Construction Specification FOR Fuel Gas Pipe Line: Mellitah Oil & Gas A-100 Trash Incinerator Project

MELLITAH OIL & GAS A-100 TRASH INCINERATOR PROJECT
CONSTRUCTION SPECIFICATION FOR FUEL GAS PIPE LINE
0 REV.
11-NOV-12
Issued for Approval DESCRIPTION
AAA ORG
SMW CHKD
HRZ LE
AWA EM MOG PROJECT # 6245 Page Page 1 of 20
DATE
Al-MOTHOUKA ELECTRICITY & ENGINEERING, 6-km, Injila Road, Injila, Tripoli, Libya MELITTAH OIL & GAS B.V LIBYAN BRANCH Dahra Kebira Street, P.O. Box 346, Tripoli-Libya
DOCUMENT TITLE: MOG-A100 TRASH INCINERATOR PROJECT, ABU ATTEFIL FIELD DOCUMENT NO: 3401-575-GS-DA-ALM-004GS-00
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MOG-A100 TRASH INCINERATOR PROJECT ABU ATTEFIL FIELD Construction Procedure for Gas Pipeline
DOC NO: 3401-575-GS-DA-ALM-004GS PAGE: Page 2 of 20 REV: 00
Table of Contents
1. MOG-A100 TRASH INCINERATOR PROJECT ABU ATTEFIL FIELD.............................................................................2 Construction Procedure for Gas Pipeline...........................................................................................................................2 1. SCOPE OF THIS DOCUMENT ...........................................................................................................................................5 2. FURTHER DEFINITIONS (FOR THE PURPOSES OF THIS SPECIFICATION) ...............................................................5 3. REFERENCE STANDARDS & CODES ..............................................................................................................................5 4. RECEIPT, LOADING, HANDLING AND STORAGE OF MATERIALS .............................................................................6 4.1 General ..............................................................................................................................................................................6 4.2 Handling of Pipe .................................................................................................................................................................6 4.3 Transporting of Pipe ...........................................................................................................................................................6 4.4 Storage of Pipe & Materials ...............................................................................................................................................6 5. SURVEYS.............................................................................................................................................................................7 6. ROW CLEANING & GRADING............................................................................................................................................7 6.1 Pipeline R.O.W. ...............................................................................................................................................................8 7. STRINGING OUT OF PIPE .................................................................................................................................................8 8. TRENCHING ALIGNMENT & EXCAVATION .....................................................................................................................8 8.1 General ..............................................................................................................................................................................8 8.2 Excavation Preparation ......................................................................................................................................................9 8.3 Trench Alignment ...............................................................................................................................................................9 8.4 Trench Depth .....................................................................................................................................................................9 8.5 Trench Width ....................................................................................................................................................................10 9. EXCAVATION ANOMALIES .............................................................................................................................................10 9.1 General ............................................................................................................................................................................10 9.2 Trench De-watering .........................................................................................................................................................10 10. BACKFILL & PADDING...................................................................................................................................................10 11. REINSTATEMENTS.........................................................................................................................................................11 12. PIPE LAYING...................................................................................................................................................................12 12.1 General...........................................................................................................................................................................12
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12.2 Lowering-In.....................................................................................................................................................................12 13. COLD FIELD BENDING ..................................................................................................................................................12 13.1 General ..........................................................................................................................................................................12 13.2 Bending Radius...............................................................................................................................................................13 13.3 Bend Test Specimens.....................................................................................................................................................13 13.4 Buckle.............................................................................................................................................................................13 14. WELDING.........................................................................................................................................................................13 14.1 General...........................................................................................................................................................................13 14.2 Surface Cleaning before Welding ..................................................................................................................................14 14.3 Pipe Swabbing Prior to Set Up ......................................................................................................................................14 14.4 Pipe Set Up ....................................................................................................................................................................14 14.5 Cover of Coating ............................................................................................................................................................14 14.6 Preheat of Pipes ............................................................................................................................................................14 14.7 Earth Clamps .................................................................................................................................................................15 14.8 Cleaning Between Runs ................................................................................................................................................15 14.9 Stub Electrodes ..............................................................................................................................................................15 14.10 Welding Electrodes ......................................................................................................................................................15 14.11 Identification of Welders and Welds ............................................................................................................................15 14.12 Welding of Fittings .......................................................................................................................................................15 14.13 Tie-In Welding ..............................................................................................................................................................15 