractor should have a work permit receiver certificate.




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17 CONCRETE COATING OF PIPE

17.1 General

This section outlines the requirements for the coating of line pipe with pneumatically applied or moulded concrete with reinforcement consisting of plastic netting.

All pipe to be concrete coated shall have been previously coated with the specified corrosion protection system. This shall be inspected and tested by the Contractor prior to the concrete coating application and any defects made good, following the procedure detailed in Section 11, coating of joints and repairs.

The Contractor shall furnish the Engineer with calculations and tests to prove that the mix, thickness and submerged density of the concrete coating will meet the negative buoyancy requirements.

Standards which are relevant to the materials and application of the concrete coating are listed below.

BS 12 Specification for Ordinary and Rapid Hardening Portland cement

BS 882 Specification for Aggregates from Natural Sources for Concrete

BS 1881 Testing Concrete

BS 31 48 Method of Test for Water for Making Concrete

BS 4027 Specification for Sulphate-Resisting Portland Cement

ASTM C33 Specification for Concrete Aggregates

ASTM C150 Specification for Portland Cement

QC10-H-147 SWCC Specification for concrete and reinforcement (C07)

The concrete mix shall be designed and tested in accordance with an accepted code of practice, which is in regular use.

Concrete weight coating shall be used for water course crossings (other than crossings which are constructed by auger boring or directional drilling), at sections at which the pipe is laid below ground water table, or wherever the pipeline crosses unstable ground or potentially unstable ground such as seasonal swamps.




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17.2 Responsibility of the Contractor

The responsibility of the Contractor includes among other things

a) The site investigation, including ground and water conditions, water currents, seasonal flooding and any other factors which may give rise to unstable conditions,

b) the determination of the parameters to be derived from a) which are to be used for the design including the factor of safety, and

c) the design of the concrete coating.

17.3 Materials

Cement shall comply with BS 12, BS 4027 or ASTM C150.

Aggregate shall comply generally with BS 882 or ASTM C33. Samples and laboratory analyses shall be submitted for approval of the Engineer before work commences. High-density aggregates shall be used if necessary to achieve the required concrete density.

Sand shall be silica type tested for organic impurities in accordance with ASTM C40. The suitability of the sand for making concrete shall be determined in accordance with ASTM C33. Grading of sand shall be checked twice weekly.

Reinforcement shall consist of suitable plastic netting to be approved by the Engineer. Sand shall be silica type tested for organic impurities in accordance with ASTM C40. The suitability of the sand for making concrete shall be determined in accordance with ASTM C33. Grading of sand shall be checked twice weekly.

The water shall be free from injurious amounts of chlorides, sulphates and magnesium salts. Water shall comply with BS 3148. Water shall be tested prior to commencement of coating operations and thereafter at weekly intervals.

17.4 Equipment

All necessary plant and equipment shall be provided by the Contractor, including

a) High impact equipment which shall be capable of applying the concrete coating and producing a reasonable degree of uniform thickness, density and strength.

b) Moulds and vibratory equipment.




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c) Weigh-batching equipment and approved methods of proportioning the cement, aggregate and water. The scales on weigh-batching and proportioning equipment shall be calibrated at regular intervals.

d) Mixers.

Any equipment, which at any stage of the Works tends to separate the constituents of the concrete, or proves incapable of meeting the requirements shall be removed from the Site and replaced.

17.5 Weather Protection

The Contractor shall provide and use suitable measures for weather protection of materials and operations.

During rain, the Contractor shall adopt measures; to enable personnel to carry out, continue and complete operations once started; to avoid washing off coating, resulting in inconsistent thickness and surface finish; to maintain and store cement in a dry condition; and to store aggregate under cover during inclement weather to maintain a reasonably consistent moisture content. Any aggregate with an increase or decrease in water content that would invalidate the proportioning of the concrete shall not be used.

No concreting shall be applied in an ambient temperature of less than 5° C when the temperature is falling. Newly deposited concrete shall be thoroughly protected and kept at a temperature not less than 2° C for three days, or until it has thoroughly hardened, by the use of tarpaulins or other suitable means agreed with the Engineer. Stored cement, fine aggregate and water shall be maintained at all times at a temperature of not less than 2° C.

