ant Js ful Qatar ae — fas TECHNICAL DIRECTORATE Technical Services Department Engineering Standard ES.5.14.0051 Specification for Onshore Pipeline Construction Revision A Indicator Ea Ce fees [oe bh St fms} p-os ou eet fe rv oof |SES.5.14.0051: Specification for Onshore Pipeline Construction Revision A Page 2 CONTENTS Foreword 1.0 Introduction 2.0 Custodian 3.0 Application 4.0 Guidelines to Interpret this Specification 5.0 Definitions and Abbreviations 6.0 Reference Codes , Standards and Specifications 6.1 Codes & Standards 2 QP Specifications & Standards 63 Conflict between Codes- Order of Precedence 64 Alternatives Codes & Standards 7.0 Pre- construction Activities and Requirements 7A Construction Plan 7.2 Pipeline Corridor/ Routing Survey &Marking 7.3. Parallel Offset Distances Requirements 7.4 Preparation of the Working Width -Grading of R.O.W 7.5 Care of Existing Features/Structures 8.0 Unloading, Stockpiling, Hauling and Stringing of Materials 9.0 Pipeline Trenches/Exeavation and Cover depths 91 ‘Trenches Excavation 9.2 Blasting and Mechanical /Hydraulic Rock Breaking 93° Pre-padding 94 Cover Depths 10.0 Crossings 10.1 General Requirements 10.2 Specific Crossing Requirements 11.0 Field Bends 12.0 Lining-up and Welding 13.0 Protective Coating of Line Pipe and Field Joints 14.0 Lowering-In 15.0 Tie-Ins 16.0 Washouts and Drainage 17.0 Padding and Backfilling of the TrenchES.5.14,0051: Specification for Onshore Pipeline Construction Revision A Page 3 18.0 Special Installations on the Pipeline 18.1 General 18.2 Valve Stations 183 Pig Launcher/Receiver 18.4 Insulation Joints 18.5 Flanged Connections 18.6 Welded Connections 18.7 Dimensional Tolerances 18.8 Pipeline Markers 18.9 Anchor Flange/Blocks 18.10. Barred Tees 18.11 Corrosion Fitting 19.0 Final Testing 20.0 Cathodic Protection -Test Stations 21.0 Final Clean up of the construction ROW 22.0 As Built Drawings and Pipe Book 22.1. “As Built” Alignment Sheets 22.2 Pipe Book 23.0 Quality Assurance Attachments: A. Typical Standard Drawings for Pipeline Construction (ES.5.60.0001-xxx) to. be developed issued as per Index of Corporate Engineering Standards ES.0.00.0000 - Master list - Rev BES.5.14,0051: Specification for Onshore Pipeline Construction Revi Foreword This Engineering Standard provides guidance and specifies minimum requirements for various activities to be performed by QP CONTRACTOR for the construction and installation of buried and aboveground pipeline cross Qatar country. This document refers to the latest international codes & standards practices as well as to QP corporate standards& specifications applicable for pipeline construction in a safety environment. This Specification shall be read in conjunction with the Standard Drawings indicated in the Contract Documents.10 2.0 3.0 40 ES.5.14.0051: Specification for Onshore Pipeline Construction Revi Introduction This Engineering Specification specifies the minimum requirements for the construction of onshore, above ground and underground pipelines, cross-country as well as onshore section of submarine pipelines connecting between Halul Island facilities and offshore production stations’ jackets, for Qatar Petroleum. The detailed scope of work for construction of the pipeline and related facilities are provided in the project contract documents. CONTRACTOR or their SUB-CONTRACTORS shall execute the work in full compliance with QP requirements and Qatar local laws, by-laws, ordinances, regulations, and shall provide all plant, services and labor inclusive of supervision thereof. CONTRACTOR or their SUB-CONTRACTORS shall be deemed to have inspected and examined the work areas and the surroundings and to have satisfied himself, as far as practicable, as to the form and nature thereof, of the extent and nature of work and the means of access to work areas. CONTRACTOR or their SUB-CONTRACTORS shall be deemed to have obtained all the necessary information related to risks, contingencies and all other circumstances, which may influence the work scope activities. Custodian ‘The Custodian of this specification is QP-Technical Services (FE ) who is responsible for the accuracy and quality of its content and for its future revisions, where are required to reflect industry trends or changes to QP business practices Application Project teams, business units and CONTRACTORS shall use this specification as part of the project specifications for design, construction and commissioning of new onshore pipelines. It is also intended for use as main guidelines to execute the work by the CONTRACTORS in compliance with local laws, by-laws, ordinances, and regulations Guidelines to interpret this Specification This specification does not cover the following activities of onshore pipeline construction: - Welding - Coating - Hydrostatic Testing - Pipeline Cleaning - Cleaning, Gauging and Flooding - Pre-Commissioning -Pigging - Hot Tapping - Detail of Permanent Cathodic Protection = Commissioning Such activities being executed under other QP Standards/Specifications, as stated in 6.2, or, provided in the Contract Documents.50 ES.5.14,0051: Specification for Onshore Pipeline Construction Revision A Page 6 Definitions & Abbreviations ‘Within the context of this Engineering Standard, the following words shall have the meanings as slated below. In case of any contradiction between various non-technical definitions, QP General Conditions of Contract definitions attached to the Contract shall govern Qe: Qatar Petroleum CONTRACTOR: EPIC CONTRACTOR SUB-CONTRACTOR: A company awarded a contract by Contractor to do part of the work awarded to the Contractor by QP. The work of Sub- Contractor is carried out under the direction and control of the Contractor. Under its ‘model contracts, QP has the right to review all proposed Sub — Contractors, and sub-contracts. Consultant Design Consultant to the EPIC CONTRACTOR EPIC Engineering, Procurement, Installation and Commissioning Contract Agreement between QP and the EPIC CONTRACTOR ROW Right of Way Corridor of land within which the pipeline owner has the right to conduct activities in accordance with the agreement with the land owner. MMAA: Ministry of Municipal &Agriculture Affairs QG.E.W.C (KAHRAMA): Qatar General Electricity and Water Corporation RLIC: Ras Laffan Industrial City MLC Mesaiced Industrial City QTel: Qatar Telecom HSE: Health and Safety Environment cP: Cathodic Protection AC Alternating Current Shall: Used where a provision is mandatory Should: Used where a provision is preferred; strong recommendation May: Used where alternatives are acceptable Must: Used where a provision is a statutory requirement Will: Used normally in conjunction with an action by Buyer or Purchaser rather by the Contractor or Vendor!6.0 Ot ES.5.14,0051: Specification for Onshore Pipeline Construction Revision A Page 7 Reference Codes, Standards and Specifications ‘The work shall comply in all respects with the latest editions of the listed codes and standards, unless otherwise amended by this Specification. Codes and Standards ASME B31.8 Gas Transmission and Distribution Pipeline Systems. ASME B31.4 Liquid Transportation Systems for Hydrocarbons,Liquid Petroleum Gas , Anhydrous Ammonia and Alcohols. ASME BI65 Pipeline flanges and flanges fittings ASME 16.9 Factory made wrought iron stee! butt-welding fittings. SSPC-SP Steel structure painting council surface preparation MSSP SP 75 Specification for high test wrought welding fittings MSSP44 —_Stee! pipeline flanges ISO 13623 Petroleum and natural gas industries- Pipeline transportation systems BS 8010 Part 2 Pipeline on land : design, construction and installation APERP 1102 Steel Pipelines Crossing Railroads and Highways APL SL Specification for Line Pipe APISLS Recommended practice for marine transportation of line pipe APISLI Recommended practice for railroad transportation of line pipe APLRP 1110 Recommended practice for pressure testing of liquid petroleum pipelines. API 1104 Standard for Welding of Pipelines and Related Facilities API RP 1109-2003; Mark ine Facilities Liquid Petroleum Pi PEL-ES-24 Pipe Bending Tolerances-Minimum Bending Radi. Minimum Tangent cswip Certification Scheme for Welding Inspection Personnel BS 7361-1-1991 Cathodic Protection Part | - Code of Practice for Land and Marine Applications (Formerly CP 102!) BS 7361-1-1-1991 : Cathodie protection part:1 ( formerly CP 1021) 1SO 9000 - 9004 :Quality Management and Quality Assurance Standards NACE -RP 0572: Design, Installation, Operation and Maintenance of Impressed Current Deep Ground Beds (latest edition/tevision). NACE RP 0177/2000: Mitigation of Altemating Current and Lightning Effects on Metallic Structures and Corrosion Control System NACE RP-0169-2002. Control of corrosion on underground of submerged metallic piping systems,62 63 ES.5.14,0051: Specification for Onshore Pipeline Construction Revision A Page 8 NACE RP 0274 : High Voltage Electrical Inspection of Pipeline Coatings Prior to Insatallation NACE RP 0286 : Electrical Isolation of Cathodically Protected Pipelines, BS 4515-1 Specification for welding of steel pipelines on land and offshore part-1 Carbon and Carbon Manganese Steel Pipelines. QP Specifications &Standards QP-SPC-L-005 Specification for External FBE coating for Onshore Pipelines QP-SPC-L-006 Specification for Field Joint FBE Coating QP- SPC-L-002 Standard Specification for Painting and Wrapping of Metal Surfaces QP-STD-R-001 QP Standard on Materials for Sour Service QsP-QC-09 Quality System Requirements for Projects. @-SID-L-009 QP technical standard for corrosion monitoring systems for oil and gas production facilities. QP-STD-L-008 QP technical standard for corrosion inhibitors and their injection package for oil and gas production facilities. QP-PHL-S-001 Corporate Philosophy for Fire and Safety QP-SPC-ENV- 006 Specification For Environmental Site Selection And The Abandonment and Restoration of Facilities QP-SPC-ENV-001 Specification for Waste Management ES.5.14.0052 Engineering Standard for Offshore Pipeline Construction. ES.5.06.0051 Design of Onshore Pipeline ES.5.06.0052 Design of Offshore Pipeline ES.5.60,0001-XXXX Typical drawings for pipeline construction ES.5.14.0951 10.0960 Corporate Engineering Standard Pipeline Technical Specification (Procurement specifications) Conflict between Codes ~ Order of Precedence. In case of any conflict between the requirements of this specification and the referenced codes, standards and specifications, the following precedence shall be applicable a) Statutory requirements of the State of Qatar b) Purchase Order/Project Specifications ©) QP Standards/Specifications (including this specification) 