14.14 Pipe Off-Cuts (PUPS) ..................................................................................................................................................16 15. WELD REPAIRS & PIPE DAMAGE................................................................................................................................16 15.1 General...........................................................................................................................................................................16 15.2 Repair or Removal of Defects ........................................................................................................................................16 15.3 Dents, Grooves and Scratches ......................................................................................................................................16 15.4 Arc Burn .........................................................................................................................................................................16 16. WELDING PARTICULARS .............................................................................................................................................16 16.1 Welding During Periods of Fire Danger..........................................................................................................................16 16.2 Wind and Weather..........................................................................................................................................................17 17. NON-DESTRUCTIVE EXAMINATIONS OF WELDS .....................................................................................................17 18. COATING .........................................................................................................................................................................17 18.1 General ..........................................................................................................................................................................17
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18.2 Coating Weld Joints .......................................................................................................................................................17 18.3 Locating Coating Defects (holidays) ..............................................................................................................................17 18.4 Fittings & Risers .............................................................................................................................................................18 18.5 Additional Wrapping .......................................................................................................................................................18 18.7 Above Ground Pipework ................................................................................................................................................19 19. CATHODIC PROTECTION & ANODES .........................................................................................................................19 19.1 General ..........................................................................................................................................................................19 19.2 Insulating Joints .............................................................................................................................................................19 19.3 Anodes & Anode Bed ....................................................................................................................................................19 20. HYDROSTATIC TESTING, PURGING AND COMMISSIONING ...................................................................................19 20.1 General ..........................................................................................................................................................................20 1.2Technical Data ..................................................................................................................................................................20 20.3 Safety .............................................................................................................................................................................20 20.4 Testing Procedure ..........................................................................................................................................................20 21. COMMISSIONING ...........................................................................................................................................................20
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1. Scope of This Document This specification sets out the standard technical requirements for the construction, installation and testing of the pipelines for the A100 area trash incinerator project at Abu Attefil field. 2. Further Definitions (for the purposes of this specification) "R.O.W." Right of way or easement "SHALL" "SHOULD" Indicates a mandatory requirement Indicates a recommendation
3. Reference Standards & Codes Insofar as applicable, the latest versions of the following listed standards and codes of practice SHALL be read and construed as though they formed part of and were incorporated in this SUBCONTRACT. The work under the SUBCONTRACT SHALL be performed strictly in accordance with the requirements set out in these documents except where such requirements conflict, or are inconsistent with other provisions of the SUBCONTRACT. Where such conflict or inconsistency arises, the most demanding requirements SHALL prevail. Other codes and regulations may have been adopted by the jurisdictional agencies at locations where the work is to be performed. It SHALL be the CONTRACTORS responsibility to determine whether local codes and regulations exist. In the event local codes and regulations do exist, CONTRACTOR SHALL determine their scope and abide by all their provisions. Standards B31.8 API RP 11 02 API Std 1104 SP-90-Q-0001 SP-90-E-0001 MS-00-L-001 SP-00-M-0017 Gas Transmission and Distribution Piping Systems Steel Pipelines Crossing Railroads and Highways Standard for Welding Pipelines Facilities and Related
Specification for Non Destructive Examination (NDE) of pipeline welds Specification for Pipeline Cathodic Protection Method statement for handling & fabrication of exotic piping materials Specification for painting and protective coatings
The SUBCONTRACTOR SHALL ensure that current copies of all Standards and Codes of Practice, including amendments, are available for reference to all of its employees and SECONDARY SUBCONTRACTORS at all times where required for the safe and efficient performance of the work under the SUBCONTRACT.
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4. Receipt, Loading, Handling and Storage of Materials 4.1 General All construction activities including handling and inspection of pipes SHALL comply with the Reference Standards and Codes, listed in section 3.0. The SUBCONTRACTOR SHALL be responsible for the pickup and transportation of all materials from the nominated CONTRACTOR collection point. The SUBCONTRACTOR SHALL inspect all materials at time of collection and notify the CONTRACTOR of any damage. Any damage not reported at the time of collection and found after receipt of material, SHALL be deemed to have been caused by the SUBCONTRACTOR and all costs to rectify the damage SHALL be borne by the SUBCONTRACTOR. Pipes SHALL not be placed on the ground during handling, storing and stringing operations. The pipe may be supported on timbers, sawdust, sand-filled bags or on a prepared storage place. Pipes SHALL be chocked with wooden wedges at each end to prevent rolling. 4.2 Handling of Pipe Rough handling of the pipe SHALL be avoided. Pipes SHALL not be lifted with rope or chain directly around the pipes. Pipes may be lifted by special hooks at each end of the pipe and utilising a spreader bar if APPROVED by the CONTRACTOR. Only one pipe SHALL be lifted at a time when not in a bundle. The end hooks SHALL be of material that is not detrimental to the pipe and of such a design that will not damage the pipe ends. If pipes are supplied fitted with "bevel protectors" then disposal of "bevel protectors" SHALL be in a manner APPROVED by the CONTRACTOR. Bevel protectors SHALL remain on the pipe until the pipe is required for welding. Coatings that are damaged as a result of handling the pipe, SHALL be repaired by the SUBCONTRACTOR, to the satisfaction of the CONTRACTOR, at the SUBCONTRACTORS cost.
4.3 Transporting of Pipe Pipe transport vehicles SHALL be equipped with padded bolsters and web belting type tie- down straps to secure the load. Bolster or tie-down straps likely to cause damage to the pipe or coating SHALL not be used.