Any material which has become injuriously affected shall be removed from the coating yard at once.

17.6 Proportions and Properties of Concrete

The Contractor shall demonstrate to the satisfaction of the Engineer that the concrete batching and mixing arrangements produce a consistent quality of concrete.

The Contractor shall so proportion the cement, aggregate and water as to obtain concrete with the required properties.

The Contractor shall prepare sample cubes and carry out crushing weighing and water absorption tests to establish compressive strengths and densities. All tests shall comply with BS 1881.




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The Contractor shall ensure that the specified required submerged weight is maintained within the allowable tolerance.

17.7 Fixing of the Reinforcement

The reinforcement fabric shall be spaced concentrically around the pipe with concrete or other non-conductive spacers which shall have a flat base of sufficient area not to damage or deform the protective coating.

The reinforcement shall be continued up to within 25 mm of the end faces of the concrete and the depth of concrete cover over the reinforcement shall not be less than 25 mm at any location. The Contractor shall ensure that the cut ends of reinforcement do not penetrate or damage the protective pipe coating nor contact the surface of the pipe.

17.8 Application of the Concrete Coating

The concrete coating shall be applied by the gunite, extrusion or casting methods provided that the proposed method produces a coating with uniform thickness, density and strength. The method adopted shall not damage the anti-corrosion coating by abrasion or impact or cause any reduction to the thickness of the anti-corrosion coating, unless allowance can be made for this where anti-corrosion and weight coating are applied in the same facility.

The nominal thickness will be determined during final design. The thickness of the coating shall be uniform around the pipe, and shall not vary by more than +/- 20 mm along its length.

The concrete shall be placed upon the pipe within 30 minutes of the water being added to the mix. If more than one application is required, the total time for completion of the operation shall not exceed 30 minutes.

Concreting shall not take place if the following conditions prevail:

The temperature of the pipe, anti-corrosion coating, reinforcement or concrete mix exceeds 35° C or is less than 3° C.

The air temperature in the concrete coating application zone is outside the range -5° C to + 30°.

Aggregates and water may be warmed; however, mixing water shall not be heated to more than 60°. At water temperature above 32° C aggregates and water shall be mixed prior to adding cement.




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The concrete mix shall not be applied over reinforcement that is damp, wet or frosty, reinforcement in this condition shall be dried prior to application of concrete.

If it is necessary to defer coating a portion of a pipe such that the previously placed material sets, the termination shall be a square shoulder. Before recommencing concrete coating, the contact surfaces shall be carefully cleaned and wetted to obtain a good bond between the fresh material and that previously placed.

The end 200 mm of each pipe section shall not be coated to enable welding to be carried out. The ends of the concrete coating shall be tapered.

17.9 Curing of Concrete Coating

Immediately after placing, the exposed surface of concrete shall be protected from the effects of sunshine, drying winds, rain or running water, and its temperature maintained above 5° C for 72 hours.

The use of water sprays in the curing process is not permitted if freezing condition exists or is imminent.

The use of curing membranes, polythene or polyethylene sheet wrapping membranes, or proprietary coatings will generally be permitted.

If steam curing is to be used as part of the process, then the Contractor shall demonstrate that the process will have no deleterious effects upon the concrete and on no account shall the pipe wall temperature be allowed to rise to a level that could cause damage to the corrosion coating.

Water curing or curing by evaporation inhibitors may be used with the approval of the Employer.

Curing additives may be added to the concrete if approved by the Employer.

Concrete coated pipes shall not be moved until the curing period is complete.

17.10 Testing and Inspection

Every length of coated pipe shall be non-destructively tested, not less than 3 days after coating, to determine whether any defects are present.

Where the test procedure indicates faulty coating the Contractor shall remove cores from the suspected pipe. If these cores indicate defective concrete coating the Contractor shall remove the coating by a method agreed with the Engineer.




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The coating shall not be replaced without the permission, in writing, of the Engineer.