4) International Codes and Standards64 10 TA Tad TAD 73 72 721 ES.5.14.0051: Specification for Onshore Pipeline Construction Alternative Codes and Standards. Any deviations from those listed in this specification shall require QP approval. Pre-Construction Activities and Requirements Construction Plan CONTRACTOR shall prepare and submit a construction plan for review and approval prior to commencement of construction. This plan shall be commensurate with the complexity and the hazards of the work and should contain as minimum: Description of the construction Health, Safety and Environmental issues Quality Plan Description of the construction The description of the construction should include methods, personnel and equipment required for the Construction Schedule, Construction Procedures, supervision! inspection and Method Statements for various installation scenarios, supported by installation calculations. Contractor shall provide all materials, equipment and appliances required for the execution of the work, ether temporary or permanent, Contractor shall submit details regarding the make, ‘year of manufacture and fitness Certificates for the items of equipment, Special construction, such as tunnels, pipelines bridges and horizontal directional drilling may require supplemental pipeline installation procedures. Health, Safety Environment ‘The construction plan should address HSE issues in detail and describe requirements and ‘measures for the protection of the environment, health and safety of the public and the personnel involved in the pipeline construction. It should take into consideration the requirements of the relevant Qatar legislation and applicable QP standards (ie QP -PHL-S-001 & QP-SPC ENV- 006), identification of the hazards, and measures required for their control, and emergency procedures. A Clearance from environmental perspective shall be obtained from the Supreme Council for the Environment and Natural Reserves before starting any construction, . Quality Plan. CONTRACTOR shall submit Method Statements and Quality Procedures for review and approval before commencement of work. A Pipeline Corridor constitutes an exclusive land area, used for pipeline and related activities, dedicated/approved by Qatar Authority (MMAA or Industrial Area governing Authority (ie RLLC,MIC)722 13 ES.5.14,0051: Specification for Onshore Pipeline Construction Revision A Page 10 All pipelines shall be placed in designated corridors, which are a minimum of 60 m wide. ‘The minimum clear space between the pipelines and normally occupied buildings shall be as per BS 8010 Part 2.8. Pre- Construction Survey & Marking CONTRACTOR shall inspect the pipeline route within the designated comidor. All surrounding work areas including the Terminal/Station Departure and Terminal/Station Arrival and if any spur-line connection to other pipelines/stations shall be inspected. Such inspections shall be undertaken after access to the route has been granted and before commencement of construction, Reports of these inspections shall state the condition of the items potentially affected by construction and record the mutual approval of all parties concemed, CONTRACTOR shall stake the entire pipeline route on the ground from the data available on the pipeline route plans enclosed with the construction contract of the pipeline. ‘The construction survey control shall be staked at a maximum of $0m intervals on the tangents and at 10m intervals on the curves. The numbering system shall be continuous. All staking shall be on the ditch centerline. Reference points shall be established for each centerline stake, offset by 25m. The stakes shall be placed at fences, existing pipelines, existing above or below ground facilities, eathodie protection test points, extra depth ditch locations and at pipelines. Stakes shall also be placed at tangent points, top of sand dunes etc.. to ensure unobstructed centerline, visibility in either direction along the pipeline route. CONTRACTOR, as part of his Scope of Work, shall investigate and establish any development with may have taken place since the topographical survey was carried out earlier and shall submit detailed documentation to support any proposed realignment of the surveyed pipeline route resulting from the actual conditions encountered during his, investigations or as required by the relevant Local Authorities. Any realignment of the surveyed pipeline route shall be subject to QP approval prior to implementation. ‘The final pipeline alignment shall be subject to QP approval. Parallel Offset Distances Requirements Spacing of parallel-buried pipelines or above grade individually supported pipelines shall be as follows: 2) A minimum clear space between any pipeline and the corridor boundary shall be 30 m, Every pipeline must have a minimum clearance of 15 m on one side. In congestion areas (ie Industrial areas) the clearances may be reduced, provided QP approval is obtained. b) Parallel offset distance ( pipe center lines) between new aboveground pipeline and existing aboveground pipeline shall not be less than 3.0m for oil and gas pipelines and 1.50m for water pipelines. ©) Where the new aboveground pipeline runs parallel with an existing buried pipeline the horizontal clearance between the pipeline supports and the existing pipeline shall be equal to the greatest of 1.0m or twice the Outside Diameter (2 x O.D) of the larger pipe whichever is greater14 Tad ES.5.14.0051: Specification for Onshore Pipeline Construction Revision A Page 11 d) Where the new aboveground pipeline runs parallel with a buried cable the horizontal clearance between the pipeline supports and the existing cable shall not be less than 1.0m ) Where the new buried pipeline runs parallel with an existing aboveground pipeline the horizontal clearance between the buried pipeline and the existing pipeline supports shall not be less than 1.0m or twice the Outside Diameter (2 x O.D) of the larger pipe whichever is greater. £) Where the new buried pipeline runs parallel with an existing buried pipeline not in the same trench, the horizontal clearance between pipelines shall not be less than 5.0m. Where new pipeline is laid near existing one in the same trench, the minimum clearance equal to the greater of one meter (1.0m) or twice the outside diameter (2 x O.D) of the larger pipe shall be maintained between them 8) Where the new buried pipeline runs parallel with a buried cable the horizontal clearance between the pipeline and the existing cable shall not be less than 3.0m. This shall be increased should there be a likelihood of any CP interference or possibility of damage to the cable during construction of the new pipeline. h) Where the new pipeline is routed parallel to the existing overhead power cable, the pipeline shall maintain @ horizontal distance more than the height of the highest overhead power cable, or 30m, whichever is greater. Contractor shall study AC mitigation and lightning effects on the pipeline. This shall be performed in accordance with NACE RP 0177-2000, or any relevant standards. AC mitigation methods shall be employed at all parallelisms, where the study finding justifies the same. i) The minimum offset distances stated above shall apply, unless otherwise stated in the design contract drawings. In specific circumstances, due to construction or site conditions, the minimum distances may be reduced. CONTRACTOR shall fully justify any reduction in the minimum offset distance. QP approval will be required for such reductions. Preparation of the working width -Grading of R.O.W Prior to clearing or grading of right-of-way or stringing of pipe, CONTRACTOR shall provide appropriate fencing where required for public safety and to prevent livestock from encroaching on the working area. Where the R.O.W passes through fenced areas, the Contractor, after notifying the owner/tenant and the Client, shall open the fence and install temporary gates therein, Adjacent (fence) posts shall be adequately braced to prevent slackening of the wire. Materials and construction of the fence and temporary gates shall be approved by the Client .The Contractor shall be responsible for any loss or inconvenience accrued to the owneritenant on account of the fences being opened and the gates not having been shut, The right-of-way (R.O.W) to be graded shall be a strip of land of minimum 20m wide, within the pipeline corridor, necessary required to properly perform the pipeline construction and to provide access to the pipeline during the construction period. 20 Meters ROW will have Sm from centerline of the outer pipe on the off side and 15 m from centre line of the outer pipe on the working (welding) side. The CONTRACTOR shall select which side of pipe system is to be working side for the construction of each section of the pipeline,742 18 75 782 ES,5.14,0051: Specification for Onshore Pipeline Construction Revision A Page 12 Restricted width of Right-of-Way (ROW) shall require QP approval. Prior to start of cleaning and grading activities, CONTRACTOR shall advise of the sections where ROW width will be restricted and obtain Client approval ‘At locations where any part of the work is routed along, over, under or across paths, walkways, roads or highways, the CONTRACTOR shall provide and maintain detours, temporary bridges and road control as may be required by the concerned authorities. Public travel shall be necessarily convenienced and shall not be wholly obstructed at any point. CONTRATOR shall furnish and maintain watchman, detours, lantems, barricades, signs, where necessary to fully protect the public. All grubbed stumps, timber, roots cuts and dislodged and similar material, rock particles etc. shall be removed from the ROW and disposed off in a manner and method satisfactory to the land owner and / or tenant, Government Authorities having jurisdiction over these. In no case shall these be left to interfere with the grading, bunding or pipe laying operations, if any, arising out of clearing, grading, bunding or clean-up operations. ‘The nght of way width shall be as indicated in the typical pipeline installation drawing enclosed with the Contract. CONTRACTOR shall grade the right-of-way to eliminate sharp high points, fill all low points, minimize bending in order to install the pipeline in stress free state.. In rocky sections CONTRACTOR shall excavate rock or other material, which cannot be graded off with normal grading equipment in order to build an adequate working space along the pipeline route. Explosive blasting techniques shall be used only after writing permission of the QP... Blasting shall be in accordance with