Padded bolsters SHALL be a snug fit so that stones cannot slip between the pipes and bolsters. Adjacent layers of pipe SHALL be separated by padded or rubber separators, or similar, of sufficient thickness to ensure adequate separation between pipes is maintained during transport. 4.4 Storage of Pipe & Materials The CONTRACTOR SHALL allocate an amount of storage and laydown area for the SUBCONTRACTOR within the CONTRACTOR controlled project-site. Any additional storage and laydown areas required, SHALL be the responsibility of the SUBCONTRACTOR to provide. Any storage area to be used for stockpiling pipe SHALL be located on properly drained land, not subject to flooding. Access in and around the area SHALL facilitate the storage and loading of pipes in any weather condition. When storage sites are no longer needed in connection with the work, they
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SHALL be cleaned up and reinstated by the SUBCONTRACTOR to original condition and the satisfaction of the CONTRACTOR. Any grass and vegetation below and immediately adjacent to the pipe SHALL be kept trimmed to prevent damage to the pipe in case of fire. Pipe of the same outside diameters but different wall thickness or grade SHALL be transported and stored in such a manner as to ensure that the different wall thicknesses or grades are not mixed. Stacking of pipe SHALL not be allowed unless SUBCONTRACTOR submits a procedure to the CONTRACTOR demonstrating the methods and equipment for stockpiling the pipe, whilst ensuring the stockpile is safe and not damaging pipe. If the SUBCONTRACTOR is APPROVED to stack the pipe, all pipe SHALL be nested and may not exceed a maximum of 6 tiers. In the event coated pipe is stockpiled for more than 90 days it SHALL be covered with tarpaulins or plastic that prevents coating degradation by UV rays, this SHALL be done to the satisfaction of the CONTRACTOR. Pipe coating materials SHALL be stored indoors for protection from weather, in a manner that is satisfactory to CONTRACTOR. Valves, fittings and other materials SHALL be stored in a manner to preserve their condition, prevent loss and permit easy access for inventorying quantities. Valves, flanges or other materials with finished surfaces SHALL be supplied fitted with caps to all openings and SHALL be placed on timbers. Valves, along with other small fittings and supplies, SHALL be stored inside until ready for use. Caps SHALL not be removed until immediately prior to installation.
5. Surveys
Limits of the R.O.W. SHALL be marked with sufficient indicators to identify the full extent of the R.O.W., pipeline, center-line and chainage. When marking the limits of the R.O.W., indicators SHALL be installed at each required place but not more than 500m point and change in direction; they may be used when identifying weld numbers, if necessary. Before cleaning and grading, stakes SHALL be placed in an offset position to enable the pipeline centerline to be re-established. The SUBCONTRACTOR SHALL locate, identify, mark and protect from damage all above and below ground services or facilities along the pipeline route. Any items requiring relocation SHALL be relocated to the satisfaction of the CONTRACATOR.
6. Row Cleaning & Grading
Cleaning and grading SHALL be performed so that the ditching requirements can be achieved and the R.O.W. has a suitable grade to facilitate the laying of the pipe. Grading SHALL be performed in a manner to minimize interference with existing natural drainage or utilities without compromising the drainage of surrounding areas.
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Topsoil, wherever it exists, SHALL be stock piled to the trench line and SHALL be kept separate from other excavated material. Any topsoil removed SHALL be replaced in the areas from which it was removed. Topsoil SHALL not be replaced until trench has been backfilled in accordance with Section 9 of this Specification. Any subsidence after replacing topsoil SHALL be rectified by CONTRACTOR with equivalent additional topsoil.
6.1 Pipeline R.O.W.
The R.O.W. width SHALL be as shown on the pipeline drawings and is typically limited to the following: 14m width for single pipeline installations in the R.O.W. . SUBCONATRACTOR may request additional working space outside the R.O.W. from the CONTRACTOR.
7. Stringing Out of Pipe Pipe SHALL be supported and handled in a safe and proper manner and in accordance with the SUBCONTRACT. All clearing, seed and rootstock layer and/or topsoil stripping, leveling and grading SHALL be completed on the route prior to pipe being placed on the R.O.W.; Normal access along roadways and/or tracks is to be maintained at all times; Pipe SHALL not be strung out on the R.O.W. for longer than 7 days in front of the mainline welding crew unless specific approval has been granted by the CONTRACTOR. Openings SHALL be provided at convenient locations for the passage of personnel or fauna, the distance between these openings SHALL not exceed 400 meters through cultivated land and 1000 meters through all other land. In built-up areas, the CONTRACTOR may direct the SUBCONTRACTOR to restrict the quantity of pipe that is strung out, at any one time to minimize inconvenience to the public. Such direction SHALL not of itself constitute grounds for an extension of time for completion or a variation to the work under the SUBCONTRACT. Pipe SHALL be strung out a safe distance from the trench to prevent subsidence of the trench wall. 8. Trenching Alignment & Excavation 8.1 General The pipeline route SHALL be as specified on the pipeline drawings. All construction activities including trench excavation SHALL comply with the pipeline drawings and the Reference Standards and Codes listed in Section 3.0 The CONTRACTOR gives 3 days written notice to the SUBCONTRACTOR in advance of intention to commence the ditching operations on the R.O.W. The
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CONTRACTOR SHALL not commence any trenching works until after receipt of APPROVAL to commence from the OWNER. The bottom of the ditch SHALL be uniformly graded to proper depths to prevent unnecessary bending of the pipe and provide even support of the pipeline along its length. The ditch SHALL not contain loose rock, large clods and other objects that might damage the pipe or coating. The spoil from the ditch SHALL not be placed in a location, or in a manner that it may become contaminated by any undesirable debris (for example, cleared vegetation, diesel fuel or oil spillage from machinery). Spoil banks from ditching operations SHALL not be placed where natural drainage will be impaired. Spoil banks are to be placed in a manner APPROVED by the SUBCONTRACTOR. Any over excavation SHALL be made good with backfill material and compacted to the APPROVAL of the OWNER.