Areas where coating has not adhered during placement, or has been damaged subsequently, in particular the ends, may be patch repaired by hand where the defective area is not in excess of 0.1 m² in any 1 metre length of coated pipe. Where the damage is more extensive the cylindrical section of pipe coating containing the damage shall be rejected.

Patching shall only be carried out by removing the affected coating down to reinforcement level, taking care not to damage the reinforcement, and making good the cavity using a similar mix to that used in the coating process with the addition of just sufficient water to allow hand application. A bonding agent or additive shall be used, in strict accordance with the manufacturer’s instructions. A similar mix shall be used to fill core holes after inspection of the holes by the Engineer.

Contractor’s proposals for other methods of repair may be considered by the Engineer.

Areas of cracking or crazing of the concrete shall be carefully examined and if considered excessive by the Engineer the affected section of coating shall be rejected.

Surface cracking or crazing in the concrete equal to or exceeding the following limits shall be considered excessive.

a) Cracks to full depth of concrete coating.

b) Cracks or crazing covering an area larger than 0.1 m in any 1.0 m length.

c) Cracks exceeding 0.3 m length.

d) Cracks at closer spacing than 0.1 m.

Where surface cracking or crazing is not excessive, the cracks shall be repaired by cutting away the concrete to the depth of the reinforcement, taking care not to damage the reinforcement, and making good the cavity so formed in a similar manner to that described above for patch repairs.

Honeycombed surfaces not greater than 0.1 m² in any 1.0 m length shall be made good immediately upon removal of the mould and superficial water and air holes shall be filled in.

Where honeycombing occurs in areas greater than 0.1 m² in any 1.0 m length, the affected cylindrical section of coating containing the defective area shall be rejected.




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At rejected sections where the concrete coating is to be replaced the concrete shall be carefully removed. The pipe coating shall be examined for damage and tested by holiday detector. All damaged coating shall be repaired in accordance with the coating specification and retested before subsequent re-coating with concrete.

Strength test of cubes shall be carried out as follows; three cubes shall be prepared in accordance with BS 1881: Part 108. One shall be tested after seven days after casting, the second shall be tested 28 days after casting, and the third is spare. The cubes shall be tested in accordance with BS 1881: Part 116. Where unsatisfactory failures occur, as defined in BS 1881: Part 116, the test shall be repeated using the spare cube.

The density of the cubes prepared for strength testing shall be measured prior to determination of compressive strength. The density of hardened and cured concrete shall be tested in accordance with BS 1881: Part 114 and shall meet the criteria specified in the Contract.

The water absorption test shall be conducted on one cube sample per test. The sample shall be oven dried at 105° C to a constant weight. When constant weight is attained, the sample shall be allowed to cool the room temperature and shall then be weighed (Wa).

The sample shall then be submerged in a tank of fresh water for at least 24 hours. The sample shall then be removed from the tank and the surface water allowed to drain off. The sample shall then be weighed (Wb). The percentage of water absorbed (Wabs) shall be less than 5 % when calculated in accordance with:

Wabs = Wb - Wa x 100 % Wa

Weights Wa and Wb shall be measured to an accuracy of +/- 1 g

Pipes shall be weighed after coating and completion of end cut back. The accuracy of the pipe weigh scales shall be checked at the beginning of each shift and shall be within +/- 1%. The allowable tolerance on the specified weight of each joint is +/- 8 %.

Coated pipes shall be 100 % examined after coating and after curing.

For acceptance, concrete coatings shall be applied uniformly over the pipe. Ridges or other surface deformations may be smoothed by hand if preferred, but in any case corrugations shall not deviate from a 2 m straight edge by more than 20 mm.




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Spalling or fall out detected immediately after guniting or impingement shall be repaired with a mixture of the same proportions, as the original mix within 30 minutes of the original coating being applied.

After coating and curing, pipes shall be examined for defects. Coatings containing spalling, other damage, cracks or voids shall be repaired in accordance with the specification.

