l01 pipeline constructuion

8/18/2019 L01 Pipeline Constructuion

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ENGINEER’S STAMP: CONTRACTOR’S STAMP:

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 CORPORATIONKINGDOM OF SAUDI ARABIA

SWCC WATER TRANSMISSION SYSTEMS

ILF CONSULTING ENGINEERS

LOCATION: TITLE:

Specification L01PIPELINE CONSTRUCTION

SCALE: DOCUMENT No.: REV:

Q C 1 0 - H - 0 2 1 2

SUBCONTRACTOR:

Sheet 1 of 130


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Subject:SPECIFICATION L01

Pipeline Construction Page 2 of 130

Doc. - No.: Q C 1 0 - H - 0 2 1 Rev. 2

Q:\prI2\I261_EASTERN_PROVINCE_PHASE2\Reports\TENDER DOCUMENTS\Voilume V\L01_Pipeline Construction-Rev2.doc

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

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

5.9 Protective Measures 22


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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 31

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 Field Bends 34

9 FIELD WELDING AND QUALIFICATION OF WELDING PROCEDURES AND WELDERS 35

9.1 Scope 35

9.2 Codes and Standards 35

9.3 General 36

9.4

Technical Requirements 37

9.5 Inspection, Testing and Certification 49

10 NON-DESTRUCTIVE TESTING (NDT) 50

10.1 Scope 50

10.2 Codes, Standards, Abbreviations 50

10.3 NDT Procedures and Qualification 51

10.4 Qualification of NDT Personnel 51

10.5 Extent of NDT 52

10.6

NDT Techniques Requirements and Acceptance Criteria 56

10.7 Safety 61


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11 COATING OF JOINTS AND REPAIRS 62

11.1 Joint Coating Properties 62

11.2 Coating Application 64

11.3 Inspection and Testing 67

11.4 Repair Procedure 71

11.5 Piping at Line Valve, Vent and Drain Stations 71

12 LINING OF JOINTS AND REPAIRS 72

12.1 General 72

12.2

Lining of Joints 72

12.3 Repair of Defects 72

12.4 Method Statement 73

12.5 Inspection of Internal Lining 73

12.6 Surface Condition 74

12.7 Lining with Fusion Bonded Epoxy (FBE) 74

13 PIPE LAYING 75

13.1 Pipe Trench Preparation 75

13.2

Pipe Internal Cleaning 75

13.3 Pipe laying in the trench 76

13.4 Overhead Sections 77

13.5 Pipe Installation in Casing 79

13.6 Pipe Laying in "Sabkhat" Sections 80

14 PADDING AND BACKFILLING 82

14.1 Padding of Pipes 82

14.2 Backfilling of Pipeline Trench 83

14.3 Duration between Welding and Backfilling Works 85

15

HYDROSTATIC TESTING 87

15.1 General 87

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 90

15.6 General Set-up of Pipeline Test Sections 91

15.7 Calibration 92

15.8

Filling 92

15.9 Performance of Hydrostatic Testing 93


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15.10 Evaluation of Results and Final Report 95

