Volume3A Mech

GAS PLANT FACILITY PROJECT

ISSUED FOR BIDDING

0

TITLE :

DOCUMENT NO:

PAGE 1 OF 2

PROJECT NO.TYPE LOCATION SEQ. NO.AREA CODE REV.

14-4985

4985-DS-1808

REV LE

DATA SHEET OF INSULATING GASKET FOR RTJ FLANGES

REVISIONS APPROVAL CLIENT APPROVAL

DATE DESCRIPTION ORIG CHKD EM LOCAL REPR.

PROJ. MAN

FSMK10-Apr-11 Issued For Bidding WRK MTZ

ENAR PETROTECH SERVICES (PVT ) LTD7-B, KORANGI INDUSTRIAL AREA,

KORANGI-KARACHI

DOC NO : 4985-DS-1808PAGE : 2 0F 2

1 Customer OIL & GAS DEVELOPMENT COMPANY LIMITED Job Number 49852 Project GAS PLANT FACILITY PROJECT Tag Number3 Location Quantity: See Bid Price schedule Annexure-X4 PROCESS FLUID AND CONDITIONS5

6 Fluid: Untreated Natural Gas7 Service: Sour8 Design Pressure : 1440 psi(g)9 Design Temperature : 82.00 C (Max)

10 -90 C (Min)11 Installation: Above ground12

13 COMPLIANCE14

15 Each Insulating Gasket set shall comprise of the following items:16 1) One central gasket consisting of a ring suitable for ring type joint flange that is 17 "snap in" fitted to inner and outer rings. The inner and the outer rings are 18 suitable for full face gasket.19 2) One full length insulating sleeve per bolt.20 3) Two insulating washers per bolt.21 4) Two steel washers per bolt.22 Each set shall be individually and securely packed in a reinforced corrugated cardboard box.23

24 DESIGN DATA25

26 Piping Design Code: ASME B31.327 Application: Electrical isolation of Cathodic Protection System

28 Flange Size:29 Flange Type:

Baluchistan

OIL & GAS DEVELOPMENT COMPANY LIMITEDGAS PLANT FACILITY PROJECT

DATA SHEET OF INSULATING GASKET FOR RTJ FLANGES

8" NPS

SPECIFICATION

RTJ RTJ5" NPS

RTJ3/4" NPS

RTJ5" NPS

29 Flange Type:30 ASME Class:

Quantity :

31 Dimensional Standard: ASME B16.2032 Gasket Material: Plain Phenolic (Uncoated) Central Ring33 Virgin PTFE Inner and Outer Rings34 Gasket Thickness: 5.6 mm35 Sleeve Material: Plain Phenolic / Polyester Mylar36 Insulating Washer Material: Plain Phenolic37 Steel Washer Material: Carbon Steel Galvanised38 NACE MR 0175 compliance: Required39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55 NOTES56

57

58

59

60

61

6263

Supplier to confirm

900#18 NO 12 NO

RTJ RTJ1500#

RTJ

6 NO900#

RTJ1500#20 NO

Data Sheet No.

Prep. By Apr. ByDateSheet of Rev.

Unit:)

30 -130 30 -130200 - 1300

30 -130 30 -130

180

Pipe Size / Pipe Thickness 8"/ sch 80S 8"/ sch 80S

Maximum Pressure (psig)

Supplier to advice Supplier to advice

1550 1550

Flare weld

700 ppm

65 37

700 ppm

8"-PF-EC-0301A

Supplier to advice

8"-PF-EC-0401A

Supplier to advice

Flare weld

8"/ sch 80S 8"/ sch 80S

Flare weld Flare weld

8"-PF-EC-0101A 8"-PF-EC-0201A

Client:Project:

Oil & Gas Development Company Limited Gas Plant Facility Project

01 (Note-1,2,3)100-CC-001

Corrosion Coupon Corrosion Coupon

200 - 1300

0 mm 0 mm180

200 - 1300 200 - 1300

180

Corrosion Coupon

1550 1550

0 mm 0 mm180

4985-DS-1809

Dimension from top of pipe to Protective cover

DATA SHEET FOR

Operating Pressure (psig)Operating Temperature (ºF)Piping Material /Corrosion Allowance

CORROSION COUPONSMK

3/1/2012

Model No.:

Order No.:Job No. :

1

01 (Note-1,2,3)

Process Fluid

Req. No.:Vendor:Vendor Dwg. No.:

ANA

TypeLine No.

P&ID No.Service

Tag No.

SERV

ICE

CO

NDI

TION

Maximum Temperature (ºF)

End Connection

Corrosion Coupon

0

4985

4985-PB-21064985-PB-2103 4985-PB-210401 (Note-1,2,3)01 (Note-1,2,3)Quantity

12

Process Fluid Process Fluid 4985-PB-2105

102-CC-001 103-CC-001101-CC-001

Process Fluid

H2S

CO2

NitrogenM th

700 ppm22.75

700 ppm22.758.418.41

65 37 65 37 65 37

22.758.41

22.758.41

NOTES:

2. Two nos of 2" Strip Corrosion Coupon, Retrievable.3. Corrosion coupons shall be NACE MR0175/ISO15156 complaince.

GA

SES

& LI

QUI

D C

OM

POSS

ITIO

N

(Mol

e %

)

RPTFEO' Ring Seal BUNA 'N' 70 BUNA 'N' 70

RPTFE RPTFE RPTFE

316L 316L 316L316SS 316SS 316SS 316SS

316L 316L 316LASTM A-182 F316L ASTM A-182 F316L ASTM A-182 F316L ASTM A-182 F316L

0.19

65.37

0.17

0.19

Flare weld Access Fitting Body

0.10

0.660.17

Ethane

Disc Coupon Holder 316L316LSolid Plug Assembly

Heavy Duty Protective Cover

Material:

BUNA 'N' 70 BUNA 'N' 70

i-Butanen-Butane

1. Two inch (2'')High pressure access fitting assembly, comprising:- Access fitting body, Flare weld.- Solid plug assembly , complete with 'O' Ring Seal, Packing and retaining Nut.-Disc Coupon Holder.-Heavy duty protective cover.

Primary Packing

Disc Coupon 316SS 316SS 316SS 316SS

Methane

Heptane+H2O

i-Pentanen-Pentanen-Hexane

Propane 0.66

0.170.06

0.040.090.19

0.170.06

0.17

0.09

1.9865.371.98

65.37

0.100.04

0.100.040.09

0.19

0.66

65.371.980.66

1.98

0.100.040.09

0.170.06

0.170.170.06

4. MANUFACTURER TO SIZE FOR " BOTTOM " OF LINE MONITORING.

Data Sheet No.


Unit:

Process Fluid Process Fluid

End Connection

TypeLine No.

CO2

Operating Pressure (psig)

Tag No.

4985-PB-2107 4985-PB-210801 (Note-1,2,3)

104-CC-001 105-CC-00101 (Note-1,2,3)

P&ID No.01 (Note-1,2,3)

107-CC-001

0

4985

4985-PB-211001 (Note-1,2,3)

2

4985-DS-1809

DATA SHEET FOR

Pipe Size / Pipe Thickness 8"/ sch 80S

Req. No.:Vendor:

12

Process Fluid

ANA

Order No.:Job No. :

Vendor Dwg. No.:

MK3/1/2012

200 - 1300

CORROSION COUPONS

Quantity


Flare weld

Process Fluid 4985-PB-2109

106-CC-001

540 ppm

Operating Temperature (ºF)Piping Material /Corrosion Allowance

H2S

0 mm

Nitrogen

200 - 1300687ppm 540ppm

44.3026.68

8"/ sch 80S

24.64 25.80 24.80

30 -130

45.78

180

Supplier to adviceSupplier to advice

Client:Project:


SERV

ICE

CO

NDI

TION Service

Supplier to advice

180Maximum Temperature (ºF)0 mm

Corrosion Coupon Corrosion Coupon8"-PF-EC-0701A 8"-PF-EC-0801A

Flare weld


8"/ sch 80S

Model No.:

1550 1550

Flare weld

1550

200 - 1300

0 mm

8"/ sch 80S

Maximum Pressure (psig) 1550

Flare weld

180

Supplier to advice

0 mm180

30 -130200 - 1300

43.9844.63

30 -13030 -130

598 ppm

NOTES:

2. Two nos of 2" Strip Corrosion Coupon, Retrievable.3. Corrosion coupons shall be NACE MR0175/ISO15156 complaince.4. MANUFACTURER TO SIZE FOR " BOTTOM " OF LINE MONITORING.

RPTFE RPTFE RPTFE


GA

SES

& LI

QUI

D C

OM

POSS

ITIO

N

(Mol

e %

)

316SS 316SS 316SS

RPTFEO' Ring Seal BUNA 'N' 70 BUNA 'N' 70 BUNA 'N' 70 BUNA 'N' 70Primary Packing

316L316SS

Heavy Duty Protective Cover 316SS 316SS 316SS 316SSDisc Coupon

ASTM A-182 F316LMaterial:

ASTM A-182 F316L ASTM A-182 F316L

316L 316L 316LDisc Coupon Holder

ASTM A-182 F316LSolid Plug Assembly 316L 316L 316L 316LFlare weld Access Fitting Body

Heptane+H2O

n-Butane0.03

n-Pentane

NitrogenMethane

i-Pentane

n-Hexane 0.020.04 0.04

i-Butane

26.6829.13 27.4824.64 25.80 24.80

0.23 0.31 0.290.07

28.82

0.08

0.050.04 0.03 0.03

0.05

0.060.34

0.03

0.54

0.09

0.05

0.03

0.27

0.03

0.090.07

0.08

EthanePropane

0.630.26

0.620.26

27.91

0.03

0.260.080.07

0.55

0.07

Data Sheet No.


Unit:

Pipe Size / Pipe Thickness 8"/ sch 80S 8"/ sch 80S


30 -130 30 -130200 - 1300

45.48

180

45.33108 ppm 319 ppm

200 - 1300 200 - 130030 -130 30 -130

40.22

180

Corrosion Coupon Corrosion Coupon8"-PF-EC-1101A

Supplier to advice

8"-PF-EC-1201A

Supplier to advice

8"/ sch 80S


1550 1550 1550

Flare weld

Client:Project:


SERV

ICE

CO

NDI

TION

Vendor Dwg. No.:

180 180Maximum Temperature (ºF)0 mm


End Connection

Type

8"/ sch 80S

25 17 24 99 16 25 22 9045.69

Corrosion Coupon Corrosion Coupon

1550

0 mm 0 mm

8"-PF-EC-0901A

Flare weldFlare weld Flare weld

608 ppm 197 ppm200 - 1300

0 mm

DATA SHEET FOR

CO2


H2S

CORROSION COUPONS

P&ID No.

Job No. :

ANA MK3/1/2012

4985-DS-1809

Quantity

Req. No.:Vendor:

Order No.:

Tag No.

Service

01 (Note-1,2,3)108-CC-001

01 (Note-1,2,3)01 (Note-1,2,3)

Model No.:

109-CC-001

Line No.

01 (Note-1,2,3)

Process Fluid Process Fluid 4985-PB-2111 4985-PB-2112

8"-PF-EC-1001A

3 12


110-CC-001 111-CC-001

0

4985

4985-PB-2114

Nitrogen

NOTE:



0.040.030.02

BUNA 'N' 70RPTFE RPTFE RPTFE

0.08

0.03

BUNA 'N' 70 BUNA 'N' 70 BUNA 'N' 70RPTFE

316SS 316SS 316SS 316SS316SS

316L 316L 316L 316L

ASTM A-182 F316L

316SS 316SS 316SS

ASTM A-182 F316L316L 316L 316L 316L

ASTM A-182 F316L

0.110.24 0.30 0.29 0.26

0.02 0.15

0.07

0.040.02 0.01 0.06 0.050.04 0.04 0.06

0.08

25.17 24.99 16.25 22.90

0.07

0.410.12

0.25

n-Hexane

0.53

0.03

MethaneEthanePropanei-Butane

27.80

n-Pentane

0.11

Disc Coupon Heavy Duty Protective CoverPrimary Packing

Disc Coupon Holder

ASTM A-182 F316L

GA

SES

& LI

QUI

D C

OM

POSS

ITIO

N

(Mol

e %

)

H2OHeptane+

Nitrogen

n-Butanei-Pentane

Flare weld Access Fitting BodySolid Plug Assembly

O' Ring Seal

Material:

30.040.760.290.09

28.040.650.260.09

41.171.11

Data Sheet No.


Unit:

%)

NitrogenMethaneth

4 12

Process Fluid Process Fluid4985-PB-2117

114-CC-001 100-CC-002

0

4985

4985-PB-21034985-PB-2115 4985-PB-211601 (Note-1,2,3)01 (Note-1,2,3)

112-CC-001

End Connection

113-CC-001

TypeLine No.

01 (Note-1,2,3)


Tag No.

Pipe Size / Pipe Thickness

CORROSION COUPONS

QuantityP&ID No.

Req. No.:Vendor:

Order No.:Job No. :

ANA MK3/1/2012

Client:Project:

Oil & Gas Development Company Limited

4985-DS-1809


DATA SHEET FOR

CO2


H2S

Supplier to adviceSupplier to advice Supplier to advice

95 ppm 95 ppm

3 mm

1550


180

8"/ sch 80S 8"/ sch 808"/ sch 80S 8"/ sch 80S

65.3721.39 21.74 23.56 8.4131.76

SERV

ICE

CO

NDI

TION

Vendor Dwg. No.:

180 180


Service

01 (Note-1,2,3)

Gas Plant Facility Project

Model No.:

1550 1550

Flare weld

Corrosion Coupon Corrosion Coupon8"-PF-EC-1501A

Supplier to advice

8"-PF-EA2-0102

1 98

180

22.75289 ppm 700 ppm

200 - 1300 200 - 130030 -130 30 -130

44.94

0 69

0 mm

0 820 79

45.2645.08

29.7931.08

200 - 1300

0 mm


30 -130 30 -130200 - 1300


1550

0 mm

NOTE:



GA

SES

& LIQ

UID

CO

MPO

SITIO

N

(Mol

e

H2OHeptane+

Ethane


O' Ring Seal


Disc Coupon Holder

n-Pentane

Material:

n-Hexane

Propanei-Butanen-Butanei-Pentane

0.31

0.100.06 0.06 0.06 0.040.05 0.05 0.04

0.090.23 0.35 0.34 0.19

0.13 0.110.12

ASTM A-105N316L 316L 316L 316L

ASTM A-182 F316L ASTM A-182 F316LASTM A-182 F316L

AISI 1018316L 316L 316L 316L

316SS 316SS 316SS

RPTFE316SS 316SS 316SS AISI 1018RPTFE RPTFE RPTFE

1.98

BUNA 'N' 70 BUNA 'N' 70 BUNA 'N' 70 BUNA 'N' 70

0.690.820.79

0.100.080.03

0.300.100.080.03

0.270.080.070.03

0.660.170.170.06

Data Sheet No.


Unit:

30 -130200 - 1300


1550

3mm 3mm

1 981 98

22.75

180

44.63700 ppm 687ppm

200 - 130030 -130

200 - 130030 -130 30 -130

22.75

180

0 6329.13

1 98

1550 1550

Flare weld

Corrosion Coupon Corrosion Coupon8"-PF-EA2-0402

Supplier to advice

8"-PF-EA2-0502

Client:Project:


SERV

ICE

CO

NDI

TION

Vendor Dwg. No.:

180 180

Corrosion Coupon Corrosion Coupon8"-PF-EA2-0202 8"-PF-EA2-0302

Service

01 (Note-1,2,3)

Line No.

8.41 8.41 24.6465.37 65.3765.37


8"/ sch 80 8"/ sch 808"/ sch 80 8"/ sch 80


700 ppm 700 ppm200 - 1300

3mm 3mm

1550

22.758.41



H2S

QuantityP&ID No.


End Connection

Type

ANA MK3/1/2012

4985-DS-1809

CORROSION COUPONS0

DATA SHEET FOR

Req. No.:Vendor:

Order No.:Job No. :

101-CC-002

4985Model No.:

102-CC-00201 (Note-1,2,3)


Tag No.


4985-PB-2104 4985-PB-210501 (Note-1,2,3)01 (Note-1,2,3)

5 12


103-CC-002 104-CC-002

4985-PB-2107

e %

)

NitrogenMethaneth

CO2

NOTE:


0.260.080.030.03

0.660.170.170.06

0.170.170.06

0.660.170.170.06

0.661.981.98 0.631.98

BUNA 'N' 70 BUNA 'N' 70 BUNA 'N' 70 BUNA 'N' 70RPTFE

AISI 1018

ASTM A-105N

AISI 1018 AISI 1018 AISI 1018 AISI 1018RPTFE RPTFE RPTFE

316L 316L 316L 316LAISI 1018 AISI 1018 AISI 1018

316L 316L 316L 316LASTM A-105N ASTM A-105N

0.080.19 0.19 0.19 0.34

0.09 0.09

0.040.04 0.04 0.04 0.040.10 0.10 0.10

n-Hexane

ASTM A-105N

0.09

Material:



Disc Coupon Holder

O' Ring Seal

Solid Plug Assembly

n-Pentane


GA

SES

& LIQ

UID

CO

MPO

SSITI

ON

(M

ole

H2OHeptane+

Ethane


Data Sheet No.


Unit:

e %

)

NitrogenMethaneth

6 12


107-CC-002 108-CC-002

0

4985

4985-PB-21114985-PB-2108 4985-PB-210901 (Note-1,2,3)01 (Note-1,2,3)

105-CC-002

End Connection

106-CC-002

TypeLine No.

01 (Note-1,2,3)


Tag No.


CORROSION COUPONS

QuantityP&ID No.

Req. No.:Vendor:

Order No.:Job No. :

ANA MK3/1/2012

Client:Project:


4985-DS-1809


DATA SHEET FOR

CO2


H2S


540ppm 598 ppm

3mm

1550


180

8"/ sch 80 8"/ sch 808"/ sch 80 8"/ sch 80

27.8025.80 24.80 26.68 25.1728.82

SERV

ICE

CO

NDI

TION

Vendor Dwg. No.:

180 180


Service

01 (Note-1,2,3)


Model No.:

1550 1550

Flare weld


Supplier to advice

8"-PF-EA2-0902

0 53

180

45.69540 ppm 608 ppm

200 - 1300 200 - 130030 -130 30 -130

44.30

0 62

3mm

0 550 54

45.7843.98

27.4827.91

200 - 1300

3mm


30 -130 30 -130200 - 1300


1550

3mm

NOTE:



GA

SES

& LIQ

UID

CO

MPO

SSITI

ON

(M

ole

H2OHeptane+

Ethane


O' Ring Seal


Disc Coupon Holder

n-Pentane

Material:

n-Hexane


0.26

0.040.03 0.03 0.02 0.020.04 0.05 0.05

0.030.23 0.31 0.29 0.24

0.05 0.060.07

ASTM A-105N316L 316L 316L 316L

ASTM A-105N ASTM A-105NASTM A-105N

AISI 1018316L 316L 316L 316L

AISI 1018 AISI 1018 AISI 1018

RPTFEAISI 1018 AISI 1018 AISI 1018 AISI 1018

RPTFE RPTFE RPTFE

0.53


0.620.550.54

0.080.070.03

0.270.090.070.03

0.260.090.070.03

0.250.080.070.02

Data Sheet No.


Unit:

30 -130200 - 1300


1550

3mm 3mm

1 110 65

40.22

180

45.08319 ppm 95 ppm

200 - 130030 -130

200 - 130030 -130 30 -130

45.33

180

0 7931.76

0 76

1550 1550

Flare weld


Supplier to advice

8"-PF-EA2-1302

Client:Project:


SERV

ICE

CO

NDI

TION

Vendor Dwg. No.:

180 180


Service

01 (Note-1,2,3)

Line No.

16.25 22.90 21.3928.04 30.0441.17


8"/ sch 80 8"/ sch 808"/ sch 80 8"/ sch 80


197 ppm 108 ppm200 - 1300

3mm 3mm

1550

45.4824.99



H2S

QuantityP&ID No.


End Connection

Type

ANA MK3/1/2012

4985-DS-1809

CORROSION COUPONS0

DATA SHEET FOR

Req. No.:Vendor:

Order No.:Job No. :

109-CC-002

4985Model No.:

110-CC-00201 (Note-1,2,3)


Tag No.


4985-PB-2112 4985-PB-211301 (Note-1,2,3)01 (Note-1,2,3)

7 12


111-CC-002 112-CC-002

4985-PB-2115

le %

)

NitrogenMethaneEthane

CO2

NOTE:


0.310.100.080.03

0.290.090.080.03

0.120.110.04

0.260.090.070.03

0.411.110.65 0.790.76


AISI 1018

ASTM A-105N




0.120.30 0.29 0.26 0.23

0.15 0.11

0.050.01 0.06 0.05 0.060.04 0.06 0.04

n-Hexane

ASTM A-105N

0.02

Material:



Disc Coupon Holder

O' Ring Seal

Solid Plug Assembly

n-Pentane


GA

SES

& LI

QUI

D C

OM

POSS

ITIO

N

(Mol

H2OHeptane+

Ethane


Data Sheet No.


Unit:

%)

NitrogenMethaneth

8 12


200-CC-001 200-CC-002

0

4985

4985-PB-21184985-PB-2116 4985-PB-211701 (Note-1,2,3)01 (Note-1,2,3)

113-CC-002

End Connection

114-CC-002

TypeLine No.

01 (Note-1,2,3)


Tag No.


CORROSION COUPONS

QuantityP&ID No.

Req. No.:Vendor:

Order No.:Job No. :

ANA MK3/1/2012

Client:Project:


4985-DS-1809


DATA SHEET FOR

CO2


H2S


95 ppm 289 ppm

3mm

1550


180

10"/ 12.7mm 10"/ 12.7mm8"/ sch 80 8"/ sch 80

65.3721.74 23.56 8.41 8.4131.08

SERV

ICE

CO

NDI

TION

Vendor Dwg. No.:

180 180


Service

01 (Note-1,2,3)


Model No.:

1400 1400

Flare weld

Corrosion Coupon Corrosion Coupon10"-PF-DA3-0108

Supplier to advice

10"-PF-DA3-0208

1 98

180

22.75700 ppm 700 ppm200-1300 200-1300

30-130 30-130

22.75

1 98

3mm

0 690 82

44.9445.26

65.3729.79

200 - 1300

3mm


30 -130 30 -130200 - 1300


1550

3mm

NOTE:



GA

SES

& LIQ

UID

CO

MPO

SITIO

N

(Mol

e

H2OHeptane+

Ethane


O' Ring Seal


Disc Coupon Holder

n-Pentane

Material:

n-Hexane


0.30

0.100.06 0.06 0.04 0.040.05 0.04 0.10

0.090.35 0.34 0.19 0.19

0.11 0.090.13

ASTM A-105N316L 316L 316L 316L


AISI 1018316L 316L 316L 316L



RPTFE RPTFE RPTFE

1.98


1.980.690.82

0.100.080.03

0.270.080.070.03

0.660.170.170.06

0.660.170.170.06

Data Sheet No.


Unit:

30-130200-1300


1400

3mm 3mm

1 981 98

22.75

180

45.33108 ppm 319 ppm200-1300

30-130200-1300

30-130 30-130

40.22

180

0 7630.04

1 11

1400 1400

Flare weld


Supplier to advice

8"-PF-DA3-1208

Client:Project:


SERV

ICE

CO

NDI

TION

Vendor Dwg. No.:

180 180

Corrosion Coupon Corrosion Coupon10"-PF-DA3-0308 10"-PF-DA3-0408

Service

01 (Note-1,2,3)

Line No.

8.41 16.25 22.9065.37 41.1765.37


10"/ 12.7mm 8"/ 11.1mm10"/ 12.7mm 10"/ 12.7mm


700 ppm 700 ppm200-1300

3mm 3mm

1400

22.758.41



H2S

QuantityP&ID No.


End Connection

Type

ANA MK3/1/2012

4985-DS-1809

CORROSION COUPONS0

DATA SHEET FOR

Req. No.:Vendor:

Order No.:Job No. :

200-CC-003

4985Model No.:

200-CC-00401 (Note-1,2,3)


Tag No.


4985-PB-2118 4985-PB-211801 (Note-1,2,3)01 (Note-1,2,3)

9 12


200-CC-005 200-CC-006

4985-PB-2119

%)

NitrogenMethaneth

CO2

NOTE:


0.290.090.080.03

0.410.120.110.04

0.170.170.06

0.660.170.170.06

0.661.981.98 0.761.11


AISI 1018

ASTM A-105N




0.110.19 0.19 0.29 0.26

0.09 0.15

0.040.04 0.04 0.06 0.050.10 0.10 0.06

n-Hexane

ASTM A-105N

0.09

Material:



Disc Coupon Holder

O' Ring Seal

Solid Plug Assembly

n-Pentane


GA

SES

& LIQ

UID

CO

MPO

SITIO

N

(Mol

e

H2OHeptane+

Ethane


Data Sheet No.


Unit: %

)

NitrogenMethaneth

10 12


200-CC-009 200-CC-010

0

4985

4985-PB-2120(sh 1 of 2)4985-PB-2119 4985-PB-211901 (Note-1,2,3)01 (Note-1,2,3)

200-CC-007

End Connection

200-CC-008

TypeLine No.

01 (Note-1,2,3)


Tag No.


CORROSION COUPONS

QuantityP&ID No.

Req. No.:Vendor:

Order No.:Job No. :

ANA MK3/1/2012

Client:Project:


4985-DS-1809


DATA SHEET FOR

CO2


H2S


95 ppm 95 ppm

3mm

1400


180

10"/ 12.7mm 10"/ 12.7mm10"/ 12.7mm 10"/ 12.7mm

29.1321.39 21.74 23.56 24.6431.76

SERV

ICE

CO

NDI

TION

Vendor Dwg. No.:

180 180


Service

01 (Note-1,2,3)


Model No.:

1400 1400

Flare weld


Supplier to advice

10"-PF-DA3-0508

0 63

180

44.63289 ppm 687ppm200-1300 200-1300

30-130 30-130

44.94

0 69

3mm

0 820 79

45.2645.08

29.7931.08

200-1300

3mm


30-130 30-130200-1300


1400

3mm

NOTE:



GA

SES

& LIQ

UID

CO

MPO

SITIO

N

(Mol

e

H2OHeptane+

Ethane


O' Ring Seal


Disc Coupon Holder

n-Pentane

Material:

n-Hexane


0.31

0.040.06 0.06 0.06 0.040.05 0.05 0.04

0.080.23 0.35 0.34 0.34

0.13 0.110.12

ASTM A-105N316L 316L 316L 316L


AISI 1018316L 316L 316L 316L



RPTFE RPTFE RPTFE

0.63


0.690.820.79

0.100.080.03

0.300.100.080.03

0.270.080.070.03

0.260.080.030.03

Data Sheet No.


Unit:

30-130200-1300


1400

3mm 3mm

0 550 54

45.78

180

45.69540 ppm 608 ppm200-1300

30-130200-1300

30-130 30-130

44.30

180

0 5327.80

0 62

1400 1400

Flare weld


Supplier to advice

10"-PF-DA3-0908

Client:Project:


SERV

ICE

CO

NDI

TION

Vendor Dwg. No.:

180 180


Service

01 (Note-1,2,3)

Line No.

24.80 26.68 25.1728.82 27.4827.91


10"/ 12.7mm 10"/ 12.7mm10"/ 12.7mm 10"/ 12.7mm


540ppm 598 ppm200-1300

3mm 3mm

1400

43.9825.80



H2S

QuantityP&ID No.


End Connection

Type

ANA MK3/1/2012

4985-DS-1809

CORROSION COUPONS0

DATA SHEET FOR

Req. No.:Vendor:

Order No.:Job No. :

200-CC-011

4985Model No.:

200-CC-01201 (Note-1,2,3)


Tag No.