Pipes that fail individual tests shall be rejected. Where batch tests fail to meet the specified requirements, the entire batch of pipes covered by the test shall be rejected.

The Contractors shall identify the causes of test failures or excessive defects in finished coatings and propose alterations to the coating procedure to prevent further failures and/or reduce the defect rate.

Frequency of Testing

Test Frequency

Strength test on cubes 1 test per shift

Density 1 test per shift

Water absorption 1 test per shift

Weighing All pipes

Records of all tests cross-referenced to unique pipe serial numbers shall be maintained and submitted to the Employer.




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18 CONCRETE WEIGHTS AND ANCHORS

18.1 General

Concrete weights or anchors may be used wherever the pipeline crosses unstable ground or potentially unstable ground such as seasonal swamps, or areas of seasonal flooding, provided that for any reason it is impracticable to use continuous concrete weight coating specified in Section 17. Concrete weights or anchors shall only be used where agreed during final design.

18.2 Responsibility of the Contractor

Among other requirements the Contractor shall be responsible for:

a) the site investigation, including ground and water conditions, water currents, seasonal flooding and any other factors which may give rise to unstable conditions.

b) the determination of parameters to be derived from a) which are to be used for the design, including the factor of safety, and

c) the design of weights and anchors.

18.3 Concrete Weights

Set-on and bolt-on type concrete weights shall be designed in accordance with an accepted code of practice for reinforced concrete.

Set-on weights shall be designed so that the legs project well below the invert of the pipe, and so that any future ground or water movement does not cause them to become dislodged. Set-on weights shall be provided with adequate lifting hooks.

Bolts for bolt-on weights shall be suitably protected against corrosion.

Concrete weights shall be handled and positioned so as not to cause damage to the pipe or the pipe coating. A suitable cushion shall be used between the pipe coating and the concrete weight (Rock shield or equivalent).

18.4 Anchors

Anchors shall be of an approved proprietary make, galvanized with augered drive rods. Full details and requirements as to their method of installation shall be issued by the contractor and is subject of approval by the engineer.




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A suitable cushion shall be used between the pipe coating and the straps or hooks to which the anchors are attached, so that the anchor arrangement does not bear directly on the pipe coating (Rock shield or equivalent).




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19 SPECIAL INSTALLATIONS

19.1 Installation of Pipe Fittings and Special Components

Prefabrication of pipe fittings and special components shall normally be carried out at field workshop.

Pipe fittings and special components shall be prefabricated so that the fitting or special component is connected to small pipe stubs not less than 2 meters long, before being inserted in the line by means of tie-in welding.

Pipe fittings or special components connected to the pipeline (for example manholes drainage pipes, etc.) shall be pre-fabricated and assembled at field workshop so that the whole assembly can be inserted into or connected to the line by means of a simple tie-in.

Welding for tie-in of pipe fittings and special components shall be made in strict compliance with the procedure described in this specification under chapter 9.4.5.

19.2 Pipeline Cable Installation

In specification S08, Doc. No. QC10-H-128 the cable conduit and its installation is specified. Specification S07, Doc. No. QC10-H-127 specifies the fibre optic cable to be installed in the cable conduit.

The following shall be considered additionally when installing the conduit and FOC along the pipeline. The cable shall be laid throughout the complete pipeline route in a protection conduit. The conduit shall be installed directly in the pipe trench after laying of the pipe and during backfilling. The position of the cable is depicted in the corresponding trench cross section drawings.

The laying of the conduits is to be carried out after pipe laying and prior to backfilling of the pipe trenches. The conduit must be embedded (30 cm) in sand or stone free material. A detectable reinforced marking and warning tape shall be laid in the ground, approx. 30 cm above the conduit.

The installation of the Communication cable in the conduit is to be carried out after backfilling of the pipe trench / clean up works and removal of all heavy pipe laying equipment. Concrete cable markers, including markers for the splicing boxes must be installed after completion of cable laying works.

19.3 Marker Posts for Pipeline cable and ROW

The purpose of pipeline and cable makers is to indicate the exact location of the Pipeline and its associated power and telecommunication cables for the benefit of




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the maintenance crew as well as for the benefit of other agencies carrying out works in its proximity, so as to avoid damages.