15.11 De-watering after Hydro test 96

15.12 Safety 96

16 CROSSINGS 98

16.1 General 98

16.2 Railway and Road Crossings 98

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

16.4 Crossing of Facilities such as Pipelines, Cables and Channels 101

16.5

Masonry Structure Crossing 104

16.6 General Requirements for SEC Power Transmission Line Crossings 104

16.7 General Requirements for STC Telephone and Telecommunication Cable Crossings 105

16.8 General Requirements of ARAMCO for Crossings with their Facilities 105

17 CONCRETE COATING OF PIPE 109

17.1 General 109

17.2 Responsibility of the Contractor 110

17.3 Materials 110

17.4

Equipment 110

17.5 Weather Protection 111

17.6 Proportions and Properties of Concrete 111

17.7 Fixing of the Reinforcement 112

17.8 Application of the Concrete Coating 112

17.9 Curing of Concrete Coating 113

17.10 Testing and Inspection 113

18 CONCRETE WEIGHTS AND ANCHORS 117

18.1 General 117

18.2

Responsibility of the Contractor 117

18.3 Concrete Weights 117

18.4 Anchors 117

19 SPECIAL INSTALLATIONS 119

19.1 Installation of Pipe Fittings and Special Components 119

19.2 Pipeline Cable Installation 119

19.3 Marker Posts for Pipeline cable and ROW 120

19.4 Connections for Cathodic Protection 122

20

CIVIL WORKS 123

20.1 Excavation 123


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20.2 Hardcore and Chippings 123

20.3 Concrete 123

20.4 Steel Reinforcement 123

20.5 Form Work 124

20.6 Concrete Kerbs and Edgings 124

20.7 Cable ducts and tiles 124

20.8 Requirements for Sheet Piling 125

20.9 Foundation Piles 125

20.10

Pipeline Maintenance Road 125

20.11 Access Roads 126

21 REINSTATEMENT, CLEAN UP AND STABILISATION 128

21.1 General Reinstatement and Clean up 128

21.2 Reinstatement of Cultivated Land and Grassland 128

21.3 Reinstatement of Roads 129

21.4 Reinstatement of Waterways 129

21.5 Renewal of Fences, Walls, Banks and Ditches 129

21.6

Irrigated Land 129

21.7 Stabilizing of Embankments with Stones 130


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1 SCOPE AND GENERAL REQUIREMENTS

1.1 Scope

This Document – Specification for Pipeline Construction – defines the technicalrequirements for the construction of water transmission pipelines made of steelpipes.

This specification is valid for the works related to the mainline only. For allstations related to the pipeline system such as pumping stations, receiving

stations, line valve, vent and drain stations, etc. separate specifications areapplicable.

1.2 General Requirements

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

b) The Construction Contractor bears the sole responsibility for the correctnessof the work and full compliance to the technical requirements defined in thisspecification.

c) The Employer and the Engineer have the right to inspect the work of theContractor 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 tothe pipeline. Such inspection does not relieve the Contractor from hisresponsibility under the contract.

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

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

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

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


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

i) Sites shall be equipped with appropriate alarm devices and other emergencyequipment in order that suitable immediate action can be taken in case of anaccident.

j) The degree of maintenance and the reliability of the emergency equipmentprovided, 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 allapparatus of other operators located within or crossing the ROW shall beobtained. Safety precautions shall be taken whenever necessary.

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

1.3 Conflicting Requirements, Exceptions

The Contractor shall notify the Employer of any conflict between thisSpecification, the Codes and Standards and any other Specifications included aspart of the Tender Documents.

Any exceptions to this Specification and referenced documentation shall beraised 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 ProjectManagement and Construction Supervision of the Project(s).

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

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

“Final Design” shall mean the design to be performed by the Contractor inaccordance 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 anintegral part of the tender documents.

The Contractor, based on the principle route as depicted in the tenderdocuments, shall survey and stake out the final route of the pipeline and preparerelevant drawings.

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

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

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

2.2 Survey Works

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

It is the Contactor’s obligation to integrate the new project survey data with thenational geodetic network through the military survey department. National gridshall 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 underconsideration of the up to date survey methods of highest standard, because the

construction of a large diameter water pipeline with internal cement mortar liningis not comparable with normal pipeline construction practice.

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

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


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

The approved alignment sheets and detail crossing drawings shall be on theconstruction site in time, 14 days prior to commencement of work at relevantsection, in order to be able to judge their correctness in view of localrequirements.

2.3 Survey Work Specifications

The survey works pertaining to the pre-construction survey and the as builtsurvey 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 ispossible and practicable in order to cause the minimum of disruption andinconvenience to Landowners, Farmers, Local Authorities and the General Publicand to enable the Engineer to exercise effective supervision of the works.

The requirements as to the permissible distance between front and backoperations of a spread and the amount of open trench that will be permittedstrongly depend on the project area and soil conditions.