4985-PB-2120(sh 1 of 2)4985-PB-2120(sh 1 of 2)01 (Note-1,2,3)01 (Note-1,2,3)

11 12

Process Fluid Process Fluid4985-PB-2120(sh 2 of 2)

200-CC-013 200-CC-014

4985-PB-2120(sh 2 of 2)

e %

)


CO2

NOTE:


0.250.080.070.02

0.260.090.070.03

0.090.070.03

0.260.080.070.03

0.270.550.54 0.530.62


AISI 1018

ASTM A-105N




0.030.23 0.31 0.29 0.24

0.05 0.06

0.040.03 0.03 0.02 0.020.04 0.05 0.05

n-Hexane

ASTM A-105N

0.07

Material:



Disc Coupon Holder

O' Ring Seal

Solid Plug Assembly

n-Pentane


GA

SES

& LI

QUI

D C

OM

POSI

TION

(M

ole

H2OHeptane+

Ethane


Data Sheet No.


Unit:e

%)


12 12 0

4985

4985-PB-2120(sh 2 of 2)

200-CC-015

End Connection

TypeLine No.

01 (Note-1,2,3)

Process Fluid

Tag No.


CORROSION COUPONS

QuantityP&ID No.

Req. No.:Vendor:

Order No.:Job No. :

ANA MK3/1/2012

Client:Project:


4985-DS-1809


DATA SHEET FOR

CO2


H2S

Supplier to advice

197 ppm

1400

Flare weld

8"/ 11.1 mm

24.9928.04

SERV

ICE

CO

NDI

TION

Vendor Dwg. No.:

180

Corrosion Coupon8"-PF-DA3-1008

Service


Model No.:

0 65

45.48


30-130200-1300

Maximum Temperature (ºF)3mm

NOTE:



GA

SES

& LI

QUI

D C

OM

POSI

TION

(M

ole

H2OHeptane+

Ethane


O' Ring Seal


Disc Coupon Holder

n-Pentane

Material:

n-Hexane


0.26

0.010.04

0.300.02

316LASTM A-105N

316LAISI 1018AISI 1018

RPTFEBUNA 'N' 70

0.65

0.090.070.03

Data Sheet No.


Unit:SE

RVIC

E C

ON

DITIO

N

Vendor Dwg. No.:

180 180 180 1800 mm 0mm 0mm

Req. No.:Vendor:

Order No.:Job No. :

Client:Project:


65.378.41 8.41 8.41 8.41

65.37 65.37 65.37

22.75 22.75 22.75 22.75700 ppm 700 ppm 700 ppm 700 ppm

200 - 1300 200 - 130030 -130 30 -130 30 -130 30 -130

200 - 1300

1550 1550 1550 1550

Flare weld Flare weld Flare weld

0mm

8"-PF-EC-0201A 8"-PF-EC-0301A 8"-PF-EC-0401A8"/ sch 80S 8"/ sch 80S 8"/ sch 80S

Corrosion Probe Corrosion Probe

Operating Pressure (psig)Operating Temperature (ºF)Piping Material/ Corrosion Allowance

Corrosion Probe

200 - 1300

End Connection


Supplier to advice

Pipe Size / Pipe Thickness 8"/ sch 80S

Dimension from top of pipe to Protector

Supplier to advice

Flare weld


H2SCO2

Ethane

DATA SHEET FORCORROSION PROBES

4985-PB-2104

ANA MK3/1/2012

4985-DS-1810

Tag No.01 0101

100-CP-001 101-CP-001 102-CP-00101Quantity

1 12


103-CP-001

4985Model No.:

Line No.

P&ID No.Service

4985-PB-2106Process Fluid Process Fluid

4985-PB-2103

8"-PF-EC-0101ACorrosion Probe

0

e %

)

NitrogenMethane

Type


1.981.98 1.981.98

NOTE:

2.Corrosion Probes shall be NACE MR0175/ISO15156 complaince.


0.10

RPTFE RPTFE RPTFE RPTFERPTFE RPTFE RPTFE RPTFE

AISI 1018 AISI 1018 AISI 1018 AISI 1018

316L Body with Carbon steel element.




316L 316L 316L 316LASTM A-182 F316L ASTM A-182 F316L ASTM A-182 F316L ASTM A-182 F316L

0.060.17

0.19 0.19 0.19 0.190.09 0.09 0.09 0.090.04 0.04 0.04 0.04

0.10 0.10

Primary Packing

n-Hexanen-Pentane

EthanePropanei-Butanen-Butane

GA

SES

& LI

QUI

D C

OM

POSS

ITIO

N

(Mol

e

H2OHeptane+

i-Pentane

1. Two inch (2'') High pressure access fitting assembly to be welded on SA-312 TP316L for EC spec comprising:- Access fitting body, Flare weld.- Hollow plug assembly , complete with Seals, Packing and retaining and sealing Nut.-Electrical Resistance probe Retrievable type, incorporating a metal element , compatible with the pipe, suitable for the continuous monitoring of internal corrosion rates and for installation and retrieval under full line pressure.-Probe to instrument adaptor.-Protective cover with hole for instrument adaptor.

Probe Packing

Material:Flare weld Access Fitting BodyHollow Plug Assembly

Thread Protector

1.980.660.170.17

0.170.17

1.980.660.170.17

Probe Material

0.06

0.661.980.660.17

0.06 0.06

1.98

0.10

Data Sheet No.


Unit:

Flare weld

0mm

0

8"-PF-EC-0801A8"/ sch 80S

%)

NitrogenMethane

TypeLine No.

P&ID No.Service


4985-PB-2107 4985-PB-2108

Corrosion ProbeCorrosion Probe

2 12


107-CP-001

4985Model No.:

Tag No.01 0101

104-CP-001 105-CP-001 106-CP-00101Quantity

ANA MK3/1/2012

4985-DS-1810


CO2

Ethane

H2S



Flare weld

1550

687ppmOperating Pressure (psig)Operating Temperature (ºF)Piping Material/ Corrosion Allowance

End Connection




Corrosion Probe Corrosion Probe8"-PF-EC-0501A 8"-PF-EC-0601A 8"-PF-EC-0701A

8"/ sch 80S 8"/ sch 80S8"/ sch 80S

1550 1550

Supplier to advice Supplier to advice Supplier to advice Supplier to advice

1550

200 - 1300 200 - 130030 -130 30 -130 30 -130 30 -130

200 - 1300 200 - 1300540ppm 598 ppm 540 ppm

44.63 43.98 45.78 44.30

28.82 27.91 27.4824.64 25.80 24.80 26.6829.13

Client:Project:


Req. No.:Vendor:

Order No.:Job No. :

SERV

ICE

CO

NDI

TION

Vendor Dwg. No.:

180 180 180 1800mm 0mm 0mm

0 63 0 54 0 55 0 62

NOTE:

2.Corrosion Probes shall be NACE MR0175/ISO15156 complaince.


GA

SES

& LIQ

UID

CO

MPO

SSITI

ON

(M

ole

H2OHeptane+

i-Pentane

n-Hexanen-Pentane

Probe Packing


Probe Material

Thread ProtectorPrimary Packing

EthanePropanei-Butanen-Butane

0.050.04 0.03 0.03 0.020.04 0.04 0.05

0.08 0.07 0.05 0.060.34 0.23 0.31 0.29

ASTM A-182 F316L ASTM A-182 F316L ASTM A-182 F316L ASTM A-182 F316L316L 316L 316L 316L





AISI 1018 AISI 1018 AISI 1018 AISI 1018RPTFE RPTFE RPTFE RPTFERPTFE RPTFE RPTFE RPTFE


0.03 0.03 0.03 0.03

0.630.260.080.03

0.540.260.080.07

0.550.270.090.07

0.620.260.090.07

Data Sheet No.


Unit:

Flare weld

0mm

0

8"-PF-EC-1201A8"/ sch 80S

e %

)


TypeLine No.

P&ID No.Service


4985-PB-2111 4985-PB-2112

Corrosion ProbeCorrosion Probe

3 12


111-CP-001

4985Model No.:

Tag No.01 0101

108-CP-001 109-CP-001 110-CP-00101Quantity

ANA MK3/1/2012

4985-DS-1810


CO2

H2S



Flare weld

1550

608 ppmOperating Pressure (psig)Operating Temperature (ºF)Piping Material/ Corrosion Allowance

End Connection




Corrosion Probe Corrosion Probe8"-PF-EC-0901A 8"-PF-EC-1001A 8"-PF-EC-1101A

8"/ sch 80S 8"/ sch 80S8"/ sch 80S

1550 1550


1550

200 - 1300 200 - 130030 -130 30 -130 30 -130 30 -130

200 - 1300 200 - 1300197 ppm 108 ppm 319 ppm

45.69 45.48 40.22 45.33

28.04 41.17 30.0425.17 24.99 16.25 22.9027.80

Client:Project:


Req. No.:Vendor:

Order No.:Job No. :

SERV

ICE

CO

NDI

TION

Vendor Dwg. No.:

180 180 180 1800mm 0mm 0mm

0.53 0.65 1.11 0.76

NOTE:

2.Corrosion Probes shall be NACE MR0175/ISO15156 complaince.3. MANUFACTURER TO SIZE FOR " BOTTOM " OF LINE MONITORING.

GA

SES

& LI

QUI

D C

OM

POSS

ITIO

N

(Mol

e

H2OHeptane+

a e

n-Hexanen-Pentane

Probe Packing


Probe Material



0.040.02 0.01 0.06 0.050.04 0.04 0.06

0.03 0.02 0.15 0.110.24 0.30 0.29 0.26

ASTM A-182 F316L ASTM A-182 F316L ASTM A-182 F316L ASTM A-182 F316L316L 316L 316L 316L





AISI 1018 AISI 1018 AISI 1018 AISI 1018RPTFE RPTFE RPTFE RPTFERPTFE RPTFE RPTFE RPTFE


0.25 0.26 0.41 0.290.08 0.09 0.12 0.090.07 0.07 0.11 0.080.02 0.03 0.04 0.03

Data Sheet No.


Unit:

8"/ sch 80

SERV

ICE

CO

NDI

TION

31.08 29.79

Vendor Dwg. No.:

180 1800mm 0mm

8"-PF-EC-1401A

Tag No.Quantity



Req. No.:Vendor:

Order No.:Job No. :

Client:Project:


65.3721.39 21.74 23.56 8.4131.76

45.26 44.94 22.7595 ppm 95 ppm 289 ppm 700 ppm

200 - 1300 200 - 130030 -130 30 -130 30 -130 30 -130

200 - 1300


3mm

1550 1550 1550 1550180 1800mm

Corrosion Probe Corrosion Probe Corrosion Coupon


Corrosion Probe

200 - 1300

Flare weld

Supplier to advice

H2SCO2 45.08

8"-PF-EC-1501A 8"-PF-EA2-0102

Supplier to advice Supplier to advice Supplier to advice

Flare weld

MK3/1/2012

4985-DS-1810

12

01112-CP-001 113-CP-001 114-CP-001

01


ANA

4985-PB-2117

100-CP-002

4985Model No.:

01 01P&ID No.Service

%)

NitrogenMethane

0 79 0 82

TypeLine No.



End Connection

8"-PF-EC-1301A

4985-PB-2116

4


8"/ sch 80S 8"/ sch 80S

Eth

8"/ sch 80S

0


4985-PB-2115

1 980 69

NOTE:


1. Two inch (2'') High pressure access fitting assembly to be welded on pipe SA-312 TP 316L for EC spec & on SA-106 Gr.B for EA2 spec comprising:- Access fitting body, Flare weld.- Hollow plug assembly , complete with Seals, Packing and retaining and sealing Nut.-Electrical Resistance probe Retrievable type, incorporating a metal element , compatible with the pipe, suitable for the continuous monitoring of internal corrosion rates and for installation and retrieval under full line pressure.-Probe to instrument adaptor.-Protective cover with hole for instrument adaptor

0.060.100.05 0.05 0.04

RPTFE RPTFE RPTFE RPTFERPTFE




316L 316L 316L 316L



ASTM A-182 F316L ASTM A-182 F316L ASTM A-182 F316L ASTM A-105N

0.23 0.35 0.34 0.190.13 0.11 0.09

0.06 0.06 0.06 0.04

0.03 0.03 0.03

0.31

0.12


n-Hexanen-Pentane

Material:Flare weld Access Fitting Body

GA

SES

& LIQ

UID

CO

MPO

SSITI

ON

(M

ole

H2OHeptane+

Hollow Plug Assembly

Probe Material

0.79 0.82

n-Butane

Propane

i-Pentane

Probe Packing

Ethane

i-Butane 0.10 0.10 0.080.08 0.08 0.07

1.980.660.170.17

0.690.30 0.27

Data Sheet No.


Unit:

0 63Eth 1 98 1 98 1 98

200 - 1300700 ppm 700 ppm

1550 1550 1550

200 - 1300

0

4985-PB-2107Process Fluid Process Fluid 4985-PB-2104 4985-PB-2105

5

4985Model No.:

%)

NitrogenMethane

TypeLine No.

P&ID No.Service

12


104-CP-00201 0101

101-CP-002 102-CP-002 103-CP-00201

ANA MK3/1/2012

4985-DS-1810


H2SCO2


Corrosion Coupon

200 - 1300




End Connection

8"-PF-EA2-0202 8"-PF-EA2-0402 8"-PF-EA2-0502Corrosion Coupon Corrosion Coupon Corrosion Coupon

Flare weld

8"/ sch 80 8"/ sch 80 8"/ sch 80



180 180

30 -130 30 -130 30 -130 30 -1303mm3mm

8.41 8.41 8.41 24.6465.37

700 ppm 687ppm22.75 22.75 22.75

65.37 65.37

Client:Project:


Req. No.:Vendor:

Order No.:Job No. :

SERV

ICE

CO

NDI

TION

Vendor Dwg. No.:

180 1803mm 3mm

8"-PF-EA2-0302

Tag No.Quantity

Pipe Size / Pipe Thickness 8"/ sch 80

29.13

44.63

200 - 1300

1550

NOTE:


0.080.03n-Butane 0.17 0.17 0.17

i-Butane 0.17Propane 0.66 0.66 0.66

0.630.26

Ethane 1.98 1.98 1.98

GA

SES

& LIQ

UID

CO

MPO

SSITI

ON

(M

ole

H2OHeptane+

i-Pentane

Probe Packing

Probe Material


n-Hexanen-Pentane


0.10 0.10 0.100.06 0.06 0.06

0.17 0.17

0.04 0.04 0.04 0.040.09 0.09 0.09 0.080.19 0.19 0.19 0.34

ASTM A-105N ASTM A-105N ASTM A-105N ASTM A-105N



316L 316L 316L 316L316L Body with

Carbon steel element.316L Body with

Carbon steel element.


RPTFE RPTFE RPTFERPTFE RPTFE RPTFE RPTFE

0.04

1. Two inch (2'') High pressure access fitting assembly to be welded on SA-106 Gr.B for EA2 spec comprising:- Access fitting body, Flare weld.- Hollow plug assembly , complete with Seals, Packing and retaining and sealing Nut.-Electrical Resistance probe Retrievable type, incorporating a metal element , compatible with the pipe, suitable for the continuous monitoring of internal corrosion rates and for installation and retrieval under full line pressure.-Probe to instrument adaptor.-Protective cover with hole for instrument adaptor.

0.03

Data Sheet No.


Unit:

8"/ sch 80

SERV

ICE

CO

NDI

TION

27.91 27.48

Vendor Dwg. No.:

180 1803mm 3mm

8"-PF-EA2-0702

Tag No.Quantity



Req. No.:Vendor:

Order No.:Job No. :

Client:Project:


27.8025.80 24.80 26.68 25.1728.82

45.78 44.30 45.69540ppm 598 ppm 540 ppm 608 ppm

200 - 1300 200 - 130030 -130 30 -130 30 -130 30 -130

200 - 1300


3mm

1550 1550 1550 1550180 1803mm

Corrosion Coupon Corrosion Coupon Corrosion Coupon


Corrosion Coupon

200 - 1300

Flare weld

Supplier to advice

H2SCO2 43.98

8"-PF-EA2-0802 8"-PF-EA2-0902


Flare weld

MK3/1/2012

4985-DS-1810

12

01105-CP-002 106-CP-002 107-CP-002

01


ANA

4985-PB-2110

108-CP-002

4985Model No.:


%)

NitrogenMethane

0 54 0 55

TypeLine No.



End Connection

8"-PF-EA2-0602

4985-PB-2109

6


8"/ sch 80 8"/ sch 80

Eth

8"/ sch 80

0

4985-PB-2111Process Fluid Process Fluid 4985-PB-2108

0 530 62

NOTE:



0.020.040.04 0.05 0.05





316L 316L 316L 316L316L Body with




0.23 0.31 0.29 0.240.05 0.06 0.03

0.03 0.03 0.02 0.02

0.03 0.03 0.03

0.26

0.07


n-Hexanen-Pentane


GA

SES

& LIQ

UID

CO

MPO

SSITI

ON

(M

ole

H2OHeptane+


Probe Material

0.54 0.55

n-Butane

Propane

i-Pentane

Probe Packing

Ethane

i-Butane 0.08 0.09 0.090.07 0.07 0.07

0.530.250.080.07

0.620.27 0.26

Data Sheet No.


Unit:

0 79Eth 0 65 1 11 0 76

200 - 1300197 ppm 108 ppm

1550 1550 1550

200 - 1300

0

4985-PB-2115Process Fluid Process Fluid 4985-PB-2112 4985-PB-2113

7

4985Model No.:

ole

%) Nitrogen

Methane

TypeLine No.

P&ID No.Service

12


112-CP-00201 0101

109-CP-002 110-CP-002 111-CP-00201

ANA MK3/1/2012

4985-DS-1810


H2SCO2


Corrosion Coupon

200 - 1300




End Connection

8"-PF-EA2-1002 8"-PF-EA2-1202 8"-PF-EA2-1302Corrosion Coupon Corrosion Coupon Corrosion Coupon

Flare weld

8"/ sch 80 8"/ sch 80 8"/ sch 80



180 180

30 -130 30 -130 30 -130 30 -1303mm3mm

24.99 16.25 22.90 21.3928.04

319 ppm 95 ppm45.48 40.22 45.33

41.17 30.04

Client:Project:


Req. No.:Vendor:

Order No.:Job No. :

SERV

ICE

CO

NDI

TION

Vendor Dwg. No.:

180 1803mm 3mm

8"-PF-EA2-1102

Tag No.Quantity

Pipe Size / Pipe Thickness 8"/ sch 80

31.76

45.08

200 - 1300

1550

NOTE:


0.100.08n-Butane 0.07 0.11 0.08


0.790.31

Ethane 0.65 1.11 0.76

GA

SES

& LIQ

UID

CO

MPO

SSITI

ON

(M

o

H2OHeptane+

i-Pentane

Probe Packing

Probe MaterialThread ProtectorPrimary Packing

n-Hexanen-Pentane


0.04 0.06 0.040.03 0.04 0.03

0.12 0.09

0.01 0.06 0.05 0.060.02 0.15 0.11 0.120.30 0.29 0.26 0.23


316L Body with 316L Body with 316L 316L 316L 316L

316L Body with 316L Body with



0.05


0.03

Data Sheet No.


Unit:

10"/ 12.7mm

SERV

ICE

CO

NDI

TION

29.79 65.37

Vendor Dwg. No.:

180 1803mm 3mm

8"-PF-EA2-1502

Tag No.Quantity



Req. No.:Vendor:

Order No.:Job No. :

Client:Project:


65.3721.74 23.56 8.41 8.4131.08

44.94 22.75 22.7595 ppm 289 ppm 700 ppm 700 ppm

200-1300 200-130030 -130 30 -130 30-130 30-130

200 - 1300


3mm

1550 1550 1400 1400180 1803mm



Corrosion Coupon

200 - 1300

Flare weld

Supplier to advice

H2SCO2 45.26

10"-PF-DA3-0108 10"-PF-DA3-0208


Flare weld

MK3/1/2012

4985-DS-1810

12

01113-CP-002 114-CP-002 200-CP-001

01


ANA

4985-PB-2118

200-CP-002

4985Model No.:


%)

NitrogenMethane

0 82 0 69

TypeLine No.



End Connection

8"-PF-EA2-1402

4985-PB-2117

8


8"/ sch 80 8"/ sch 80

Eth

10"/ 12.7mm

0


4985-PB-2116

1 981 98

NOTE:


1. Two inch (2'') High pressure access fitting assembly to be welded on API-5L X-52 (PSL2) Pipe for DA3 spec, and SA-106 Gr.B for EA2 spec comprising:- Access fitting body, Flare weld.- Hollow plug assembly , complete with Seals, Packing and retaining and sealing Nut.-Electrical Resistance probe Retrievable type, incorporating a metal element , compatible with the pipe, suitable for the continuous monitoring of internal corrosion rates and for installation and retrieval under full line pressure.-Probe to instrument adaptor.-Protective cover with hole for instrument adaptor

0.060.100.05 0.04 0.10





316L 316L 316L 316L




0.35 0.34 0.19 0.190.11 0.09 0.09

0.06 0.06 0.04 0.04

0.03 0.03 0.06

0.30

0.13


n-Hexanen-Pentane


GA

SES

& LIQ

UID

CO

MPO

SSITI

ON

(M

ole

H2OHeptane+


Probe Material

0.82 0.69

n-Butane

Propane

i-Pentane

Probe Packing

Ethane

i-Butane 0.10 0.08 0.170.08 0.07 0.17

1.980.660.170.17

1.980.27 0.66

Data Sheet No.


Unit:

0 76Eth 1 98 1 98 1 11

200-1300700 ppm 700 ppm

1400 1400 1400

200-1300

0


4985-PB-2118 4985-PB-2118

9

4985Model No.:

%)

NitrogenMethane

TypeLine No.

P&ID No.Service

12


200-CP-00601 0101

200-CP-003 200-CP-004 200-CP-00501

ANA MK3/1/2012

4985-DS-1810


H2SCO2


Corrosion Coupon

200-1300




End Connection

10"-PF-DA3-0308 10"-PF-DA3-1108 8"-PF-DA3-1208Corrosion Coupon Corrosion Coupon Corrosion Coupon

Flare weld

10"/ 12.7mm 10"/ 12.7mm 10"/ 12.7mm



180 180

30-130 30-130 30-130 30-1303mm3mm

8.41 8.41 16.25 22.9065.37

108 ppm 319 ppm22.75 22.75 40.22

65.37 41.17

Client:Project:


Req. No.:Vendor:

Order No.:Job No. :

SERV

ICE

CO

NDI

TION

Vendor Dwg. No.:

180 1803mm 3mm

10"-PF-DA3-0408

Tag No.Quantity

Pipe Size / Pipe Thickness 8"/ 11.1mm

30.04

45.33

200-1300

1400

NOTE:


0.090.08n-Butane 0.17 0.17 0.11


0.760.29

Ethane 1.98 1.98 1.11

GA

SES

& LIQ

UID

CO

MPO

SSITI

ON

(M

ole

%

H2OHeptane+

i-Pentane

Probe Packing

Probe Material


n-Hexanen-Pentane


0.10 0.10 0.060.06 0.06 0.04

0.17 0.12

0.04 0.04 0.06 0.050.09 0.09 0.15 0.110.19 0.19 0.29 0.26




316L 316L 316L 316L





0.04

1. Two inch (2'') High pressure access fitting assembly to be welded on API-5L X-52 (PSL2) Pipe, comprising:- Access fitting body, Flare weld.- Hollow plug assembly , complete with Seals, Packing and retaining and sealing Nut.-Electrical Resistance probe Retrievable type, incorporating a metal element , compatible with the pipe, suitable for the continuous monitoring of internal corrosion rates and for installation and retrieval under full line pressure.-Probe to instrument adaptor.-Protective cover with hole for instrument adaptor.

0.03

Data Sheet No.


Unit:

10"/ 12.7mm

SERV

ICE

CO

NDI

TION

31.08 29.79

Vendor Dwg. No.:

180 1803mm 3mm

10"-PF-DA3-1408

Tag No.Quantity



Req. No.:Vendor:

Order No.:Job No. :

Client:Project:


29.1321.39 21.74 23.56 24.6431.76

45.26 44.94 44.6395 ppm 95 ppm 289 ppm 687ppm

200-1300 200-130030-130 30-130 30-130 30-130

200-1300


3mm

1400 1400 1400 1400180 1803mm



Corrosion Coupon

200-1300

Flare weld

Supplier to advice

H2SCO2 45.08

10"-PF-DA3-1508 10"-PF-DA3-0508


Flare weld

MK3/1/2012

4985-DS-1810

12

01200-CP-007 200-CP-008 200-CP-009

01


ANA

4985-PB-2119

200-CP-010

4985Model No.:


%)

NitrogenMethane

0 79 0 82

TypeLine No.



End Connection

10"-PF-DA3-1308

4985-PB-2119

10


10"/ 12.7mm 10"/ 12.7mm

Eth

10"/ 12.7mm

0

985-PB-2120(sh 1 of 2Process Fluid Process Fluid

4985-PB-2119

0 630 69

NOTE:



0.030.040.05 0.05 0.04





316L 316L 316L 316L




0.23 0.35 0.34 0.340.13 0.11 0.08

0.06 0.06 0.06 0.04

0.03 0.03 0.03

0.31

0.12


n-Hexanen-Pentane


GA

SES

& LIQ

UID

CO

MPO

SSITI

ON

(M

ole

%

H2OHeptane+


Probe Material

0.79 0.82

n-Butane

Propane

i-Pentane

Probe Packing

Ethane

i-Butane 0.10 0.10 0.080.08 0.08 0.07

0.630.260.080.03

0.690.30 0.27

Data Sheet No.


Unit:

0 53Eth 0 54 0 55 0 62

200-1300540ppm 598 ppm

1400 1400 1400

200-1300

0

985-PB-2120(sh 2 of 2Process Fluid Process Fluid

985-PB-2120(sh 1 of 2985-PB-2120(sh 1 of 2

11

4985Model No.:

%)

NitrogenMethane

TypeLine No.

P&ID No.Service

12

Process Fluid Process Fluid985-PB-2120(sh 2 of 2

200-CP-01401 0101

200-CP-011 200-CP-012 200-CP-01301

ANA MK3/1/2012

4985-DS-1810


H2SCO2


Corrosion Coupon

200-1300




End Connection

10"-PF-DA3-0608 10"-PF-DA3-0808 10"-PF-DA3-0908Corrosion Coupon Corrosion Coupon Corrosion Coupon

Flare weld

10"/ 12.7mm 10"/ 12.7mm 10"/ 12.7mm



180 180

30-130 30-130 30-130 30-1303mm3mm

25.80 24.80 26.68 25.1728.82

540 ppm 608 ppm43.98 45.78 44.30

27.91 27.48

Client:Project:


Req. No.:Vendor:

Order No.:Job No. :

SERV

ICE

CO

NDI

TION

Vendor Dwg. No.:

180 1803mm 3mm

10"-PF-DA3-0708

Tag No.Quantity

Pipe Size / Pipe Thickness 10"/ 12.7mm

27.80

45.69

200-1300

1400

NOTE:


0.080.07n-Butane 0.07 0.07 0.07


0.530.25

Ethane 0.54 0.55 0.62

GA

SES

& LIQ

UID

CO

MPO

SSITI

ON

(M

ole

H2OHeptane+

i-Pentane

Probe Packing

Probe Material


n-Hexanen-Pentane


0.04 0.05 0.050.03 0.03 0.03

0.09 0.09

0.03 0.03 0.02 0.020.07 0.05 0.06 0.030.23 0.31 0.29 0.24




316L 316L 316L 316L316L Body with





0.04


0.02

Data Sheet No.


Unit:SE

RVIC

E C

ON

DITIO

N

Vendor Dwg. No.:

1803mm

Tag No.Quantity



Req. No.:Vendor:

Order No.:Job No. :

Client:Project:


24.9928.04

200-1300197 ppm

30-130

1400

Corrosion Coupon


Supplier to advice

CO2 45.48

Flare weld

MK3/1/2012

4985-DS-1810

12

01200-CP-015


ANA

4985Model No.:

P&ID No.Service

ole

%) Nitrogen

Methane


0.65

TypeLine No.