Pipeline and cable markers shall be installed along the route of the pipeline; Markers need not be installed within the premises of pumping stations and terminals.

The Contractor shall submit a comprehensive proposal for the pipeline and cable markers, in accordance with theses specifications, which will be subject to the approval of SWCC.

The posts for the markers as well as the marker plates shall be prefabricated in accordance with the approved drawings and specifications. The installation of markers shall be as per approved procedure.

The marker post shall be a 4 inches galvanized steel pipe of length 3.0 meters. The top part of the post shall be flattened for fixing the marker plate, as per approved drawing.

All markers posts shall project from the surrounding ground by sufficient length, in order to safeguard them from being buried in sand.

All markers posts located near inhabited areas, road crossings, railway crossings, or running along the right of way roads shall be painted with black & yellow strips of luminous paint and reflective sheeting for clear visibility.

Markers plates of the pipeline in the town or densely inhabited areas where is not possible to fix marker posts because the pipeline is under road pavement etc. Markers plates shall be fixed on the nearest building or the fence. The distances (X and Y) between the marker plate and the centre of the pipeline should be indicated on the marker plate in m. The indication of the crossing of the pipeline with other facilities as cables and pipes should be mentioned. The contractor should propose the dimension and design of marker plates fixed on the buildings which could be smaller and similar to the pipeline or cable markers for other facilities in the cities.

The main marker plate shall be 1.5 mm thick steel plate of size 564 mm x 150 mm. Holes for fixing bolts shall be punched in the plate as shown on the approved drawing. The plate shall be given a factory applied coat of stove enamel (on both faces) of approved colour. The markings and lettering on the plate shall be in enamel paint, as per approved drawing. The plate shall be fixed to the post, as per approved drawing.

The additional plates (4 nos.) for providing information regarding the system, cathodic protection, and power and TLC cables shall be 1.5 mm thick stainless steel (grade 316) plates of sizes shown on the approved drawings. Relevant information, as approved, shall be engraved for clear visibility; all bolts and nuts for fixing shall be of stainless steel (grade 316).




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The galvanized steel posts shall be fixed in cement concrete (min. characteristic strength 50 N/mm2) foundations of size 400 x 400 x 900 mm (minimum), or as approved by SWCC. Cement used in the concrete shall comply with ASTM C 150 (of the approved type). The concrete foundations shall be protected by a bituminous coating system consisting of:

a) a penetrating bituminous primer applied in one coat.

b) A high build bituminous coating with a content of fibres, applied in minimum three coats. Total dry film thickness of the coating shall not be less than 1.0 mm.

The locations of markers shall be such as not to cause hindrance to normal cultivation of crops or traffic. Particular care shall be taken in setting markers in flat desert areas and in areas of sand dunes where geographic maps do not have fixed reference points.

Generally the markers shall be installed at regular intervals as per the following guidelines:

Spacing – Maximum spacing of the markers shall not exceed 500 meters.

Inter-visibility – From each marker, the markers immediately ahead, and immediately behind shall be clearly visible.

Markers shall be installed close to all pipeline crossings with roads, railways, wadis, electrical lines etc.

A marker shall be installed at the crossing of the pipeline with another pipeline system.

Crossing markers shall indicate SWCC pipeline depth and type and depth of crossed installations (e.g. pipelines, cables, etc.).

A marker shall be installed at the beginning, middle, and end of every bend in the pipeline.

One marker shall be installed at every cable joint.

A marker shall be installed at every cathodic protection station.

A marker shall be installed at the point where the diameter of pipe changes or where the pipe wall thickness changes.

The distance between the marker post and the centre of the pipeline should be indicated on the marker plate.

ROW demarcation markers shall be installed at intervals of 100 meters at each side of the permanent ROW along the complete pipeline route, except




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at the areas where the pipeline is routed within the ROW of the roads (MOT/ Municipality).

Concrete monuments of 20 x 20 cm cross section, sufficiently long enough and with a concrete base shall be used.