8.2 Excavation Preparation Buried service pipes, drains, underground cables, gas and water mains (In this clause referred to as "services") and other obstructions intersecting the pipeline route SHALL be exposed by hand tools when working within a meter of the service. A record of the size, nature and depth of cover over such obstructions SHALL be submitted to the OWNER. The pipeline SHALL clear any such obstructions by a minimum of 300mm, or otherwise as required by the relevant code listed in section 3.0, whichever is the greater.
Prior to excavating in the vicinity of poles, including power poles, the poles SHALL be properly secured to the satisfaction of the owner or relevant authority at the cost of the CONTRACTOR. 8.3 Trench Alignment The trench SHALL be excavated to permit the as-laid center line of the pipeline to be within 200mm of the design center line alignment of the pipeline. Where there are multiple lines in parallel, the minimum separation distances SHALL be maintained. The CONTRACTOR may make changes in the pipeline alignment as deemed necessary, such changes SHALL be communicated to the SUBCONTRACTOR in writing before or during the construction of the pipeline and recorded on AsBuilt documentation. In order to facilitate construction the SUBCONTRACTOR may make minor alterations to the proposed pipeline alignment provided the pipeline remains within the R.O.W. When obstructions within the easement will not allow installation of the pipeline on design alignment, the CONTRACTOR SHALL approve an alternate alignment. 8.4 Trench Depth Unless otherwise specified or shown on the pipeline drawings forming part of the SUBCONTRACT, or directed by the CONTRACTOR, all parts of pipelines
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forming part of the Works SHALL be buried at sufficient depth to ensure a minimum cover from the top of the pipe to the finished ground surface level of not less than 1000 mm. Unless otherwise shown or specified in the SUBCONTRACT, at roads /other crossings the pipeline SHALL be installed horizontal between the toe of each bank, or table drain, with a minimum cover of 1200mm. Extra depth ditch SHALL be provided at locations where, in the opinion of CONTRACTOR, extra depth is necessary to ensure proper installation of the pipeline. These locations include crossings and approaches to existing roads, ditches, existing underground
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8.5 Trench Width Width of the trench SHALL be in accordance with the following:
a)
At ground level it SHALL be the minimum width required for the safe installation of the pipeline without damaging the pipe, people or property. The trench SHALL be adequately battered so that the trench sides SHALL not be at risk of collapsing. For a single pipe trench, unless otherwise specified or shown on the pipeline drawings, the minimum trench width at the bottom of the trench SHALL be the pipeline diameter plus 150mm clearance either side of the pipe to the trench walls.
b)
9. Excavation Anomalies 9.1 General All surplus excavated material SHALL be removed from the Site and the Site SHALL be left in a clean and tidy state that is acceptable to the CONTRACTOR. When excavating vehicle crossings and roads, both foot and vehicular traffic access SHALL be provided using APPROVED crossover plates or boards and APPROVED road signs. Alternatively the SUBCONTRACTOR may propose, subject to APPROVAL of the CONTRACTOR, a temporary detour around the working area. Excavations across roads and paths SHALL be completely filled in during the hours of darkness. Where necessary, personnel SHALL be provided for directing the flow of traffic. 9.2 Trench De-watering
Trenches SHALL be kept free from water during the time that work is in progress to prevent damage to the works or other properties. De-watering of trenches SHALL be carried out using De-watering equipment by the CONTRACTOR.
10. Backfill & Padding
Where suitable material is available, and if APPROVED by the CONTRACTOR, the padding and bedding material may be selected from trench spoil (not topsoil). SHOULD the excavated spoil be unsuitable, as determined by the OWNER, clean
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and material SHALL be imported by the CONTRACTOR for this purpose. Immediately prior to lowering the pipe into the trench, the bed SHALL be inspected and found to be free from any material likely to be injurious to the pipe or coating. Where any stones, metal, wood, vegetation, clods of earth or other deleterious material are lying loose on the bottom of the trench, they SHALL be removed by CONTRACTOR before commencing the lowering-in. After lowing in has been completed, but before backfilling, the line SHALL be inspected again to ensure it is free of loose materials and that these and other debris are not in the ditch, on the pipe, or on the spoil bank. After the pipe has been inspected backfilling may begin. Compact clean sand padding of not less than 150mm in thickness SHALL be placed around the pipe and 300mm above the pipe before backfilling with other material.
In rock and other areas where the trench bed is likely to cause damage to the pipe, the pipeline SHALL be supported along it's length by a bed of clean compacted sand not less than 150mm deep. In trenches excavated in clay or sand, the pipe may be laid directly onto the trench bottom, unless otherwise directed by the OWNER. No deleterious materials are to be included in the backfill. Unless otherwise specified on the pipeline drawings, backfill SHALL be compacted to a density which will ensure that there will be no subsidence at the surface at any time following completion of the work. The OWNER may approve spoil compaction by wheel rolling. Bedding and backfill SHALL be placed and compacted in a manner that will ensure that no damage occurs to the pipe or coating and no voids are left around the pipe. Upon completion of the backfill, the CONTRACTOR SHALL clear the R.O.W. of all rock, stumps or other remaining debris. Holes, ruts and depressions SHALL be filled and the R.O.W. SHALL be left in a neat condition to the APPROVAL of the OWNER. Completed backfilling of the ditch and grading of the R.O.W. SHALL be done in a manner that restores the natural contour of the ground.