relevant legislation and environmental constraints and shall be performed by competent and qualified personal. . [At locations where easement or permit restrictions limit the right of way width, or, where the construction of the R.O.W passes over, through, or along roads, paths, pole lines, or any other improved or confined areas, CONTRACTOR shall grade only the width of the right-of-way necessary for digging the pipeline trench and constructing the pipeline. In areas, which require a greater width for construction activities, prior approval from QP. ‘Where the construction R.O.W. passes through Sabkha (loose sand or soil) area, fill material duly approved by the QP, shall be provided to support construction equipment. CONTRACTOR shall perform all necessary grading at road crossings and at any other location required to permit the passage of construction equipment. Care of existing features/structures CONTRACTOR shail submit to QP a detailed proposal of the precautions to be taken in providing temporary fencing and other protective devices according to each situation, to avoid damaging existing pipelines, electrical lines and cables, fences, roads, drainage, irrigation systems and any other existing above or below ground structures, or property, adjacent to or crossing the pipeline being constructed. CONTRACTOR shall perform any clearing necessary to accommodate the installation of the pipeline and related facilities,783 154 188 186 78.7 158 159 7510 ES.5.14,0051: Specification for Onshore Pipeline Construction Revision A Page 13 Great care shall be taken of cultivated ground. For these areas the topsoil shall be carefully removed and protected against erosion and contamination by blown sand and kept for reinstatement by CONTRACTOR after the pipeline is constructed. Any archeological monuments and remains uncovered during trenching and right-of-way clearance shall be brought to the attention of the QP immediately on discovery. ‘The CONTRACTOR shall stop operations in the area of an archeological find until the significance and extent of the find is determined and the QP gives approval to proceed with the work and instruct CONTRACTOR of any special action(s) to be taken. During any work on pipelines influenced by high voltage lines, safety measures are necessary for the protection of personnel. These protective measures shall be detailed in CONTRACTOR's Safety Manual. This shall include protection to cranes, side booms and all other construction ‘equipment. CONTRACTOR shall obtain from the operator or owner of any existing pipelines a ermit-to-work. Provision of a permit-to-work by QP does not release CONTRACTOR from obligation of obtaining relevant permits to expose or work near utilities/facilities not under QP area or responsibility. Example: Q.G.E.W.C(KAHRAMAA), Q-TEL ete. ‘When the bund is removed from any existing pipeline or cable for access by construction traffic, CONTRACTOR shall clearly indicate its buried route by pegs and warning signs. CONTRACTOR shall protect the existing facility from vehicle wheel loads (30 t. axle load) by the placement of protective slabs as approved by the operator or owner of the existing facility . Bunds of existing lines so removed shall be replaced to its original condition. ‘A maintenance access road shall be constructed by CONTRACTOR concurrent with the ROW along the route of the pipeline through all Sabkha areas. The road shall require compaction and grading as per other areas. The grade level of the ROW after consolidation and compaction of the fill shall be as per the applicable installation standards, drawings and other specifications issued with the Contract Documents, ‘The CONTRACTOR shall also grade a maintenance track along the ROW of the pipeline, such that year-round vehicular access along the pipeline routes is available, for maintenance. 7.8.11 CONTRACTOR shall make full provision for ramps, temporary cross-overs, ete. for crossing tracks and above ground pipelines to permit the crossing of men and machinery for the purpose of continuous ROW preparation. ‘Their continued availability to vehicular and other traffic shall be ensured. The banks and structure of cach crossing shall be preserved. No existing crossings shall be filled or otherwise obstructed without approval of the QP. 7,512 The CONTRACTOR shall be liable for any and all remedial work required as a result of 7513 damages to existing pipelines and associated equipment, tracks, roads, highways and all other utilities caused by him. The CONTRACTOR shall carry out remedial work as and when required by the QP. CONTRACTOR shall, before starting any clearing operations, familiarize himself with all the requirements of the Authorities having jurisdiction over the ROW for work along the pipeline route or in connection with the use of other lands or roads for construction purposes, including access. All necessary permits for road crossings and crossing of existing pipelines, cables and structures shall be obtained.8.0 81 83 84 87 88 89 8.10 8.11 8.12 8.13 ES.5.14.0051; Specification for Onshore Pipeline Construction Revision A Page 14 Alll provisions and conditions of all permitting authorities and all instructions given by QP or its representative shall be complied with. Details of underground utilities are generally (for information) indicated on the drawings. However, CONTRACTOR shall make all efforts to obtain plans and full details of all existing and planned underground services from relevant authorities and shall follow these plans closely at all times during the performance at the work. CONTRACTOR shall be responsible for locating and protecting all underground lines, cables and structures, whether or not indicated on drawings, using underground detection equipment or hand digging. Pipeline locators, trial pits and all other means of locating lines, cables and substructures shall be used, if required, Unloading, Stockpiling, Hauling and Stringing of Materials CONTRACTOR shall unload, stockpile, load, haul and string all materials and shall make all necessary arrangements and agreements in accordance with Client approved procedures. After unloading, the pipe shall be supported above ground level in a manner that will prevent rain, runoff water and sediments from entering the pipe CONTRACTOR shall be responsible for maintaining the linepipe in good condition. All end caps removed for inspection shall be replaced. Nesting of pipes is not permitted. The method of stacking pipes shall be subject to review by the QP. It is CONTRACTOR's responsibility to ensure that no distortion of pipe shape or any other damage occurs during storage and pipe lay ‘operations. CONTRACTOR shall be responsible for providing suitable trucks and equipment in sufficient quantity to transport materials to construction sites in accordance with agreed schedules, CONTRACTOR shall prepare a procedure describing the methods of inventory and material transfer so as to provide accurate accountability of all material at all times during the contract. CONTRACTOR shall use a Pipe Traceability System that shall enable control and tracing of all pipe from source through to its "as built” position, CONTRACTOR shall handle pipe with equipment of a suitable capacity using approved, non- metallic, non-abrasive slings, spreader bars, and protected hooks. The slings, spreader bars and ‘hooks shall have necessary certificates of approval from approved Inspecting Authorities before loading or unloading is commenced. Pipes shall not be rolled into or from conveyances, nor handled in any manner, which distorts the round form of the ends, or scratches, gouges or dents the pipe. Pipes shall not be dragged along the ground. Any damage to the bare pipe or coating resulting from hauling, stockpiling, subsequent handling or any other cause shall be repaired by CONTRACTOR at CONTRACTOR's expense. QP shall be notified prior to any repairs taking place. Pipes strung on the construction right-of-way shall be protected by setting the pipe in a manner that shall cause no damage to the pipe coating Pipe stringing in rock ditch areas shall not be permitted until ditching is complete. Pipe shall be strung in such a manner as to result in the Teast amount of interference tothe normal use of the land crossed, and gaps shall be left at approximately S00 m intervals or at existing tracks to permit the use of the land and the passage of equipment, or other normal traffic across the construction right-of-way. Materials shall be stored, hauled to the site of the work and assembled on the site in accordance with vendor and supplier instructions and Contract Documents as to prevent damage. CONTRACTOR shall be fully responsible for providing and paying for all storage areas. CONTRACTOR shall be responsible for construction and maintenance of any necessary temporary roads for the construction of the pipeline.8.17 8.18 8.19 8.20 9.0. 94 OAt 912 ES.5.14.0051: Specification for Onshore Pipeline Construction CONTRACTOR shall be responsible for any repairs to existing roads or any property damaged by hauling and stringing operations, Pipe shall not be strung on the ROW more than three kiloms in advance of the mainline welding, unless specifically permitted in writing by the QP. Alll materials other than line pipe, shall not be stored on the ROW, but shall be transported to the installation site, in a covered conveyance on the day of use. The timing of issue of materials will be as per QP approved work schedule. Stored materials shall be protected from ground surfaces by use of timber or, by an approved method. Ground surfaces in Storage areas shall be clean and flat. Fragile materials shall not be stored or transported in more than one layer. Welding Consumables shall be stored under clean, dry conditions in accordance with manufacturers recommendations, where possible, in their original unopened containers until required. Electrodes shall be stored and handled in an orderly manner to prevent damage. Coating materials shall be suitably stored and protected so that they do not deteriorate as a result of exposure to high thermal conditions or adverse weather conditions. Deteriorated materials shall not be used and shall be replaced by the CONTRACTOR. Each joint of pipe shall be swabbed with a leather or canvas belt disc of the proper diameter or cleaned to the satisfaction of the client to remove ditt, loose mill scale or other foreign substances before placing in alignment for welding. The open ends of the pipe shall be securely closed at the end of each day's work and shall not be opened until work is resumed After the pipes have been strung, these shall be inspected