19.4 Connections for Cathodic Protection

For connection of the cathodic protection facilities to the pipeline see specification E16, Document No. QC10-H-096.




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20 CIVIL WORKS

20.1 Excavation

Excavations shall be taken out to the depths, widths and profiles indicated on the Drawings or to such other depths and widths as may be required.

Any excavation undertaken in excess of requirements shall be lied in by the Contractor with concrete, hardcore or other suitable backfill.

Excavated material where approved for use as filling shall be laid in layers not exceeding 300 mm thick and each layer rolled and compacted with a 6-10 ton roller or other suitable equipment. Degree of compaction shall be as per approved drawings and documents or as per minimum requirements defined in Project Specifications.

20.2 Hardcore and Chippings

Hardcore shall consist of clean hard stone, hard bricks or other suitable material, clean and well graded to pass through a 100 mm ring. The hardcore shall be spread, levelled and compacted by rolling with a 6-10 ton roller.

Chippings shall be of approved stone to pass through a 12-25 mm ring.

20.3 Concrete

Concrete shall be mixed and built in accordance with the Concrete Specification C07, Document No. QC10-H-147.

All concrete shall be compacted by means of power vibrators expelling all air from the mix. Particular care shall be taken at edges and corners.

Any cement, which has become contaminated or has deteriorated, shall not be used in the Works. Aggregate shall be derived from a suitable source.

All sampling and testing of concrete shall be carried out in accordance with Specification C07.

20.4 Steel Reinforcement

Steel and steel mesh reinforcement shall comply with Specification C07 similarly with recognized codes and standards.

The steel shall be free from oil, dirt, paint, loose rust, mill scale or other deleterious matter immediately before placing the concrete. No weld shall be




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allowed in any reinforcement. The reinforcement shall be fixed in position to avoid displacement before and during concreting. All intersections of reinforcement shall be securely tied by appropriate tie wire or other suitable method before concreting is commenced. All reinforcement shall be maintained accurately in position during and after concreting.

20.5 Form Work

Formwork shall comply with Specification C07. In general all formwork and supports shall be of such dimensions and strength fixed in a manner that will ensure that they remain rigid during the placing, compaction and setting of the concrete. All joints on formwork shall be close fitting so that there will be no leakage of cement grout through the joints. Formwork shall be of such material as to ensure a true surface on the finished concrete.

The surface of formwork against which the concrete is to be deposited shall be coated with a suitable preparation to prevent absorption and adhesion of the concrete. Care shall be taken to ensure that the steel reinforcement is kept free from this coating.

Immediately before concreting, all formwork shall be carefully examined to ensure that all dirt, shavings and refuse have been cleaned out.

20.6 Concrete Kerbs and Edgings

If not otherwise specified by owners or authorities kerbs and edgings shall be set on approx. 300 mm x 150 mm concrete (grade D) foundation and haunched with 150mm x 150 mm of similar concrete. Kerbs shall be laid to give a 100 mm finished upstand above finished carriageway level.

20.7 Cable ducts and tiles

Cable ducts shall be supplied in sizes not less than 100 mm and in accordance with a standard acceptable to the Employer.

They shall be laid with a draw wire of sufficient strength to pull the specified cable through the duct.

Cable tiles shall be manufactured from either precast concrete or fired clay.




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20.8 Requirements for Sheet Piling

Steel from which permanent sheet piles are rolled shall comply with a recognized standard and shall be straight, true to section and free from seams, flaws, cracks, laminations and other injurious defects.

Before being driven, permanent steel sheet piles shall be wire-brushed to remove loose rust and dirt, and be coated with a suitable paint. If piles will be in contact with water subsequently to be used for a potable supply this shall be taken into account in selecting paint.

Pile surfaces which are to be embedded in concrete shall be left uncoated.

Piles shall be driven true to the lines and levels specified. Piles, which deviate, excessively from line shall be extracted, replaced, and re-driven.

Taper piles shall not be introduced in order to correct piles, which have developed a lean, unless approval of the Engineer has been obtained.