End Connection

8"-PF-DA3-1008

H2S

12

8"/ 11.1 mm

Ethane

0

Process Fluid4985-PB-2120(sh 2 of 2)

NOTE:



RPTFE

0.04

RPTFE


AISI 1018

316LASTM A-105N

0.30

0.01

0.03

0.26

0.02

i-Pentane

Probe Material

Thread Protector

n-Hexanen-Pentane


GA

SES

& LIQ

UID

CO

MPO

SSITI

ON

(M

o

H2OHeptane+


n-Butane

Propane

Primary PackingProbe Packing

i-Butane 0.090.07

4985-DS-1804

Client: OGDCL Job No 14-4985

Project Gas Project Doc No 4985-DS-1804

ENAR

Data Sheet Item Anchor Flanges Sheet 1 of 1

Revision 0 Issued for Bidding Date 20/12/11 By WRK Checked MK Approved FS Client

1 Process Data 2 Fluid Untreated natural gas 3 Pressure (psig) Min 142 Max 178 4 Temperature (oF) Min -30o Normal 100o Max 180o

5 Flow lb/hr Min 18880 Max 93005 6 Design Data See Note 2 Construction 7 Pressure Design (psig) 1400 Type - 8 Temperature (oF) 30o - 180o Seals - 9 Flow m3/h 93005

10 Design Code ASME VIII 11 Design Factor Note 2 12 Location WT (mm) 11.1 9.5 13 Design Load (Axial KN) 1135 730 14 Quantity 30 6 15 Size 10” 8” 16 Pup Material API 5L X52 17 Pup Length Note 2 18 Pup WT Note 2 19 20 End Connections BW/BW to ANSI 16.25 21 Corr’n Allowance (mm) 0 22 Suppl’y Requirements 23 Materials 24 Hubs ASTM A-694 Grade F52 25 Flanges and Forgings - 26 Plate - 27 Inspection and Testing 28 Mechanical Tests NDT to ASME VIII (See Note 1) 29 Hydrostatic Tests - 30 Electrical Tests - 31 Surface Treatment 32 External Removable Skin for Corrosion Protection 33 Internal Approved Rust Inhibitor 34 Remarks 35 Note 1 Supplier shall refer to 4985-PA-2010 for full Technical Requirements 36 Note 2 Flanges to be designed and calculations furnished by supplier, using design

loads given.

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SPECIFICATION FOR ERECTION & INSTALLATION OF SKID MOUNTED/ FIELD ERECTED EQUIPMENT Project: UCH-II Development Project Owner: Oil & Gas Development Co. Ltd. Prepared by: NJ Checked by: Mk Approved by: FS Revised by: FAS

0 ISSUED FOR BIDDING 04/12/2012

Rev. Description of Revision Date Revised Page Nos.

Job No. 14 – 4985

Spec. No. 4985-GS-9504

Sheet 1 of 20 Rev. 0

Specification for Erection/Installation of Skid Mounted/Field Erected Equipment

UCH-II Development Project

Spec. No. 4985-GS-9504 Rev. 0 Sheet 2 of 20

TABLE OF CONTENTS

SECTION NO.

DESCRIPTION SHEET NO.

1.0 SCOPE .............................................................................................3

2.0 REFERENCE CODES AND STANDARDS ..................................4

3.0 GENERAL .......................................................................................5

4.0 STATIC EQUIPMENT ERECTION ...............................................6

5.0 ROTARY EQUIPMENT ERECTION ............................................9

6.0 GROUTING ...................................................................................12

7.0 PREPARATION OF LUBE OIL PIPING SYSTEMS ..................19




1.0 SCOPE The specification covers the care and procedures to install the mechanical equipment belonging to UCH-II Development Project.




2.0 REFERENCE CODES AND STANDARDS The reference codes and standards to be referred within mechanical equipment installation are:

• Local laws or decrees on safety during working.

• OSHA (Occupational Safety and Health Administration) to back up the previous

ones, for special duties.

• Manufacturer's instructions.

• Enclosed specifications.




3.0 GENERAL As a general rule, all mechanical equipments shall be installed strictly following the manufacturer's instructions. Said instructions are a part of Technical Documentation to be supplied to OGDCL/Engineering Consultant.




4.0 STATIC EQUIPMENT ERECTION 4.1 This section refers to all static equipments e.g. vessels, columns, re-boilers, flare

stacks, tubular heat exchangers, oil water separator packages, skid mounted equipments, filters, etc., to be erected/installed by the Contractor. The erection work should conform in each specific case to the following codes, standards and relevant Specifications: • ASME Section VIII Div. I.

• Instructions and drawings issued by Manufacturer.

• Layout of each equipment and orientation for correct positioning, shown in the

piping drawings. 4.2 Handling of each equipment or part should be performed such as to eliminate over-

stressing. 4.3 Use of slings, where indicated in the equipment drawings shall be used. 4.4 Wherever the equipment is provided with lifting lugs they shall be used as the only

main points for lifting. 4.5 The nozzles and/or the man ways may be used as lifting points only if specifically

indicated so. 4.6 All stiffeners, protection covers, temporary supports and all other facilities provided

by the equipment manufacturer should be left in their places until erection time. 4.7 Before placing the equipment on foundations, the top of concrete should be chipped

by hammering to remove the surface layer, which has low strength and to ensure a suitable bond between the foundation concrete and grouting.

4.8 The equipment should be laid on blocks of steel wedges and/or shims to ensure a

grouting space as specified in the drawing, if not, than 25 to 35mm, to be maintained.




4.9 Minimum two blocks of wedges and/or packages of shims should be considered for each foundation bolt (one on each side of each bolt).

4.10 The sliding supports of the horizontal equipment should rest on intermediate

bedplates of steel and the necessary blocks of wedges and/or shims should be installed under such bedplates only.

4.11 The two nuts of each foundation bolt shall be tightened to each other above the base

plates of the sliding supports such as to ensure free spaces of 1.5 to 3mm. 4.12 No welding shall be permitted on the equipment supplied as completely shop

assembled. Site welding of certain external attachments may be considered when specifically ordered only.

4.13 All welding procedure test and welders qualification should be done as per ASME

Section IX & other Specification prepared by OGDCL/Engineering Consultant. 4.14 Preheat and post weld heat treatments (stress relieving) when required, should be

done using electric induction equipment provided with temperature recorders. 4.15 Nozzle of the equipment should be checked for tension/stresses. All the piping

attached with the equipment should be free of tension/stresses. 4.16 The telltale hole is to be used to pneumatically test attachment welds on reinforcing

pads. The telltale hole shall be plugged after hydrotest with non-hardening sealant or grease.

4.17 The final tightening of all the studs should be done uniformly and in the proper

diametric sequence to impose equal pressure on the gasket and to avoid distortion or over-stressing of equipment.

4.18 Colloidal molybdenum disulfide or other approved lubricants shall be applied to all

studs before the joints are assembled. 4.19 All equipment components shall be sorted separately as per PC Contractor's

instructions and stored on wooden sleepers above the ground.




4.20 Access and service platforms which affect the erection of equipment and sub-assemblies should be erected after box-up of equipment.

4.21 Field hydrostatic pressure testing of all equipments shall be conducted in accordance

with the equipment manufacturer's instructions. 4.22 Test records shall be maintained for all tests conducted. Format for test record shall be

provided by the Contractor for OGDCL’s/Engineering Consultant’s approval, which would include the following:

a) Date of test b) Equipment number c) Test medium d) Inspector's name and signature e) Duration of test f) Pressure records g) Ambient Temperature

4.23 The following inspection should be made in the presence of representative of

OGDCL/Engineering Consultant and a certificate must be signed for each inspection:

a) Correct leveling and orientation of equipment b) Hydrostatic testing c) Stress relieving and hardness testing d) Refractory drying if required/applicable e) Mechanical completion f) Box-up g) Equipment Acceptance Certificate




5.0 ROTARY EQUIPMENT ERECTION 5.1 This section refers to all compressors (centrifugal and reciprocating), centrifugal

blowers, pumps (centrifugal pumps), screw pump, gear pumps, proportioning (meter-ing) pumps, reciprocating pumps with or without gear-box driven by electric motors, gas turbines, stream turbines, or diesel engines single stage or multistage, air coolers, etc. Steel structure attached with air cooler is also part of equipment. It also includes assembly and installation of packaged skid mounted rotary equipment like chemical injection packages, air generation unit and packaged reciprocating compressor.

5.2 Handling of each unit should be performed by placing the slings such as to eliminate

over-stressing. The eye bolts on the top of the drivers or driven casings (if such eye bolts are

provided by manufacturers) shall be used when lifting those parts separately and not when lifting the complete unit.

5.3 Storage conditions before erection on foundations and preservations after erection on

foundations should conform in all respects to the instructions issued by manufacturers. Suction and discharge flange covers as well as all the protection plugs provided by manufacturers to the other openings must be left in their places until the piping is connected with them. If no covers or protection plugs have been provided by manufacturers or if such covers or plugs are not suitable for protection after removing the units from their boxes, they should be replaced by sub-contractor with the suitable ones.

Each equipment should be inspected periodically and additional steps should be

considered when necessary (periodic cleaning, filling with oil, etc.). 5.4 Before placing the units on foundations, the top of concrete should be chipped by

hammering to remove the surface layer, which has low strength and to ensure a suitable bond between the foundation concrete and grout.

5.5 The equipment should be laid on blocks of wedges and/or shims to ensure a grouting

space as specified in the drawing between the concrete top and base plate bottom. The blocks of wedges and/or shims should be placed near each foundation bolt and




adjusted as necessary to ensure a correct level (horizontality) in all directions. After leveling, the nuts of the foundation bolts should be lightly tightened. Grouting should be performed as per Section 6.0 of this specification.

5.6 Alignment of the unit (a) driver and speed reducer unit, (b) speed reducer unit and

driven (if any) should be performed to conform strictly to the accuracy indicated by the manufacturers using dial “Laser alignment tool”.

Use of dial indicator straight edges and sensor gauges cannot be considered unless

approved by OGDCL/Engineering Consultant. Each alignment should include accurate checking of radial and axial deviations fas-

tening the dial indicator bracket, sequentially to each half of the coupling. Alignment should be checked:

• Before grouting • After grouting and • After connection of piping to the equipment

5.7 Lubrication, installation of auxiliary piping and accessories installation of packing or

mechanical seals (if the mechanical seals have not been installed by the Manufacturer) as well as all operations on the equipment itself like dismantling and reassembling (if required) must conform strictly to the instructions given by the Manufacturer for each equipment.

5.8 The piping attached to the compressor should be cleaned chemically before com-

missioning. 5.9 Flanged connections to pumps, compressors, turbines and all other machines shall be

left un-tightened and protected by suitable covers until the machines are made available for final connections.

5.10 The suction and discharge nozzle flange faces and piping flange faces shall match

within the tolerances stated herein and following the Manufacturer's requirement. 5.11 No additional stresses shall appear when flange bolts are tightened.




5.12 After piping is connected onto pumps and before starting-up of said machinery, a final check of coupling(s) lining-up will be performed, using a dial type indicator. This check shall show the same values, which have been read before piping was connected. This will allow checking that no additional stresses have been induced by piping connection. After agreed-upon operation time, a final check of the shaft lining-up shall take place.

5.13 The erection of auxiliary equipment like coolers, pulsation bottles, dampeners, separa-

tors, etc. should also include inspection and pressure tests. Running test of each item should be performed after all necessary facilities are

available to check for proper operation. Temporary provisions may be considered if safe enough only.

5.14 All fabrication and erection of steel structure shall comply with American Institute of

Steel Construction (AISC). 5.15 All welding procedure tests and welders qualification should be done as per ASME

Section IX. 5.16 The following inspection should be made by representative of OGDCL/Engineering

Consultant and a certificate must be signed for each inspection:

a) Correct leveling and orientation of equipment. b) Alignment:

– Before grouting – After grouting – After connecting the pipe to the equipment

c) Mechanical completion certificate. d) Test run certificate/acceptance certificate.

5.17 No spare parts should be used for replacing the defective ones during erection work,

unless specifically agreed upon.




6.0 GROUTING 6.1 Scope

This section defines the materials and workmanship related to grouting for the following applications:

i) Bonding of new concrete to existing concrete

ii) Grouting of base plates and equipment bases Materials include - regular cement grout, no shrink cement-based grout, epoxy grout

and bonding mixtures. 6.2 Reference Codes and Standards

The standards to be taken into consideration in addition to the terms of the present specification are:

ASTM-C33-79 Standard Specification for Concrete Aggregates ASTM-C109-77 Standard Test Method for Compressive Strength of Hydraulic

Cement Mortars (using 2" or 50mm Cube Specimens) ASTM-C125-79 Standard Definition of Terms Relating to Concrete and Con-

crete Aggregates ASTM-C150-78 Standard Specification for Portland Cement ASTM-C191-79 Standard Test Method for Time of Setting of Hydraulic Cement

by Vicat Needle ASTM-C531-74 Standard Test Method for Shrinkage and Coefficient of

Thermal Expansion of Chemical-Resistant Mortars, Grouts and Monolithic Surfacing

ASTM-C579-75 Standard Test Methods for Compressive Strength Surfacing.




ASTM-C827-78 Standard Test Method for Early Volume Change of Cementi-tious Mixtures

CRD-C588-79 Specification for Nonshrink Grout (Corps of Engineers) AASHTO-T26-78 Quality of Water to be used in Concrete ANSI A10.9-70 Safety Requirements for Concrete Construction and Masonry

Work

6.3 Delivery, Storage & Handling

a) Nonshrink Cement-Based Grout and Epoxy Grout aggregate shall be delivered to the site in sound dry bags and Epoxy Grout liquid components in sealed hardener and resin containers. The Contractor shall be responsible for storing the grout in a dry, weatherproof area and within the temperature range of 4ºC to 32ºC.

b) The total job storage time for non-shrink grout shall be limited to ten months.

6.4 Materials a) General

Sand-cement grouts shall be proportioned at the site. All non-shrink grouts shall consist of pre-measured, prepackaged materials, supplied by the Manufacturer, except water. All grouts shall be non-corrosive, non-staining and resistant to effects of moisture.

b) Water, Sand and Cement

Water shall conform to AASHTO T26. When conforming water is not available, mortar test cubes shall be made with non-conforming water in accordance with the requirements of ASTM C109. Tested cubes shall have a minimum of 90% of the 28 day specified strength.




Sand shall be used as defined by ASTM C125 and shall conform to ASTM C33, grading for fine aggregates (No. 4 to 100). Sand for bonding mixture shall pass a No. 16 sieve. Cement shall be Portland Cement Type I or Type II, ASTM C150.

c) Cement Grouts

Plain Cement Grout shall be two parts sand for every part cement, by weight; with a minimum 28 days compressive stress of 20 MPa (3000 psi) in accordance with ASTM C109.

d) Non-shrink Cement-Based Grout shall meet the following requirements:

Plastic Volume Change: No shrinkage (0.0%) and a maximum of 4.0% expansion at any time before initial set when tested according to ASTM C827.

Hardened Volume Change: No shrinkage (0.0%) and a maximum of 0.1% expansion in the hardened state when tested according to CRD C588.

Compressive Strength: Minimum allowable compressive strength at 28 days to be 40 MPa (6000 psi) as measured by ASTM C109.

Initial Set Time: Not less than 60 minutes when tested according to ASTM C191.

Soundness: No grout shall contain metallic substances (catalyzed or non-catalyzed), aluminum powder, water reducing agents, fluidifiers, accelerators, super plasticizers, or other materials known to increase drying shrinkage and/or compromise long-term durability.

e) Non-shrink Epoxy Grout shall meet the following requirements:

Volume Change: No shrinkage and a maximum of 4.0% expansion when tested according to ASTM C827 (modified).

Compressive Strength: Minimum allowable compressive strength at 7 days to be 40 MPa (6000 psi) as measured by ASTM C579.




Heat Development: The peak exothermal temp of a 50 mm (2") diameter by 100 mm (4") high cylinder of grout not to exceed 35ºC (95ºF) when tested at 24ºC (75ºF) material and laboratory temperatures.

Thermal Expansion: Not to exceed a coefficient of thermal expansion of 54 x 10-6 mm/mm/ºC (30 x 10-6 in/in/ºF) when tested according to ASTM C531.

f) Bonding Mixtures and Adhesives

The following bonding mixture or adhesive can be used to create cohesion or water tightness between new concrete and existing concrete: – Cement Bonding Mixture - Neat cement and water mixed to the consistency

of creamy paint.

– Epoxy Adhesive - Mixture consists of a proprietary epoxy adhesive, mixed and applied in accordance with manufacturer's instructions. Epoxy adhesive to be approved by Client\Company.

6.5 Applications

Grout to be provided between the top of foundation concrete and the bottom of bearing plates. Thickness of grout shall be as specified in drawing, if not, than to be a nominal thickness of 25 mm (1") with a minimum thickness of 12 mm (½") in order to avoid feather edging.

Non-shrink grout or epoxy grout to be used for the following applications. Nonshrink

grout to be used unless epoxy grout is specified by equipment Contractor or OGDCL/Engineering Consultant.

• All compressors.

• Reciprocating pumps greater than 75 kW (100 HP) and centrifugal pumps greater than 375 kW (500 HP).

• Structures with a height to width ratio over 2, or with large vibrating equipment, if one column load is over 500 kN (110 kips).

• Normal structures if one column load is in excess of 1000 kN (220 kips)




Drawings to indicate where non-shrink grout is to be used.

For grouts that will experience temperatures above those listed below, high tempera-ture grouts to be used.

Maximum Temp. Cement based grout – 200ºC Epoxy grout – 135ºC

High temperature cement-based grout sets faster than normal temperature grout.

Because of the difference in thermal coefficient of expansion between epoxy grout and concrete, stresses are formed at grout edges. Grout details to allow for expansion joints, grout cut back, corner reinforcing or added epoxy depth at corners

6.6 Execution

a) Surface Preparation

Surface of the existing concrete of grease shall be cleaned from oil, paint and other coatings. The surface shall be roughened to expose the aggregate and thoroughly flushed with clean water. Before grouting, equipment bases and base plates shall be leveled and aligned in accordance with recommendations of equipment manufacturer and drawings. When any cement-based grout or bonding mixture is used, the concrete surface shall be thoroughly soaked until absorption stops. Excess water shall be removed just before grouting of bonding. When epoxy grouts or adhesives are used, all surfaces shall be kept dry before application.

b) Form work

Forms or back braces used shall be securely anchored to withstand the forces of the placement of grout.




For nonshrink cement based grout tight forms shall be provided with tape sealed joints. Form oil to be applied for easy form release. For nonshrink epoxy grout, watertight forms shall be provided with chamfer strips in place where chamfer edge is required. Forms to be lined with polyethylene or heavy wax for easy form release.

c) Placement

Grout placement shall be done in a manner that will assure the filling of all surfaces and the intimate contact of grouting materials with surfaces grouted. Grout to be placed rapidly and continuously to avoid cold joints under the baseplate. Grouting to be done from one side to the other in one direction with tamping or rodding to eliminate voids.

d) Finishing

Cement-based grout shall be trimmed back to the level indicated on the drawings after the grout has reached an initial set. Surfaces to be sloped away from base plate and protruding edges cut back. Epoxy grout cannot be trimmed after set. Top surfaces shall be finished to proper slope prior to initial set. Finish coating shall be applied over grout holes and vent holes after grout has set.

e) Curing

Immediately after placement, cement-based grout shall be protected from premature drying, excessively hot or cold temperatures and mechanical injury. Grout to be maintained with minimal moisture loss by implying proper methodology at relatively constant temperature for the period necessary for hydration of cement and hardening of concrete. Epoxy grout shall be cured in accordance with manufacturer's instructions.




f) Shims and Wedges

Removal of shims and wedges is not required unless specified by equipment manufacturer. All shims or wedges left in place shall be completely encased in grout.

g) Anchor Bolts and Pipe Sleeves

For anchor bolts and pipe sleeves requiring grout, all surfaces shall be cleaned from oil, grease and other foreign substances. Where anchor bolts or pipe sleeves are to remain isolated, sleeves shall be filled with a pliable material such as Silicone Rubber molding compound or other material shown in the drawings.

h) Bonding New Concrete to Existing Concrete

The bonding mixture shall be applied by working it into the surface with a stiff brush. New concrete to be placed before bonding mixture dries out. Epoxy adhesive shall be applied in accordance with manufacturer's instructions.

i) Testing

Cement-based grout shall be tested under ASTM C109 and epoxy grout under ASTM C579. Cubes shall be prepared for each type of grout and tested for required compressive strength according to the following schedule. Grout Type 24 Hrs. 2 Days 7 Days 28 Days Plain Cement Grout – 2 2 2Nonshrink Cement Grout 3 – 3 3Epoxy Grout 3 3 3 –




7.0 PREPARATION OF LUBE OIL PIPING SYSTEMS 7.1 General

Prior to testing of rotating main machinery fitted with lubricating oil piping, the preparation works defined hereunder shall be undertaken.

7.2 Pickling of Oil Piping

After all welding, fabrication and erection of oil piping has been completed, the piping shall be dismantled in suitable sections configuration, so that efficient flow of liquids could be performed through said piping sections.

• Cleaning

Before pickling procedure performance, all oil equipment shall be opened inspected, to determine condition of internal parts. When deemed necessary, such material shall be cleaned, using a solvent previously agreed upon by the equipment Manufacturers.

• Pickling

After proper and careful preparation every pipe section will be flushed, using hot caustic soda. This will be performed until perfect cleanliness has been reached. Then the pipe sections shall be flushed with fresh clean water up to elimination of caustic soda. After performance of this operation flushing with hot muriatic will take place. Pickling shall be repeated until the system is completely clean and to OGDCL’s/Engineering Consultant’s satisfaction.

• Rinsing

The piping shall then be rinsed by flushing with fresh clean water, until all traces of acid are removed.

• Drying

The piping shall, after that procedure, be dried by blowing air or gas, until complete removal of all water and humidity.




• Miscellaneous

After drying the piping shall receive a coat of clean engine oil to prevent oxidation. As an alternative, the system may be filled with approved oil, run for 6 hours and kept as it is, up to test operation until the final oil will be filled. After flushing has been performed, the oil will be drained from the system and the filters’ cartridges replaced by new ones. All new cartridges cost will be borne by the Contractor. For lube oil flush, the tube bundle shall be removed from coolers and stored with care to prevent damage. Upon completion of flushing operations, the bundle shall be thoroughly cleaned using same solvent used (in para cleaning above). It shall then be reinstalled in the oil coolers.

SPECIFICATION FOR PAINTING & PROTECTIVE COATING

Project: UCH-II Development Project Client: Oil & Gas Development Company Limited Prepared by: FAS Checked by: AJ Approved by: FS Revised by: -

0 ISSUED FOR BID 28/11/12 Rev. Description of Revision Date Revised Page Nos.

Job No. 14 – 4985

Spec. No. 4985-GS-9523

Page 1 of 23 Rev. 0

Spec. No.4985-GS-9523-0 Page 2 of 23


Specification for Painting & Protective Coating

TABLE OF CONTENTS

1.0 INTRODUCTION....................................................................................................... 3 2.0 CODES AND STANDARDS ...................................................................................... 4 3.0 SCOPE OF SUPPLY .................................................................................................. 5 4.0 ENVIRONMENTAL DESIGN CRITERIA ............................................................. 6 5.0 APPLICATION PROCEDURE ................................................................................ 7 6.0 GALVANISING ........................................................................................................ 13 7.0 PREPARATION OF NON FERROUS SURFACES............................................. 14 8.0 SURFACES NOT TO BE COATED ...................................................................... 15 9.0 DEVIATIONS ........................................................................................................... 16 10.0 COATINGS REPAIR PROCEDURE .................................................................... 17 11.0 APPROVED PAINT MANUFACTURERS ........................................................... 19 12.0 PAINT SYSTESM .................................................................................................... 20 13.0 COLOUR CODING.................................................................................................. 23

Spec. No.4985-GS-9523-0 Page 3 of 23



1.0 INTRODUCTION 1.1 General

This specification covers Company's requirements for the surface preparation, selection of material, and material application procedures for Protective Coating systems to be used on steel structures, equipment and production facilities for the UCH-II Development Project during fabrication, construction and/or operation.

1.2 Terminology

Company Oil and Gas Development Company Limited

Company Representative A Company designated Engineer, Party/Parties duly

authorized by the company to act on behalf of the

company with whom the Supplier shall consult at all

reasonable times and whose instructions, request and

decision shall be binding on Supplier.

Supplier Entity with whom the Company will execute a

Contract for supply of equipment/material as per this

document

Project UCH-II Development Project

Spec. No.4985-GS-9523-0 Page 4 of 23



2.0 CODES AND STANDARDS 2.1 Codes, Standards and Regulations

The surface preparation and coatings shall be in accordance with this specification, the latest editions of the following Codes and Standards and Statutory Regulations (where applicable): "Steel Structures Painting Steel Structures Painting Council Manual Vol. 1" "Good Painting 4440 Fifth Avenue Practice". Pittsburgh, PA 15212, U.S.A. "Steel Structures Painting Steel Structures Painting Council Manual Vol. 2 "Systems and 4440 Fifth Avenue Specifications". Pittsburgh, PA 15212, U.S.A. "Swedish Standard S.I.-05.5900" Swedish Stds. Inst. "Pictorial Surface Preparation Box 3295 Standards for Painting Steel S-10366 Stockholm 3, Surfaces". Sweden "Echelle European de Degres European Committee of Paint and D'Enrouillement pour Peintures Printing Ink manufacturers Association Antirouille" ("European Scale obtainable from: of Rusting for Anti Corrosive Paint Manufacturers Assn. of Great Paints"). Britain,

Alembic House, Albert Embankment, London A.S.T.M. A123 American Society for Testing and Materials "Zinc (Hot Galvanized) Coatings on 1916 Race Street Products from Rolled, Pressed and Philadelphia, PA 19103 Forged Steel Shapes, Plates, U.S.A. Bars and Strip".

2.2 Order of Precedence

In case of conflict between this specification and its associated specifications and the above codes and standards, the Application Supplier shall bring the matter to the Company’s attention for resolution and approval in writing. In all cases the most stringent requirement shall apply. Should any conflict occur as a result of applying paint manufacturers data sheets and specifications, the order of precedence shall be as follows: Data Sheets This Specification Other reference Project Specifications Codes and Standards referred to within this specification and its attachments.

Spec. No.4985-GS-9523-0 Page 5 of 23



3.0 SCOPE OF SUPPLY 3.1 General

The overall scope of supply for the preparation and painting shall be as indicated within this specification.

3.2 Scope of Supply

The application Supplier appointed to carry out surface preparation and painting shall provide the following as a minimum: Supply of all labor sufficient to complete the work Supply of all equipment, special tools and power Supply of suitable grit/sand Supply of all coating materials Responsibility for safe storage of consumable materials ambient conditions

during operations Inspection and testing in accordance with this specification and its attachments All documentation as required by this specification and its attachments.

Spec. No.4985-GS-9523-0 Page 6 of 23



4.0 ENVIRONMENTAL DESIGN CRITERIA 4.1 General

Unless otherwise stated on the data sheets, all equipments and structures will be located in an open exposed area.

4.2 Site Environmental Data

Environmental conditions for all equipments and structures covered by this specification will be listed in the Project Specification on Site Data and Utilities Spec. No. 4985-A-1000.

Spec. No.4985-GS-9523-0 Page 7 of 23



5.0 APPLICATION PROCEDURE 5.1 General 5.1.1 Supplier's Representative/Guarantee

The Application Supplier shall arrange for the services of a technical representative of the selected coating manufacturer to visit the worksite before the beginning of cleaning and coating operations to advise the Application Suppliers personnel regarding proper equipment, surface preparation and coating procedures. The technical representative shall thereafter make periodic visits to assist the Application Supplier in applying and curing the products and systems at the recommended dry film thickness. Coating manufacturer and Application Supplier shall give a joint 5 year guarantee as follows: All coatings will be 'sound' and giving a degree of paint protection efficiency' similar to scale 8 of the European Scale of Degree of Rusting for Anti Corrosive Paints" - for a period of five years. The guarantee period will start from the provisional acceptance of the completed work.