11. Reinstatements Pipeline Markers SHALL be installed along the R.O.W. in quantity and located as follows: As a inter-visible or maximum 500m At change of direction. Both sides of each and every road At the entry to and from the process plan or well sites. Boundary Fences. At other locations as directed by the Owner.
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12. Pipe Laying 12.1 General This section must be read in conjunction with Section 9 of the Specification. Pipe Laying SHALL conform to all the requirements of the codes listed in section 3.0. The method used in the pipe laying operation SHALL not damage the pipe or in any way endanger personnel. 12.2 Lowering-In The coated pipe SHALL be lowered into the ditch gradually and uniformly in a manner with evenly spread lifting straps that allows proportionate distribution of the total weight of the pipe in order to prevent excessive stress in the pipe and prevent damage to the coating. The following practices SHALL be adopted:
a) b)
The pipe SHALL not be dropped. All welds, weld joint coating and coating must be completed and accepted by the CONTRACTOR prior to lowering-in of a pipe string. When coated pipe is lowered in, care SHALL be taken to prevent the pipe from swinging against or rubbing against the sides of the ditch. The pipe coating SHALL be visually inspected for coating defects during the lowering-in operation. During the lowering in operation, coated pipe SHALL be handled by belt slings or rubber-tyred lowering in cradles. The minimum width of the belts SHALL be equal to the diameter of the pipe being handled. Open ends of pipe in the trench SHALL be securely covered using plugs or caps APPROVED by the CONTRACTOR and SHALL not be removed until work is commenced to tie-in the pipe.
c)
d)
e)
f)
13. Cold Field Bending 13.1 General Bends SHALL be installed with the entire length of the bend in firm contact with the trench bed. External force SHALL not be used to achieve this condition. At bends, the as-laid intersection point SHALL be within one pipe diameter of the design intersection point, and a) b) c) Roped bends for steel pipelines are allowed for changes in alignment of 12 degrees or less. Changes in alignment of greater than 12 degrees SHALL be cold bent in the field. Bends SHALL be made using a bending machine APPROVED by the CONTRACTOR, an internal mandrel SHALL be used where necessary to ensure ovality tolerance is achieved.
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d) e)
Fire or wrinkle bends SHALL not be used. All the overbends SHALL be made in a manner to limit the mid-point clearance of the bend with the bottom of ditch to a maximum 25 mm and provide uniform support for the pipeline.
f)
g) h)
All sag bends SHALL fit snug against the bottom of the ditch.
Completed field bends SHALL not show evidence of buckling, denting, flattening, gouging or wavy surface. Particular care SHALL be taken to limit the ovality in the area of bend. The internal diameter at any point in the bend SHALL not be less than 96.5% of the nominal internal diameter. Pipe bends showing evidence of ovality greater than stated in (h) SHALL be cut out and replaced. Any damage to the pipe or coating, or separation of the coating from the pipe, during the bending process SHALL be repaired in accordance with APPROVED procedures.
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13.2 Bending Radius The minimum bending radius SHALL be as per ASME B31.8 unless otherwise specified on the pipeline drawings. An accurate method of measurement, APPROVED by the CONTRACTOR, SHALL be used for determining the bend radius. The distance between centerlines of bending points SHALL be sufficient so that there will not be any distortion of the pipe or in the bend previously made. Bends SHALL not be made within 1.5 meters of the end of a single pipe length being bent. When pipe is double jointed before bending, the bend may not be closer than 500mm from the circumferential weld. 13.3 Bend Test Specimens Before bending any pipe for inclusion in the permanent works, the SUBCONTRACTOR SHALL perform bending trials for each size pipe, wall thickness and bend radius combination to be used in the work. The purpose of the bending trials is to determine the optimum bending and distortional limitations. 13.4 Buckle A buckle SHALL be deemed to be a defect where
It does not blend smoothly with the adjoining surfaces; or Its height is greater than 25% of the nominal thickness and the width of its base is less than eight times its height.
14. Welding 14.1 General All welding procedures, production welding, welding, welding electrodes and welder qualifications utilized on the work under the SUBCONTRACT SHALL comply with the requirements of API 1104, for the carbon steel pipeline (as
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described in ASME B31.8) Mechanical and metallurgical testing of weld procedures and welder qualification for Carbon steel pipe lines SHALL be in accordance with API 1104, (as described in ASME B31.8). The SUBCONTRACTOR SHALL specify the welding procedures to be used as prescribed by API 1104 for the carbon steel pipeline Repair procedures SHALL be developed as part of the weld procedures and welder qualifications. Welding procedures and welder qualifications SHALL be qualified not less than four (4) weeks prior to the commencement of welding. Welds made with a TIG process SHALL not contain any contamination by carbon steel or Tungsten fragments. 14.2 Surface Cleaning before Welding Before welding, the surfaces of the bevels SHALL be power-wire brushed to remove all scale, rust, slag, enamel and priming paint near the welding zone. Cleaning SHALL extend a minimum of 12mm inside the pipe. Where wire brushing is insufficient to adequately clean the bevel, the SUBCONTRACTOR SHALL grind or hand file to give a satisfactory preparation. 14.3 Pipe Swabbing Prior to Set Up Prior to setting up, each pipe (including double joints) SHALL be internally inspected and swabbed along its length with a pull through APPROVED by the CONTRACTOR. 14.4 Pipe Set Up The pipe SHALL be set up resting on soft material not less than 150mm wide, with a clearance around the pipe for radiographic examination and coating inspection of not less than 300mm. Internal alignment clamps may not be removed until the root bead is completed. When external line-up clamps are used, the root bead SHALL be in equal segments and uniformity spaced around the circumference of the pipe and SHALL have a cumulative length of not less than 50 percent of the pipe circumference before the clamps are removed. 14.5 Cover of Coating A suitable material SHALL cover coated line-pipe during welding to prevent damage to coating from weld splatter. 14.6 Preheat of Pipes Any pre-heating of pipes SHALL be performed in accordance with the approved weld procedure. Repair procedures SHALL nominate the preheat temperatures required to perform the repairs. Any moisture present near the welding zones SHALL be dried using a LPG heating torch. Oxygen & Acetylene torches are not to be used.