Piles which reach refusal before achieving the designed penetration shall not be cut off without the approval of the Engineer. A record shall be kept of piles, which are cut and the length cut off.

All holes in the piling for tie rods and anchor bolts shall be made at Site after the piling has been driven to the final levels.

After the piles, which form part of the permanent works, have been finally driven, the heads shall be trimmed to the levels specified and shall have a neat appearance.

20.9 Foundation Piles

Foundation piles shall be used according to design, or at request of the Engineer, for piping support structure foundations in crossings or overhead sections. They shall be of iron or concrete, with a diameter and in number resulting from final design to be performed by the Contractor. Piles shall be securely driven as deep as possible by means of a pile driver.

20.10 Roads

Generally four (4) types of roads are to be constructed:

Pipeline Maintenance Road

Access Road to all valve, drain and vent stations and to all feed-in stations for cathodic protection




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Construction Road

Paved Service Road (if defined in specification G02)

20.11 Pipeline Maintenance Road

A permanent maintenance road shall be provided along the pipeline, at all sections, where no public road is parallel running in the vicinity of the pipeline. The length and location of the maintenance road is shown on the route maps. The maintenance road shall be at least 3.50 m wide with compacted subbase and shall allow the transit of motor vehicles (30 metric tons) according to DIN 1072.

The maintenance road shall be constructed during the restoration phase using suitable material, properly levelled and compacted. The road surface shall be stabilized by means of an asphalt oil film. The standards of road construction of MOT are to be followed.

The thickness of the road structure shall be 25 cm at the minimum. The material to be used shall be a well graded sand-gravel mixture with the following properties:

Sand content 0 - 2 mm 20 %

Gravel content > 2 mm 35 - 80 %

Silt content max. 11 %

Maximum grain size 70 mm

compacted to 95 % proctor density.

Based on the different characteristics of the areas to be crossed, the maintenance road shall be as follows:

The maintenance road will have the general characteristics indicated above and will be constructed maintaining the same slopes and levels used for the ROW. Wherever required suitable drainage channels, culverts and/or bridges have to be constructed.

At major crossings the maintenance road will be interrupted.

The maintenance road shall be constructed according to approved drawings (route maps and typical drawings).




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20.12 Access Roads

Access Roads shall be constructed from the parallel leading road or highway to all valve, drain and vent stations and to all feed-in stations for cathodic protection, if no maintenance road is foreseen.

Connection to 2-lane roads shall be performed in such a way that access is possible from both lanes. Connection to highway shall allow access in one direction from and to one roadway. Branch-off and approach spurs are to be constructed by the Contractor.

The Contractor is obliged to obtain all necessary agreements and permits from the competent authority prior to starting of work. The Contractor has to prepare adequate construction drawings, which are subject to approval by the Owner and the Engineer.

Access roads to the valve, drain, vent and all feed-in stations for cathodic protection shall have a width of min. 3.50 m and shall be constructed according to the requirements of the maintenance road.

20.13 Paved Service Road

The Paved Service Road is a permanent access road to major stations. It is an asphalted road along the pipeline with a minimum width of 7.0 m and 1.0 m hard core shoulders at each side. Wherever required suitable drainage channels, culverts and/or bridges have to be constructed.

Specification C04 and MOT standards shall be followed.

The road cross section consists of the following layers:

Wearing course (thickness 40 mm)

Tack coating (0,3 kg/m²)

Bituminous base course (thickness 100 mm, 250 kg/m²)

Prime coating (0,3 kg/m²)

Subbase (min. thickness 350 mm, Ev2 > 120 MN/m²)

Subgrade (Ev2 > 45 MN/m²)

A complete detailed design according to MOT standards shall be submitted to SWCC/Engineer for approval prior to start of construction.




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20.14 Construction Road

The construction road is a temporary road along the pipeline used for pipeline construction and transport during the entire construction period.

If not otherwise specified, after construction this road shall be upgraded to a permanent maintenance road as described above. In this case the thickness of the subbase and used materials shall be as specified for the maintenance road. Otherwise, any suitable hardcore material or surface stabilization shall be used.