5.1.2 Inspection

The Company's representatives and the Paint manufacturer's representative shall have access to the Application Suppliers worksites at all times during blasting and coating application and shall be permitted to inspect the work at will. Both representatives shall be given at least two days' notice prior to initial starting of any work covered by the specification. The Company's representatives shall have the authority to reject any work that does not conform to the specification.

5.1.3 Supplier's Personnel

The Application Supplier shall select only competent and fully skilled personnel and shall keep an experienced foreman on the job at all times when work is in progress.

Spec. No.4985-GS-9523-0 Page 8 of 23



5.2 Surface Application - General 5.2.1 Cleaning

All steel surfaces to be coated shall be cleaned by abrasive blasting. Blasting abrasives shall be dry, clean and free from contaminations. Preliminary blasting may be done at night with the prior consent of the Company's representatives provided that all surfaces so blasted shall again be blasted to within the specified tolerances before any coating materials are applied. Final blast cleaning shall be permitted only during daylight hours and in the presence of the Company’s representative. All blast cleaned surfaces shall be coated with the specific primer within four hours after blasting, prior to sundown on the same day before rusting occurs. All dust and abrasive particles shall be thoroughly removed from surfaces before the application of any coating. A minimum of 50mm around the edges of blast cleaned surfaces shall be left uncoated unless joining a coated surface. No acid washes or other cleaning solutions or solvents shall be used on metal surfaces after they are blasted. This includes inhibitive washes intended to prevent rusting. Blast cleaning shall not be done on surfaces that are moist or that may become moist before the application primer. All N.D.T. of components and surfaces to be coated must be ascertained to have been completed prior to preparation and coating. Any steel not primed on the same day as it was blasted or any steel wet by rain or moisture shall be reblasted. No blasting shall be permitted when metal surface temperatures are less than 3°C above the dew point, or when the relative humidity of the air is greater than 80%. Temperatures and humidity shall be recorded twice a day. Blast cleaning shall not be done in proximity to surface coating operations or near other surfaces susceptible to dust and particle contamination. Any portion of the fabrication to be blast cleaned, including the drilling of bolt holes, shall be complete and in final condition before blasting is started, unless otherwise authorized by the Company. All welded areas shall be given special attention for removal of weld flux slag, weld metal spatter, weld heat oxides, weld flux fumes, slivers and other foreign objects before blasting. Any oil or grease contamination shall be removed by solvent cleaning and the area re-blasted. Blasting shall continue a minimum of 20mm into adjacent coated surfaces.

Spec. No.4985-GS-9523-0 Page 9 of 23



5.3 Blast Cleaning Requirements

5.3.1 As a minimum, all cleaning shall be to a NEAR-WHITE-BLAST CLEANING in accordance with and as illustrated by Swedish Standard SIS 05 5900 Grade SA 2½.

A Near-White-Blast Cleaned Surface Finish is defined as 'one from which all oil, grease, dirt, mill scale, rust, corrosion products, oxides, paint and other foreign matter have been completely removed from the, surface except for the very light shadows, very slight streaks or slight discolorations caused by rust stain, mill scale oxides, or slight residues of paint or coating that may remain. At least 95 per cent of each 5 sq. cm. of surface area shall be free of all visible residues, and the remainder shall be limited to the light discoloration mentioned above". Size of abrasive particles shall be such that anchor profile achieved is a maximum of 50 microns unless otherwise approved by Company. The abrasive selected for use, which will be angular in nature, shall be in accordance with the recommendations of the coating manufacturer. The anchor profile shall be measured and recorded or replicated with: - • The "Testex Press-O-Film" system or equivalent • The "Rugotest LCA-CFA No. 3" or equivalent

Sand blasting equipment is to be inspected in respect of discharge rate and pressure, hose sizes and air drying. Sand/grit is to be stored under cover and shall be "DRY" for feeding into the spray hopper. After blasting, all grit/sand shall be removed by dry air blowing or vacuum.

5.4 Coating 5.4.1 Supply of Materials

All coating materials and thinners shall be furnished by the Application Supplier in original, unopened containers bearing the manufacturer' label and instructions. For materials having a limited shelf life, the date of manufacture and the length of life shall be shown.

5.4.2 Preparation of Materials

All coating materials shall be stirred in a pot with a power mixer before use to, thoroughly remix the pigments and thinners. Only thinners specified by the coating manufacturer shall be used. Mixing and thinning directions as furnished by the coating manufacturer shall be followed.

Spec. No.4985-GS-9523-0 Page 10 of 23



5.4.3 Use of Materials

If the coating material requires the addition of a catalyst, the pot life under application conditions shall be clearly stated on the container label and this pot life shall not be exceeded. When the pot life limit is reached, the spray pot shall be emptied, remaining material discarded, the equipment cleaned and new material catalyzed.

Coating materials which have livered, gelled or otherwise deteriorated during storage shall not be used. Thixotropic materials which may be stirred to obtain normal consistency are not subject to this restriction.

Depending upon location, the Application Supplier shall employ the suitable system as listed in this Specification.

Coating systems shall be supplied by one manufacturer who shall assure the Application Supplier that the various components of the coating system are compatible.

5.5 Coating Application

5.5.1 Surface Defects All surface defects including cracks, surface laminations and deep pitting, likely to be detrimental to the protective painting system shall be removed in accordance with the relevant equipment, vessel, piping or structural code or specification covering surface defects. All fins at saw cuts, barbs and sharp edges shall be similarly removed. Where extensive grinding has been necessary, the dressed areas shall be reblasted to remove all rust and provide an adequate paint key.

5.5.2 Weather

No coating shall be applied during fog, mist, rain, frost, or when the metal surface temperatures are less than 3°C above the air dew point or when the relative humidity of the air is greater than 85% (95% for application of inorganic zinc silicate paints). The Company or his representative may suspend application of coating when, in their opinion, damage to the coating may result from actual or impending weather conditions.

5.5.3 Coating Each coat shall be applied uniformly over the entire surface. Skips, runs, sags and drips shall be avoided. When these occur they shall be brushed out immediately or the material shall be removed and the surface recoated. On beams and irregular surfaces, edges shall be coated first and an extra pass made later.

Spec. No.4985-GS-9523-0 Page 11 of 23



Each coat shall be allowed to dry for the time specified by the coating manufacturer. Paint rollers shall not be used.

5.5.4 Film Thickness Specified film thickness for coating materials shall be strictly observed. Film thickness shall be checked with appropriate film thickness gauges furnished by the Application Supplier. The Application Supplier shall calibrate gauges for the thickness range to be checked, over the type of surface to be coated. When dry film thicknesses are less than those specified, additional coats shall be applied as required at no additional cost to the Company.

5.5.5 Integrity of Coating

Coating shall be free from pin holes, voids, bubbles and other discontinuities. Any such defects shall be repaired at the Application Supplier's expense. Prior to the application of a coating, any damage to the previous coating shall be repaired with the specified material. Upon completion, any damage of fault to the coating system shall be repaired to the satisfaction of the Company at no additional cost.

5.5.6 Contaminations Precautions shall be taken to prevent the deposition of dust, moisture or other foreign matters on the surface after coating. Any coated surface that becomes contaminated with dirt etc. shall be air blasted or washed down and allowed to dry. If the contamination still exists the affected surfaces shall be reblasted.

5.5.7 Spray Application

The Company reserves the right to inspect all equipment for spray application prior to commencement of spraying. Spray guns, lines and pressure pots shall be clean before adding new material. An adequate moisture trap shall be installed between the air supply and each pressure pot. Suitable pressure regulators and gauges shall be provided for both the air supply to the pressure pot and the air supply to the spray gun. Spray equipment and operating pressure shall comply with the recommendations of the coating manufacturer. The length of the material hose between pressure pot and spray gun shall not exceed 15 meters. Pressure pot, material hose and spray gun shall all be kept at as nearly the same elevation as possible. The spray gun shall be held at right angles to the surface and each pass shall overlap the previous pass by 50%.

Spec. No.4985-GS-9523-0 Page 12 of 23



Large surfaces shall receive two passes (except when applying solvent based inorganic zinc) at right angles to each other (crosshatched). Spray shall be applied in a heavy, wet coat. Coating materials containing heavy or metallic pigments that have a tendency to settle shall be kept in suspension in the pressure pot by a power driven, continuous agitator. Other coating materials shall be agitated as frequently as work-ability requires. The Application Supplier shall follow the paint manufacturer's recommendations in his selection and use of paint spray equipment, and any specific instructions for application.

5.5.8 Brush Application When coatings are to be applied by brushing, brushes shall be of a style and quality that will permit proper application of material. Round or oval brushes are generally most suitable for bolts, irregular surfaces and rough or pitted steel. Flat brushes are suitable for flat area. Flat brushes shall not be more than 100mm wide. No extending handles shall be used on brushes. Brushing shall be done so that a smooth coat, as nearly uniform in thickness as possible, is obtained. There shall be no detrimental brush marks. Paint shall be worked into all corners and crevices. When applying solvent type coatings, care shall be taken to prevent lifting of previous coats. Adhesion tests shall be made at the discretion of the Supplier or his representative.

5.6 Protection

The Application Supplier shall protect buildings, structures and equipment from droppings and spray, and shall be solely responsible for all damage to other equipment and facilities as a result of coating operations.

5.7 Field Welds

No coating shall be placed on edges or surfaces prepared for field welds or within 50mm of these areas.

5.8 Bolt Holes Care should be taken to ensure that bolt holes receive the required coatings.

Spec. No.4985-GS-9523-0 Page 13 of 23



6.0 GALVANISING 6.1 General

All grating, and other items so specified dipped on the Project Drawings, shall be hot-dipped galvanized in accordance with ASTM A.123.

6.2 Repair of Galvanized Surfaces

All galvanized surface that require welding, cutting, drilling or other preparation and any galvanized surface that has been damaged shall be repaired with the specified coating repair system. Before application of repair coating, surface shall be washed with fresh water; rust and other deposits shall be removed by power sanding and the area thoroughly cleaned with solvent and / or grease removing agent. Coating material shall be applied immediately after completion of surface preparation.

Spec. No.4985-GS-9523-0 Page 14 of 23



7.0 PREPARATION OF NON FERROUS SURFACES 7.1 General

Prior to applying coating material, surfaces shall be degreased using an emulsifying agent and then washed thoroughly in fresh water and allowed to dry. All surfaces shall be given a 'sweet blast' immediately before coating.

7.2 Stainless Steel Parts

Stainless steel parts shall not be painted.

Spec. No.4985-GS-9523-0 Page 15 of 23



8.0 SURFACES NOT TO BE COATED

Equipment and component drawings will indicate areas that do not require coatings, which will generally include: Flanged faces Tapped holes Machined parts Stainless steel parts Plastic or PVC based materials Cupro-nickel parts

Grit or sand blasting is NOT to be carried out local to: Machined surfaces Running bushes or bearings Instrument glasses Cables Or any other items of equipment that will incur damage without adequate

covering or protection

All openings in mechanical equipment and process piping are to be adequately plugged or covered prior to blasting to prevent the ingress of sand or grit.

Any coatings, drips, runs or streaks that go accidentally onto the above listed surfaces, are to be removed without the use of power tools.

All tapped holes are to be re-tapped after painting of equipment.

Name plates and "Tag" identifications shall not be painted so obliterating markings thereon.

Prefabricated parts that require welding shall not be painted local to the weld preparation.

A strip 50mm wide from the weld bevel is to be left unpainted.

Spec. No.4985-GS-9523-0 Page 16 of 23



9.0 DEVIATIONS

"Small" items of proprietary equipment can be supplied with a preparation and protective coating system and finish to the equipment Vendors "own standard"; provided that the Vendor confirms to the Company or his representative, in writing, that the Vendor's "own standard" is "as good as" or "better than" the preparation and finish as required by this Specification inclusive of the "five year" guarantee specified in Para. 5.1.1. of this specification. Upon request, the Vendor will be supplied with details of climatic and environmental conditions applicable. Vendors who 'choose' the above deviation are required to provide. A written data sheet of "own standard" paint system and top coat color to, be

included in the Vendors data book or installation maintenance manual. A written data sheet of a 'Repair Procedure' for the paint system to be, included in

the Vendors data book or installation/maintenance manual.

A quantity of 'primer - tie coat' and 'top coat' (matching color), for making good by others. The paint is to be included as part of the equipment.

THE SUPPLIER PAINT SYSTEM MUST BE COMPATIBLE WITH THE PAINT SYSTEMS (FOR SPECIFIC AREAS) AS LISTED IN THIS SPECIFICATION.

Spec. No.4985-GS-9523-0 Page 17 of 23



10.0 COATINGS REPAIR PROCEDURE 10.1 General

This Repair Procedure is to be used for repairing 'small' areas of coating damage incurred: During fabrication in equipment supplier works During fabrication/construction of steelwork During hook-up work During pre-commissioning and start up During full on stream operation, up to a five year period from start up.

10.2 Exclusions

This Repair Procedure does not cover:

Major or extensive areas of repair Major or extensive repair/maintenance of areas after start up

In such cases, the remaining 'undamaged' coatings are to be removed back to base metal and the applicable preparation and coating system is to be applied anew.

The Company or his representative is to be informed of any major damage to coatings during all stages of fabrication and/or construction.

10.3 Small Areas

Repairs to 'small,' areas of coatings will apply to two separate standards: 10.3.1 The Standard Coating Systems as listed in this Specification. 10.3.2 The Standard Coating System as used by a Vendor of some small items of

equipment.

Repairs covered by (10.3.1) are to be as per systems shown. Repairs covered by (10.3.2) are to be as per the specific 'Coatings Repair Procedure' which will be located within the equipment Vendors installation/maintenance manual, for the item of equipment requiring repair. The Vendor will have also included for quantities of 'primer' 'tie coat' of mating color in his 'spares' supply.

Spec. No.4985-GS-9523-0 Page 18 of 23



10.4 Dressing Back

For all small repairs, the damaged coating is to be removed back to base metal and to an area that overlaps into 'sound' undamaged coating. Damaged areas of coatings are to be removed with hand tools or power tools and not 'grit or sand blasting'. The preparation (prior to coating) shall be as per this Specification (10.3.1) or Supplier specification (10.3.2) whichever is applicable.

Spec. No.4985-GS-9523-0 Page 19 of 23



11.0 APPROVED PAINT MANUFACTURERS

Coating systems listed in this specification are to be applied with suitable materials from the following approved list of paint manufacturers available in Pakistan: ICI BERGER SIGMA COATINGS Any deviation from this list shall be subject to prior approval by the Company.

Spec. No.4985-GS-9523-0 Page 20 of 23



12.0 PAINT SYSTESM 12.1 Key List

Code Work Location 1A Shop or Field Surface preparation – Blast clean SA-3 1B Shop or Field Surface Preparation – Blast clean SA 2 ½ 2 Field Surface Preparation – needle gun, water wash and scrub,

power tool clean ST-3 5 Shop Primer – 75 microns DFT zinc phosphate (high build) 8 Shop or Field Primer 40 microns DFT urethane zinc rich (moisture

tolerant) 9 Shop or Field Primer 50 microns DFT urethane zinc rich (moisture

tolerant) 10 Field Intermediate – 75 microns DFT urethane M10 (moisture

tolerant) 11 Shop or Field Top Coat – 75 microns DFT modified Alkyd gloss (high

build) 12 Shop or Field Top Coat – 150 microns DFT urethane pitch (moisture

tolerant) 13 Shop or Field Top Coat – 50 microns DFT urethane gloss (moisture

tolerant) 14 Shop or Field Undercoat – 30 microns DFT urethane undercoat

(moisture tolerant) 15 Shop Primer – Inorganic zinc silicate 75 microns DFT 16 Field Top Coat – Aluminum silicone 25 microns DFT 17 Field Tough up – Inorganic zinc silicate 75 microns DFT

12.2 Application Details of paint systems and the applications are listed below:

System 1 - Structural steel for Buildings

System 2 - Structural supports, tank internals

System 3 - External roofs, tank externals

System 4 - Structural steel, piping and vessels below 100°C

System 5 - Piping and Vessels above 100°C

Spec. No.4985-GS-9523-0 Page 21 of 23



System1

System2

System3

System4

System 5

Surface preparation 1B 1B 1B 1A 1A

Primer 5-AS 9-AS 8-AS 5-AS 15-B

Undercoat 14-AS 10-AS 10-AS 14-AS -

Top Coat 13-AS 12-AS 13-B 13-AS 16-AS

TOUCH UP 13- 12- 13- 13- 17- Brush Brush Brush Brush Brush Minimum DFT 150 250 130 150 90 (microns)

Maximum DFT 170 280 160 170 100 (microns

Legend: AS - Airless spray application

B - Brush application 12.3 Pumps, Machinery and Electrical Equipment 12.3.1 Surface Preparation and Painting at manufacturer's Works for Equipment Installed

Outside Buildings.

Manufacturers shall specify their standard painting system for the site conditions, and

shall specify surface preparation, type of coating, number of coats, dry film thickness

and color. Should this system be unacceptable to the Company, the requirements of

this specification shall govern.

Painting at Site No painting is permitted but the shop finish shall be made good if damaged. Color matching If required by the Company, finish painted items shall be painted for color matching.

12.4 Instruments, Instrument Panels, Consoles and Cabinets

12.4.1 Surface Preparation and Painting at Manufacturer's Works for Equipment Installed

Inside Fully Enclosed Buildings.

This equipment shall have its surface prepared, primed and finished in accordance with Manufacturer's standards. In general this shall consist of:

Spec. No.4985-GS-9523-0 Page 22 of 23



One coat of primer and two coats of enamel

12.4.2 Surface Preparation and Painting at Manufacturer's Works for Equipment Installed

outside Buildings this equipment manufacturer shall specify their standard system for the site conditions and shall specify surface preparation, type of coating, number of coats, dry film thickness and color. Should this system be unacceptable to the Company, the requirements of this specification shall govern. Painting at Site No painting is permitted but the shop finish shall be made good if damaged. Colon Matching If required by the Company, finish painted items shall be painted for color matching.

12.5 Protective Coatings for Valves 12.5.1 Scope

This specification covers the preparation and external coating requirements for assembled valves.

12.5.2 Surface Preparation and Application

Following complete assembly of valves, all oil and grease shall be completely removed and surface thoroughly wire brushed to remove all loose and friable material.

Apply one coat of System No. 2 (a Zinc Dust Filled Primer) to a dry film thickness of 75 microns. All valve stems and stuffing box guides shall be suitably protected with grease after coating has been completed. This does not apply if the Supplier's standard practice of preparation is by grit or shot blasting either before assembly or, with proper masking precautions, after assembly. If abrasive blasting is carried out, the use of an inorganic primer (System No. 1) is to be applied.

Spec. No.4985-GS-9523-0 Page 23 of 23



13.0 COLOUR CODING

Fire water piping shall be painted solid red in a suitable weather resistant paint available in Pakistan.

Pipe work shall generally be painted silver with color coding as below.

Color coding of pipe work shall be as per the Piping Service Designations. Each pipe shall be color coded with three painted bands (with the exception of Fire Water piping) identifying Product Medium ANSI Piping Class Piping Material

Color coding shall be prepared by Supplier and agreed by Company/Company representative from the appropriate range of suitable paints available in Pakistan.

SPECIFICATION FOR PACKING & PROTECTION OF MATERIAL AND EQUIPMENT


0 ISSUED FOR BID December 1, 2012


Job No. 14 – 4985

Spec. No. 4985-GS-9524

Page 1 of 25 Rev. 0

Spec. No.4985-GS-9524-0 Page 2 of 25


Specification of Packing & Protection of Material & Equipment

TABLE OF CONTENTS

1.0 GENERAL…………………………………………………03

2.0 TYPES OF PACKING & PROTECTION

RECOMMENDED ACCORDING TO TYPE OF

MATERIAL………………………………………………05

3.0 PACKING FOR AIR TRANSPORT…………………….18

APPENDICES

Spec. No.4985-GS-9524-0 Page 3 of 25



1.0 GENERAL 1.1 Scope

This specification represents the minimum requirements which the Supplier shall follow for the packing and protection of materials and equipment during their transportation, storage and handling for UCH-II Development Project. Supplier shall proceed under his own responsibility and according to the general practice to the sea packing or sea protection of his supply. This packing shall also be carried out in order to satisfy the transportation conditions. The packing shall be strong enough to support without damage sea transportation as well as long duration storage in harbor facilities and/or site. In no case, shall material/equipment belonging to different orders be packed in one single packing. It shall be mandatory to pack the spare parts in separate packing. The spare parts packages may be included in the main equipment packing.

1.2 Definitions

Company Oil and Gas Development Company Limited

Company Representative A Company designated Engineer, Party/Parties duly

authorized by the company to act on behalf of the

company with whom the Supplier shall consult at all

reasonable times and whose instructions, request and

decision shall be binding on Supplier.

Supplier Entity with whom the Company will execute a

Contract for supply of equipment/material as per this

document

Project UCH-II Development Project

Spec. No.4985-GS-9524-0 Page 4 of 25



1.3 Purpose

All the materials are subject to certain fragility due to physicochemical and mechanical risks of their own. Therefore, each material shall have its particular protection and packing taking into account: • Different transportation they shall go through (vibrations, shocks, etc…)

• Transshipment, handling and lifting

• Storage, for more or less long periods, in the open air.

• Every packing should stay reliable for duration of one year minimum.

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2.0 TYPES OF PACKING & PROTECTION RECOMMENDED ACCORDING TO TYPE OF MATERIAL

2.1 Sea Packing

The packing shall be strong enough to support without damage during transportation as well as long duration storage in harbor facilities and/or site.

2.1.1 Pallets

Every material delivered in pallets such as certain products in bags, bricks, etc. a) Protection

i Against Humidity: plastic coating ii Mechanical:

– Corners reinforcement through metallic or iron angles – Face protection to be insured by bituminous paper or cardboard.

The whole being secured by stainless steel strips.

2.1.2 Bundles (Appendix – A)

Constitution of bundles strapped by metallic strips, or dunnage in order to avoid twisting: • Either by strips belting the bundle if it is not too heavy

• Or by U bars tied together by threaded rods with nuts and lock nuts

• Or by wedges, intermediate or circular wooden pieces to ensure protection against sharp edges and rigidity of the sets, the wedges being tied together by nails, bolts or strips.

a) Concerned Materials

• Straight pipes of ¼", 20′ - 43′ long • Steel bars • Plain sheets • Structural steel • Structures

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b) Protection Protection against Corrosion

Protection against corrosion is to be made in accordance with the particular conditions of the order. Protection of Mechanical Items

• Threaded ends shall be protected by screwed bushings. • If necessary, ends shall be supplied with metallic plastic or wooden protec-

tive devices, bevel protectors/companion flanges • When handling stainless steel pipes:

– Do not use steel slings – Do not hook up pipes by their ends – Use leather straps

2.1.3 Reels

( fig. attached as Appendix – A)


Metallic or electric cables, ropes, flexible pipes, etc. b) Protection

i Against corrosion: ends to be enveloped or lambed, steel metallic cables

must be coated with a film of grease. ii Mechanical: cables are to be coiled around wooden or metallic reels and

protected by a wooden stave.

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2.1.4 Cradles

(fig attached as Appendix – B)


Materials of great dimensions, heavy weight, neither fragile nor needing me-chanical or physicochemical protection such as oily water separators, corrosion inhibitor packages, drag reducer packages etc.

b) Protection

• Against Corrosion

Cleaning and coating are to be made in accordance with the particular conditions of the order. A good protection of nozzles, nozzle flanges and machined pars shall be done by plugging or by applying coating process. Utilization of a corrosion inhibitor will be recommended in certain cases.

• Protection Against Mechanical Items

Wooden or metallic cradles with belts made of flat steel bars attached through turnbuckles to the cradles. In every case, Supplier shall provide lifting devices (rings, lugs or hooks) in definite and easily spotted points for sling lifting. When belting by flat steel bar or by cradle, it is necessary to place another material avoiding friction such as felt, rubber or plastic in between the material and the belt. Moreover if it is not possible to use a crane hook for handling, Supplier shall supply for the transportation duration, the necessary accessories such as spreader bars, slings, ropes, etc.

2.1.5 Frames for Shaped Steel Sheets

(fig. attached as Appendix – C)

In order to avoid shaped steel sheets deformation/twisting during transportation and handling, they are layed on top of the other with intermediate shims inside a rigid frame. Such frame shall have pad eyes for easy handling by hooks and slings.

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2.1.6 Crates

(fig. attached as Appendix – D)


Vessels with external elements/equipment not allowing the utilization of cradles or the barge transportation such as piping, air coolers, steel structures, etc.

b) Protection

Protection against corrosion is to be made in accordance with the particular conditions of the order and in every case: • Machined parts shall be wrapped with adhesive plastic tape • Contact surfaces of metallic structural parts shall be protected by a

rustproof material. • Pipe ends shall be coated with kraft paper or jute cloth or fitted with proper

protective devices. Protection for Mechanical items (anti-shocks): material shall be steadied either directly on the crate bottom tray or by means of cradles. Another wedging shall be made on the cove tray for complete immobilization.

2.1.7 Full Packing Cases a) Concerned Materials

Sets requesting mechanical protection against shocks and eventually physico-chemical protection such as machined pieces, small fragile piping, mechanical parts, valves, fittings, bolts, hand tools, insulation material, glass parts etc.

b) Protection

Against corrosion: • Machined parts shall be wrapped with an adhesive plastic coating

• Tools, valves accessories shall be wrapped in paper with corrosive inhibitor.

• Bolts and nuts shall be greased and wrapped in jute bags according to size.

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Mechanical Protection shall be by wooden case with one face planed; joined edge, with bituminous kraft paper for internal with an overlapping coating. The cover shall be made of 2 layers of wood bituminous kraft paper in between the 2 layers.

2.1.8 Groove & Tongue Wooden Package a) Concerned Materials

Those requiring physicochemical protection such as electric material (motors, panels, equipment) electro-mechanical generators, electronics, electro-pumps, control valves, motorized reducing gears.

b) Protection

• Protection against corrosion is such that material shall be placed inside

plastic bags with dehydrating products. Machined parts shall be protected by a waterproof plastic film.

• Protection for Mechanical items: wooden case with both faces planed and

grooved, with waterproof paper for internal coating. The cover shall be made of 2 layers of planed and grooved wood with an overlapping bituminous kraft paper in between the two layers. Mobile pieces inside the equipment shall be tightly fixed to structures.

2.1.9 Protective Packing


Fragile materials such as: • Pressure gauges, vacuum meters, thermometers • Measuring and control equipment • Control panels, electronic equipment, laboratory equipment, electric mate-

rial, and glass equipment.

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b) Protection • Protection against corrosion and humidity shall be plastic bags and de-

hydrating products. Cases are to be coated internally with bituminous kraft paper.

• Protection for Mechanical items: material shall be fixed on shock absorbers

or in an internal case placed on shock absorbers. Shock absorbers may be springs, wedges, mats, expanded plastics, etc. Mobile pieces and delicate components shall be blocked before packing.

Cases shall be planed, grooved and tongued: cover shall be made of two layers of wood with an overlapping bituminous kraft paper in between the two layers.

2.1.10 Steel Barrels


Chemical products, coal tar, catalysts, powders, chemical reactive, coils, etc.

b) Protection

Sealed closure in order to avoid any loss or moisture penetration

Containers

Containers used for grouping parcels shall be in accordance with ISO 668 standards. 2.1.11 Special Containers

Valuable turbine rotors shall be packed in pressurized hermetic sealed containers filled with low pressure dry air or nitrogen.

2.2 Types of Packing Case Fabrication 2.2.1 Quality of Wood

Compact and dry fir wood or any similar wood available in the country shall be used or even phenolic Douglas fir wood reinforced by fir boards.

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Wood shall have the following essential characteristics: • Dyness: about 20% • Diameter of vicious or unstable knots shall be less than half of the board width • Free of cracks longer than 12". • Flaws accepted on condition they do not include bark and within the following

limits:

– Length: 1/5 of the length of the wooden piece – Width: ½ of the width of the wooden piece – Thickness: ¼ of the thickness of the wooden piece.

• board thickness and rail thickness shall be in accordance with the case weight

and dimensions. It shall be in accordance with the type of material packed and the way it is straddled inside the packing.