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14.7 Earth Clamps Earthing clamps SHALL be made of a material that is compatible with the pipe to be welded. Earth clamps are not to be made out of copper or similar material and SHALL be placed so as not to cause arc burns when in contact with the pipe, or cause damage to the pipeline coating. 14.8 Cleaning Between Runs All scale and slag SHALL be removed from each run. Power driven "abrasive" wheels SHALL be used to carry out cleaning between the first and second runs. Cleaning between subsequent runs SHALL be performed using a power driven wire brush. When grinding or brushing, the SUBCONTRACTOR SHALL ensure that particles do not become embedded in the pipe coating, nor left in the pipeline after completion of welding. 14.9 Stub Electrodes Stub electrodes SHALL not be discarded into the trench or upon the ground, but SHALL be placed into a suitable container and removed from the Site and disposed of on a daily basis. 14.10 Welding Electrodes Welding electrodes are to be stored as recommended by the manufacturer. Opened cans of electrodes SHALL be stored in an APPROVED "Hot Box". Electrodes on which the coating has been damaged or contaminated in any way SHALL be rejected and immediately removed from site. All low hydrogen electrodes at the welding site SHALL at all times be stored in APPROVED portable ovens. 14.11 Identification of Welders and Welds For the purpose of weld records, the SUBCONTRACTOR SHALL identify all qualified and APPROVED welders with a unique welder number (WI, W2, W3 etc). The SUBCONTRACTOR SHALL ensure that all welds are identified with a unique weld number. This information SHALL be entered into the Weld Traceability Sheets and marked adjacent to each weld on the pipe. 14.12 Welding of Fittings The welding of all steel, flanges, valves, "o-lets, test point pads, tees, reducers, manufactured bends and other fittings into and onto the pipeline SHALL be made in compliance with API 1104 for Carbon steel. Where the use of line up clamps is impractical, the work SHALL be spaced and supported and tack welded in accordance with the APPROVED welding procedure and with the same electrodes which are to be used for the root run. Only qualified welders SHALL make tack welds. 14.13 Tie-In Welding Tie-in welding SHALL be performed in accordance with API 1104 for carbon steel. Setting of gaps at tie-ins SHALL be done by mechanical means only utilizing an
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external line up clamp. In no instances will the use of manual force or gap "hinging" be permitted. The supports holding the pipe SHALL not be moved until at least the second run has been deposited. 14.14 Pipe Off-Cuts (PUPS) The SUBCONTRACTOR SHALL coordinate its pipe setting and laying operations to minimize the number of pipe off-cuts less than one meter in length. All pipe PUPS less than 1 m in length SHALL be removed from site to a location as determined by the CONTRACTOR. All PUPS SHALL have the pipe identification and heat number information transferred to them from the original pipe from which they were cut. 15. Weld Repairs & Pipe Damage 15.1 General Weld repairs to carbon steel pipe SHALL comply with API 1104 and the relevant OWNER APPROVED welding repair procedure and this Specification. Authorization to repair steel welds not complying with the requirement will normally be given, however if the OWNER considers the weld to be grossly defective, it SHALL be cut out and the joint re-welded. 15.2 Repair or Removal of Defects Before authorized repairs are made, injurious defects SHALL be entirely removed by grinding using a 50mm run in at each end of the repair area. All slag and scale on the last run SHALL be removed by power-driven wire brushing. Welding over without grinding, where APPROVED by the CONTRACTOR, may be used to repair undercutting. After repair, the weld SHALL be tested non-destructively. If the weld does not comply, it SHALL be cut out and re-welded. 15.3 Dents, Grooves and Scratches The repair or removal of injurious dents, grooves and scratches SHALL comply with API 5L, ASME 831.8 and API 1104 for carbon steel pipelines 15.4 Arc Burn Metallurgical notches indicated by a blackened spot caused by arc burns or arc strikes, SHALL be removed by grinding and/or filing. Once completed the repair SHALL be inspected by Magnetic Particle Inspection. Acceptance criteria SHALL be in accordance with API 11 04 for carbon steel pipelines. If the wall thickness is reduced by more than ten percent of the nominal wall thickness of the pipe, after removal of the defect, then that section of pipe SHALL be cut out. The minimum length of pipe cut out SHALL be one meter. 16. Welding Particulars 16.1 Welding During Periods of Fire Danger During periods of high fire danger extra care SHALL be taken to prevent welding activities causing fire, the CONTRACTOR may suspend welding on days of total fire ban or other days when conditions are hazardous, e.g. extreme temperatures accompanied by strong winds and work areas adjacent to combustible matter.