and all defective pipe ends repaired. Defective pipes shall be repaired or rejected as directed by the client. Repairs requiring the replacement of a section of the pipe must be done before the string containing the defective pipe is connected to the pipeline. If such a repair is necessary after the pipe is connected to the pipeline and is not practicable to carryout the repair within the tie-in temperature range, then the repair must be made in accordance with clients instructions, Defective longitudinal welds shall not be repaired. Any defective portion of pipe shall be cutout and removed. The minimum length of pipe to be cutout shall be 1.20m Exposure of the coated pipe to sun shall not exceed the period recommended by coating mill / manufacturer. Pipeline Trenches Excavation and Cover depths ‘Trenches Excavation CONTRACTOR shall stake the centerline of the pipeline and flag the limits of the working area of the R.O.W in accordance with the approved construction drawings. CONTRACTOR shall excavate the pipeline trench on the staked centerline of the pipeline in a manner and to a standard approved by the QP Prior to excavation of the pipeline trench, CONTRACTOR shall obtain plans and details of all existing and planned underground services ftom the relevant Local Authorities and shall follow these plans closely at all times during the performance of work,913 914 OS 916 94.7 918 ES.5.14,0051: Specification for Onshore Pipeline Construction Revision A Page 16 CONTRACTOR shall locate all existing underground utilities and structures that may be crossed or encroached by electronic scanning (detectors) and by hand excavation in areas where services are known to exist. The depth and alignment of the service shall be marked. CONTRACTOR shall employ equipment and methods to keep the ditch to the line established regardless of the type of soil and rock encountered and regardless of the depth of excavation necessary. CONTRACTOR shall furnish all equipment, materials and supplies necessary for the completion and maintenance of the ditch, including shoring, and sheet piling, dewatering and any other incidental for the completion of the work in an approved manner. ‘To minimize the required number of bends to lay the pipe in conformity with the contour of the ground and maintain the minimum standard cover, the CONTRACTOR shall cut the trench slightly deeper at the crest of ridges and by gradually deepening the trench in approaches to crossings of roads, highways, ditches, crecks, rivers, ravines and other water courses. The CONTRACTOR shall, wherever practicable, eliminate unnecessary bending by cutting the trench at various depths and not by grading the right-of-way. CONTRACTOR shall carefully preserve all sets and/or benchmarks set by the QP. CONTRACTOR shall be liable for any extra expense due to his failure to maintain such stakes/bench marks. All trenching shall be carried out in compliance with the applicable typical Standard drawings for rocky areas, sandy areas, sabkha areas issued with the Contract Documents. The width of a pipeline trench shall be as narrow as practicable where mechanical compaction is not required, typical width shall be pipe O.D + 0.6m so as to provide on each side of the installed pipeline, 2 clearance of 0.3m. Where two pipelines are Iaid in the same trench, the width of pipeline trench shall be in accordance with parallel offset distances requirements (7.38). CONTRACTOR shall provide sand bags at appropriate intervals to maintain spacing during padding and backtilling. Trench width may be reduced where narrow trenching techniques are employed. In special locations indicated by client, ifrequired by the authorities having jurisdiction, where the use of trenching machine / backhoe may result in unnecessary damage to property and subsurface structures likely to be encountered during excavation, trench shall be excavated manually to the same specifications. Dewatering equipment, shoring and any other equipment and materials shall be provided as required to excavate the ditch, install the pipes and backfill the ditch in accordance with the specifications and drawings. Appropriate measures to prevent pipe flotation, such as applying soil dams and dewatering of ditch or temporary filling of water into the line (in exceptional cases) shall be taken wherever calculations indicate that floatation of the pipe ean be possible. In the case of water on the trench bottom when the pipe is being laid, the trench shall be drained to the extent and for the time required to make a visual inspection of the trench bottom and to install the pipes. After pipe installation, the presence of water will be allowed provided its level does not cause sliding of the trench sides and pipe flotation before back filling. The water pumped out of the trench shall be discharged in a manner to client’s approval. At points where the contour of the earth may require extra trench depth to fit the radius of bends according to relevant drawings and specifications or to eliminate unnecessary bending92 924 9.2.2 9.2.3 924 92.5 9.2.6 9.2.7 9.2.8, 92.9 9.2.10 921 ES.5.14,0051: Specification for Onshore Pipeline Construction Revision A Page 17 of the pipe according to customary good pipeline practices, the CONTRACTOR shall, at no, additional cost to the client, excavate to the additional depth as may be necessary. Blasting and Mechanical/Hydraulic Rock Breaking In_seotions where the CONTRACTOR elects to use explosive blasting techniques, CONTRACTOR shall keep trenching operations ahead of stringing, bending and welding ‘operations unless permission to perform the construction work in another manner is obtained in writing from the QP. Blasting shall not be permitted in any ROW, which contains an existing Pipe. No blasting shall be allowed without prior and due notice given to adjacent work crews and ‘other interested parties and written approval of e QP. Every possible precaution shall be taken to prevent injuries and damages to persons and properties. ‘The CONTRACTOR shall apply for the necessary permits and shall fully comply with the laws, rules and regulations of the jurisdictional authority governing the importation, handling, hauling, storage, accounting/inventory control and use of explosives in QATAR. The CONTRACTOR shall comply with requirements of the Blasting Specification, enclosed with the Contract Documents. and the blasting procedure approved by QP. CONTRACTOR shall comply with all local regulations in force at time of blasting and obtain all required approvals from relevant local Authorities and interested parties. CONTRACTOR shall notify the QP of its intent to use explosives at least three (3) weeks in advance of any blasting or import of materials. The size of the charge shall be determined by CONTRACTOR in accordance with Contract Documents and approved procedures. ‘The size shall be based on trial blasts performed at an approved location. Vibration levels shall be recorded at various distances from the blast location CONTRACTOR shall make use of blasting blankets and pads to prevent damage to coated pipe and nearby structures, including communication towers and power lines. CONTRACTOR shall protect ground structures, such as cables, conduits, pipelines, water springs, wells and underground watercourses in accordance with the approved procedure. CONTRACTOR shall remove all scattered rock and debris caused by the blasting to dumping areas approved by the QP. CONTRACTOR shall use only experienced workmen with proven experience and certification to supervise, handle and use explosives. The certification and licenses duly approved by ‘competent authorities shall be submitted to the QP prior to work commencement. CONTRACTOR shall properly dispose ofall explosive packaging materials and in no case shall they be disposed of in the backfill of the trench. Disposal methods shall be described in the procedures and approved by the QP. CONTRACTOR shall maintain the trench in good condition until the pipe is lowered in. Ilis intended that there shall be a minimum amount of hand grading of the trench bottom. To accomplish this, CONTRACTOR shall, as far as practicable, excavate vertical faces and flat ottom for the trench. CONTRACTOR shall do such hand excavation in the trench as is necessary to free the bottom of the trench of loose rock and hard lumps and to trim other foreign matter from the bottom and sides of the trench. The trench bottom and sides shall be free from any hard objects (sharp rocks or otherwise) so that the pipe and coating are not damaged, punctured or abraded9212 9243 92.14 9215 9.2.16 9247 93 93 9.3.2 933 98 9.41 ES.5.14,0051: Specification for Onshore Pipeline Construction Revision A Page 18 Mechanical / Hydraulic rock breakers shall not be used within two (2) m of existing pipelines or cables, If jackhammers are required to be used within two (2) m of any buried pipelines and between any pipelines running in the same easement, circumferential pipe protection (approved by the QP) shall be provided by CONTRACTOR before commencement of work. Existing pipelines, utilities and foreign installation shall be excavated using hand tools before allowing mechanical equipment to operate within five (5) m. Precautions must be taken at these exposed pipe/bund areas to ensure that no erosion of the soft sand fill takes place during trenching operations. Prior to exposure of any existing pipelines or utilities, CONTRACTOR shall erect a barrier in accordance with approved procedures to prevent any damage to the pipelines or utilities. This is particularly important where there are heavy vehicles in the vicinity and the possibility that removal of the bund for trenching operations opens up an unauthorized vehicle crossing. When trenching between pipelines in the same easement, vehicle access between the pipelines shall be maintained. For depth of cover purposes, rock in trench is defined as that which cannot be removed by ditching machine, rock ploughs, back hoe or ripper. Pre-Padding All trenches shall be padded to the required depth before lowering-in of the pipeline. No padding shall be placed until the QP has inspected and approved the trench. ‘Only dune sand having a particle size of less than 3.0 mm shall be used as pre-padding ‘material. The sand shall be free of rock, metal parts, and other debris. The bottom of the trench shall be padded with sand throughout its length, whether in normal ground or rock, so as to provide 2 minimum compacted thickness as specified in Contract Documents. Cover Depths ‘The minimum pipeline depth of cover from top of pipe to the lowest possible ground surface level, including coatings and attachments shall be as specified in Table 1. The height of the bund shall not be taken into consideration in the cover depth ‘Table 1. Minimum Cover Depth for Pipeline on Land ation Cover depth" "for | Cover depth” for Normal Ground (m)_| Rocky Ground (m) ‘Areas of limited or no human activity” | 1.0. 