In accordance with these parameters, the following parameters are given as guidance:

GROSS WEIGHT BOARD THICKNESS BEFORE PLANNING

RAIL THICKNESS BEFORE PLANNING

Up to 1100 lbs From 1100 to 4400 lbs From 4400 to 11000 lbs From 11000 to 22000 lbs From 22000 to 48500 lbs From 48500 lbs and over

¾" to ⅞" ¾" to ⅞" ⅞" to 11/16" 11/16" 11/16" to 1¼" 1¼" or 1½"

¾" to ⅞" ⅞" to 11/16" 11/16" to 1¼" 11/16" to 1¼" or 1½" 1¼" to 1½" 1½"

2.2.2 Case Fabrication

a) Crates

(fig. attached as Appendix – D)

Crates shall be erected in such a way that empty surfaces shall match filled surfaces.

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Material placed inside the cases or crates shall be covered with a polyethylene bag specially treated to fight against sun and heat and to prevent rain or water jet infiltration.

b) Full Packing Cases

Boards must be placed side by side or jointed by male and female interlocking having a minimum depth of ½" specially if sea traveling is forecast through traditional ships where several handlings are expected. Boards width shall not exceed 10" or be less than 5". Up to 1100 lbs weight and if the length is limited to 8′-2" and if the contained material allows it, cases may be built without bottom timber beam. Such beams shall be replaced by supporting rails 1" thick for the walls and 1½" thick for the bottom. Distance between rails shall be one meter along case length. Supporting rails shall have a minimum width of 3". Bottom boards shall have 1¼" thickness. Over a net weight of 1100 lbs, cases shall be provided with longitudinal timber beams at their bottom. Their cross section shall be in accordance with the type of packed material and its weight. Concerning timber beams and reinforcing bars the following data is used: – up to a net weight of 2200 lbs, use pieces of 3" × 3" cross section – from 2200 lbs up to 3370 lbs, use pieces of 4" × 4" cross section – from 3370 lbs to 13200 lbs, use pieces of 5" × 5" cross section – from 13200 lbs up to 19850 lbs, use pieces of 8" × 8" cross section – from 19850 lbs up to 44100 lbs, use pieces of 8" × 8" cross section. Spacing between bars shall be from 2′-8" to 6′-6". This spacing shall never-theless be in accordance with the dimensional, qualitative and constructive char-acteristics of the contained material. Ends of reinforcing elements shall be beveled at 45 deg to facilitate lifting slings insertion.

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Beneath the case, small rails 1½" to 2" thick shall be placed as spacing pieces to protect the case against the lifting slings. Position and length of such rails shall be established in accordance with the case length and its center of gravity.

c) Cases for More Than 11,000 lbs

For cases weighing more than 11,000 lbs net weight, it is recommended to place angle irons where the lifting slings are to be applied. The walls and the cover may also be made out of Douglas fir phenolic marine plywood but shall have a fir structure of 1½" × 5" minimum. Cases shall always be internally coated with bituminous paper of high imper-meability and capable of withstanding strong temperature variation, whatever be the protection adopted for the contained material.

d) Plywood Utilization

Plywood panels may be used for pickings instead of sawn wood. Panel thickness will depend on the cases dimensions and weight and will depend also on the density of the goods, the structure of the case and the way it is steadied. Plywood quality shall be that one which can withstand humidity. In accordance, following data is given as guidance: – Gross weight up to 1100 lbs thickness ¼" to 5/16" – From 1100 lbs to 11000 lbs thickness ⅜" – From 11000 lbs to 33000 lbs thickness ½" – Over 33000 lbs thickness ⅝"

2.3 Modules/Packages/Assemblies 2.3.1 Weight & Dimensions of a Module

a) Available Transportation Capacities

Spec. No.4985-GS-9524-0 Page 14 of 25



b) Available Lifting Capacities

For onshore locations, modules up to 150 tons may be carried out if roads with hard coating are available. Limit shall be brought down to 50 tons if only tracks are available. It is even preferable to bring down this limit to 36′ × 8′-2" × 13′ in order to take into account classical obstacles such as bridges, electric lines, tunnels, etc. afford only this lower limit. For offshore locations, modules up to 400 tons and more may be carried out. However, this last tonnage can be shipped only on specialized ships of 10,000 or 15,000 tons. Exceptional weight may go up to 2,000 tons derrick barges or lifting means are consequently forecast.

2.3.2 Module Structures

A module constitutes a lift able and transportable assembly. Bearing structures will, therefore, be made up of standard rolled sections or box girders. Structure calculation basis shall take into account the whole module life, especially the very short and stressful periods that constitute transshipment. Module shall be provided with the necessary slings, lifting beams, shackles, etc. for crane handling. a) Close Modules

These modules shall be closed by simple wind cutter partitions of fireproof separators according to request. They shall be mechanically ventilated and even air conditioned if requested for safety reasons or weather conditions.

b) Cage modules

Cage modules shall be adopted when modules have to be piled up.

c) Skids

Skids shall be used preferably for mechanical equipment such as diesel generat-ing sets, motor pumps, filters, separators, etc.

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2.3.3 Shipping Preparation

Mobile elements (spring supports, etc.) shall be immobilized. Equipment shall be protected as follows: a) Measuring and control equipment, which are too fragile for transportation, shall

be dismounted, packed separately, carefully marked and shipped with the module.

b) Valves, control valves and other equipment, dismounted for the hydraulic tests

and replaced by plugs, shall stay dismounted but will be packed separately, carefully marked and shipped with the module.

c) Tanks and pipes shall be emptied and dried. d) Stainless steel elements shall be coated with a coating which shall be in

accordance with the steel grade. e) All the openings shall be closed. f) Flanges and screwed fittings shall be mechanically protected and also rust proof

protected. g) Equipment such as electric motors, relay, panels, MCC shall be heated by their

own equipment or by provisional means. h) If the internal equipment request an inert atmosphere, this atmosphere shall be

introduced and maintained in the module or in the compartment of the module where these equipment are housed.

i) In the same way, if the equipment inside the module requests air conditioning,

this air conditioning shall be maintained through an external source of energy.

j) Enough desiccant material shall be placed inside certain equipment such as motors, pumps, valves, etc.

2.3.4 Slings & Lifting Accessories

As soon as the module get a certain weight (over a few tens of tons), it is recommended to fit the module with its slings, shackles, with the pins blocked or even welded and eventually with the lifting beam as soon as it leaves for the field.

Spec. No.4985-GS-9524-0 Page 16 of 25



This necessitates that the structure and the sea fastening be designed to this effect. This arrangement will prove to be most efficient especially when there will be several crane handlings. This construction shall provide the calculating notes of the lifting elements and especially for the cables (test load, deflection angle between the strands, safety factor, etc.).

2.3.5 Center of Gravity

It will be determined through calculation but verified through weighing. In certain cases the lifting ears will be welded only after the practical determination of the center of gravity.

2.3.6 Orientation

In order to facilitate handling operations on the job site, the orientations marks North South or East West shall be marked, when possible, on the module, in the manufacturing plant, in accordance with the layout drawing.

2.4 Special Regulations

2.4.1 Steadying

All packed material shall be internally steadied in an adequate manner in order to avoid any displacement during transportation.

2.4.2 Protective Products

When transporting material coated with protective products. Supplier and/or company in charge of the packing shall indicate the effective duration of the protective material and give all information concerning a good transportation of the merchandise.

2.4.3 Protection Against Humidity

Hot sealed plastic bags, composed of cloth, aluminum and a double layer of polyethylene, shall be used for material such as panels, electric gears, hydraulic gears and similar ones which are much affected by humidity. Introduction of dehydrating products shall maintain above mentioned material in an atmosphere having less than 35% humidity. Polyethylene bags must not be used.

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Polyethylene bags can be used only as open covers to allow free air circulation. These covers shall be special for protection against heat and sun and will serve only to protect material against rain and water jets.

2.4.4 Fork Pockets

For all parcels, which cannot be manually handled, especially those exceeding 1100 lbs, special pockets shall be provided to allow the handling with fork lift trucks.

2.4.5 Trimming Points

As far as possible and particularly for parcels uneasy to handle manually, trimming points shall be provided preferably at the higher angles of the parcels in order to avoid damage to the pickings when trimming operations are carried out for transportation.

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3.0 PACKING FOR AIR TRANSPORT

Packing for air-transported goods shall be identical to that provided for above sea-transported goods. Anyway the following features shall be taken into account when packing: • Many handlings on site by means of motorized equipment (lift trucks,

transpallets, etc)

• Extended storage (at least one year) in the open air, sea environment, tropical climate.

Consequently, cases or packages shall be conditioned accordingly. Each part contained in the said package shall be protected to take the above conditions into account so as to allow partial unpacking of cases or packages.

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A P P E N D I C E S

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APPENDIX – A

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APPENDIX – B

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APPENDIX – C

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APPENDIX – D

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APPENDIX – E

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General Specification for Supply, Construction and Installation of Steel structure



Job No. 14 – 4985

Spec. No. 4985-STA-4002

Page 1 of 21 Rev. 0

UCH-II Development Project General specification for supply, construction and installation of Steel structure

Spec. No. 0105-STA-4002 Page 2 of 21

TABLE OF CONTENTS 1.0 SCOPE .......................................................................................................................... 3 2.0 CODES AND STANDARDS ....................................................................................... 4 3.0 EXTENT OF SUPPLY ................................................................................................ 5 4.0 MATERIALS ............................................................................................................... 7

4.1 Structural Steel......................................................................................................... 7 4.2 Bolts ........................................................................................................................... 7 4.3 Steel Flooring ............................................................................................................ 7 4.4 Roof & Wall Cladding ............................................................................................. 7

5.0 MATERIAL QUALITY AND CHARACTERISTICS ............................................ 8 6.0 ROOFING AND SIDING ........................................................................................... 9 7.0 FABRICATION ......................................................................................................... 10 8.0 WELDING .................................................................................................................. 11

8.1 Quality ..................................................................................................................... 11 8.2 Qualifications of Welders ...................................................................................... 11

9.0 ERECTION ................................................................................................................ 12 9.1 Erection Generally ................................................................................................. 12 9.2 Erection Tolerance ................................................................................................. 14

10.0 PROTECTION OF STEEL SURFACES ................................................................ 16 10.1 Equipment & Materials ......................................................................................... 16 10.2 Surface Preparation & Painting ........................................................................... 16 10.2 Coating System ....................................................................................................... 18

11.0 INSPECTION ............................................................................................................. 19 12.0 TRANSPORTATION ................................................................................................ 20 13.0 RUNWAY BEAMS .................................................................................................... 21



1.0 SCOPE This specification covers the minimum requirements for the Supply, Construction and

installation of steel structures such as compressor shed, pipe rack, valve access platform, pipe support etc for UCH II Development Project. The PC Contractor shall bring his own consumable equipment/ machinery and other material and provide all services, skilled and unskilled labor including supervisory and testing personnel needed during construction.



2.0 CODES AND STANDARDS All steel structural work shall, as a minimum, comply with the requirements of this specification and the latest editions of the following codes, standards and regulations (where applicable).

BS 499: Part 1 Welding Terms & Symbols BS 639 Specification for Covered Carbon & Carbon Manganese Steel

Electrodes for Manual Metal arc Welding. BS 709 Methods of Destructive Testing of Fusion Welded Joints &

Weld Metal in Steel. BS 729 Specification for Hot Dip Galvanized Coatings on Iron & Steel

Articles BS 1706 Specification for Electroplated Coatings of Cadmium & Zinc

on Iron & Steel BS 2853 Specification for the Design & Testing of Steel Overhead

Runway Beams BS 2997 Aluminum Rainwater Goods BS 4190 Specification for ISO Metric Black Hexagon Bolts Screws &

Nuts



3.0 EXTENT OF SUPPLY 3.1 Supply shall include the following:

a) supply of material

b) prefabrication and pre-assembly

c) primerizing

d) packing

e) transportation

f) erection

3.2 Characteristics and quality of materials shall be:

– structural steel: grade Fe 430C or equivalent (BS EN 10025) – high strength bolts: grade 8.8 (BS 3692)

3.3 Operating floors, conform to BS 4592, shall be grating panels shaped as detailed on

drawings and bordered. Each panel shall be hot dip galvanized as per BS after

fabrication.

Grating shall be electro-forged, 25×50 meshes, 25×5 bearing plates with an antis lip serrated top surface. The grating panels shall be fixed on structure by galvanized ties included in supply.

3.4 Roofing and siding (according to BS5427 and 5950) shall be made by galvanized

ribbed steel sheet with the following characteristic:

– thickness: 7/10 mm – corrugation pitch: 170mm or similar – corrugation height: 50mm or similar

3.5 Supply includes all sheets fixing pieces as hooks, screws, nuts, washers and every

other steel fitting of section and type useful to ensure the sheets and the finishing pieces on the structure or to complete the work.



All described steel materials and fitting shall be hot dip galvanized as per BS. 3.6 Test certificates shall be furnished for all materials.



4.0 MATERIALS 4.1 Structural Steel

Structural steel shall comply with BS EN 10025. Grade Fe 430 C (BS EN 10025 Fe 580C) or equivalent. All steel shall be from a source approved by the OGDCL/ Engineering Consultant

4.2 Bolts

High tensile structural bolts and nuts shall comply with BS 3692 Strength Grade 8.8. ISO Metric black bolts; screws and nuts shall comply with BS 4190. Bolts and washers shall be zinc plated in accordance with BS 1706. Class Zn2. Nuts may also be plated to the same specification, or may, alternatively, be supplied with a cadmium finish in accordance with BS 1706 Class Cd 2 in order to facilitate tightening. Holding down bolts shall normally be supplied black with a light coating of oil. Each bolt shall be supplied with hexagonal nut(s) and washer.

4.3 Steel Flooring

The steel used for steel flooring and stair treads shall conform to BS EN 10025 Grade Fe 430 C, or equivalent.

4.4 Roof & Wall Cladding

Roof and wall cladding shall be profiled sheeting as defined in BS 5427 and shall be either aluminum to BS 4868 or steel.

Steel sheeting shall be in accordance with the structural design rules of BS5950 Part6. Aluminum sheeting shall not be less than 1.2mm (18 SWG) thick unless otherwise

directed or approved by the OGDCL/ Engineering Consultant. Cladding shall be supplied complete with all necessary purpose made accessories

including rigid pieces, aprons, flashings and filler pieces, brackets and fixings. The complete roof and wall cladding system and accessories shall be from one

manufacturer and to the approval of the OGDCL/ Engineering Consultant



5.0 MATERIAL QUALITY AND CHARACTERISTICS 5.1 PC Contractor shall use materials specified in the relevant specifications and

drawings. 5.2 The technological characteristics of the steel used shall be confirmed by the mill

certificates and/or by certificates related to the mechanical tests carried out, in accordance with the applicable laws. Such certificates are issued by the official laboratories pursuant to local law for test pieces previously selected and punched by OGDCL.

5.3 All materials shall be new and free from any defects both basic material and

workmanship. 5.4 Galvanized ribbed steel sheets for roofing and siding shall have an allowable stress of

1400 kg /cm2 minimum. For painted elements, steel sheets shall be galvanized with 275 gr/m2 of zinc for each face. Galvanized steel sheets shall be prepared for painting by means of phosphating. A test of bending shall be carried out. Certificates of origin, conformity and test shall be delivered to OGDCL.



6.0 ROOFING AND SIDING 6.1 All panels roofing and siding with relevant accessories (flashing, gutters, etc.) will be

supplied with spare parts not less than 2%. That is that for each mark the PC Contractor shall provide the 2% spare for each building, with a minimum of one element each 50 elements of fraction. Fixing elements and gaskets shall be supplied with 10% spare, while sealing material with 20% spare.

6.2 If the supply foresees metal elements painted, the PC Contractor shall provide a

quantity of paint necessary to cover a surface equal to 2% of total painted surface. Paint shall be same color of that of panels, recent production. Manufacturer instructions for employ and storage shall be provided.



7.0 FABRICATION 7.1 Connections shall be welded or bolted according to drawing requirements. 7.2 If the structure calls for welded connections, the PC Contractor shall, prior to start of

work, qualify the welders by testing in the presence of OGDCL/ Engineering Consultant. In addition PC Contractor shall be responsible for the type of electrodes used, for the careful execution of welding as well as for welder's qualification.

7.3 Checkered plate and floor grating shall be properly shaped and cut to required size.

Grating and hold down fittings shall be galvanized. 7.4 All connections shall be made in a preliminary form by tacking with bolts or gudgeon

pins to assure the correct positioning of all elements thus avoiding the necessity for measurements or markings on the jobsite for erection purposes. Sizing of tacking elements shall be for PC Contractor’s account. Location and diameter of erection holes shall be such as to allow assembling and to avoid the need for additional work on the jobsite (i.e. piercing, reaming, etc.) 12mm (min.) diameter erection bolts shall be supplied with 52 spares.



8.0 WELDING 8.1 Quality

Welding shall be carried out only under the direction of an experienced and compe-tent supervisor. Unless otherwise agreed by the OGDCL/Engineering Consultant a record shall be kept to enable major welds to be identified with the welders responsi-ble for the work.

Electrodes and fluxes shall be used in accordance with the manufacturer's instructions

and shall be so chosen that the properties of the deposited metal are not inferior to those of the parent metal.

The use of welding processes other than those covered by BS 5135 shall be subject to

the approval of the OGDCL/Engineering Consultant The general welding program for shop and site welds, including particulars of the

preparation of fusion faces, the method of preheating where required, the methods of making the welds, and the type of electrodes shall be submitted to the OGDCL/ Engineering Consultant for their approval.

The position of welds required for temporary fabrication attachments shall be subject

to approval by the OGDCL/Engineering Consultant. 8.2 Qualifications of Welders

Welders shall be suitably qualified and evidence shall be given of their having satis-factorily completed the appropriate tests as laid down in BS 4872: Part 1.



9.0 ERECTION 9.1 Erection Generally

Erection on concrete foundations shall not commence unless the concrete has acquired sufficient strength. The PC Contractor shall properly align each part of the structure before making field connections. The steel frames shall be true and plumb. Temporary bracing shall be introduced to prevent instability due to lateral loads acting on the structure during construction, including loading from erection or operating of equipment. Minor misfits which can be remedied by a moderate amount of reaming and slight cutting and chipping may be corrected by the PC Contractor when in the OGDCL/En-gineering Consultant opinion it will not be detrimental to the strength or appearance of the structure. All errors shall be reported without delay to the OGDCL/Engineering Consultant. Fitting-up bolts and drift pins shall not be used to bring improperly fabricated mem-bers and parts into place, thus causing a strain on bolts in finished work. Drift pins shall not be driven with such force as to injure adjacent metal. No packing, shimming or wedging will be permitted to correct imperfect work unless specifically approved by the OGDCL/Engineering Consultant. No welded connection shall be made until the member or structure has been properly aligned. All members in completed frames shall be true to line and free from bends, twists and open joints. Field connections shall be welded or bolted as shown on the drawings. Permanently bolted connections of primary construction members shall be made with the use of bolts as shown on the drawings and in conformity with all Local, National, Provincial and Municipal Laws and Regulations and the OGDCL/Engineering Consultant safety ordinances.



Holes, cutouts, etc., shall be provided only where indicated on the drawings and any

additional holes, cutouts, etc., made at site will require prior approval from the

OGDCL/Engineering Consultant. Bolt holes shall only be drilled. Any damage to materials on the site due to inadequate precautions being taken during

the erection of the steel work shall be made good to the satisfaction of the OGDCL/

Engineering Consultant at the PC Contractor's expense.

For major structures, the PC Contractor shall submit to the OGDCL/Engineering

Consultant an erection plan complete with data on heaviest lift, weights and

calculations involved. Approval of this erection plan by the OGDCL/Engineering

Consultant shall not relieve the PC Contractor of his responsibility for the erection of

the structure.

Before setting bases and bearing plates for structural steel, concrete surfaces to

receive grout shall be chipped to a minimum depth of 6mm to remove laitance and to

expose aggregate. Bottom surface of base and bearing plates shall be cleaned then

supported on steel wedges, shims, or other adjustable devices.

After the supporting members have been properly positioned and plumbed, the

holding down bolts shall be tightened. The entire bearing area under the base or

bearing plate shall be packed with grout. The grout shall be thoroughly worked to

eliminate voids and provide a uniform bearing surface. After the grout has cured for

72 hours, the shims and wedges shall be removed, the voids packed with grout, and

the holding down bolts re tightened.

After erection, the various members forming part of a completed frame or structure

shall be aligned and adjusted before being permanently fastened. The finished

structure shall conform to the lines and elevations shown on the drawings.

Splicing of structural members where not detailed on the drawings is not permitted,

without prior approval of the OGDCL/Engineering Consultant as to the location and

type of splice to be used.



9.2 Erection Tolerance

Erection tolerances shall generally be in accordance with BS 5950: Part 2. • Beams

The maximum tolerance for level and alignment shall be ±5mm across any particular floor of the structure. Maximum differential between connecting beams or adjacent beams shall not exceed 2 mm.

• Stanchions

Plan Position The distance between the centers of adjacent stanchions at any one-floor level shall not exceed ±5 mm.

The cumulative tolerances over three or more bays shall not exceed the following:

Upto and including 30m ±10 mm Over 30m ±15 mm

9.3 PC Contractor Duties

PC Contractor shall provide following services:

– he shall provide personnel and means to check correctness of structures installa-tion;

– supply of means of transportation and lifting;

– organization of material storage according to OGDCL/Engineering Consultant; – material unloading at site arrival; – erection works including adjustments, execution of holes for pipe crossing and

any other accessory work to give the work complete and usable; – restoration of primer and surface protection damaged;



– after structure test, installation of roofing and siding, including windows, doors, and any other accessory to give work complete and usable.

9.4 Material Storage

– Before the arrival at site of materials. PC Contractor shall define storage areas according to OGDCL/Engineering Consultant.

– Open storage shall be provided on wood sleepers to avoid contact with soil and

prevent a damage of painting. – Each element of supply shall be examined at sight during unloading. – Damaged elements shall be storage separately to permit the restoration.



10.0 PROTECTION OF STEEL SURFACES 10.1 Equipment & Materials

All the necessary materials and equipment shall be supplied by the PC Contractor unless stated otherwise in the Contract. All paint shall be supplied in unopened original containers clearly showing expiry date and manufacturing date. All paint shall be stored in accordance with manufac-turer's directions. No paint is to be used within 3 months of the expiry date.

10.2 Surface Preparation & Painting

– The PC Contractor shall paint all new equipment, structure materials, as appropriate, together with any existing paint work, damaged during execution of the Works in accordance with this Specification.

– All new steel surfaces requiring to be painted shall be grit blasted.

– If heavy scale is present it must be removed by hammering or scraping. Any

heavy scale contaminated by oil must be removed using non-sparking tools. Grease or oil shall be removed by swabbing the affected surface area with a solvent or cleaning agent specified by the OGDCL/Engineering Consultant, and dried using clean cloths.

– Any seams, welds, sharp edges and laminations shall be ground smooth prior to

blasting. Any area not requiring to be blasted shall be masked with suitable masking material.

– The surface shall be blasted to Swedish Standard SIS 055900, Grade S.A. 2.5

using commercially available grit (type to be approved by the OGDCL/Engineering Consultant and a source of dry compressed air at a minimum of 250 cfm at 100 psi. Pitted areas shall be blasted such that there is no residual scale in the bottom of the pits. On certain occasions other forms of surface preparation may be accepted at the discretion of the OGDCL/Engineering Consultant.



– Blasting must not be carried out if the relative humidity is greater than 80% or the temperature of the steel is within 2ºC or Dew Point. Care should be taken to ensure that no water contacts the blasted surface.

– After blasting, the surface should be "blown down" with compressed air to

enable an inspection to be made; unsatisfactory areas are to be marked with chalk and re blasted. When the surface preparation has been approved by the OGDCL/Engineering Consultant all surfaces should be cleaned of residual dust by, thorough "blowing down" or brushing with clean nylon brushes or preferably with an industrial vacuum cleaner. Grit blasting shall be removed and disposed of by the OGDCL/Engineering Consultant.

– Airless spray (using correctly sized spray nozzles) is the preferred method of

application. Application by brush and/or roller may be acceptable. In all cases the minimum film thickness specified for each individual paint coat must be achieved prior to final approval of the coating. Over coating intervals recommended by the paint manufacturer must be adhered to unless the OGDCL/ Engineering Consultant advise otherwise.

– When over coating, the relative humidity must be less than 80% and comply

with paint manufacturer's data sheets. The steel temperature must not be within 2ºC of the Dew Point. The previously applied paint coating must be free of any grease or oil, dust or water before over coating and each coat must be inspected and approved by the OGDCL/Engineering Consultant before over coating is permitted.

– Final color shall be specified later stage on the drawings; or Particular

Specification; or as determined by the chemistry of the paint system specified.

– All seams welds and sharp edges shall be stripe coated before spraying commences.

– Painting shall only be undertaken upon satisfactory completion of all NDT and

hydro testing.



10.3 Coating System

• Surface Preparation

Cleaning with proprietary degreasing agent, flush with fresh (sweet) water and allow to dry. Grit blast with one way abrasive to SiS Grade Sa 2.5 (SIS refers to Swedish International Specification 05-59-00).

• Primer Coat

1 coat, 2 Component Epoxy Polyamide to DFT 50 pm. Color - as specified by OGDCL/Engineering Consultant.

• Intermediate Coat

2 coats, 2 component Epoxy Polyamide high build to 100 pm DFT.



11.0 INSPECTION During fabrication following shall be checked by OGDCL for:

– material compliance to the required mechanical characteristics – size of the single structural elements

– size of the structure as a whole

– fitness of welders assigned to the work, by means of qualification tests

– correctness of welded and/or bolted connections

– easy erection of structural elements

– correctness of preparation for painting

– correctness of item marking. The OGDCL reserves the right to check the compliance of fabrication with present specification, relevant and a good engineering practice.



12.0 TRANSPORTATION

– Loading on transportation means shall be carried out with the necessary care to prevent any deformation and damage to the machined material.

– Nuts and bolts shall be packed in boxes. The boxes shall be marked on the

outside at 2 points using water resistant paint, as follows, job number and drawing number, type and quality of bolts. Each box shall contain only one type bolt.

– Roofing and siding elements shall be separated on the basis of marks and

separately packed.

– For short distance truck transportation galvanized steel panels shall be provided packed with metallic strap and with wood spacer (3 cm min.) interposed. Prepainted steel panels in addition shall be wrapped in bituminized Kraft paper.

– For short distance railway transportation material shall be provided in wood

crates.

– For sea transportation or long distance material shall be provided in normal box type containers packed but wrapped in polythene sheet with silica gel inside.



13.0 RUNWAY BEAMS – The testing of all runway beams shall be carried out in accordance with BS 2853

and such statutory requirements as may be specified. – Runway beams shall be erected free from twist and the bottom flange shall be

horizontal.

Scope & Specification Hydrostatic Testing Project: UCH-II DEVELOPMENT PROJECT Owner: Oil & Gas Development Co. Ltd. Prepared by: IN Checked by: MMM Approved by: TH Revised by: -

0 ISSUED FOR BID 20/11/2012


Job No. 14 – 4985

Spec. No. 4989-PA-2004


Specification for Hydrotesting UCH-II Development Project

Spec. No.0105-PA-2004 Page 2 of 15

TABLE OF CONTENTS

1.0 SCOPE ............................................................................................................................. 3 2.0 GENERAL ....................................................................................................................... 4 3.0 CODES & STANDARDS ............................................................................................... 5 4.0 PROCEDURE ................................................................................................................. 6 5.0 SAFETY ........................................................................................................................... 7 6.0 MATERIALS AND EQUIPMENT ............................................................................... 8 7.0 FILLING THE PIPES .................................................................................................... 9 8.0 TEST PRESSURE ........................................................................................................ 10 9.0 FAILURES .................................................................................................................... 11 10.0 TEST RECORDS .......................................................................................................... 12 11.0 DEWATERING ............................................................................................................ 13 12.0 DRYING ........................................................................................................................ 14 13.0 TREATING ................................................................................................................... 15



1.0 SCOPE This Specification covers minimum requirement for hydrotesting i.e. pressure testing, together with dewatering, line flushing and drying.