The requirements and limitations will be discussed prior to commencement of theworks and mutual agreement shall be reached under consideration of theflexibility 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 writtenconsent of the Engineer. In the event of the length being exceeded without writtenapproval, the Contractor shall cease work on the front of the spread andaccelerate 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 theauthorities and the owners of pipelines and any other installations which will beconcerned during the construction of the Pipeline System, before entering theROW. In principle, the permanent Right-of-Way Contracts with the landownerswill be settled by the Employer.

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

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

Marker posts of ROW-line should be erected in concrete monuments accessibleand 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, roadcrossings and cable crossings, etc. where the exact level of the pipeline to be laidis of great importance, the Contractor shall install fixed bench marks with definedaltitude. These bench marks will be used for checking the level of the pipelinebefore backfilling.

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

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

The provision of the right-of-way, way leaves and other facilities implies noobligations 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 bythe Employer, such as but not limited to any additional access routes and workingareas which the Contractor may subsequently require.

The Contractor shall be responsible throughout the contract duration formaintaining the right-of-way and other land and for their reinstatement, whetheror 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 hardwoodpegs or hardwood or metal stakes of sufficient height and at spacing, whichensures visibility. Pegs or stakes shall be firmly driven into the ground at the outerlimits of the working width, at all crossings, changes of direction, above-groundstructures and at such other places as are necessary.

The Contractor shall peg the pipeline route in accordance with the surveyspecification.

Construction limits for special sections, including but not limited to, extra workingwidth at crossings, steep gradients, parallel pipelines, overhead and buriedutilities 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 trenchis excavated.

4.3 Location and Protection of existing Services

Without prejudice, the Employer shall provide the Contractor with a list ofstatutory authorities, companies, agencies or other known organisations who mayown and/or be responsible for the operation and maintenance of the servicesand/or equipment that cross or are within close proximity to the pipeline ROW. Inconjunction with the Employer, the Contractor shall contact and coordinate withall relevant owners and/or operators prior to locating and identifying the existingservices 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 excavatormats or geo-textile membrane or any other suitable means of protection acrossthe service. The service shall have a fenced barrier erected to each side of theplant crossing location.

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

The Contractor shall locate the precise position of all existing undergroundservices and apparatus utilizing the latest underground detection equipment and


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confirm the location by means of trial holes which shall be hand dug well ahead ofany work which could cause damage. Services located shall be clearly indicatedby warning signs, which shall be maintained throughout the construction periodindicating the type, size and depth. The location shall be recorded on crossingdrawings (plans and sections) to be prepared by the Contractor.

Without prejudice to this obligation, the Engineer and the Employer may issue theContractor with drawings showing locations of existing underground services.Such information shall be for guidance only and no guarantee is offered orimplied as to its completeness or accuracy. The Contractor shall prepare

drawings showing his proposals for the support and protection of existingunderground services during construction for approval by the Engineer andrelevant authority.

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

The Contractor shall be responsible for, and shall bear the cost of, any damagecaused to existing service, apparatus, overhead lines or structures when locatingtheir 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 theEngineer and the Contractor shall agree which trees are not to be removed. TheContractor shall suitably mark such trees. The Contractor shall ensure that nodamage 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 theproperty of the Employer, who shall be responsible for its disposal in timelymanner so that the Contractor’s progress is not delayed.

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

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

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


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

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

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

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

4.5 Temporary Fencing and Gates

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

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

The Contractor shall install gates to all enclosures where necessary. These gatesshall be kept closed at all times, except during the passage of Contractor’sEquipment and for other reasons necessary for the Works. He shall preventlivestock 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 trackcrossings and temporary fencing shall also be provided as necessary at the

boundaries of public roads and tracks wherever they intersect and cross theROW.

The Contractor shall ensure that an adequate supply of drinking water ismaintained wherever temporary fencing prevents livestock from having access towater.