0.6 | Agriculture or horticultural activity* 1.0. 08 Canals, Rivers 2.0 10 | Roads, railways’ 2.0 10 (Residential, and commercial areas” [2.0 12 Notes: 1. Increased burial depths may be required for buried pipelines operating at higher ‘temperatures than ambient, for mitigation of upheaval buckling, 2. The height of the bund shall not be taken into consideration in the cover depth. 3. Equivalent to Class location 1 4, Equivalent to Class location 2 5, Equivalent to Class location 2,3,4,5 | 6. Equivalent to Class location 3,4,59.4.2 943 10.0 10.1 10.1.1 10.1.2 10.1.3 ES.5.14.0051: Specification for Onshore Pipeline Construction Revision A Page 19 Fill material or migrating sand (sand dune) in right-of-way will not be considered to add to the depth of cover. However, surface of the fill material placed to fill low points to accommodate pipe-bending limitations may be used to determine depth of cover subject to QP approval. In transition areas between normal construction and rock construction, where the rock head is between 0.4 m and 2,0 m below normal grade, the pipeline shall be constructed as per rock construction method. A pad of selected bedding material shall be placed around the pipe to cover the pipe to a depth of 0.15m. When trenching between pipelines in the same easement, vehicle access between the pipelines shall be maintained When the pipeline under construction passes through Sabkha areas above ground, with R.O.W on embankment or on natural grade, the minimum pipeline depth of cover shall be considered from the natural ground surface or embankment surface level to the top of stabilized bund. Typical installation details are shown in the Standard Drawings. The pipeline bed and surround material shall consist of a minimum thickness of 300 mm of sweet selected sand, Its maximum particle size shall be 3 mm and it shall be free from gravel, boulders and other objects, which might damage the pipe coating, ‘The bund shall consist of a minimum thickness of 600 mm graded desert fill material surrounded by a minimum thickness of 300 mm of Cleache or equivalent material. The Client shall approve the source of all materials and the material itself. At bends, a compaction of 85% to 95% Standard Proctor with a relative density of ‘minimum70% shall be obtained within 20 Meters of tangent points upstream and downstream of the bends, Crossings General Requirements Use of casing for any erossing shal! not be permitted, unless as an exception QP decides to utilize any existing spare casing. Details of underground utilities, as available, are generally indicated in the drawings (for CONTRACTOR information only). However, CONTRACTOR shall make all reasonable efforts to obtain plans and full details of all existing and planned underground services from. the relevant local authorities and shall follow these plans closely at all times during the performance of the work. CONTRACTOR shall be responsible for locating and protecting all underground lines and structures. Pipeline locators, trial pits and all other means of locating lines and substructure shall be used. ‘The permission of appropriate authorities shall be obtained in writing, before commencing work and CONTRACTOR shall ensure that all regulations and requirements of the authority having jurisdiction over such roads are complied with. Proper warning sign shall be placed and maintained while such crossings are open. If such crossings are open at night, waming lights of a type approved by client and responsible authorities shall be provided and used.ES.5.14,0051; Specification for Onshore Pipeline Construction Revision A Page 20 10.1.4 Unless otherwise specified by QP in specific procedures and drawings, crossing roads and highways, track crossings shall be performed according to API RP 1102. Trafic load shall be established and stress calculations to be performed for road crossings, to ensure against failure and stresses to be within permissible limits. 10.1.5 The applicable QP requirements and regulations of Qatar State Authority (MMAA or other regulation authorities) having jurisdiction over the pipelines or the facility to be crossed shall be observed during the installation of a crossing. 10.1.6 Where the pipeline crosses road, existing pipelines, water lines, cables, conduits or other underground structures of any kind, CONTRACTOR shall dig and grade the trench to a depth ‘meeting the requirements indicated in the installation standards and drawings enclosed with the Contract. CONTRACTOR shall carry out necessary site investigations to establish all details that are required to install the crossing, CONTRACTOR shall prepare and submit to QP individual and detailed crossing installation procedure and drawings for QP approval. 10.1.7 CONTRACTOR shall provide supports for all foreign services during the construction operations including concrete slabs/beams. A procedure shall be submitted to the QP for approval. 10.1.8 Prior to ditching, all buried services shown on Pipeline Alignment Sheets shall be exactly located on site by CONTRACTOR, in order to prevent damages by heavy ditching equipment and proceed to expose the service by hand excavation. 10.1.9 In locations where the trench is cut across roads, paths, wadis, walkways, and other access routes, temporary bridges shall be provided. CONTRACTOR will evaluate each situation and the proposed solution will be submutted to the QP for approval. 10.1.10 Bypass roads as required by and in accordance with the regulations and code of practice of the State of Qatar Ministry of Public Works shall be constructed in accordance with procedure, in order to allow the passage of normal traffic with a minimum of inconvenience and interruption arrangements with local Police shall be made as required, 10.1.11 Whenever, it is permissible to open cut a paved road crossing, the paving shall be removed and replaced in accordance with the restrictions and requirements of the Ministry of Public Works having jurisdiction thereof. 10.1.12 Where possible CONTRACTOR shall arrange to complete the trenching, laying and backfilling of such crossings and to remove the temporary bridging before the end of the regular work day. 10.1.13 Warning signs and barricades shall be placed and maintained while such crossings are open. If the crossings are open at night, CONTRACTOR shall provide and uses electrically operated warning lights or lantems in accordance with the requirements of the responsible authorities, and, if necessary, provide watchmen 10.1.14 Breaks in the bund for a vehicle crossing at every Two Kilometer Post (KP).or, as otherwise stated in the Contract documents, shall be constructed as a track crossing. This provision does not apply to pipelines in existing energy corridors where no corresponding crossing is provided over the existing pipelines. In existing energy, corridors the QP will instruct CONTRACTOR on the correct location for such crossings. Crossing will be constructed in accordance with the approved drawings. 10.1.15 The sections of pipeline route crossing under overhead power line way shall be buried without bunds and constructed as a track crossing, 10.1.16 CONTRACTOR shall provide trench crossing at other location as necessary to permit other CONTRACTORS to perform their work with a minimum of inconvenience and interruption.ES.5.14.0051: Specification for Onshore Pipeline Construction Revision A Page 21 10.1.17 Protection provided along the construction access roads shall be left in place to be used for maintenance and inspection purposes. The width and design axle loads shall be as per the Contract document, 10.1.18 Where existing pipelines run across the area of the proposed Right of Way of the new pipelines, 102 10.2.1 10.2.2 effectively restricting the Right of Way access, a permanent reinforced concrete culvert shall be built around the existing pipelines, so as to allow unrestricted movement along both the pipeline routes if specified in the CONTRACT . Culverts shall be designed for a 30T axe load or as indicated in the Project Specifications, whichever is critical Specific Crossing Requirements Pipeline Crossing Angle ‘The new pipeline shall cross an existing pipeline at an angle between 90° ; in no case shall and 60° but the angle be less than 30°, Buried Pipeline Crossing Existing Roads Crossings of all major road crossings shall be by boring / jacking / directional drilling technique. For the purpose of definition, any road, which has a metalled wearing surface, shall be considered as major. The major crossing installation by open cut may be allowed by QP subject to permission from the regulatory authorities and bypass road satisfactory 10 QP Tequirements, To avoid settlement in open cut crossings, the trench bottom shall be well compacted for a distance of not less than five meters beyond each side of the crossing ROW limits to provide a firm bearing. The pipe shall then be laid on the compacted trench bottom. At all road crossings the wall thickness of the pipe shall be increased if shown on the crossing detail drawings. Contractor shall hydro test the carrier pipe separately at all major road crossings In order to protect the corrosion coating of the pipeline while boring / jacking / drilling, corrosion coated carrier pipes and field joints shall be additionally concrete coated to a minimum of 50 mm thickness, CONTRACTOR shall submit the design of concrete coating for the approval of client. The machine used for boring / jacking / drilling will be approved by client. All detailed crossing procedure will be prepared for each crossing for client's approval. Boring / jacking drilling machine will have position monitoring and control. The profile of the pipe shall be monitored. For Any horizontal / vertical deviation, CONTRACTOR will submit the profile of the crossing along with stress calculations for any deviations. Total stresses shall be within the limit required by the code. Any crossing, which fails to meet the requirements, will be filled with concrete and plugged at either ends. CONTRACTOR shail, in such case, re-bore at an alternative alignment as approved by client at no extra cost to client. Concrete crash barriers shall be installed at all metalled road crossings to protect the installed pipeline from third party damage. Crash barrier design shall extend a minimum