The minimum width of the construction road shall comply with Contractors requirements for construction.




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21 REINSTATEMENT, CLEAN UP AND STABILISATION

21.1 General Reinstatement and Clean up

As soon as practicable after completion of backfilling the Contractor shall permanently reinstate all areas disturbed as a result of the Works, including surfaces, walls, fences and land drains, to a condition at least equal to that existing before the commencement of the Works, and shall provide all materials required. All such reinstatement shall be to the reasonable satisfaction of the authorities, owners and occupiers concerned.

The Contractor shall be responsible for maintaining the reinstatement, and making good any sinkage, scouring, erosion or other defects until the expiry of the Warranty Period.

The Contractor shall remove all surplus excavated material (other than topsoil), waste and unwanted material and shall leave the ROW and any additional lands used by him in a tidy condition upon completion of the works.

21.2 Reinstatement of Cultivated Land and Grassland

The Contractor shall only carry out reinstatement of cultivated or grassed areas when weather and ground conditions are suitable.

Topsoil which has been previously stripped and stacked shall be replaced over the stripped areas.

The subsoil shall be broken down to a depth of 350 mm by tined cultivators, broken down to a loose and friable condition and levelled before the final top treatment is undertaken. Stones in excess of 100 mm diameter shall be removed from the site.

The Contractor shall leave the land ready for replanting and shall provide all topsoil required returning the depth of topsoil over the Working Width to its original full depth. The Contractor shall provide turf or seed as appropriate and approved by the landowner/Engineer. All inert surplus and waste materials from the Works shall be removed to a location approved by the Employer.

After the completion of the work described in the foregoing provisions, the Contractor shall, at his own cost, maintain the surface of the trench and make good all shrinkages and defects for the Contract’s Warranty Period from the completion of such reinstatement.




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21.3 Reinstatement of Roads

The Contractor shall temporarily reinstate road surfaces through which the trench has been cut as soon as possible after backfilling the trench at the crossing.

Temporary reinstatement shall be maintained until such time as permanent reinstatement has been completed. Both temporary and permanent reinstatement shall be to the standard and specification required by the relevant authority for the type of road, which has been excavated. The Contractor shall provide all hardcore, tarmac, asphalt and other materials required for reinstatement.

All access routes shall be reinstated to a condition at least equal to that existing before the Works. See Section 4, Clause 4.11.

21.4 Reinstatement of Waterways

The Contractor shall carry out the permanent reinstatement of all waterways, which have been crossed by the pipeline in accordance with the requirements of the waterway authority concerned.

The bed of the watercourse shall be restored to its original level, and the banks and any launching and work area excavations shall be restored to their original levels and contours. The banks shall be stabilized, where necessary with earth filled sacks, rocks, gabions or riprap in compliance to good engineering practice.

21.5 Renewal of Fences, Walls, Banks and Ditches

All fences, walls, banks and ditches within the ROW shall be reinstated to their original standard, and any damage in other areas shall be made good. Where necessary to reinstate banks and ditches the Contractor shall layer the area with earth filled sacks or gabions.

After the completion of the work described in the foregoing provisions, the Contractor shall, at his own cost, maintain the surface of the trench and make good all shrinkages and defects for the Contract’s Warranty Period from the completion of such reinstatement.

21.6 Irrigated Land

Where the pipeline runs through permanently irrigated cultivated land, the backfill shall be thoroughly compacted and the surface finished so as to permit normal irrigation to continue as soon as possible after installation.




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21.7 Stabilizing of Embankments with Stones

Dry-stone revetments for stabilizing of embankments and protection of wadi banks and beds are to be placed with suitable equipment and properly arranged in a workman-like bond.

The stones must have a minimum weight of 0.5 tons (approx. 0.2 m3) and must be puddled with suitable material.

If smaller size stones are used they shall be installed in form of gabions.

l01 pipe line construction rev5a

Documents

general update poelzer

general requirements

general update poelzer

general excavation

pipeline bends

pipeline route

approval poelzer neumann

draft tender poelzer