4.6 Right-of-Way Clearing

Prior to any clearing operations, the Contractor shall be fully conversant with allconditions and provisions detailed in the Contract and the agreements with landowners. The Contractor shall comply fully with all such provisions and avoid


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damage to property, other pipelines and utility services on or adjacent to theROW.

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

The Contractor shall clear the full width of the right-of-way (except trees identifiedin 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 ofwater across the right-of-way.

The Contractor shall install temporary culverts in all drainage ditches andwatercourses, which would otherwise be obstructed during constructionoperations.

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 withSection 5 of this Specification.

4.8 Surface Stripping

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

The Contractor may apply for modification to these requirements in rocky groundand semi-desert terrain taking into consideration the local conditions and theneed to satisfactorily reinstate the pipeline route. Stripped topsoil shall be stackedon one side of the right-of-way and kept free from the passage of vehicles andplant. Topsoil and subsoil stacks shall be placed to ensure that they are freedraining. Gaps shall be left in the topsoil stack to permit reasonable accessacross the right-of-way and at low areas where surface water may be heldagainst 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 otherstripped or excavated materials.


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4.9 Grading

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

The graded width of the ROW shall be in accordance with the Contract Drawingsfor the ROW. The Contractor shall select which side of the pipeline is to be theworking side for the construction of each pipeline section subject to siteconditions and third parties. Any existing ROW shall not be used without priorapproval from the relevant authority.

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

The Contractor shall maintain and preserve all survey control points alreadystaked, such as benchmarks and intersection points, until construction operations

are completed. The Contractor shall reinstate missing benchmarks; to allowaccurate 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 awayfrom 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 writtenpermission from the owner or appropriate authority and shall make due allowancefor restrictions placed by authorities on movement of vehicles on such accesses.

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

The Contractor shall maintain such accesses in a usable condition and shall oncompletion of construction, reinstate the accesses to a condition at least equal tothat 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 ofaccess roads. The Contractor shall grade the ROW and construct access roadsto allow the safe movement of loaded trucks and equipment without causingundue wear and tear to the graded surface. Where necessary, the Contractorshall form cuts through hilly terrain to allow vehicle access.

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

Contractor shall construct all temporary accesses such as ramps, temporarybridges, etc., to enable plant, equipment and personnel to cross obstructionssafely and efficiently. The temporary accesses shall permit continuous use ofvehicles and construction traffic and shall preserve banks and structure ofcrossings. Existing crossings shall not be filled or otherwise obstructed withoutapproval of the Employer or Authority having effective control or ownership of thecrossing. Prior to commencement of the work, the Contractor shall provide theEmployer with the originals of the respective approval notices. The Contractorshall maintain such accesses in a usable condition and shall upon completion ofconstruction activities, reinstate such access to a condition equal or better to that

existing before the commencement of the work.


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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 closeproximity to highways or runs parallel to SWCC existing pipelines, other pipelinesor underground facilities within the same right of way or close to it, blasting is notpermitted. 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 preferenceto blasting.

Any landowners or tenants who may be affected shall be notified far enough inadvance so that adequate steps can be taken to protect livestock or otherproperty.

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

Extreme care shall 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 explosivesrequired. In addition to shot holes being fully stemmed, blasting mats or othereffective means shall be used if necessary to prevent rock being scattered overthe right of way and adjacent property.

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

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

The Contractor shall use only authorized and suitably certified personnel orsubcontractors.

5.2 Legal Requirements

The acquisition and storage of explosives and detonators and all blasting workundertaken shall be in accordance with statutory regulations. The Contractor shallat this own expense, obtain any permits required and shall comply with theprovisions of such permits.


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5.3 Procedure

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

The Contractor shall comply with all good blasting practice and shall submit to theEmployer and the Engineer his detailed procedures for approval prior to anyblasting taking place. Any proposed revision on procedure arising during blastingshall 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 thecontractor in writing. Only workmen thoroughly experienced in handlingexplosives shall be permitted to supervise, handle, haul, load and fireexplosives.