of 20 m either side of the crossing boundary, The crash barrier design shall be submitted to client for QP approval.10.2.3 10.2.4 ES.5.14.0051: Specification for Onshore Pipeline Construction Revision A Page 22 ‘The minimum spacing between any pipe and the overhead or side portion of the culvert structures shall be 1.2 m unless otherwise stated on the Standard Drawings. The design of the culvert shall ensure that it will be able to withstand the anticipated traffic loading and ensure that water stagnation does not occur. Crossing of public roads shall comply with the requirements of the roads division of the Ministry of Municipal Affairs and Agriculture. The CONTRACTOR shall obtain approval of the crossing design from this organisation. Pipeline Crossing Tracks a) Buried Pipeline Crossing Tracks Track crossings shall be provided with a concrete protection slab over the new pipeline. ‘The concrete protection slab shall have a minimum thickness of 0.3 m with a width of not less than trench width + 2 m, centred over the pipe centreline. The concrete protection slab shall cover the entire width of the track being crossed and extend for 1 m on each side of the track. The clearance between the bottom of the concrete protection slab and the top of the new pipeline shall not be less than 0.6 m. ‘The design of crossing shall be in accordance with API RP 1102 and the calculations shall not take the concrete protection slab into consideration. Track and minor unmetalled crossings may be performed using an open cut, providing the necessary road closure permits can be obtained from the relevant authorities and interested third parties, CONTRACTOR will provide diversion road, if required by the authorities. To avoid settlement in open cut crossings, the trench bottom shall be well compacted for a distance of not less than five meters beyond each side of the crossing ROW limits to provide a firm bearing, The pipe shall then be laid on the compacted trench bottom. Steel safety barriers shail be installed at all track and road crossings to protect the installed pipeline from third party damage. Safety barriers shall be installed in accordance with the approved typical drawings. b) Above Ground Lines Crossing Tracks Where above ground lines cross tracks, the lines shall be buried at the crossing and given slab protection. Alternatively, the lines shall be laid in culverts, Buried Pipeline Crossing (Existing) Buried Pipeline and/or Existing Underground Services. At underground service crossings of utility cables (power and telecom) and existing pipelines a minimum vertical separation of 0.6 m shall be kept between the new pipeline and the underground service. ‘Where the new pipeline crosses below the existing service and/or existing buried pipeline, a concrete protection slab shall be installed between the new pipeline and the underground service. The clearance between the bottom of the concrete protection slab and the top of the new pipeline shall not be less than 0.3 m. In certain circumstances ( rocky soil, deep existing buried pipeline/facilities...) , the new buried pipeline may cross above existing pipeline/facility provided approval is obtained from QP or the existing facility owner.,10.2.5 10. 6 ES.5.14.0051: Specification for Onshore Pipeline Construction Revision A Page 23 Where the new pipeline crosses above the existing service a concrete protection slab shall be installed above new pipeline. The clearance between the bottom of the concrete protection slab and the top of the new pipeline shall not be less than 0.3 m. ‘The concrete protection slab shall be 0.1 m thick and shall extend for 3 m upstream and 3 m downstream of the new pipeline at the crossing point. The width of the slab shall extend across the width of the trench. Where there is an existing pipeline ROW associated with the underground service, this shall be considered as a track crossing, ‘The crossing design for power and water utilities shall comply with the requirements of the Ministry of Electricity and Water. The CONTRACTOR shall obtain approval of the crossing design from this organisation. Buried Pip. ‘The new pipeline shall cross below the existing aboveground pipeline. The new pipeline shall be at the minimum depth of cover as defined in Table 1 and a concrete protection slab installed between the new pipeline and the aboveground service. The clearance between the bottom of the concrete protection slab and the top of the new pipeline shall not be less than 300mm. 1e Crossing Existing Aboveground Lines The concrete protection slab shall be 100mm thick and shall extend for 300mm upstream and 3000mm downstream of the new pipeline at the crossing point. ‘The width of the slab shall extend across the width of the trench. ‘The crossing design for water utilities shall comply with the requirements of the Ministry of Electricity and Water. The CONTRACTOR shall obtain approval of the crossing design from this organisation. Where there will be a new pipeline ROW, the existing aboveground pipeline shall be protected with a concrete culvert across the whole width of the ROW. Aboveground Pipeline Crossing Existing Aboveground Lines ‘The new pipeline shall eross above the existing aboveground pipeline. The separation distance between the two pipelines shall be a minimum of 300mm. ‘The crossing design for water utilities shall comply with the requirements of the Ministry of Electricity and Water. The CONTRACTOR shall obtain approval of the crossing design from this organisation. Where there will be a new pipeline ROW, the existing aboveground pipeline shall be protected with a conerete culvert actoss the whole width of the ROW, 10.2.7 Overhead Power Cables When pipelines and power lines (cables) cross, the horizontal angle of intersection shall be within 70 to 110 angular degrees. Poles or structures for overhead power lines shall not be located in pipeline corridors. The new pipeline shall maintain separation distance of 30 m from the base of the power line pylon (High Voltage > 66KV). Where the distance is less than 30m but not less than 5 m, concrete protection slabs shall be installed, ‘The concrete protection slab shall have a minimum thickness of 0.3m with a width of not less than trench width + 2m, centred over the pipe centreline. The concrete protection slab shall extend 25m each side of the crossing point. The clearance between the bottom of the concrete slab and the top of the new pipeline shall not be less than 0.6m, ‘AC mitigation methods, where required by study findings, shall be employed at all crossing points, in accordance with NACE RP 0177-2000,10.2.8 10.2.9 11.0 Wad 2 ES.5.14.0051: Specification for Onshore Pipeline Construction Revision A Page 24 Underground Cables crossing Corridor Underground cables crossing pipeline corridors shall do so by means of concrete duct bank. The minimum vertical distance between the bottom of any pipe and the top of the duet bank is 1.0m. ‘The concrete duct shall be continuous across the width of the pipeline corridor. Cables shall have no servicing points within pipeline corridors. However if servicing points are to be installed, no portion of the service points (manhole) shall be closer than 25 m to any pipeline in the corridor. ‘Wadi crossing The pipeline should be buried at a minimum of 1.0 m from grade level. Long radius hot induction bends (factory made bends) of radius 5 times the nominal diameter, or , cold field bends with minimum radius of 40 times the nominal diameter, if required, for burying the pipeline deeper underneath the Wadi. Concrete slabs shall be placed above the pipeline crossing at a distance of about 0.4 m from top of the pipeline, across the width of the WADI crossing. In case of crossing flooded Wadi, pipeline shall be installed with concrete coating across the width of the Wadi, Concrete weight/ thickness shall be in accordance with buoyancy calculation procedure to be agreed by QP. All Wadi crossings shall be made in accordance with the Standard Drawings. Pipeline Bends General CONTRACTOR shall make all necessary pipe bends required for the construction of the pipeline. In order that the weld-up line on the construction right-of-way fits the pipe trench properly, the Contractor shall calculate the side bends, over bends, sags and combination bends precisely. Cold field bends or hot induction bends shall be used at locations of horizontal or vertical changes in direction in accordance with the approved construction drawings, Mitre or lobster-back bends shall not be used. Factory made hot induction bends shall be used where there is a requirement for a tighter bend radius, ‘These bends shall have a minimum bend radius of 5 times the nominal diameter, in order to facilitate passage of pigs. Elastic Bending Elastic bending shall only be employed for gradual changes in elevation, achieved by cutting or filling and leveling the trench profile and laying the pipeline to fit the natural contour of the trench. Where change in grade is such that, clastic bending limits are crossed, field bends shall bbe used. The minimum elastic bend radius shall be expressed as a change in elevation over a fixed distance. Field cold bending in no case shall be less than forty (40) times the outside diameter of the pipe being bent ‘Changes of vertical and horizontal alignment shall preferably be provided by elastic bending, Cold field bends may be provided for change of direction and change of slope. Factory made hot bends shall be used only where such bends are specifically shown in client's drawings Calculations, by manual methods or otherwise, shall be submitted to show that combined stress is limited to within the design code limits. No tie-in shall be made within any section of a bend . All bends shall allow the passage of current generation intelligent pigs. ‘The bending machine utilized shall be capable of making bends without wrinkles and buckles. The pads, dies and rolls of the bending equipment shall have soft surfaces to avoid damage toES.5.14,0051: Specification for Onshore Pipeline Construction Revision A Page 25 the pipe coating. Bending machines shall be of a type to be approved by the QP and shall be suitable for bending coated pipe in accordance with a QP approved procedure. 