2.0 GENERAL PC Contractor shall furnish all necessary equipment, materials and labor to successfully complete the hydrostatic leak test and the cleaning and drying defined herein. The hydrostatic leak test and the cleaning and drying include: • Locating and procuring acceptable water for testing.

• Preparing Piping profiles and test procedure for approval by the OGDCL/Engineering Consultant.

• Filling the test section with water including addition of required chemicals.

• Performing the leak test at the specified pressure.

• Investigating for leaks or breaks, making any necessary repairs and retesting.

• Displacing and disposing of test water.

• Cleaning, flushing, drying, treating and capping off the tested Piping.

• Recording of all test data.

PC Contractor shall assign and designate a construction crew, with equipment, to the testing operations. The testing operations shall be conducted diligently, thoroughly and in a safe manner in accordance with accepted Piping Testing Practices. Any work by PC Contractor or existing conditions, which in the opinion of OGDCL/Engineering Consultant are deemed to be unsafe shall be corrected. The testing operations shall not continue until the unsafe conditions have been corrected to the satisfaction of OGDCL/Engineering Consultant. PC Contractor may not receive additional compensation for time lost caused by unsafe conditions.

PC Contractor shall furnish a representative who shall be responsible for supervising all testing operations. OGDCL/Engineering Consultant will witness and accept all tests.



3.0 CODES & STANDARDS PC Contractor shall conduct the testing operations in accordance with ASME B31.3, Section 345.4, “Hydrostatic Leak Test”. Where there is a conflict between any Code and these specifications, the Code shall govern over the portions or sections of these specifications, which contain the confliction. When a Code covers same requirements as these specifications, the most demanding requirements shall be complied with. PC Contractor shall review inform employees of and abide by safety standards of OGDCL/Engineering Consultant. Also, best industry standards will apply to the work defined. PC Contractor shall notify the OGDCL/Engineering Consultant as to the individual within his organization who is responsible for the safety practices of the PC Contractor.



4.0 PROCEDURE At least four weeks prior to the start of testing, PC Contractor shall submit to OGDCL/Engineering Consultant a detailed procedure for the hydrostatic tests listing equipment, manpower and program for testing all Piping. The PC Contractor must submit a profile of each Piping indicating the elevation of the Piping, the test pressure at the low and high points for each test section and the number of test sections required. This procedure shall include the safety measures to be taken, proposed water source, water analysis, proposed chemical additives, water disposal method and water disposal locations. Also the procedure shall include field preparations such as placement of pumps, lying of water supply lines, and connection to the water source, location and implementation of all equipment, and a detailed test procedure. PC Contractor shall not proceed with testing until OGDCL/Engineering Consultant has approves the test procedure.



5.0 SAFETY PC Contractor shall take all necessary precautions to ensure the safety and protection of all construction personnel and the construction supervision and operational staff at Qadirpur at all times. PC Contractor shall furnish and place such guards, and install and maintain such facilities necessary to secure the safety of everyone involved in the construction and testing of the facilities.



6.0 MATERIALS AND EQUIPMENT PC Contractor shall furnish and install all test-header pipes, valves, fittings, test instruments, water, chemicals, strainers and filters, fill and pressuring pumps, meters and all piping incidental to filling, sectionalizing, transferring and disposing water. PC Contractor shall also furnish adequate materials for capping off both ends of completed test sections. PC Contractor shall furnish an enclosed weatherproof, properly lighted, temporary shelter of sufficient size to house the pressure recorders, calibration equipment and test personnel at the data collection site of each test section during the testing operations. PC Contractor shall also furnish sufficient lighting in the pump and test header areas during periods of darkness when testing operations are in progress. Calibration of all test instruments shall be performed by the PC Contractor and witnessed by the OGDCL/Engineering Consultant. The equipment furnished by the PC Contractor shall meet the following requirements: • The filter shall be of a quality to remove 95 percent of all particles 40 microns in

diameter and larger. The filter shall be provided with a means of cleaning either side without disconnecting the piping or interrupting the flow of testing media.

• The pumping system used for filling the test section shall be capable of filling the

pipe test sections at the rates specified in this section.

• The pumping system used for pressurization of the sections shaft' be capable of attaining the test pressure required at a slow and steady rate of pressure increase.



7.0 FILLING THE PIPES The PC Contractor supplies the test water. The water shall be analyzed to determine its suitability for use in the testing operations. PC Contractor shall present recommendations as to the type of corrosion inhibitor, oxygen scavenger, and bactericide to be used in the test water. Suspended matter in the fill water shall be removed before injection into the Piping by use of a filter of the quality as stated earlier in this section. Water shall be pumped in sufficient quantities at the minimum fill rate until the test water is clean and free of suspended matter. Before the pressuring operation commences, each valve capacity shall be filled with water by partially closing and opening each valve. Valves shall be tested in the full open position. Discs shall be removed from check valves prior to any testing operations if the testing operations require reverse flow. PC Contractor shall carefully replace discs after drying operations are complete.



8.0 TEST PRESSURE After filling the test section and remaining any entrapped air, the pressure in the test section may be increased to the test pressure. The minimum and maximum test pressures are to be specified by PC Contractor for OGDCL/Engineering Consultant approval. The test pressure must remain within the range of pressure (between minimum and maximum) during the test period, which may vary from half (½) hour – four (4) hours, depending on size and length of the section to be used at all points within a given test section. Each test section shall be pressurized to the specified test pressure by maintaining a constant pumping rate and continuously observing the line pressure. After the minimum test pressure has been reached, the pump shall be stopped, disconnected and the pressure allowed to stabilize. The PC Contractor shall then adjust the pressure within the test segment, if necessary, and begin the test period. The pressure and temperature recorders shall then be started using charts in real time orientation. During the test period, pressures shall be recorded every 5 minutes and when asked to unchecked with deadweight taken. The deadweight gauge shall be read to the nearest psi. If a drop in pressure occurs during the test period, which cannot be attributed to changes in temperature or if the pressure in the test section falls below the minimum test pressure, the test is unsuccessful and the leak must be located by the PC Contractor or the piping pressure increased to an acceptable level. After the repairs have been made, the pressure test shall be repeated until it has been determined to be successful by the OGDCL/Engineering Consultant. The test pressure shall increase due to a change in the ambient temperature: the PC Contractor shall reduce the pressure in the test section to keep the pressure below the maximum test pressure. OGDCL/Engineering Consultant shall witness and certify hydrostatic testing. Authority for acceptance/rejection of all hydrostatic test operations ties with the OGDCL/Engineering Consultant



9.0 FAILURES Failures in the piping disclosed by the loss of pressure not attributable to temperature changes shall be located and repaired by PC Contractor. If the failure is in the seam of the pipe, the entire joint in which the seam failure exists shall be removed. A minimum of one pipe diameter each side of the failure will be removed on all other failures. The piece(s) removed shall be marked for orientation with respect to the position in the. Piping and with the approximate location of the failure. PC Contractor' shall not cut on or damage the failed edge of the pipe during removal, transit or unloading at the storage location. All portions are to be retained. The failure shall be photographed prior to and after removal from the Piping, if possible.

Care must be taken to ensure that external coating and backfilling at repair sites is carried out in accordance with these specifications.

All welds in pipe repairs shall be 100 percent inspected by radiography. Upon completion of a pipe repair. PC Contractor shall at his expense, repair all defects found resulting from inferior workmanship or defective materials furnished by the PC Contractor.



10.0 TEST RECORDS The Piping pressure and temperature for the test period shall be continuously recorded with recording instruments. The pressure recording shall serve only as information data and may not be used to determine pressure drop for piping leakage. Test sections will not be accepted until a predetermined test period can be recorded without pressure loss unless the loss can be attributed to temperature change. All data and charts shall be clearly marked with the following information: • OGDCL/Engineering Consultant name and authorized representative. • Testing PC Contractor's name and authorized representative. • Description of facilities tested. • Date and time of test. • Test: pressure and duration. • Test medium used. • Explanation of any pressure discontinuities that appear on any chart. • Signature of OGDCL/Engineering Consultant and Testing PC Contractor's

authorized representatives

All permanent records shall become property of the OGDCL/Engineering Consultant. Fabricated assemblies and piping for tie-ins to existing Piping shall be tested in accordance with this Specification. All data and charts shall be clearly marked in the same manner the Piping test records are marked.



11.0 DEWATERING After acceptance of the hydrostatic leak test, the pressure shall be released until atmospheric pressure has been reached. Reduction of pressure shall be conducted in a manner to prevent severe vibration. PC Contractor shall then purge the water from the line by using compressed air. PC Contractor shall continue to run the injections to the piping until all free water is removed. Water should be drained from any low point drains, block valve body bleeds, etc. during the dewatering operation. PC Contractor shall be responsible for the, proper disposal of test water at locations and at a time satisfactory to OGDCL/Engineering Consultant. Damage to the Piping, or adjacent piping, equipment or any property or personnel other than PC Contractor’s own caused by the improper disposal procedure shall be compensated by the PC Contractor. PC Contractor shall abide by any Governmental or local jurisdiction regulations governing the method and location of the disposal of test water.



12.0 DRYING The PC Contractor will be asked to completely dry sections of piping after completion of hydrotesting activity. The PC Contractor shall supply all equipment, labor and materials. Drying shall be performed immediately acceptance of the dewatering operation. The PC Contractor shall prepare a procedure and schedule for Piping Drying. These shall be submitted to the OGDCL/Engineering Consultant for approval at least one (1) week prior to the scheduled start of drying.



13.0 TREATING Depending on the schedule for commissioning the Piping, the OGDCL/Engineering Consultant may require the PC Contractor to fill the Piping with Inert Gas after drying is complete.

SPECIFICATION FOR FABRICATION & INSTALLATION OF PIPING

Project: UCH-II Development Project Owner: Oil & Gas Development Co. Ltd. Prepared by: NJ Checked by: MK Approved by: FS Revised by: -



Job No. 14 – 4985

Spec. No. 4985-PA-2021


TABLE OF CONTENTS

1.0 SCOPE .......................................................................................................................... 3 2.0 APPLICABLE CODES AND SPECIFICATIONS .................................................. 4 3.0 TYPICAL LINE AND VALVE CODE ...................................................................... 7 4.0 MATERIALS ............................................................................................................... 8 5.0 STORAGE AND HANDLING ................................................................................... 9 6.0 WELDING APPROVALS ........................................................................................ 10 7.0 WELDING REQUIREMENTS ................................................................................ 13 8.0 FABRICATION ......................................................................................................... 20 9.0 INSPECTION AND TESTING ................................................................................ 26 10.0 CORROSION PROTECTION ................................................................................. 34 11.0 MARKING ................................................................................................................. 36 12.0 INSTALLATION OF PIPEWORK ......................................................................... 38

FIGURE 1: BRANCH REINFORCEMENT DESIGN FIGURE 2: DIMENSIONAL TOLERANCES FOR FINISHED PIPEWORK FIGURE 3: PROXIMITY OF WELDS FIGURE 4: EFFECT OF ALLOYING OF THE WELD PREFERENTIAL CORROSION

TABLE 1: TYPE AND NUMBER OF MECHANICAL TEST SPECIMENS AND NDE REQUIREMENTS FOR WELDING PROCEDURE QUALIFICATIONS TESTS

TABLE 2: PRE-HEAT REQUIREMENTS FOR CARBON STEEL TABLE 3: WELDING INSPECTION REQUIREMENTS APPLICABLE FOR DESIGN,

SUPPLY & COMMISSIONING APPENDIX A - ADDITIONAL REQUIREMENTS FOR LOW TEMPERATURE

SERVICE APPENDIX B - ADDITIONAL REQUIREMENTS FOR 300 SERIES STAINLESS

STEEL PIPING

Specification for Fabrication & Installation of Piping UCH-II Development Project


1.0 SCOPE

This Specification covers the minimum requirements for the fabrication, installation, inspection and testing of piping works for UCH-II Development Project.

This Specification shall be used in conjunction with the ASME B31.3, Process Piping Code. The additional requirements for specific materials and/ or service conditions, in the Appendices to this Specification, shall be applied as appropriate to each particular piping class.

The PC Contractor shall bring his own consumable equipment/machinery and other material and provide all services, skilled and unskilled labor including supervisory and testing personnel needed during construction.



2.0 APPLICABLE CODES AND SPECIFICATIONS Work shall be carried out according to the requirements of this specification and will

conform to the technical specifications, data sheets and fabrication/ installation drawings.

Where specific details about the execution of any items of work are not included,

work shall be carried out according to the requirements of the latest editions of the following standards and Engineering's general specifications described below:

American Society of Mechanical Engineers (ASME) Section I Power Boilers

Section II (Part C) Welding Rods, Electrodes and Filler Metals

Section V Non Destructive Examination

Section VIII Pressure Vessels

Section IX Welding and Brazing Qualifications

B31.3 Process Piping (Latest Edition)

B31.8 Gas Transmission and Distribution Piping Systems

B.1.20.1 Pipe Threads General Purpose (Inch).

B.16.5 Pipe Flanges and Flanged Finings.

B.16.9 Wrought Steel Butt Weld Fittings.

B.16.11 Forged Steel Fittings. Socket Weld and Threaded.

B.16.20 Ring Joint Gaskets and Groves, for Steel Pipe Flanges.

B.16.25 Butt Welding Ends

B.36.10 Welded and Seamless Wrought Steel Pipe.

B.36.19 Stainless Steel Pipe



American Society for Testing and Materials A370 Mechanical Testing of Steel Products

El 10 Test Method for Indentation Hardness of Metallic Materials

E146 Hardness Conversion Tables for Metals

E380 Metric Practice

E562 Practice for Determining Volume Fraction by Systematic Manual

point count

British Standards & Project Specifications BS 427(Part 1) Testing of Metals

BS 709 Destructive testing fusion welded joints and weld metal in steel

BS 4870 Specification for Approved Testing of Welding Procedures

BS 5555 Specification for SI Units

BS 5750 Quality Systems

International Organization for Standardization ISO R 148 Beam Impact Test V-notch for steel

Manufacturers Standardization Society MSS SP44 Steel Pipe Line Flanges National Association of Corrosion Engineers/ International Organization for Standardization NACE MR-0175/ Sulfide Stress Cracking Resistant Metallic Materials ISO 15156 In case of conflict between this specification and its associated specifications and the above codes and standards, the PC Contractor shall bring the matter to the OGDCL’s/ Engineering Consultant’s attention for resolution and approval in writing. In all cases the most stringent requirements shall apply.



All deviations from the requirements of this specification, its attachments and the referenced codes and standards shall be stated in the Tender. In the absence of such a statement, full compliance will be assumed. Compliance by the PC Contractor with the provisions of this specification does not relieve him of his responsibility to furnish material of a proper mechanical design suited to meet the specified service conditions and/or local codes governing health and safety.



3.0 TYPICAL LINE AND VALVE CODE 3.1 Typical Line Code

Key: Line Size - First/ Second Identifiers - Third/ Fourth Identifiers First/ Second Identifiers - Product Medium Identifiers

PF - Process Fluid PG - Hydrocarbon Gas PL - Hydrocarbon Liquid B - Blowcase CD - Closed Drain OS - Oily sewer FW - Fire Water FG - Fuel Gas F - Flare IA - Instrument Air N - Nitrogen PA - Plant Air D - Diesel RW - Raw Water PW - Potable Water PW - Process Water PC - Process Condensate Cl - Corrosion Inhibitor DW - Demin Water HO - Hot Oil

Third Identifier - ANSI Piping Class

A - 150 lb B - 300 lb D - 600 lb E - 900 lb Fourth Identifier – Piping Material

A1 - Carbon Steel (C.A 1.5mm)



A2 - Carbon Steel (C.A 3.0mm) A3 - Carbon Steel (C.A 6.0mm) B - Carbon Steel Low Temperature (C.A. 3.0mm) C - Stainless Steel Type 304L (C.A. 0.0mm) G - Carbon Steel Galvanized (C.A 1.5mm) P - Glass Fiber Reinforced Plastic (C.A. 0.0mm)

3.2 Valve Code

A five digit code is provided for each valve coded as follows: First and Second digit: Valve type (VG= Valve Gate etc) Third digit: Specification Number e.g 100, 101 etc.

For valves additional requirement refer document#4985-PA-2003.

4.0 MATERIALS 4.1 Piping materials shall be as specified in the piping detailed fabrication drawings

(isometrics). Alternative materials may only be substituted subject to specific approval of OGDCL/ Engineering Consultant.

4.2 Materials for non-pressure items, or for reinforcing pads or saddles, which are welded

to a pressure part, shall be of the same type and quality of material as for the pressure part.

4.3 All pressure parts and attachments shall comply with the requirements of ASME

B31.3.



5.0 STORAGE AND HANDLING 5.1 All piping material shall be stored by the PC Contractor in areas demarcated for this

purpose. 5.2 Pipes and fittings shall be stored in a roofed area on dry wooden platforms. 5.3 Valves, Control valves, instruments, steam traps, strainers, stud bolts & nuts, small

fittings and gaskets shall be stored in a covered, locked premise. In no case shall the marking on the equipment be removed. Valves and other equipment provided with protective caps shall be stored with the caps up to the moment they are installed.

5.4 PC Contractor shall be entirely responsible for safekeeping of all the material and

equipment. If any item is lost or damaged, the PC Contractor shall be required to replace it at his own expense.

5.5 Handling of material shall be done with suitable mechanical equipment and safety of

workers shall be given top priority. 5.6 Unless indicated otherwise, covered space for storage of material shall be considered

as PC Contractor's responsibility. 5.7 All material stored shall be distinctly marked. Especially for NACE compliance

material. 5.8 PC Contractor shall maintain at all times, the record of material received as

“Free Issue” from the OGDCL/ Engineering Consultant. OGDCL/Engineering Consultant shall be at liberty to check such record any time without prior notice.

5.9 Upon project completion the PC Contractor shall hand-over all records of all material

after reconciliation. 5.10 Material of one specification shall not be placed with different kind of material. Care

must be taken to ensure that alloy piping materials, such as stainless steel and similar, are not contaminated by contact with carbon steel.



6.0 WELDING APPROVALS

6.1 Welding Procedure Specifications (WPS) 6.1.1 Every WPS and supporting PQR's shall be compiled and submitted for OGDCL’s/

Engineering Consultant’s approval, in accordance with the Submission of Procedures Specification.

6.2 Procedure Qualification

6.2.1 Each welding procedure shall be qualified in accordance with the Code and ASME

IX. Care shall be taken to ensure that restraint and thermal conditions are at least as severe as production welds represented.

6.2.2 The validity of a welding procedure qualification test certificate is restricted to the site

at which the test weld was conducted.

6.2.3 All mechanical testing and inspection shall be conducted after any post-weld treatment that may be required. The procedure qualification test assembly shall be subjected to the same inspection and NDE as required for production welds.

6.2.4 The extent of examination and mechanical testing shall be as defined in Table 3,

unless otherwise specified.

6.2.5 In addition to mechanical testing required by the code, the following tests shall be undertaken on each procedure qualification test assembly:

− Bend Tests

Full thickness root and face specimens are required for thicknesses below 19 mm. For material thicknesses 19 mm and above side bend test specimens shall be used.

− Macro-etch Test

Macro-specimens shall be prepared to a 600 grit finish or better and then etched to show the fusion boundary clearly. For 5G and 6G test positions, the specimens shall be extracted at the 12 o'clock and 6 o'clock positions.



The macro specimens shall be polished and examined under a magnification of minimum x3.

The macro specimens shall be free of unacceptable defects. A macrograph shall be prepared for each specimen, and submitted as part of the test report, for OGDCL’s/ Engineering Consultant’s approval.

− Hardness Survey

For all procedures which cover the welding of a pressure part, a hardness survey shall be carried out on the macro-etch test section. The Vickers hardness test method shall be used in accordance with BS 709. For carbon steel, the hardness value shall not exceed 325 HV. For other materials, hardness requirements shall be approved prior to testing.

Hardness traverses using Vickers test equipment with 22.05 lb load shall be carried out where applicable at the locations detailed below. In the weld metal, 5 indentations evenly spaced along each traverse are to be made. In the HAZ, indentations shall be made along the traverse, starting as close to the fusion line as possible, with a spacing of 0.5 mm. A minimum of two indentations is also required in the parent metal either side of the HAZ. The traverses shall be located 2 mm from both the inner and outer surfaces

− Notch-toughness Testing

For ferritic steel and duplex steel items which operate below 32 °F, austenitic steels operating below minus 158°F and any instances when impact tested base materials are specified, Charpy V-notch impact tests are required. Unless specified in other applicable specifications, the requirements shall be as detailed in Appendix A.

Procedure qualification tests in accordance with BS 4870: or other national standard may be approved in place of those required by the Code.

6.3 Essential Variables

6.3.1 A welding procedure shall be re-qualified when any of the essential variables change

from the values used for qualification.



6.3.2 The essential variables shall be: − Any of applicable essential variables listed in the Code and given in ASME IX.

− Joint Design

Change from single sided to double sided weld or vice versa. Change in root alignment beyond the range of qualified. An increase of more than 2 mm in root gap.

− Welding Process

Change in welding process or in combination of welding processes. Change in polarity or from AC to DC or vice versa.

− Material

Any increase in carbon equivalent of carbon steels greater than 0.04% above that qualified.

− Welding Consumables

A change in electrode diameter used for root runs. Change in type of shielding gas or type of 'bare’ filler metal. Change in brand name of flux or flux coated filler metal or filler metal which incorporates flux.

− Pre-heat/ Interpass Temperatures

Increase of more than 212°F or any decrease in the margin applied to the pre-heat temperature required by Table 4. Any increase in interpass temperature.

− Heat-Input Energy

Decrease in heat input by more than 10%.

− Post-weld Heat Treatment



Change in heat treatment temperature beyond the range qualified, or change in holding time by more than a factor of two. Any increase in cooling rate.

− Positions

Change in welding position beyond qualified positions indicated in ASME IX.

6.3.3 For procedures subject to impact testing, the additional essential variables shall be:

− An increase in the specified current range. An increase in the maximum electrode

diameter.

− An increase in the width of bead or a change from string to weave bead technique.

− An increase in maximum interpass temperature above 482 °F. Any change in consumables.

6.4 Welders (Including Welding Operators)

6.4.1 Welders shall be qualified in accordance with the applicable Code, ASME IX or BS

4871 Part 1.

6.4.2 Welder qualifications in accordance with other recognized national standards may be substituted subject to OGDCL’s/ Engineering Consultant’s approval.

6.4.3 All Procedures Qualification Record (PQR) & Welders Qualification Test (WQT) are

subject to the OGDCL’s/ Engineering Consultant’s witness and approval. 7.0 WELDING REQUIREMENTS

7.1 General

7.1.1 This section defines the general requirements for all materials and those specific to

carbon steel and low alloys steels. For materials other than carbon steel, welding and fabrication shall also comply with the requirements of the appropriate Appendix to this Specification.



7.2 Weld Bevels and Preparations

7.2.1 Weld bevels and preparations, including those necessary for repair welding may be prepared by machining, arc-air gouging, chipping, grinding or guided gas torch cutting. Thermal cutting or arc-air gouging shall be carried out using the same pre-heat as required on the approved welding procedure. Items cut from bulk material shall be identified to material type.

7.2.2 Where the method of preparation is other than machining or grinding, cut surfaces

shall be finally prepared by grinding or machining to clean, bright, sound metal.

7.2.3 The finished weld preparation shall conform with the geometry specified in the approved welding procedure and shall be visually inspected to confirm that the preparation is smooth, uniform and free from tears, cracks, gouges, scale, or any discontinuities which might affect weld quality.

7.2.4 Before thermal cutting or welding of galvanized steel, the galvanizing shall be

removed from immediate work area by grinding or pickling, such that molten zinc does not contact work piece during cutting or welding.

7.2.5 Welding onto surfaces painted with a weldable primer may be carried out, when

Approved.

7.3 Care and Protection

7.3.1 Welding areas shall be protected from adverse weather conditions at all times during pre-heating, welding, post-weld heat treatment and non-destructive examination. For gas shielded welding, special precautions shall be taken to protect the welding area from draughts.

7.3.2 When the base metal temperature falls below 41 °F, and to remove dampness, the weld preparation and surrounding metal for a distance of three times the wall thickness or 25 mm whichever is greater shall be pre-heated to 86°F prior to welding.

7.3.3 Contamination of one material by another shall be avoided by segregation of materials

within the fabrication area.

7.3.4 Arc strikes outside the weld preparation are not permitted. Any stray arc marks shall be removed by grinding and inspected by magnetic particle or dye penetrates



methods. Confirmation of maintenance of the minimum design wall thickness shall be required.

7.3.5 Weld metal shall be deposited in a controlled sequence to minimize distortion and

prevent the build up of excessive internal stresses.

7.3.6 Pipes shall not be moved (except for rotation on rollers) or lifted until at least 50% of the final weld depth has been deposited in circumferential seams.

7.4 Alignment and Fit-Up

7.4.1 Root alignment of butt-welds shall be within the limits of the qualified WPS.

Tolerances of ±0.75 mm for GTAW and ±1.5 mm for other fusion welding processes shall apply, unless wider tolerances are approved subject to qualification

7.4.2 When misalignment cannot be overcome by repositioning of work pieces one of the

following methods shall be employed:

Grinding or machining, provided that minimum design thicknesses are maintained and a maximum taper of 1 in 4 (or 14°) is applied.

Weld buttering, in accordance with an approved procedure, to produce a maximum taper of 1 in 4 (or 14°).

7.4.3 Hammering shall not be used to achieve fit-up or overcome misalignment.

7.4.4 Other methods of overcoming misalignment, such as heating or working with jacks

shall not be used unless specifically Approved, after the Contractor has demonstrated that the mechanical properties of the material will subsequently meet the relevant requirements.

7.4.5 Where clamps or other methods of support are used to achieve fit-up, they shall not be

removed until at least 10% of the final volume of weld metal has been deposited.

7.4.6 Dimensions shall conform to those shown on the drawing.

7.4.7 Parts to be welded shall be securely held by clamps or tack welds to maintain the required alignment and geometry.



7.5 Welding Process

7.5.1 The following welding processes are generally permitted:

Manual shielded metal-arc welding (SMAW) Gas tungsten arc welding (GTAW) Flux cored arc welding (FCAW) Submerged arc welding (SAW)

7.5.2 Other processes may also be permitted, subject to Company’s approval.

7.5.3 When GMAW process is used, deposition shall be in the spray mode. The dip-

transfer mode is not permitted, except, if specifically, approved, for root runs in carbon steel.

7.5.4 When GTAW process is used, the welding current shall be either alternating (AC) or

direct with the tungsten electrode connected to the negative supply terminal (DC-) the arc shall be initiated by a high frequency device and terminated by a current decay (crater fill) device. Electrodes shall be 2% thoriated tungsten. Shielding gases shall be oxygen-free and shall flow at 11-21 ft3/hour. This process shall be used with the addition of filler metal. At each weld interruption, the hot end of the filler metal shall be cooled in the gas shield or shall be discarded. The torch shall have a gas lens.

7.5.5 Complete GTAW Process shall be used for butt / fillet-welds in pipe of diameter

2”and less, also root and hot passes of all welds except utility piping shall be GTAW Process. Filling, caping in pipe diameter greater than 2” can be done by SMAW Process.

7.5.6 All welds shall be multipass, with a minimum of two runs.

7.5.7 Peening is prohibited on all passes.

7.5.8 All pressure-containing butt-welds, including branch welds, shall be full penetration

welds. This shall be achieved by the following means:

For carbon steel, a single sided weld with a SMAW, GTAW root run. SMAW electrodes for utilities service lines the root pass in pipe of 3" NB or larger shall not



exceed 2.5 mm wire size. GTAW shall be used for the root pass in less than 3" NB pipe.

For non ferrous metals, a single sided weld with a GTAW root run using an inert gas back purge.