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

(3) Before shot firing commences the shot firer shall give clear and adequatewarning to all persons within, near or approaching the danger zone. Inaddition, 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 indicatingclearly 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, onthe perimeter of the danger zone.

(6) On completion of blasting the shot firer shall examine the area for misfiresand 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 andinstruct 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 shotfiring cable from the exploder and not before 5 minutes have elapsed fromthe last attempt to fire the shot.

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

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

(5) In the event of a further miss-fire, the shot firer shall take steps to ensurethat 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 unexplodedcharges after the clearance of the miss-fires.

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

5.5 Programme

The contractor shall submit his blasting programme to the Engineer at least 5days 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 electricdetonator using a system, such as Magnadet, that minimizes current leakage.Detonating cord shall not be used outside holes and any used within drill holesshall be kept to the absolute minimum that is necessary for safety. Goodstemming 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 thelocations of blasting, the charges used, the timing of the blasting operations, andany other specified information such as may required by the Engineer or asspecified in the procedure.

5.8 No Blasting Outside Daylight Hours

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

5.9 Protective Measures

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

The Contractor shall give adequate notice to all members of the public, residentowners, tenants, nearby residents and local authorities and any landowners ortenants who may be affected in order that adequate steps can be taken to protectlivestock 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 necessaryprecautions 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 aspreader bar and wide strong textile or leather belt slings, to avoid damage of thecoating and lining of pipes. Vacuum lifts of appropriate capacity may also be usedfor pipe handling. Chains, metal hooks, etc. shall not be used to lift the coatedand/or lined pipes.

During the loading/unloading operations, pipes and bends shall be handledaccording to modalities and suitably to avoid dents, cuts, cracks and otherdamages especially at beveled ends. If the pipes are damaged during handling inthe yard, the damages shall be marked and damaged pipes shall be storedseparately 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 becarried out in a manner at all times that will prevent damage to the cement mortarlining, to the external coating, and distortion of the pipe.

Pipe handling, shall be carried out by experienced personnel under thesupervision of the yard foreman. Pipes shall be lifted using a crane of suitablecapacity with a lifting beam attached to textile or leather belt slings. The slingsshall 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 suitablebearing supports (sand berms) in the storage area. Bearing supports shall be freeform any objects, which may damage the pipe external coating or damage thesteel pipe end. The bearing supports shall be covered with PE sheets of suitablethickness.

The bearing supports shall provide a minimum ground clearance and be spacedapproximately 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 bestacked 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 beinserted to avoid ovality.

Particular care is required for handling of FBE coated or liquid epoxy coatedpipes to avoid coating damage. Epoxy coated pipes shall not be stacked in morethan 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 andnecessary precautions to be taken for transportation, handling and stringing ofthe line pipes after their coating and CM lining are completed. The requirementsstart from taking over of the pipes from the CM lining yard after they are ready fortransportation, describes the transportation methods and measures up to the sitewhere they are to be strung along the right of way. This section also enumeratesthe 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, asdetailed 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 bestrictly observed.

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

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

For this purpose the pipes must be fitted with end caps of sufficient strength towithstand 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 equalstrength. 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 pipeitself during transport.

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

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, toavoid damage of the coating and lining of pipes. Vacuum lifts of appropriatecapacity may also be used for pipe handling. Chains, metal hooks, etc. shall notbe used to lift the coated and lined pipes.

During the loading/unloading operations, pipes and bends shall be handledaccording to modalities and suitably to avoid dents, cuts, cracks and otherdamages especially at beveled ends. If the pipes are damaged duringtransportation, the damages shall be marked upon delivery and stored separatelyfrom 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 ensurethe integrity of the coating and the canvas covers at the end of the pipes as wellas the curing water contained inside the pipes. If any damage or leaks on the endcovers are observed, they shall be immediately repaired/replaced upon delivery.If the water quantities inside the pipes are not sufficient, they shall be increasedbefore transportation.

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

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

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

Loading arrangements of different size pipes shall be worked out by theContractor and provided for approval by the Engineer. In case two (2) layers ofCM lined pipes will be transported by trucks, proper saddles supported by goalposts 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 notbe 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 tointerrupt the transportation activity.