11.5 CONTRACTOR shall, before start of the work, submit and demonstrate to QP a bending procedure, which shall conform to the recommendations of the manufacturer of the bending machine. The procedure shall include as a minimum, step-length, maximum degree per pull and method and accuracy of measurement during pulling of the bend, This procedure and the equipment used shall be submitted to QP for approval. CONTRACTOR shall employ an experienced Bending Specialist/Subcontractor, who will supervise the bending of pipe in accordance with approved procedures and will ensure uniform bearing under the pipeline and will maintain the required depth of cover indicated on Alignment Sheets Cutting of factory made bends and cold field bends for any purpose is not permitted, 11.6 All bends shall be of a uniform radius and the curvature shall be distributed over as great a length of pipe as is reasonably possible. ‘The configuration of field bends shall be in accordance with the following: ‘¢ Bending shall not be made within 2 m of the end of a joint of pipe or girth weld, # Longitudinal weld shail not be on the bend curve. © No bend shall be acceptable if the difference between the largest diameter of the pipe and the smallest diameter, at any point in the bend, is more than 2.5% of the inside diameter. © A check shall be performed on all bends in the presence of QP by passing a gauge consisting of two discs with a diameter equal to 95% of the nominal internal diameter of the pipe connected rigidity together concentrically at a distance equal to 350 mm. 11,7 All factory made bends shall be provided with anti-corrosion coating in accordance with the Contract Documents. 11.8 Damage to yard applied coating due to bending of line pipe shall be made good in accordance with Contract Documents at the CONTRACTOR’s expense. 12.0 Lining-up and Welding 12d CONTRACTOR shall align and weld together the joints of pipe into a continuous pipeline, and all welds in the pipeline made by CONTRACTOR shall be of strength equal to that of the pipe. Welding acceptance criteria shall be in accordance with API Standard 1104 (latest edition). Welds shall comply with welding procedures to be submitted to QP for approval. 12.2 Coated pipe shall be temporarily supported on padded supports giving a ground clearance not less than 0.3 m according to detailed procedures to be submitted to QP for approval. 123 Each pipe joint shall be thoroughly swabbed to remove all dirt and foreign matter from the inside of the pipe before the joints are lined up and welded. The swabbing operation shall not be carried out on more than six (6) pipe joints ahead of the stringer bead welders. Where the pipeline is welded in long sections by the firing line method, the ends of the long sections shall be capped in accordance with the procedures to be approved by the QP, until the long sections are tied-in. During the laying operations, close attention shall be given to open ends to insure an open and clean line free of any obstructions. All precautions shall be taken to prevent water from entering the pipeline. ‘The open end of the line shall be securely closed at the end of each day's work to prevent entrance of small animals or the introduction of foreign matter of any nature and shall not be reopened until work is resumed. CONTRACTOR shall remove all obstructions in the line after the completion hereof.124 125 12.6 13.0 13.4 13.2 1B3 ES,5.14.0051: Specification for Onshore Pipeline Construction Revision A Page 26 Tack welding of end caps to the line pipe shall not be permitted CONTRACTOR shall be responsible for the repair of internal and/or external pipe defects to the extent that they are acceptable to the QP. Acceptability of defects in the pipe detected during inspection at work site shall be determined in accordance with Contract Documents for line pipes or ASME B31.8/ASME B 31.4 whichever is more stringent. If, due to cutting or repairs, the pipe identification number is removed, it shall be reprinted immediately by the CONTRACTOR in the presence of QP. No pipe without identification number shall be transported and/or welded into the pipeline. CONTRACTOR shall ensure during the line-up operation that longitudinal welds are offset and are in accordance with API 1104 latest revision and any applicable amendment agreed by QP. All pipe joints 10” NPS and above shall be aligned with an intemal line-up clamp approved by QP except for tie-in welds or other exceptional conditions approved by QP on which occasion an external line-up clamp may be used. All welding procedures, welder and NDT personnel shall be qualified in accordance with the WPS. and all pipe fittings and coupons required for these qualification tests shall be furnished by CONTRACTOR. The material used for qualification tests shall be the same pipe as that procured for the Project. The material shall be metallurgically selected for the weld qualification fest. All testing facilities, welding and Non Destructive Examination procedures used by CONTRACTOR shall be certified by a qualified authority approved by QP. Pipelines, which are constructed within the area of high voltage lines, may be electrically influenced by these high voltage lines. The induced voltage caused by the influence may at times be high enough as to pose a danger to personnel working on the pipeline. The CONTRACTOR shall specify detailed safety aspects of working under such conditions in the Contractor's Safety Manual. Protective Coating Above Ground Pipeline ‘The above ground pipeline shall be protected by an external coating as detailed in the Contract Documents and according to QP Standard QP-SPC-L-002. Painting All exposed surfaces such as pipe work, valves, steel work; supports, conduits and other miscellaneous equipment shall be painted ( coated ) in accordance with QP Standards Specifications , QP-SPC-L-002. Buried Pipeline Coating ‘The coating of pipeline field joints, tie-ins shall be made in accordance with QP Specification, QP-SPC-L-006 and to the procedure to be submitted for QP approval. All buried flow tees, factory made bends, anchor flange and other in-line fittings shall be coated with suitable coating compatible with the main line coating. Contractor shall develop a coating procedure and submit the same QP approval, prior to implementation. ‘The anti-corrosion coating applied to buried pipe work shall terminate approximately 100em above the finished grade level. CONTRACTOR shall provide a clear interface between the below ground coating and above ground painting system. CONTRACTOR shall apply cold tapes at the interface as part of his scope of work.BA ES,5.14,0051: Specification for Onshore Pipeline Construction Revision A Page 27 Anticorrosion coating exposed above ground shall be provided with additional coating for protection against Ultraviolet degradation, CONTRACTOR shall apply cold tapes at the interface as part of his scope of work. In areas like metalled road crossings and wadi crossings, where damage to the protective crossings is likely, additional protective coating shall be provided such as concrete. The additional protective coating will be subject to QP approval Coating Control& Repairs The coating condition shall be inspected by QP prior to backfilling .AIl holiday and damaged places in the coating shal! be repaired by CONTRACTOR until the detector has passed over the entire pipe joint without disclosing any holiday or imperfections in the coating Repairs to coatings shall be made in accordance with QP Specification QP-SPC-L-005 and to the procedure as recommended by the coating material manufacturer. CONTRACTOR shall make detailed inspection of the coating for holidays and imperfections with a holiday detector immediately preceding the lowering in of the pipe as specified in Specification QP-SPC-L-005 for the pipe coating and Specification QP-SPC-L-006 for the field joints. CONTRACTOR shall furnish high voltage electric holiday detectors set to manufacturer's recommendations. CONTRACTOR shall handle coated pipe , shrink sleeves at all times with equipment designed to prevent damage to the coating according to a detailed procedure duly approved by QP. 14.0 Lowering-In 14.1 14.2 143 Method Statement for lowering-in, with selection criteria for side booms, slings and other lifting/handling devices shall be furnished. ‘The distance between the lowering-in operation and the back-fill operation shall not exceed 1 tile or as approved by client’s authorized representative. Laying shall be carried out under safe conditions so as to avoid stress and temporary deformations, which may cause to the pipeline itself and to the coating. In localized points where the Right-of-Way is restricted to less than the minimum necessary for the tansit of mechanical equipment, the laying shall be carried out using other suitable means. The pipes shall be placed in their final position without jerking, falling, impact or other similer stresses. In particular, care shall be taken that the deformation caused during the raising of the pipes from the temporary supports, does not exceed the minimum allowable radius of elastic curvature so as to keep the stress on the steel and on the coating within safe limits ‘The suspended portion of the pipeline during installation to its final position shall be supported by side-booms. Contractor shall submit to client for approval a procedure indicating the required number of side booms for holding the line in gentle s-curve maintaining minimum of clastic bend radius as specified in the specification for bending, Contractor shall perform the installation in accordance with the procedure. CONTRACTOR shall lower the pipe into the trench after the coating of field joints checked in accordance with Contract Documents to ensure # 100% holiday free pipeline coating system, Pipe shall not be lowered into the trench until after pre-padding of trench bottom. CONTRACTOR shall request and receive approval from the QP prior to lowering-in any pipe.144 147 148 15.0 15.1 15.2 153 154 155 15.7 158 ES,5.14,0051: Specification for Onshore Pipeline Construction Revision A Page 28 CONTRACTOR shall be required to provide padded slings for handling coated pipe. The use of belting reinforced with wire cable shall not be permitted. Lowering-in method shall be described in a procedure to be submitted to the QP for approval. However, the use of pneumatic cradles is preferred. A holiday detection survey shall be run continuously behind the cradle and any repairs necessary shall be made prior to bedding the pipe in accordance with the approved procedure. ‘The handling of the pipe shall be done in such a way and in accordance with procedure, and shall ensure that the pipe in its final position in the trench is free of abraded spots or holidays. Where water is present in the trench no lowering-in shall be permitted until the ditch has been dewatered to the extent and for the time necessary to make visual inspection by the QP of the bedding material on which the pipe is to be laid. Following such inspection the