7.6 Welding Consumables 7.6.1 Welding consumables shall conform to ASME II, Part C or a recognized national or

industry standard, unless otherwise approved. When two or more brands of consumable are in use, they shall be positively identified and segregated to avoid confusion.

7.6.2 All welding consumables shall be identifiable & compatible with base materials being

welded. Deposited weld metal shall be of similar chemical composition to base material (except for dissimilar metal joints) and shall exhibit mechanical properties at least equal to those of the base material. When different grades of material are joined, weld metal shall not significantly overmatch the lower grade material.

7.6.3 Alloying elements shall be introduced to the weld pool primarily from the filler wire,

not from flux. Bare filler wires shall be free from grease and oil before use.

7.6.4 Welding consumables shall be supplied and stored in sealed, dirt-proof and moisture-proof containers or bags.

7.6.5 Welding electrodes and fluxes shall be stored and dried in accordance with

consumable Manufacturer's recommendations. Low hydrogen electrodes shall be segregated from other types during storage, and shall be baked to produce a weld metal hydrogen content of 10 ml H2/l00g maximum.

7.6.6 Submerged arc flux may be reclaimed for recycling after use, only according to the

Approved procedure. Recycled flux shall be mixed with new flux in accordance with Manufacturer's recommendations, but at a maximum of 40% of the total volume.

7.6.7 Consumables for dissimilar metal combinations shall be subject to OGDCL’s/

Engineering Consultant’s approval



7.7 Tack Welds

7.7.1 Tack welds shall be made by qualified Welders on 5G / 6G, using Approved consumables as specified in the Approved WPS. Tack welds shall only be made within V or groove and not outside.

7.7.2 When tack welds are to be incorporated into the final weld, they shall be ground and

feathered and visually inspected to be crack free. 7.7.3 Defective tack welds and tack welds which are not to be incorporated into the final

weld shall be carefully removed by grinding, to leave a correct weld preparation.

7.8 Pre-Heat

7.8.1 The pre-heat temperature for welding and thermal cutting shall be specified in the WPS and shall meet the requirements of the Code.

For carbon steel, pre-heat shall be as indicated in Table 2, unless alternative pre-heat levels are justified by the PC Contractor on the basis of an appropriate national standard or recognized calculation method. If the pre-heat temperature used in the qualification test exceeds the level determined, the same margin shall be applied in calculating pre-heat temperatures for all combined thicknesses applicable to the relevant weld procedure.

7.8.2 Pre-heat shall be applied by electrical resistance heating or by oxy-gas torch or by

other Approved means. Deposition of carbon or direct flame impingement shall be avoided. Cutting torches shall not be used for pre-heating.

7.8.3 Pre-heat shall be applied in a gradual and uniform manner to the entire length of the

joint and shall be maintained throughout the welding operation or as required in the Approved WPS.

7.8.4 The pre-heat temperature shall be established throughout the joint and surrounding

parent metal for a distance of three times the parent metal thickness or 50 mm whichever is the greater from the joint.

7.8.5 The pre-heat shall be measured, using a contact pyrometer or temperature indicating

crayons, at representative positions including the extremities of the required heated



zone and both root-side and face-side of the joint. Where access to only one face is possible, the heat source shall be removed for a period of one minute per 25 mm of parent metal thickness to allow for temperature equalization prior to measuring the pre-heat temperature.

7.8.6 For tack welds and welds involving high restraint or severe stress concentrations, such

as patch welds, cruciform joints, partial penetration welds or where misalignment exceeds 3 mm, the required pre-heat shall be raised by at least 77°F above that required by Item 5.8.1.

7.8.7 Pre-heat is not required for stainless steel except when joined to ferritic steel. 7.9 Temporary Attachments

7.9.1 Temporary attachments which are welded to the work piece shall be of the same

quality material as the work piece. Such attachments include cleats, bridges, backing strips, etc.

7.9.2 Temporary attachments shall be welded to the work piece by qualified Welders using

the same consumables and pre-heat as specified on the Approved WPS for permanent attachments.

7.9.3 Temporary attachments shall be removed, prior to post weld heat treatment, by

grinding, machining or thermal methods, not by hammering. When thermal cutting is used, the attachment shall be cut 3 mm from the work piece surface and the remnants shall then be removed by grinding or machining.

7.9.4 After removal of any attachment, the work piece surface shall be ground and

examined by magnetic particle or dye penetrate method.

7.9.5 Carbon steel attachments shall not be welded to stainless steel or other non-ferritic materials.

7.10 Precaution against Preferential Weld Corrosion

7.10.1 Any mill-scale present shall be removed by abrasive blasting.



7.10.2 Weld metal nominal composition shall be selected to avoid preferential weld corrosion with any particular parent material. For carbon steel in the absence of specific test data or specific recommendations, Figure 4 may be used to determine optimum nickel and/or copper contents.

8.0 FABRICATION

Fabrication of all piping shall be in accordance with the requirements of piping drawings and specifications. Where specific details of fabrication are not included, work shall be carried out in accordance with the latest edition of ASME B31.3, Process Piping.

8.1 General

8.1.1 Piping shall be fabricated by the method stated in this specification; i.e. welded,

screwed or flanged.

8.1.2 Internals of valves and other in-line equipment, which may be damaged due to heat from welding, shall be removed prior to welding.

8.2 Butt-Welded Piping

8.2.1 Permanent backing strips shall not be used. Temporary backing strips shall be used

only with OGDCL’s/ Engineering Consultant’s prior approval.

8.3 Socket Welded Piping

8.3.1 All material entering this type of piping specification shall comply with the relevant piping specification.

8.3.2 Pipe ends shall be cut square and deburred prior to being located in the fitting. 8.3.3 Minimum rating of socket welded fittings shall be class 3000#. When socket welding

fittings or valves are used, pipe shall be spaced approximately 1.5 mm to avoid “bottoming” which could result in excessive weld stress.



8.4 Screwed Piping

8.4.1 The PC Contractor shall use thread cutting lubricant of an approved type.

8.4.2 The correct number of threads shall be cut on pipes to comply with standard for threads.

8.4.3 Minimum rating of screwed fittings shall be class 3000#.

8.4.4 Jointing compounds and thread sealing tapes shall be approved by the Company and

shall be used for all threaded joints except those requiring seal welding. 8.4.5 Generally seal welding is not allowed. When seal welding is required, jointing

compounds or tapes shall not be used; all exposed threads shall be covered by seal weld. Seal welding shall be performed by qualified Welders, in accordance with the Approved WPS.

8.4.6 Excessive wrench markings on pipe and fittings due to joint making shall be avoided

and cause for rejection. 8.5 Flanged Joints

8.5.1 Flanges shall preferably be welding neck with bore matching pipe internal diameter

(ID) unless otherwise specified and / or authorized.

8.5.2 Flange bolt holes shall straddle horizontal and vertical centre-lines, except when otherwise specified on approved drawings, and shall match the orientation of mating flanges.

8.5.3 Internal weld surfaces at orifice flanges and other flow measuring devices shall be

ground flush. The length over which this requirement applies will be specified elsewhere.

8.5.4 All loose weld neck flanges to be field welded shall be tacked in position for shipping.

Alternatively, they may be bolted to fixed, mating flanges or shipped in hessian sacks which are securely attached to the spool.



8.6 Bending

8.6.1 Unless specified otherwise on drawings and specifications or unless Approved, bends

in pipes shall be affected using proprietary manufactured elbows.

8.6.2 Bends shall be free of cracks, wrinkles, bulges, kinks and other serious defects and shall not be excessively scaled. 'Cut and shut', creased or corrugated bends are not permitted. Weld repair of defective bends is not permitted.

8.6.3 When permitted, 'cold' bends shall be made at or below 1202°F for carbon steel.

8.6.4 After bending, cold bends shall be suitably heat treated, unless it can be demonstrated

that the strength, hardness, ductility and notch toughness conform to specified requirements, in the "as-bent" condition.

8.6.5 All traces of bending filler materials and other contaminants shall be removed prior to

heat treatment. No lead-or sulphur-containing materials shall be used as fillers.

8.6.6 When permitted, 'hot' bends shall be made as per procedure approved by the Company.

8.6.7 All heating and heat treatments shall be performed in a uniform and controlled

manner using an enclosed furnace, electrical resistance heaters or electrical induction methods. The use of hand held gas torches is permitted only on low pressure, utilities (stream trace, drain & cooling water etc.) and small bore piping of less than 1½” ∅ pipes.

Any bending, hot or cold and any post-bending heat treatment shall be performed in accordance with a written procedure that has been approved.

8.6.8 After bending, the pipe wall thickness at the thinnest point shall not be less than the

nominal wall thickness minus tolerance and corrosion-and erosion-allowance. Bends intended for use in lines which will require pigging shall be gauge tested to ensure true bore and radius, prior to installation.

8.6.9 Mechanical properties after bending shall be determined for bends of Inspection

Classes 1 and 2. One production test bend shall be made for each cast of pipe, with



bend radius and pipe diameter representative of minimum bend radius/pipe diameter ratio to be used in production. One tensile test and one set of notch toughness specimens (when impact testing is required) shall be removed from the extrados of each test bend. Transverse samples shall be used when the pipe size permits and are mandatory for pipe diameters of 12 inches NB and larger.

8.6.10 When bending is performed on longitudinally welded pipe, the weld shall be

positioned at the neutral axis and test bends shall additionally be tested in the weld zone by taking tensile tests and notch-toughness test samples as required for weld procedure qualification testing. Welds shall be subjected to 100% crack detection after bending. Girth welds shall not be incorporated into bends.

8.6.11 All production tests shall meet the requirements for yield strength and elongation of

parent metal, ultimate tensile strength and notch-toughness energy at appropriate temperature.

8.7 Prefabricated Pipework

8.7.1 Proposed maximum sizes of prefabricated spools shall be submitted for Company’s

approval.

8.7.2 When piping spools are fabricated for free issue to site, spool ends may be identified as 'cut to fit' (CTF) on the approved drawings.

8.7.3 When 'CTF' spools are specified, a minimum of 100 mm additional length to that

dimensioned on drawings shall be left for cutting at the installation stage. 'CTF' ends shall be Left Square and plain.

8.8 Post Weld Heat Treatment (PWHT)

8.8.1 PWHT shall be carried out according to a heat treatment procedure which shall meet

the requirements of the Submission of Procedures Specification.

8.8.2 PWHT shall be achieved by one of the following methods:

− In an enclosed furnace − By local electrical resistance heating − By local inductive heating.



8.8.3 Manual gas torches or exothermic chemical heating packs shall not be used for

PWHT. 8.8.4 When local PWHT is used, the work piece shall be heated symmetrically. For butt-

welds and branch/attachment welds, a full circumferential band around each pipe extending a distance, 1.5 x e on either side of the weld centre-line shall be heated to the minimum soaking temperature, and at least half the soak temperature shall be reached at a distance of L either side of the weld,

Where L = 2.5 √Re R = internal radius of tubular component e = wall thickness.

8.8.5 To avoid adverse thermal gradients, thermal insulation shall be applied over the

heated band to a distance 2 x L either side of the weld centre-line.

8.8.6 When heating is by gas burners, direct flame impingement on the work piece shall not occur. The furnace atmosphere shall be controlled to avoid excessive oxidation.

8.8.7 The temperature of the work piece shall be measured by pyrometers or attached

thermocouples. Sufficient pyrometers/thermocouples shall be used to ensure an even distribution of temperature throughout the heated zone.

8.8.8 Pipe ends, flange faces, threads and any other machined surfaces shall be suitably

protected against oxidation during the heat treatment cycle.

8.8.9 The temperature of the work piece shall not exceed the upper limit of the holding temperature specified on the approved heat treatment procedure.

8.8.10 The temperature of the work piece throughout its heated portion shall be continuously

and automatically recorded on a chart. PWHT records shall be retained as part of the documentation required by the Company.

8.8.11 All temperature measuring and recording equipment, including thermocouples, shall

be suitably calibrated. Calibration records will be subject to scrutiny by the Company.



8.8.12 Welding on to a part which has been heat treated is not permitted, except by Company’s approval, when the requirement for further PWHT shall be as indicated in the applicable code.

8.9 Dismantled Piping Fabrication 8.9.1 For connecting every cut at relocated dismantled piping spool, a 200mm long pipe

spool shall be welded after beveling of relocated pipe. PC Contractor shall adjust and prepare the relocated pipe as per site requirement.

8.9.2 For every Tee connection at relocated piping which will not be useful for further connection shall be replaced with piping spool of same length as respective Tee length.



9.0 INSPECTION AND TESTING

9.1 General

9.1.1 Inspection and non- destructive examination shall be carried out in accordance with procedures which have been approved.

9.1.2 NDE Operators shall be qualified in accordance with a recognized standard and shall

be approved prior to commencement of NDE work. As a minimum requirement, NDE shall be supervised by an Operator qualified to ASNT-TC-1A Level II or suitable equivalent.

9.1.3 The Company shall be given the opportunity of witnessing all inspection, NDE and

testing.

9.2 Fabrication Tolerances

9.2.1 All fabricated piping shall meet the tolerances shown in Figure 2.

9.3 Extent Of Non-Destructive Examination

9.3.1 Inspection classes for welding procedure qualifications tests are shown in Table 1.

9.3.2 The extent of examination to be carried out for each inspection class shall be as shown in Table 2. All fabricated piping shall be examined to the extent shown.

9.3.3 Welding Inspection requirements applicable for design, supply and commissioning

are shown in Table 3. 9.3.4 NDE and final inspection shall be carried out after any PWHT which may be required

but not before the weld has cooled to ambient temperature. When PWHT is not required, NDE and final inspection shall be carried out at least 48 hours after the completion of welding.

9.3.5 Where less than 100% examination is specified, the prescribed examination shall be

carried out at those locations where the presence of defects is deemed to be most harmful to the structure, and/or locations where experience has shown that defects are most likely to occur. The percentage shall be based upon actual number of welds with



100% examination performed on each weld to be tested. The extent of examination shall include welds made by each and every Welder/Operator.

Radiographic examination (to the specified extent) shall be performed after the

completion of the post weld heat treatment (if any). If during radiography inspection 20% or more defective found then inspection requirement will increase to 40% and if 20% or more again defective found then 100% radiography inspection have to perform.

9.4 Methods of Non-Destructive Examination (NDE) 9.4.1 Visual examination shall be carried out before, during and after fabrication in

accordance with Article 9 of ASME Section V and the Code.

9.4.2 Magnetic particle examination, liquid penetrates examination and radiography shall be carried out in accordance with ASME Section V and the Code.

9.4.3 Radiographic testing (RT) shall comply with the following:

− Where possible the single wall-single image technique shall be used.

− Wire type Image Quality Indicators (IQI) to a national standard shall be used.

− Only lead intensifying screens shall be used.

− Film density shall be 2 to 3. Fully processed films shall not be further treated to

alter film density.

− Unless otherwise specified, the sensitivity of the technique shall be a maximum of 2% of section thickness but shall not exceed 1% for thickness of 50 mm or greater.

− The film shall be high contrast, fine grained (Agfa D5 or equivalent) or better.

9.4.4 When MPI is used, the following shall apply:

− Surface condition shall be sufficiently smooth to avoid false defect indications.



− MPI shall be performed using electromagnetic yolks. The "prod" method shall not

be used, except with Purchaser's specific approval.

9.4.5 Generally, MPI shall be used for ferritic steels and DPI shall be used for all other materials.

9.4.6 Ultrasonic examination in accordance with Article 5 of ASME Section V may be

substituted for radiography of a completed weld subject to Company’s approval and only providing following conditions are met:

− Inside surface of weld shall be 100% visually examined.

− When welding is performed from both sides of joint, inside surface of weld shall be 100% inspected by magnetic particle technique.

− Outer surface of weld shall be 100% inspected by magnetic particle technique.

− Purchaser shall be given the opportunity to witness all NDE on weld in question.

− Transducers shall operate at a frequency between 1 MHz and 5 MHz.

9.4.7 NDE reference points shall be marked on the work piece by an Approved method and

clearly identified in NDE reports.

9.4.8 The general substitution of ultrasonic examination for radiography is not acceptable for hydrocarbon services except for systems where the wall thickness exceeds 19 mm or when approved.

9.5 Acceptance Levels For Defects

9.5.1 Limitations on defects shall be as stated in the Code, except as follows:

− Incomplete penetration is not allowed for any butt or branch welds of Inspection

Classes 1 or 2

9.5.2 Additional limitations for various materials are to be approved by the Company.



9.6 NACE Service Material 9.6.1 For CS, LTCS and Stainless Steel Type 316L or 304L, hardness measurements shall

be carried out on specimens from the parent metal, weld metal and the heat affected zone (HAZ). Hardness shall be less than 22 HRC.

All process piping as indicated in isometrics shall fulfill the requirements of NACE MR-0175/ ISO 15156. Accordingly heat treatment where required shall be performed as per ASME section VIII to achieve the required hardness of welding joints.

9.7 Repair Welding

9.7.1 Repairs shall be carried out in accordance with the approved procedure and shall be

subjected to 100% NDE using the same methods as specified for the original weld.

9.7.2 Weld repair procedures shall be qualified by a test weld which simulates the repair technique, unless the repair is effected using an identical weld procedure to that of the original weld.

9.7.3 All repairs to pipe work shall be specifically recorded. 9.8 Production Mechanical Tests

9.8.1 For inspection, when required in case of high pressure lines, when the number of

welds made using a particular weld procedure exceeds fifty, one production joint shall be cut out for mechanical testing for every one hundred (or part thereof) welds made. Joints to be cut shall be selected by the Company. The Contractor shall restore the affected line by welding a new piece of material of the required quality and size.

9.8.2 Each production test weld shall be subjected to the same mechanical testing as the

corresponding procedure qualification test and shall meet the same requirements. In the event of failure to meet specified requirements, the Company may require additional tests to be made or may require more stringent NDE acceptance criteria.

9.9 Production Hardness Testing

9.9.1 For carbon steel subject to PWHT and/or post bending heat treatment hardness checks

shall be performed on welds and/or bends as follows:



− Where complete spools are furnace heat treated, 10% of welds and 10% of bends

in each furnace charge.

− For any other method, 100% of welds and bends.

The extent of testing may be reduced at the Company’s discretion if satisfactory results are consistently being achieved.

9.9.2 The test shall be performed by the portable Brinell method according to ASTM E110

using a "Poldi", "Tele Brineller" or other tester (such as "Equotip) subject to written agreement with Company. For welds each check shall consist of two indents with one in the weld bead and one in the base material as close as practicable to the edge of the weld. The macro-hardness values shall not exceed 200 BHN for carbon steel welds or 225 BHN for ferritic alloy welds.

9.10 Hydrostatic Testing

9.10.1 Contractor shall submit a detailed procedure for hydrostatic testing for Company’s

approval. Testing shall be performed in accordance with the approved procedure.

9.10.2 Pressure testing shall be carried out after completion of cleaning and flushing operations and before painting or insulation of the pipe work. Pressure testing may be integrated with flushing following pickling operations; however, if rusting of the pipe work is likely to occur after pressure testing, pickling shall be carried out after pressure testing and before drying.

9.10.3 Pipework which is to be pressure tested shall be prepared as follows:

− Positive displacement meters and their strainers, turbine meters, orifice plates,

rupture discs, control valves, relief valves and all in-line instruments shall not be installed or, if already installed, shall be removed and replaced by a dummy spool, spacer or blind flange, as appropriate;

− All in-line valves shall be in the fully-open position; check valves may be left in-

situ provided that the source of pressurization is upstream and that, after testing, a the system can be relieved/drained downstream;



− Block valves shall be in the fully-open position, with a blind flange fitted; − All equipment, such as vessels, pumps etc., shall be blanked off; − The pipe work to be tested shall be fitted with a vent at each high point and a drain

at each low point;

− Spring pipe supports and other variable type supports shall be blocked to prevent movement.

9.10.4 At least two pressure gauges shall be fitted and these shall be positioned at the highest

and lowest points in the pipe work. The pressure gauges (dial size 4”) shall be selected to show the required test pressure at between 50% and 90% of full-scale deflection and shall be calibrated prior to use. To permit temperatures effect to be correctly accounted for, pipe work temperature shall be monitored in representative locations by thermocouples; where possible, combined pressure/temperature/time recorders shall be used to provide a permanent record of each test.

9.10.5 Unless otherwise specified, the test fluid shall be clean, fresh water. For pipe work

which includes stainless steels, the water shall contain 15 ppm maximum chloride. The pipe work shall be filled slowly with the test fluid, with all vents and other connections which may serve as vents, open to allow air to be expelled.

9.10.6 Pressure testing shall be carried out, generally in accordance with the Code. The test

pressure shall be as shown on the relevant piping class data sheet (see project Piping Material Specification). The test pressure shall be held for sufficient time to permit all joints to be inspected, with a minimum duration of 1 hour.

9.10.7 After completion of the test, the pressure shall be released slowly. The vents shall be

opened and then the test fluid shall be drained out. All drains shall be opened to ensure that the test fluid is removed.

9.11 Flushing 9.11.1 After successful completion of hydrostatic testing, the lines shall be cleaned by

flushing, blowing or swabbing.



9.11.2 The PC Contractor shall provide the equipment required and shall carry out all operations involved in cleaning.

9.11.3 All foreign material e.g. scale, rust, dirt, welding rods, etc., shall be removed form the

inside of the piping system. 9.11.4 Compressors, pumps, control valves, relief valves, filters, steam trap and instruments

shall be removed before cleaning operations. The PC Contractor shall provide temporary connections to bypass these items. After these items in the piping system using new gaskets.

9.11.5 Steam and gas piping shall be blown with compressed air until it is completely clean. 9.11.6 Other lines shall be flushed with water till they are completely clean. 9.11.7 Cleaning operations shall be performed until OGDCL/ Engineering Consultant is

satisfied that the piping systems are thoroughly cleaned. 9.12 Test Records

Records shall be made of each piping system or pipe section thereof, during the testing procedure. All related documentation shall be sent to the OGDCL/Engineering Consultant for information. These records shall include: 1) Date of test 2) Isometric view of tested pipe section with test duration and identification. 3) Test fluid full specification including possible inhibitor etc. 4) Test pressure in gauge bar 5) Certification by the field OGDCL/Engineering Consultant 6) Photocopy of the chart showing both pressure and time of test

The following requirements are additional with regard to the article 345.2.7 of chapter VI of ASME B31.3 code.

9.13 Post Test Works The PC Contractor shall be the only person fully responsible for removal of the water

used for cleaning and testing operations, under the OGDCL's previous approval.



The PC Contractor shall supply all necessary devices and works, such as temporary connections, draining lines and/or ditches as may be necessary, connected to the general plants drainage system with the previous approval of the OGDCL/Engineer-ing Consultant.

Upon completion and acceptance of tests, provisory devices as previously described, shall be removed, and jobsite left in its final contractual like condition according to the relevant drawings issued and/or approved by the OGDCL. The gaskets shall be renewed on dismantled flanged joints.

9.14 Repairing

In case leaks have been detected, the following procedure shall apply:

• Repairing works shall be performed according to ASME B31.3. • The repaired section shall be brought up to full test pressure. • The pipe section shall be allowed to stabilize with respect to temperature, and

the test started and run for the full time period required. See here above Para about testing.

• In all cases, leaks with develop during the test and cause the pressure to fall shall be cause for the test to be restarted.

• The documentation to be supplied shall be according to MW-1031 and the present specification.

9.15 Cleanup and Acceptance 9.15.1 Cleanup

Further to welding, testing back filling and OGDCL’s acceptance of said works, the PC Contractor shall be in charge of clearing up the job site.

Structures shall be placed in condition as good as or better than at the beginning of

constructions. These repairs shall be satisfactory to the OGDCL and his tenant. PC Contractor shall restore to original condition all public Rights-of-Way, which have been interested by the works.

PC Contractor shall remove from site all materials, including the pipes, left along the

right-of-way after the construction work, whether owned by himself or by OGDCL and shall deliver OGDCL's materials, at points as designated by OGDCL.



PC Contractor shall remove from the premises all equipment, tools and appliances, which were used by him in the performance of the work.

PC Contractor shall be responsible for all claims, which may result from damage done

by him off the right-of-way of the pipeline and plants area. PC Contractor shall make all and any repairs and restorations and shall satisfy all proper claims.

9.15.2 Acceptance

Upon completion of the works, and conformity with the here stated rules being checked, the OGDCL's acceptance will take place according to the terms and procedures as defined in API Standard 700 latest edition and completed and/or amended by the contract terms.

10.0 CORROSION PROTECTION

10.1 Cleaning 10.1.1 On completion of fabrication, the Contractor shall clean inside and outside of all

fabricated assemblies to ensure removal of all loose scale, dirt, sand, weld spatter, cutting chips, etc.

10.1.2 When pipe work is to be pickled, pickling of pipe work shall be carried out in

accordance with the appropriate specification.

10.2 Galvanized Pipework

10.2.1 Unless otherwise specified, pipe work of 1½” NB and smaller, designated as galvanized shall be fabricated from pre-galvanized pipe and fittings and shall be of screwed construction.

10.2.2 Pipework 2 inch NB and above designated as galvanized, shall normally be of welded

construction and shall be hot dipped galvanized after fabrication. Spool sizes shall be chosen to suit available galvanizing facilities.

10.2.3 Cleaning, galvanizing and subsequent painting of fabricated pipe work shall be in

accordance with the Painting Specification.



10.2.4 Any damage to galvanized coatings, such as cutting back for field welding, shallow wrench markings or exposed pipe threads shall be repaired in accordance with the Painting Specification.

10.3 Coating

10.3.1 Surface preparation and painting or coating shall be carried out in accordance with the

Painting Specification.

10.3.2 Shop fabricated pipe spools in carbon steel shall be prepared and primed as soon as possible after completion of fabrication, inspection and testing.

10.4 Preservation

10.4.1 After internal cleaning and inspection, all ends; shall be closed off and sealed to

prevent mechanical damage and ingress of dirt or water. Flange gasket surfaces shall be protected with a corrosion preventative compound, in accordance with the Project Specification for Preservation and Packing, and covered with either 3 mm thick cover of the same metal as the flange or high density polyethylene sheet with 10 mm thick plywood cover. Covers shall be secured by at least 4 bolts.

10.4.2 Threaded connections shall be sealed using caps or plugs distinctively colored to

identify threaded connections.

10.4.3 When open ends of pipes are to be left overnight or between shifts, cover plates or caps shall be fixed to avoid ingress of dirt or water.



11.0 MARKING

11.1 General Requirements

11.1.1 Pipe spool identification shall be clearly written on the pipe using non-corrosive white paint. Die stamping; scratching or bead welding of pipe identification is not permitted.

11.1.2 If temporary identification markings will be obscured by cleaning, painting, heat

treatment or other operations, marking shall be die stamped on a compatible metal disc securely wired to the fabrication.

11.1.3 Loose piping items and fabrications too small for individual paint marking, which will

be supplied in hessian or canvas sacks shall be identified using die stamped metal discs securely wired to individual items or to the sack in which case the identification disc shall also denote the contents of the sack.

11.2 Material Certification

11.2.1 Each batch of free issue piping material will be marked and identified by the Mill

with the Heat Number corresponding to Heat Number on the Material Certificate.

11.3 Line Identification Code

11.3.1 Each line will be designated with an identification code which will be referenced and used on Company’s approved drawings and schedules.

11.3.2 Line identification code will be a composite code containing reference numbers and

abbreviations for the following:

− Area − Service − Line Number − Nominal Line Size − Piping Pressure Class − Piping Material Class



11.4 Spool Identification Numbers

11.4.1 Each individual spool supplied as a separate item for installation shall be allocated a spool identification number with which it shall be identified.

11.4.2 Spool sequence numbers shall be of two digits, commencing with 01 and shall follow

numerical sequence in the direction of flow indicated on the piping isometric. Unless pre-specified on the approved drawings, spool numbers shall be agreed between the Contractor and the Company.

11.4.3 Composite spool identification numbers shall comprise the line identification code

without insulation code, plus a spool sequence number plus an additional area or module reference if advised by the Company.



12.0 INSTALLATION OF PIPEWORK 12.1 General Requirements

12.1.1 Pipe work shall be installed in accordance with the codes and standards specified in Section 2.0 and the OGDCL/Engineering Consultant approved piping general ar-rangements, supporting drawings, specifications and schedules.