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

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

The transportation vehicles shall not be over loaded.

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

At delivery to site, the pipes shall be inspected and delivery records shall befilled-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 shallbe completed. Stringing shall be done after trench excavation. Pipes may bestrung directly form the truck into the pipeline trench or be strung along theworking strip.

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

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

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

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

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


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The lengths of the pipes shall be adequately spaced in order to facilitatesubsequent handling. Pipes shall be laid on bags filled with sand and inappropriate position to avoid the impact of vehicles in transit or the danger ofbeing 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 avoidany 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 bemonitored daily by a special team of workers designated for this purpose.

Defective pipe end caps shall be immediately replaced. Reduced water inindividual pipes is likewise to be restored immediately to suitable levels. Theprogress of the stringing interval may precede the welding interval by 5 days atthe most.

The end caps may be removed from the ends of the pipe only just beforebeveling and welding of the pipe is undertaken. In case of longer constructionbreaks, 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, deterioratingor suffering from damages, especially from humidity, exposure to hightemperature or other adverse weather conditions shall be suitably stored andprotected. 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 anydamage, alteration and dispersion. When supplied in containers and envelopes,they shall not be dropped or thrown, or removed by hooks which might damagethe material during the unloading and during the following handling operations tilltheir use.

Wood or glass felt or tape for outer protective coating and cement mortar mixtureshall be permanently stored, hoisted from the ground in a dry and weatherprotected location and transported to the point of utilization only at the momentand 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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7 TRENCHING

7.1 General Excavation

The pipe trench shall be carefully excavated and the trench bottom graded sothat the pipeline is evenly supported throughout its length. The trench bottomcontour shall be such as to obtain a smooth profile for the pipeline and tominimize 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 specifiedminimum radius of pipe bend. A clearance shall be maintained between the bendand the trench walls to conform to the trench dimension requirements set out onthe Drawings.

In cases where excavation by the use of mechanical excavation equipment isunsuitable or hazardous in the existing ground conditions, or may cause damageto other property or existing facilities, the Engineer may require the pipe trench tobe 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 thanthat shown in the alignment sheets or required for obtaining a smooth profile, theContractor shall re-fill the trench to such a depth and with such materials anddegree 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. Thetrench width shall be at least 600 mm greater than the outside diameter of coatedpipe. At points where work on the installed pipe is to be performed, such aswelding, coating, etc. sufficient extra excavation shall be made so that the workcan be performed satisfactorily around the pipe in the trench.

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


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7.3 Extra Depth

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

Where there is extra depth all additional safety precautions shall be taken toensure adequate access and egress and the trench shall be supported with closesupports 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 toavoid the risk of problems and additional work caused by earth slips and falls inrainy weather, the Contractor shall plan his construction program and excavatingoperations so that the trench remains open for as short a period as practicable.

7.5 Earth Spoil Bank

The bank of earth spoil produced by pipe trench excavation shall not becontaminated by organic and other foreign materials that would produce anunsatisfactory backfill. The Contractor shall make gaps in the spoil bank so thatrainfall 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 (otherthan concreted or paved surfaces of roadways) which in the opinion of theEngineer cannot be removed by heavy mechanical excavators, rippers or manualmeans and therefore requires the use of pneumatic drills or rock breakers, rockcutting machines or blasting.

The trench depth in rock shall be such that the cover is not less than depicted inthe 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 afurther 300 mm across the full width, so as to accommodate the necessary


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thickness of soft bedding material. The trench shall be of sufficient depth toaccommodate the soft bedding, pipe and specified cover.

Blasting in connection with trenching operations shall be in accordance withSection 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 beprovided 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 remainstable for the period of time between trenching operations and lying of the pipe,the Contractor shall provide trench support units, piling or timbering and supportsto 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 inrunning sand and in areas of high water table, also details of the grounddewatering equipment to be used. Inlet filters shall be fitted and used on allpumps used for dewatering.