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16.2 Wind and Weather Adequate arrangements SHALL be made to shield the welding operation during periods of high winds or inclement weather. Welding SHALL not proceed when the wind or dust generated by the wind is detrimental to the quality of the welds, irrespective of the shielding method used. 17. Non-Destructive Examinations of Welds All NDT SHALL be in accordance with the requirements of Specification SP-90-Q001, titled Specification for Non Destructive Examination of Pipeline Welds. 18. Coating 18.1 General Line-pipe for buried application SHALL be externally coated with 3 layer polypropylene (3LPP) or 3 layer polyethylene (3LHDPE). Each length of line-pipe will be supplied with the coating cutback a distance of between 150mm k 20mm from each end to facilitate welding. Alternatively POLYKEN GoCoat-250 tapes wrap system or equivalent may also be used. All pipe and pipe coating damaged during construction detected prior to the end of the defects liability period, SHALL be repaired to the satisfaction of the CONTRACTOR. 18.2 Coating Weld Joints All field welded joints, including pipe fittings, SHALL be abrasive blasted to achieve a surface finish in accordance with NACE No. 2 (SA 2 %) and anchor pattern of 50-70 microns. Blasting material for Carbon Steel SHALL be Garnet or sand. Any portion of the 3LPP or 3LHDPE coating affected by heat from welding SHALL be removed. The coating SHALL be abraded circumferentially, to achieve an anchor pattern of minimum 30 microns, for a length of 150mm, and SHALL be feathered to provide a smooth transition from the bare metal to existing coating. During the abrasive blast cleaning operation, all operators SHALL be adequately protected and provided with PPE in accordance with the SUBCONTRACTORS Safety Management Plan. Immediately after cleaning the bare metal and abrading the pipeline coating it SHALL be primed and wrapped with the POLYKEN GoCoat-250 tape wrap system or other SUBCONTRACTOR APPROVED equivalent. The tape wrap system SHALL be applied in accordance with the manufacturers application requirements. The primer SHALL extend at least 125mm onto the factory applied 3LHDPE / 3LPP coating. Unless otherwise specified by the manufacturer of the tape system, a minimum 50% overlap SHALL be achieved for the tape wrapping and the tape SHALL overlap the pipeline coating by a minimum of 100mm. The SUBCONTRACTOR SHALL comply with the Polyken Go-Coat 250 tape wrap system in accordance with the manufacturers requirements. 18.3 Locating Coating Defects (holidays) A coating defect SHALL be any inadequacy in the coating or damage to the coating which may reduce its insulating and corrosion protection qualities. A coating defect SHALL also include areas of apparent flattening or compression of the coating as a result of pressure on its surface, cracked or shattered coating,
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lack of bonding of the coating to the steel pipe and pin-holing or porosity. The pipe coating SHALL be inspected visually for such defects and its dielectric strength SHALL be tested by carrying out a high voltage "holiday" test along its length, using test equipment made for this purpose and APPROVED by the CONTRACTOR. The testing equipment and procedure SHALL be in accordance with NACE RP0274. APPROVED holiday testing equipment SHALL be supplied for the aforementioned high voltage testing of the coating. The test equipment SHALL be of the low amperage adjustable DC voltage type and SHALL have: a) An audible signal to indicate when a defect is detected. b) A full encirclement brush or spring electrode. c) The operating voltage SHALL be in accordance with NACE RP0274 and SHALL not exceed the breakdown voltage of the coating. d) The test equipment SHALL be calibrated each day to the satisfaction of the CONTRACTOR. Records of all calibrations SHALL be maintained and made available for inspection of the CONTRACTOR upon request. Before lowering the pipe into the trench for backfill, the pipe coating SHALL be visually inspected and checked for defects in dielectric strength along its length using a "holiday" detector as described in this Clause. During "holiday" testing, the coating surface SHALL be dry and free of moisture and dust contamination and the brush electrode SHALL be propelled along the pipe at a rate of no greater than 18 meters per minute. All defects found SHALL be properly marked on the pipe coating for repair and repaired prior to installation of the pipeline. All high voltage "holiday" testing of the coating SHALL be conducted in the presence of the CONTRACTOR. All tie-in sections and CP connection locations SHALL be subject to Holiday detection. 18.4 Fittings & Risers Unless otherwise directed by the CONTRACTOR, all pipe fittings, risers and other below ground steel surfaces, supplied uncoated or with standard mill coatings, SHALL be cleaned by garnet blasting to NACE 2 (SA 2 %) then in accordance with manufacturers requirements. Where required, approved high build mastic may be used to smooth out sharp changes in wrapped with POLYKEN GoCoat-250 tape system before burial to the satisfaction of the CONTRACTOR. The tape system SHALL be applied direction and irregularity of shapes prior to application of the tape system. 18.5 Additional Wrapping The additional wrapping may be required to carried out by the SUBCONTRACTOR. At these locations, when directed by the CONTRACTOR, the pipe SHALL be wrapped with POLYKEN GoCoat-250 tape system or CONTRACTOR APPROVED equivalent applied in accordance with the manufacturers requirements. Any additional wrapping will be at the discretion of the SUBCONTRACTOR.