presence of water shall be permitted provided that it is not so high as to cause cave in of the walls of the trench or floating of the pipeline before padding and back filling, when weighting of the pipe is not provided. Where the expected water, after construction may cause flotation or buoyancy, buoyancy calculations for determining thickness of weight coating for combating buoyancy, shall be submitted to QP approval Care shall be exercised while removing the slings from around the coated pipe after it has been lowered into the trench, No sling shall be put around field joint coating All measurements required for the preparation of “as-built” drawings, to the extent required, shall be made prior to backfilling, Tie-Ins CONTRACTOR shall perform all work necessary to tie-in separate welded sections of the pipeline into a continuous system. ‘All beveling, aligning and welding shall be done in accordance with Specification. API 1104 latest revision and any applicable amendment agreed by QP. Welding after the pipe has been lowered into the ditch (bell hole welding) shall be performed only where sufficient clearance had been provided to enable the welder to exercise normal welding skill and ability. All safety measures shall be taken into consideration ‘The provisions of Clause 8.6 of this specification as regards handling of the pipe shall apply. ‘The protective coating of tie-in welds shall be done in accordance with Clause 13.3 of this specification. All pipes 2 meters or more in length cut off at tie-in points shall not be allowed to accumulate but shall be moved ahead daily as the work progresses and welded into the pipeline at tie-in locations as directed by QP. CONTRACTOR shall observe the maximum and minimum tie-in temperature to be used based on the prevailing temperature conditions and the calculations reports as submitted by the CONTRACTOR for approval by QP. CONTRACTOR shall perform tie-in as soon as practicable after lowering-in of the strings. Extended periods between lower-in and tie-in shall only be allowed when specified tie-in temperatures cannot be reached, Backfilling and tie-in temperature shall be on the allowable range: min. 20°C, max. 35°C, or, as recommended by the calculation reports performed during the detailed design by the Contractor. Ifa pup is to be added for a tie-in, the minimum length that may be used shall be 1.5 m. Two ‘or more such pipes shall not be welded together.15.9 16.0 161 170 174 172 173 174 175 176 177 178 179 17.10 ES,5.14,0051: Specification for Onshore Pipeline Construction Revision A Page 29 All tie-in welds shall be 100% radiographically and ultrasonically examined. All welding and NDT shall be in accordance with the applicable specification enclosed with the Contract and the approved welding procedure. Washouts and Drainage Wherever the possibility exists of washouts due to surface water run-off (e.g. wadis or upwelling of underground water), CONTRACTOR shall provide washout protection for the pipeline and install drainage so that the original water course is reinstated in accordance with approved Project drawing. Padding and Backfilling of the Trench CONTRACTOR shall pad and backfill the trench after the pipe is in place as set forth in the applicable Standards Drawings provided in the Contract Documents. CONTRACTOR shall supply all padding material for pipe bedding and padding. Only dune sand having a particle size of less than 3 mm shall be used for pipe bedding and padding, If excavated material is the same material as described in Clause. 17.2, it shall be used for bedding and padding, In areas, where excavated material is not suitable for padding, the padding material to be placed around the pipe for 2 minimum cover, as specified in the Contract drawing and shall be as described in the Clause 17.2 above. The remaining backfill may be completed with excavated material provided it is free from organic material and does not contain stones larger than 0.1 m in diameter. In Sabkha arcas, CONTRACTOR shall supply and haul material to form the berm and bund in accordance with the approved drawings. In areas containing buried cables, backfilling shall not be performed until all tiles have been replaced and all cables have been supported and protected to QP’s satisfaction. CONTRACTOR shall grade the trench bedding material to give the maximum amount of support to the pipeline when lowered into place. The material shall be compacted to the degree specified on the construction drawings and as approved by the QP. CONTRACTOR shall place padding material in such a manner as to cause no damage to the pipe coating and compact it to the degree specified in the construction drawings as approved by the QP. ‘The depth of padding shall be such as to give the pipe, in place, the specified clearance from the hard material, as per typical installation drawings approved by the QP. CONTRACTOR shall not commence the padding operation until the QP has inspected and approved the lowered-in pipe. If any backfilling is done without QP's approval, QP shall have the right to require removal of the backfill for examination, and the cost of such uncovering shall be bome by CONTRACTOR. CONTRACTOR shall survey and record "as built" ‘measurements, including location and record pipe joint numbers and welds before padding material is placed. Before backfilling the trenches at the crossings, inspection by other Government Departments and agencies including maintenance of their utilities shall be allowed. Padding material to cover the pipe shall be applied immediately after the trench is approved for back-filling to give shade and protection. All pipe being lowered into the pipe trench shall be covered with padding material at the end of each working day to give shading and protection ‘After padding operations are complete, the backfill and bund installation shall take place as specified in the Standards Drawings contained in the Contract Documents.1741 17.12 17.13 17.14 1745 1716 17.47 18.0 18.1 ES.5.14,0051: Specification for Onshore Pipeline Construction Revision A Page 30 ‘The bund shall not be constructed in areas where evidence of running water or wadi,s can be found. CONTRACTOR shall obtain QP's approval for the wadi crossing proposals where the bund removed to allow the wadi flow to pass through. The pipeline construction in these wadi-crossing areas shall be buried and protected with concrete slabs as shown in the typical installation standards and as approved by QP. Backfill material shall be piled over the ditch to at least 1 m above original ground and the exterior of the bund reinforced with rock as soon as possible for stabilization as specified on Standard Drawings contained in the Contract Documents. In rocky areas, the pipeline bund shall be constructed using desert fill or excavated material. Bund material shall be free from organie material and course graded. Fines shall be placed at the bottom of the bund with 150 mm particles and greater on the top. Bund angle shall be less than the normal angle of repose for the bund material as per the approved Standard Drawings contained in the Contract Documents, Compaction of padding and bedding material shall be in accordance with typical installation standards and approved construction drawings. The backfill around existing facilities shall be compacted by hand, ‘Where the trench has been excavated through tracks, ete, all backfill shall be thoroughly compacted to 95% Proctor Density. This will have to be followed up by stabilization of the surface of the backlill with suitable material, In all cases, the CONTRACTOR shall comply with the requirement of Authorities concerned. ‘At the end of each day's work, backfill shall not lag more than 1000 m behind the head end of lowered-in pipe, which has been approved for backfill Where wadis or roads are graded, trenched or otherwise disturbed, the CONTRACTOR shall restore the property to its original contour and conditions to the satisfaction of the QP and relevant Authorities. For all the pipeline crossing sandy rocky and normal terrain, the backfilled trench shall be provided with a berm formation as detailed on the typical drawings and approved by QP. CONTRACTOR shall ensure that the berm is centered over the pipeline using the temporary markers for guidance. The temporary markers shall only be removed following commencement of berming operations. Suitable provision of drainage system for the pipeline corridor shall be kept at low points so as, not to disturb the natural flow of rainwater. Thus avoiding any impact on the ecology. The detail of such provides shall be approved by QP The berm formation in Sabkha arca shall be as detailed on the drawings. The bund shall consist of a minimum thickness of 600mm graded desert fill material surrounded by a minimum of 300 mm of Cleache or equivalent material. The sources of all materials and material itself shall be approved by the Client. On straight sections of pipeline, a compaction of 75% to 85% standard Proctor with a relative density of 40% to 60% shall be obtained. At bends, a compaction of 85% to 95% standard Proctor with a relative density of minimum 70% shall be obtained within 20 meters of tangent points upstream and downstream of the bend. Special Installations on the Pipeline General In addition to constructing the pipeline, CONTRACTOR shall also install other facilities and appurtenances as described in the Contract Scope of Work. The work required to complete the installations shall include all site surveys, site preparation, filling, grading, fencing, foundations, installation of block valves, side and vent valves, pipe work, pipe supports,18.2 18.3 18.4 ES.5.14,0051: Specification for Onshore Pipeline Construction Revision A Page 31 insulation joints, anchor blocks, pressure gauges, mechanical facilities, civil work, painting, electrical and instrumentation works. All works shall be as per applicable Codes and Standards, specifications, approved drawings and as directed by QP. Valve Stations Valve stations shall be installed as shown on the approved drawings. It is CONTRACTOR’s responsibility to have the units completely assembled, tested and made fully functional, including all related instruments, equipment, etc. Valves with flow arrows shall be installed according to the normal flow direction in the pipeline. During welding, the valves shall be in fully open position. Care shall be take to avoid entry of sand particles etc. to valve body, seals ete. during transportation, storage, assembly and installation. All inline assemblies shall be prefabricated and tested hy

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