7.10 Disposal of Water

Water shall not be pumped onto the right-of-way or adjacent land, but shall bedisposed of 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 theWorks shall as far as possible be avoided, but if so caused, shall be cleared outby the Contractor.

7.11 Existing Services

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


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

The trench shall be excavated so that the clearance between a buried pipelineand any other underground service or structure is not less than specified in therelevant 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 bythe 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 orother materials which could damage the pipe coating, shall be selected from theexcavated material other than top soil, and sieved if necessary for use as beddingor initial backfill. Where excavated material is unsuitable for use as beddingunderneath 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 furtherdiminution 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 three (3) types of bendsmay be used:

Type 1:

Factory bends with a center-line radius of 5 x outside diameter. These bendsshall 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 (Miterbends).

These bends are only permitted up to an angle of max. 3° per joint (cutting of thetwo pipe ends in an angle of 1 ½° each. Pipe length between cuts approx. 12 m.

Type 3:

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

•••• only pipes without lining may be bent

•••• bending shall be performed in accordance with the applicable API and ASMEregulations

•••• 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”

8.2 Factory Bends

Factory-made, hot-formed bends shall be used where indicated on the Drawingsor specified in the Particular Specifications. The Contractor shall not use a fieldbend where a hot-formed bend is shown on the Drawings. Requirementspertaining to factory bends are defined in specification MO4 Factory Made Bendsfor Mainlines, Doc. No. QC10-H-044.


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8.3 Field Bends

Field bends shall be cold formed on an approved bending machine of the correctsize with an internal mandrel. The pipe shall be bent to a radius to be defined bythe Contractor based on applicable code and diameter respectively wall thicknessof the pipe. All bends shall have a tangential straight of adequate length on eachend. On seam welded pipe the seam shall be aligned along the neutral axis priorto 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. Thepipe 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 thepipe circumference. The difference between the maximum and minimumdiameters of the bent pipe due to ovality shall not exceed 2.5 % of the nominaldiameter. All bends shall have a tangential straight no less than 2 meter on eachend.

Prior to the start of field bending, the Contractor shall carry out a bendingprocedure on each and every pipe size and wall thickness in the presence of the

Engineer. The completed bend shall be ultrasonically checked before and afterthe test to ensure that any reduction in the wall thickness does not exceed themaximum under thickness tolerance as specified in API 5L.

Before they are incorporated in the pipeline, all bends shall be proved with agauging device fitted with two sizing plates of the min. permitted pipe internaldiameter 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 that the cold bend was pulled

•••• The bend angle

•••• Pipe Number

•••• KP Location


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9 FIELD WELDING AND QUALIFICATION OF WELDING PROCEDURES ANDWELDERS

9.1 Scope

This chapter defines the minimum technical requirements for all field weldingoperations and relevant qualifications of welding procedures and welders forcross country pipelines designed in accordance with ASME B31.4. This includeslarge 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 asproduction 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 shallapply unless amended by this specification.

The detailed technical requirements, the extent and the acceptance criteria fornon-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 theminimum standards for the work.

ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons

API 1104 Welding of Pipelines and Related Facilities

ASME Section IX Qualification Standard for Welding and Brazing Proceduresand Welders, Brazers and Welding and Brazing Operators

EN ISO 9001 Quality management systems – Requirements

EN 10204 Metallic products - Types of inspection documents

ASTM A370 Standard Test Methods and Definitions for Mechanical Testingof Steel Products

ASTM E92 Standard Test Method for Vickers Hardness of MetallicMaterials

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. underwhich 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 engineeringpractice, listing the materials, detailed method and parameters to be employedduring welding of a joint

Procedure Qualification (PQ)

A demonstration of welding a joint (qualification weld) by using approvedequipment and methods, utilizing the parameters outlined in the proposed WPS

to demonstrate that the given weld will have suitable mechanical properties andsoundness. The qualification weld has to be subjected to non-destructive anddestructive 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 resultsof the subsequent tests, material certificates, calibration certificates etc.