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18.7 Above Ground Pipework All above ground carbon steel pipework SHALL be coated in accordance with specification SP-00-M-0017, titled, Specification for Painting and Protective Coatings. The coating system to be used SHALL be system 1. The coating SHALL extend down to grade level. 19. Cathodic Protection & Anodes 19.1 General The buried pipeline SHALL be cathodically protected, all cathodic protection installation SHALL be in accordance with Drawings and Specification No. SP90-E-001, titled "Specification for Pipeline Cathodic Protection". For Carbon steel pipelines the cable SHALL be attached by thermit (cadweld) welds or other manufacturer approved method. Particular care SHALL be taken by the CONTRACTOR when backfilling around cables to ensure the cables are not damaged or stretched during the backfill operation. All coating of the cable attachments to the pipelines SHALL be in accordance with the drawings. The CP connections SHALL be terminated at the time of lower-in and prior to backfill. SHOULD attachments be done prior to lower-in and backfill the SUBCONTRACTOR SHALL ensure all coating of the joints are completed at the time of connection and that loose ends for attachment to the Cathodic protection are secured to the pipe for protection during lowering-in. The CONTRACTOR SHALL inform the SUBCONTRACTOR 24 hours prior to pipe being backfilled at CP locations to allow the SUBCONTRACTOR time to arrange terminations. 19.2 Insulating Joints The insulating joints SHALL be either monolithic or compressed gasket type. They SHALL be installed at locations as shown on the pipeline drawings. When installing insulating joints, additional care SHALL be taken to ensure that joints are not damaged due to welding heat conducted along the pipe or cracked due to over-tightening of bolts. The bolt tightening torque SHALL be within the limits specified for the insulating joint by the Manufacturer. Monolithic joints if and when installed SHALL not be allowed to hold the weight of the pipeline section during lowering in as this may damage the insulation and render them ineffective. Insulating Gasket Kits SHALL be installed in accordance with the Manufacturers installation procedures. The SUBCONTRACTOR SHALL strictly comply with the insulating joint manufacturer's requirements. 19.3 Anodes & Anode Bed Anodes SHALL be installed at locations as specified in alignment sheets and in accordance with the drawings, specifications and Manufacturers requirements. 20. Hydrostatic Testing, Purging and Commissioning The following section SHALL be used as a guide line by the SUBCONTRACTOR for preparing a specific Hydrostatic Testing Procedure. The procedure SHALL be written for a pressure controlled combined strength and leak test.
1.
20.1 General Hydrostatic pressure testing of the Works SHALL be completed in accordance with ASME B31.8 unless inconsistent with the following requirements, which SHALL take precedence. 1.2 Technical Data
PIPELINE / FLOW LINE
Fuel Gas Pipeline HIGH PRESSURE Fuel Gas Pipeline LOW PRESSURE
DlA (in)
PIPE
SMYS (PSI)
MAOP (PSI)
HYDROTEST FACTOR
HYDROTEST PRESS (PSI)

600
1.5
AP15LX60
1.25
1 ~ 1.5
AP15LX60
1.25
20
20.3 Safety Prior to the commencement of testing operations, the SUBCONTRACTOR and CONTRACTOR SHALL conduct a Hydrostatic Testing Risk Assessment to identify all hazards and develop a strategy to manage the works safely. The recommendations of the risk assessment SHALL then be incorporated into the Job Hazard Assessments prior to hydrotesting works commencing. 20.4 Testing Procedure The SUBCONTRACTOR SHALL identify test sections and prepare a procedure, including any necessary pre-test procedures. This SHALL include proposed source of water, manner of disposal of flushing and test water, etc. The pressure gauges used in the test procedure shall have certification / calibration. 21. Commissioning After successful completion of pressure testing, drying and tie-in, the pipeline may be gassed and commissioned. Commissioning SHALL be by the CONTRACTOR. The pipeline SHALL be filled with nitrogen from one end and purged until oxygen cannot be detected in the gas expelled from the other end of the pipeline. The pipeline shall then be sealed. SHOULD the Carbon Steel pipeline be required to be left uncommission for an extended period, the pipeline SHALL be blanketed with nitrogen. The Nitrogen SHALL be used to purge the pipeline and SHALL be left positively pressurized to 10 kPa (g) minimum. A Nitrogen vessel with suitable regulator SHALL be attached to the pipeline during the time it remains idle, to top-up the nitrogen in the pipeline SHOULD a leak occur.

Construction Specification FOR Fuel Gas Pipe Line: Mellitah Oil & Gas A-100 Trash Incinerator Project

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Construction Specification FOR Fuel Gas Pipe Line: Mellitah Oil & Gas A-100 Trash Incinerator Project

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MELLITAH OIL & GAS A-100 TRASH INCINERATOR PROJECT

CONSTRUCTION SPECIFICATION FOR FUEL GAS PIPE LINE

Issued for Approval DESCRIPTION

AWA EM MOG PROJECT # 6245 Page Page 1 of 20

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HYDROTEST PRESS (PSI)

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