Welder Qualification

Demonstration of the abilities of the welder to produce a weld that meets therequirements of the applicable qualified WPS. The qualification weld has to besubjected to non-destructive and 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 oneaccredited and experienced test laboratory hast to be nominated to perform allnecessary 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 procedurequalification and related testing.

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

b) Proposed Welding Procedure Specification (pWPS)

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

The proposed WPS`s shall be in accordance with the requirements of theapplicable standards, i.e. ASME Section IX or API 1104 and this Specification forthe entire scope of work, including procedures for repair welding.

The pWPS shall briefly contain the information as required in the relevantstandards.

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 thenotch-toughness properties of a weld than also the Supplementary Essential


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Variables for the relevant welding process as indicated in ASME Section IX shallbe qualified.

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

d) Grouping of Materials

The applicable welding standards API 1104 and ASME Section IX allow a widerange 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, stresslevels etc., in case of pipeline failure into consideration a qualified, separateprocedure shall be prepared for cases where materials of considerable differentstrength, chemical properties, heat treatment conditions etc. shall be weldedtogether.

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 andreflecting the specific conditions, like clamping, lifting and lowering etc.

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

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

f) Testing of Qualifications WeldsPreparation of test samples and testing shall be performed at an approved testlaboratory.

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 toNDT.

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 thatwill be employed for production. NDT of a Qualification weld may serve as aqualification test for NDT procedures.

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

For destructive testing as a minimum all Qualification Welds shall be subjected toMacro Examination, Hardness Test and Fracture Toughness Test as describedbelow, 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 theheat-affected zone shall be prepared for macro examination. The preparedsurfaces shall be etched using a suitable enchant to reveal the grain structure.The sections of the weld taken for macroscopic examination shall be used forhardness testing.

The hardness shall be measured in accordance with ASTM E92 or equivalentstandards using a 10 Kg load. The hardness indentations shall be evenlydistributed 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 indentationsincluded 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 pipewall thickness exceeds 5 millimetres.

One set of three specimens shall be taken, with the notch location at each of thefollowing 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 thesedimensions are not possible, sub-size specimen shall be extracted. The testtemperature shall be minimum 0°C or below if specified in the base materialstandards.

The acceptance criteria of Charpy V-Notch test shall as minimum fulfil therequirements 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 repairwelding WPS and shall be executed by qualified welders. The repair weldingWPS is separate from the original welding procedure with the addition of thefollowing:

• 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 aftercompletion. If acceptable, a section within the allowable limits has to be removedand re-welded in accordance with the proposed repair procedure. Finally thisrepair weld has to pass all required tests described in the relevant sections of theapplicable standards and this specification.

h) Re-Tests

GENERAL

If the mechanical tests fail for whatever reason, the CONTRACTOR shallimmediately 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 theminimum requirements, a new WPS proposal shall be established andqualification welding and testing repeated.

TENSILE AND BEND TESTS

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


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CHARPY V-NOTCH IMPACT TESTS

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

HARDNESS TESTS

If only one hardness result exceeds the specified maximum then three furtherimpressions 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 specifiedmaximum then the test shall be accepted.

If the test joint finally fails to meet the minimum requirements, a new WPSproposal 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. Aftercompletion 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 andapproval. 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

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

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

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

Qualification shall be valid for a period of six months unless otherwise stated inthe applicable standards. This period may be extended by a further six monthswhen it can be shown by NDT from production welding that the welder hasproduced satisfactory welds. Therefore a “Welder Performance Record” shall bemaintained, showing the number of welds and NDT results for each welder and/oroperator.

b) Welder Identification

A unique identification number shall be assigned to each welder and a welderidentification card with the welder's name, photograph, identification number, andWPS’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 shallproduce the card to the welding inspector if asked for. Welders performing workwithout identification card shall be suspended from production welding until suchtime as the card can be produced and shown. In case a welder terminates hiswork, the identification number shall not be reassigned to another we