12.1.2 Installation of pipe work shall be carried out under conditions satisfactory to OGDCL/

Engineering Consultant. 12.1.3 All work performed and complete must meet the approval of OGDCL/Engineering

Consultant. 12.1.4 The scheduling of work to carry out the installation of pipe work shall be coordinated

with the work schedule of other trades and discipline involved in the overall construction. The schedules shall be prepared to the satisfaction of and agreed with OGDCL/ Engineering Consultant.

12.2 Pipe Work Erection

12.2.1 All pipes shall be inspected before erection to ensure that they are perfectly clean internally.

12.2.2 Where possible, pipe work shall be erected on permanent supports designated for the

line. 12.2.3 During erection of pipe work, suitable supports are to be provided to ensure that no

undue stresses are imposed on the pipe. 12.2.4 Control or block valves shall not primarily be used to support pipe work. 12.2.5 Temporary supports and assemblies used to facilitate the erection of pipe work shall

meet the approval of OGDCL/Engineering Consultant regarding safety and suitability. 12.2.6 Care shall be taken to avoid undue strain being placed on a vessel or item of equip-

ment etc., by unsupported lengths of piping.



12.2.7 Drainage falls shall be maintained throughout as specified on the drawings. 12.2.8 It should be noted that vessel flanges generally are not set sufficiently true to permit

prefabrication of the mating pipe flanges without prior checks being made. 12.2.9 Where drawings show flanges loose on a closure length of piping, a careful physical

check shall be made of closing distance and alignment of flange before cutting and pipe and welding on the flanges.

12.2.10 The PC Contractor shall ensure that piping connected to equipment is supported so

that minor equipment, valves etc., can be readily removed without further supporting of the pipe and with the minimum of dismantling.

12.2.11 The erection of a spool incorporating cut to fit requirements shall be carried out

taking full advantage of the inbuilt adjustment to avoid undue stresses in the completed pipe line, the only exception to this shall be when ‘cold pull’ is specified on the piping drawings, in which case the specified pre-mating gap shall be carefully maintained and the pull made against permanent and secure support anchors.

12.2.12 Pipe work shall be fitted into place without springing or forcing. 12.3 Flanged Joints

12.3.1 All flanged joints shall be brought up flush and square so that the entire mating

surfaces bear uniformly on the gasket, and then made up with uniform bolt tension.

12.3.2 It is recommended that the maximum differential stress between two bolts in a flange joint shall not exceed 20% of the lower stress.

12.3.3 When bolting flange joints with spiral wound gaskets, the gasket shall be compressed evenly to the thickness of the guide ring. This would be equal to 25% to 35% compression of the original gasket thickness (gasket compression shall be spot checked during bolt tensioning),

12.3.4 Steel to cast iron flanged joints (if any) shall be made with extreme care, taking up

bolts uniformly after careful lateral and parallel alignment.



12.4 Equipment Flange Connections

12.4.1 Flange covers shall be retained on all flange connections to pumps, compressors,

turbines and similar mechanical equipment until ready to connect the mating piping.

12.4.2 Unless called for hydrostatic test blanks are fitted at the connections to equipment covered in 9.4.1 above. A thin metal plate shall be inserted to protect the equipment against ingress of internal pipe debris resulting from the continuing erection of the piping.

12.4.3 Flanges connecting to strain sensitive mechanical equipment e.g., pumps,

compressors, turbines, inline instruments etc. shall be fitted up in close parallel and lateral alignment prior to tightening the bolting. To achieve this true alignment, full advantage shall be taken of the 'cut to fit’ allowances and loose flanges provided.

12.4.4 Flange connections to strain sensitive equipment shall be the last connection made on

completion a line or interconnecting system of lines complete with permanent supports.

12.4.5 All openings in vessels, columns and other similar equipment items shall be clean and

free from obstruction prior to being connected to the pipe work. 12.5 Clamp Type Connector Joints (if specified)

12.5.1 Clamp type connectors shall be installed in accordance with the manufacturer's installation instructions.

12.5.2 Hub protectors shall remain on the hubs until they are welded into place or when the

connection is toeing assembled. 12.5.3 All lubricants and foreign matter shall be cleaned form the hub seating surface and

seat ring prior to installation of the connector. The sealing ring should be lubricated only when no coating or plating is present on the seating surface.

12.5.4 Correct alignment of the stubs, seal ring & clamps shall be checked before assembly.



12.5.5 Torque wrenches are recommended for large stud sizes (1⅝" and larger) to ensure that the minimum preload values are met.

12.6 Gaskets and Jointing 12.6.1 The PC Contractor shall ensure that the correct gasket material and thickness as

specified in the OGDCL/Engineering Consultant approved Piping and Valve Materials Specification is used.

12.6.2 The PC Contractor shall ensure that correct gasket lubricant as specified and required

by the OGDCL/Engineering Consultant approved Piping and Valve Materials Specification is used.

12.6.3 Care shall be taken to ensure that the gasket and mating flanges are clean true and free

from defects. 12.6.4 Joint rings will be supplied as pre-cut joints and shall be set inside the bolt circle. 12.6.5 The PC Contractor shall ensure that joint rings do not under any circumstances

protrude into the bore. 12.6.6 The PC Contractor shall install insulated joint rings, sleeves and washers where

indicated on the isometric piping drawings. 12.6.7 Electrical testing on insulated joints shall be carried out by the PC Contractor. Each

stud bolt shall be 'meggared' in turn to each flange and between adjoining flanges. 12.6.8 The annular space between insulated flanges shall be completed filled after testing

with either hot or cold electrical compound or the whole outer periphery of the flanges shall then be wrapped with 0.3 - 0.5mm thick PVC tape.

12.7 Bolting 12.7.1 The PC Contractor shall ensure that all bolting materials and types used are in

accordance with the service requirements as specified on individual material specifications in the OGDCL/Engineering Consultant approved Piping and Valve Materials Specification.



12.7.2 All flanges bolting shall be checked for correct grade and damage prior to fittings. 12.7.3 All flange bolting shall be free to move through mating flanges holes to a plane at

right angles to the flange (ace and parallel to the pipe run (misalignment of flange holes resulting in knurling of the nut on the flange will be rejected).

12.7.4 All flange stud bolts shall extend fully through their nuts. 12.7.5 Stud bolts cut from long lengths of studding shall have the material grade stamped on

the end at each cut. 12.7.6 All nut bearing faces, bolt threads shall be lubricated with suitable lubricant during

fittings. 12.7.7 Bolt tension shall be applied in three stages using the diametrical sequence. 1st stage

25%. 2nd stage 50%. 3rd stage 100%. 12.7.8 The PC Contractor shall re-check all bolting for tightness and correct tension on

completion of pressure testing. 12.7.9 Bolting for ANSI Class 600# and above on size 1½" and over will be one diameter

longer and installed using a hydraulic tensioning device. 12.8 Valves 12.8.1 Valves shall be orientated in the line so as to be readily operable, and removable,

either fully or in part. 12.8.2 Gate, Butterfly and Globe valves in horizontal lines shall be installed with their stems

orientated as follows in order of preference: Manual a) Vertically upwards b) Horizontal (Preferable for Butterfly Valves) c) Upwards of 45 deg.



Actuated a) Gate/Globe, (including 3 way and Y type) shall only be mounted with the stem

vertically upwards. b) Rotary valves (butterfly, throttling ball. etc.) shall only be mounted with the

stem horizontal. 12.8.3 The PC Contractor shall provide for the checking of gland packing in all valves and

for leakage during hydrostatic testing. 12.8.4 All but welds and socket welded valves shall be tack welded in the position show on

the piping drawings and approval of position obtained from OGDCL/Engineering Consultant before carrying out final welding.

12.9 Pipe Supports 12.9.1 Pipe supports shall not be welded to the pipe unless specified in the design and piping

isometric drawings. 12.9.2 Pipe support elements which are welded directly to the pipeline shall be attached by

non-penetrating welds during the fabrication of the pipe or pipe spool. Welding shall be to approve welding procedures in accordance with Welding and Inspection of Piping Specification.

12.9.3 The PC Contractor shad ensure that only supports of the type specified in the design

and piping drawings are used. 12.9.4 During installation pipe lines shall not be forced so as to suit the installed support and

thereby introduce undue stresses into the line. 12.9.5 Permanent pipe supports shall be installed before the erection of pipe work associated

with them. 12.9.6 The PC Contractor shall, ensure that adequate support of (heavy valves and fittings

before the pipe work is subjected to pressure test or put into service. 12.9.7 Attachment by drilling or welding to structural steel on site shall be carried out only

with the approval of OGDCL/Engineering Consultant.



12.9.8 The burning of holes in structural steelwork or component parts is strictly forbidden. 12.9.9 Supporting steelwork shall be set at the correct elevation, being true and level in all

respects. 12.9.10 Metallic surfaces of supports which will be inaccessible after erection shall receive

a protective coating of paint before assembly of the component, in accordance with the General Painting Specification.

12.9.11 All welding of supports shall be carried out using continuous fillet welds. 12.9.12 Hanger rods shall be adjusted to hang correctly after tightening of all component

parts/surplus threading may be removed. 12.9.13 Pipe hangers shall not be used as temporary lifting attachments. 12.9.14 The use of adjacent structures or equipment as temporary supporting of listing at-

tachments shall not be permitted unless authority has been obtained from OGDCL/ Engineering Consultant.

12.9.15 Spring support units shall be installed in accordance with the manufacturer's instruc-

tions and shall not have 'stops' removed until completion of testing. 'Stops' shall be color tagged by manufacturer for identification.

12.9.16 The PC Contractor shall ensure that all temporary supports and lashings are

removed after the pipe work has been flushed and pressure tested. 12.10 Branch Connections

The branch connections shall be in full compliance with the material specifications according to the piping system. They shall also comply with the ASME B 31.3 article 304-3, branch connections in metallic piping. In case of conflictual statement the piping classes overrule the ASME B31.3 require-ments. All branch connections shall be jointed to the header with full penetration welds.



All instrument air connections, if any, shall be from the top of the header.

12.11 Instrumentation

12.11.1 In-line instruments e.g. Orifice plates, control valves, meter etc. shall be installed by

the PC Contractor under the direction and control of the OGDCL’s/Engineering Consultant's Instrument Engineer.

12.11.2 All instruments installed shall be capable of complete or part removal for mainte-

nance purposes 12.11.3 Unless otherwise instructed by Instrument Engineering, in-line instruments shall not

be installed prior to pressure testing of the pipe work. 12.11.4 As specified by the Flushing & Pressure Testing Specification the PC Contractor

shall fit "dummy" spools in place of in-line instruments during erection to facilitate pressure testing.

12.12 Field Run Pipe work

12.12.1 Field run lines shall normally be restricted to pipe work of 1.5" nominal bore and

below. Galvanized pipe will be field run at sizes 2" NB and below.

12.12.2 Field run lines shall be run in accordance with the routing indication on the piping drawings and to the satisfaction of OGDCL/Engineering Consultant.

12.12.3 All field run lines shall be installed in an orderly manner, consistent with good

operation, neatness of appearance, safety of personnel, economy and usage of the minimum number of fittings consistent with provision for expansion and flexibility.

12.12.4 All piping shall be arranged to facilitate supporting and shall be planned for ease of

removal of equipment for inspection and servicing.



FIGURE 1: BRANCH REINFORCEMENT DESIGN

Note – 5

Full Pen" Butt

Full Penetration



6mm Vent Hole to be tapped NPT Dimensions for Root Face and Gap

THICKNESS SMAW GTAW/GMAW (mm) g(mm) f (mm) g(mm) f (mm) ≤ 22 l.6-4.0 0.8-2.4 0.8-l.6 l.2-2.5 >22 2.5-4.0 0.8-2.4 l.6-3.0 1.2-2.5

Notes (1) Reinforcement pads may be split circumferentially or along the axial centre-line

and rewarded to the header by full thickness/full penetration weld. (2) In all cases the reinforcing pad shall be attached after the branch to header weld

has been made and examined. (3) Fig l(a) applies to angled branches in which the branch to header angle is less the

75°. Angles less than 60° are not permitted unless otherwise specified. (4) If the crotch weld of angled branches cannot be made from the outside with

reliable penetration, the weld at "E" shall be made from the inside for 1/3 times diameter of the branch, i.e. 1/6 x D on each side of the axial centre-line.

(5) Dimension R = 6 times thickness of the header as a minimum. (6) If branch reinforcement pads/plates are used the branch connection weld shall be

inspected before the reinforcement pad/plate is fitted. The reinforcement weld shall also be examined.

(7) When socket welds are permitted, they shall be subject to 100% MPI/DPI only.



FIGURE 2: DIMENSIONAL TOLERANCES FOR FINISHED PIPEWORK

±3 mm from indicated dimensions for face to face, centre to face location of Branch and Attachments. 8% max. (for internal pressure) 3% max. (for external pressure) flattening measured as difference between the max. and min. OD at any cross section. ±3 mm misalignment between branch centre line and pipe run centre line. ±1.5 mm max. rotation of flanges from the indicated position. 0.75 max. out of alignment of flanges from indicated position measured across any diameter.



FIGURE 3: PROXIMITY OF WELDS

Separation S = Sp or Sa as applicable. Where Sp = Separation between any two pressure containing welds = 100 mm (above 4" NB) =1 diameter (4" NB or less) - can be reduced to 'the greater of 3 times the wall thickness or 40 mm minimum. and Sa = Separation between an attachment weld and any other weld = 40 mm minimum.





TABLE 1: TYPE AND NUMBER OF MECHANICAL TEST SPECIMENS AND NDE REQUIREMENTS FOR WELDING PROCEDURE QUALIFICATIONS TESTS

Joint Configuration

Pipe Wall Thick. t (mm)

Non –Destruct. Examination (100%)

Cross Weld Tensile Tests

Bend Tests

Charpy V-Notch Tests

Hardness Macro Tests

Butt-weld t < 19 19 ≤ t < 30 t ≥ 30

RT+MPI+Visual RT+MPI+Visual RT+MPI+Visual

2 2 2

2 root + 2 face 4 side 4 side

4 4 5

2 2 2

Branch-weld t < 19 t ≥ 19

UT+MPI+VisualUT+MPI+Visual

2 2

Fillet/Part Pen. Weld

All

MPI+Visual

2

TABLE 2: PRE-HEAT REQUIREMENTS FOR CARBON STEEL

Combined Minimum pre-heat, °F

Thickness, Low Hydrogen (max 10 ml/100 g) Heat Input: <1 (kj/mm) >1 (kj/mm) >2 (kj/mm)

<30 - - <35 122 - - <40 167 - -<45 212 - -<50 212 - - <55 257 68 - <60 257 122 -



TABLE 3: WELDING INSPECTION REQUIREMENTS APPLICABLE FOR DESIGN, SUPPLY & COMMISSIONING

Piping Class

Visual Inspection

Service Radiography Rating

A,B 100% Non-hydrocarbon 5% 150#, 300#

Hydrocarbon 10%

D 100% Non-hydrocarbon 10% 600#

Hydrocarbon 20%

E 100% Non-hydrocarbon 20% 900#

Hydrocarbon 100%

Above 100% ALL 100% 1500#

Any line with wall thickness over ½" (12.7mm) shall be 100% radio graphed. All Tie-in but welded joints shall be 100% radio graphed. All Stainless steel piping shall be 100% radiographed.



APPENDIX A - ADDITIONAL REQUIREMENTS FOR LOW TEMPERATURE SERVICE

1.0 GENERAL 1.1 This Appendix applies to all pressure-containing materials and direct attachments

which may be subjected to low temperatures during their operational life. It includes low temperatures arising from non-normal service such as auto-refrigeration during blowdown.

1.2 All Carbon steel piping systems shall comply with the requirements of the Codes.

1.3 All charpy impact tests shall be V-notch type, performed in accordance with ISO

R148.

1.4 When weld metal impact tests are specified sufficient sets of samples shall be taken and so notched as to represent each process and consumable brand used in the welding of the joint. Branch and attachment weld procedures shall be qualified by a butt-weld joint which has been subjected to Charpy impact testing.

2.0 IMPACT TESTING REQUIREMENTS

2.1 Carbon Steel 2.1.1 All pressure-containing items, and attachments directly welded to such items, shall

comply with ANSI B31.3, except as modified by the Piping and Valve Specification.

2.1.2 All weld procedures for pressure-containing welds shall be qualified by appropriate procedure qualification tests which shall include charpy impact testing of weld metal and heat-affected zone, in accordance with ANSI B31.3,.

2.1.3 Heat affected zone impact testing is required on all production test coupons

representing low temperature piping.

Heat affected zone impact tests shall comply with the requirements for the parent material, as stated in the Piping and Valve Specification.



2.2 Stainless Steels and Dissimilar Metal Joints 2.2.1 Weld procedures for welds in austenitic stainless steels and for welds between these

materials and ferritic steels, shall be subject to charpy V-notch impact testing of the weld metal only. Test requirements shall be the same as specified by ANSI B31.3.

2.2.2 When dissimilar joints, which include ferritic steel, are tested, additional impact tests shall be taken from the ferritic heat affected zone. Test requirements shall comply with ANSI B31.3.

2.2.3 Weld procedures for welds in duplex austenitic - ferritic steel shall be subject to the same requirements as for carbon steel. When the impact energy requirements of the above cannot be met, impact tests may be accepted if they comply with a minimum average lateral expansion of 0.38 mm, minimum individual lateral expansion of 0.25 mm.



APPENDIX B - ADDITIONAL REQUIREMENTS FOR 300 SERIES STAINLESS STEEL PIPING

1.0 SCOPE 1.1 This appendix covers the special requirements for the fabrication of stainless steels

(300 series).

1.2 This appendix applies to the following materials: "18-8" type austenitic stainless steels, including: 304, 304L, 316L, 321 types and other stainless steels as specified by the Company.

2.0 GENERAL 2.1 Fabrication of stainless steel shall be carried out in an area separate from that used for

carbon/low alloy steels and copper alloys.

2.2 Saws, grinders and other tools used on stainless steel shall not be used on other materials.

2.3 Cold bends shall be made at or below 797°F, followed by solution annealing.

2.4 Hot bends when permitted shall be made at 1697°F - 2102°F followed by solution

annealing. Prior to hot bending, stainless steel shall be free from grease, soap and any compound containing sulphur, halogens or low melting point metals.

3.0 WELDING 3.1 Preparation

Cutting shall be by cold sawing or plasma-arc process. Fused edges and heat-affected zone from plasma-arc cutting shall be removed by grinding or machining.

3.2 Process 3.2.1 Gas Tungsten Arc Welding (GTAW) shall be used for root runs of single-sided welds.

The argon gas back purge shall be maintained during the first filler pass.



3.2.2 Submerged arc welding (SAW) shall not be used, except for welding of heavy sections with Company’s prior approval, when heat input shall be restricted to 4 kJ/mm maximum.

3.3 Consumables 3.3.1 Welding consumables for conventional austenitic stainless steel shall be as follows:

Material Consumable Type (AWS designation) Type 316 or 316L E316L or ER316L Type 321 E347 or ER347 Type 304 or 304L E308L or ER308L

3.3.2 For the welding of conventional austenitic stainless steels to carbon steel, E309/ER309 (or E309Mo/ER309MO for joining Type 316/316L to carbon steel) shall generally be used, provided post-weld heat treatment is not required. When post-weld heat treatment is required, E Ni Cr Fe-3 consumables shall be used.

3.3.3 Consumables for stainless steels shall produce deposits with 3 to 10% ferrite.

3.4 Heat Control 3.4.1 Maximum interpass temperature shall be 302°F.

3.4.2 Pre-heating and post-weld heat treatment are not required unless required for ferritic

steel in a dissimilar-metal joint.

3.5 Procedure Qualification 3.5.1 Weld procedure qualification tests for stainless steel shall be carried out on the same

type and grade of material as used in production.

4.0 CLEANLINESS REQUIREMENTS

4.1 Protection of Bore 4.1.1 The bore of pipes and other components shall be protected from oxidation during

welding by inert gas purge.



4.1.2 The extent of purging and/or the use of dams to confine the gas purge shall be specified in the weld procedure specification.

4.2 Limits of Oxidation 4.2.1 Light oxidation of the weld/HAZ is acceptable. This is generally evidenced by

discoloration varying from straw to dark brown.

4.2.2 Heavier oxidation, as evidenced by dark blue weld metal and/or the formation of a coke-like surface, has a deleterious effect on the corrosion resistance in service and hence is unacceptable.

4.3 Remedial Action 4.3.1 Heavily oxidized surfaces, spatter, welding slag and other residues shall be removed

by grinding. The final surface condition shall be attained by light grinding with rotary abrasive papers/cloths and by pickling.

5.0 INSPECTION AND TESTING

5.1 Visual Examination 5.1.1 All welds shall be 100% visually examined after completion.

5.1.2 Weld procedure qualification test assemblies for all stainless steels shall be subject to

internal bore examination for correct weld profile and discoloration.

5.2 Non-Destructive Examination 5.2.1 The extent of examination shall be as indicated in ANSI B31.3.

5.3 Acceptance Criteria 5.3.1 Criteria for cleanliness are given in 4.2 and 4.3.

5.3.2 The following features are unacceptable:

− Any cracks − Any lack of fusion or lack of penetration at the bore surface

Surface-breaking porosity.

SPECIFICATION FOR PIPELINE CONSTRUCTION Project: UCH-II Development Project Client: Oil & Gas Development Co. Ltd. Prepared by: WRK Checked by: MK Approved by: FS Revised by: -

0 ISSUED FOR BID 1-Mar-12 Rev. Description of Revision Date Revised Page Nos.

Job No. 14-4985

Spec. No. 4985-PA-2022

Page 1 of 49 Rev. 0

Pipeline Construction UCH-II Development Project

Doc. No. 4985-PA-2022 Page 2 of 49

TABLE OF CONTENTS

1.0 GENERAL ............................................................................................................ 4

2.0 CODES, STANDARDS & SPECIFICATIONS ................................................ 6

3.0 PIPELINE ROUTE . ........................................................................................... 6

4.0 UNLOADING, STOCKPILING, HAULING & STRINGING OF

MATERIALS ................................................................................................................... 7

5.0 RIGHT-OF-WAY ................................................................................................ 9

6.0 TRENCHING ..................................................................................................... 12

7.0 BENDING ........................................................................................................... 18

8.0 CLEANING & INSPECTION OF PIPES & BEVELS .................................. 20

9.0 WELDING .......................................................................................................... 21

10.0 LOWERING IN ................................................................................................. 33

11.0 TIE-INS ............................................................................................................... 34

12.0 BACK-FILLING OF THE TRENCH .............................................................. 34

13.0 SPECIAL MECHANICAL PROTECTION ................................................... 36

14.0 CROSSINGS ...................................................................................................... 38

15.0 SPECIAL ITEMS .............................................................................................. 39

16.0 APPURTENANCES .......................................................................................... 39

17.0 FINAL TESTING .............................................................................................. 39

18.0 PAINTING.......................................................................................................... 43

19.0 CONCRETE ....................................................................................................... 43

20.0 WET AREAS, SWAMPS DITCHES AND AREAS SUBJECT TO

FLOODING .................................................................................................................... 43


Doc. No. 4985-PA-2022 Page 3 of 49

21.0 LINE MARKERS AND CATHODIC TEST ASSEMBLIES ........................ 44

22.0 FINAL CLEAN-UP OF THE CONSTRUCTION RIGHT-OF-WAY AND

PERMANENT JEEPABLE TRACK. .......................................................................... 44

23.0 COMMISSIONING AND START-UP ............................................................ 45


Doc. No. 4985-PA-2022 Page 4 of 49

1.0 GENERAL 1.1 Scope

OGDCL intends to develop the Gas field by installing Plant comprising surface facilities, flow lines, commingling system and gas purification plant. The gas purification plant unit will be capable of to processing on an average 300 MMSCFD raw gas stream. For implementation of the project, Flowlines/Pipelines to be installed from wellheads to UCH-II Development. This construction specification outlines the minimum basic pipeline construction requirements for Flowlines/Pipelines to be installed from wellheads to UCH-II Development.

This specification establishes the methods of construction, testing and repair,

acceptable construction tolerances, construction record requirements and such details

as ditch dimensions, amount of cover required, allowable change of slope and tie-in

temperature limits etc. Installation of Mobile Scraper Traps, Insulating Joints, Anchor

Flange and Barred tee etc are also included in the scope. 1.2 Definitions

“Company” means “Oil and Gas Development Company Limited (OGDCL)”.

“Engineering Consultant” shall mean “ENAR Petrotech Services (Pvt.) Limited”.

“Supplier” means Entity with whom the Company will execute a Contract for supply

of equipment/material as per this document.

“Project” means “UCH-II Development Project”.

1.3 Error or Omission

All deviations to this specification, other referred document or attachments shall be

brought to the knowledge of the Company/Engineering Consultant in the bid. All

deviations made during the installation, testing and inspection shall be with written

approval by the Company/Engineering Consultant prior to execution of work. Such

deviations shall be shown in the documentation prepared by the Contractor.


Doc. No. 4985-PA-2022 Page 5 of 49

1.4 Conflicting Requirements

In the event of any conflict, inconsistency or ambiguity between these documents,

referred documents, codes & standards referenced in the documents the Contractor

shall refer to the Company/Engineering Consultant whose decision shall prevail.


Doc. No. 4985-PA-2022 Page 6 of 49

2.0 CODES, STANDARDS & SPECIFICATIONS

- API specification 5L Specification for line pipe, (Latest Edition)

- ANSI B 31.8 Gas Transmission & Distribution Piping System

- API specification 6D Specification for pipeline valves (Gate, Plug, Ball & Check Valves)

- API 1110 Pressure testing of liquid petroleum pipelines

- API Standard 1104 Standard for welding pipelines and related facilities

- API RP 1102 Recommended practice for liquid petroleum pipelines crossing railroads & highways

- API RP 5LW Recommended practice for transportation of line pipe on barges and marine vessels

- ASME SE-709 Standard Guide for Magnetic Particle Examination

- ASME SE-165 Standard Test Method for Liquid Penetrant Examination

Project Specifications Relevant Specifications

Relevant Typical Drawings

Certain codes and regulations may have been adopted by the jurisdictional agencies

over the locations where the work is to be performed. It shall be the Contractor’s

responsibility to determine whether local codes and regulations exist. In the event

local codes and regulations exist the Contractor shall determine their scope and abide

by all their provisions on its own cost.

3.0 PIPELINE ROUTE

Company/Engineering Consultant has surveyed and prepared drawings for the

pipeline route and set survey markers in order to establish the edge of pipeline route.

However, it shall be the Contractor's responsibility to establish working grades, and

levels in accordance with design and drawing provided by the Company/Engineering


Doc. No. 4985-PA-2022 Page 7 of 49

Consultant and maintain/establish survey markers/monuments at every 500m along

the route on ground at its own expense. Demarcation

The pipeline route drawings (plan/profile) show generally the alignment that is to be

followed by the Contractor and pipeline corridor shall be marked accordingly on

ground.

Contractor shall at its own expense carryout all necessary survey to locate under-

ground/buried services such as electric cables, telephone lines, gas lines, foreign

pipelines etc. and other permanent structures in order to protect and prevent any

accident or damage to other's work.

4.0 UNLOADING, STOCKPILING, HAULING & STRINGING OF

MATERIALS Contractor shall receive, load-out, transport and stockpile coated pipes at the

designated delivery points, and shall reload and string with equipment of a suitable

capacity using Company/Engineering Consultant approved slings, spreader bars and

protected hooks. Coated pipes shall not be handled in any manner, which distorts,

scratches, scars, or dents the pipe. Unloading of pipes from trucks shall be done

carefully. Pipe shall never be dropped. It shall be handled and transported to prevent

any damage. The pipe coating, insulation and, concrete coating, if any, shall be

protected from damage. Pipe shall be stockpiled as directed by Company/Engineering

Consultant.

Pipes shall be loaded on truck in a pyramid form and tiers shall be according to ANSI

B31.8.

Materials other than pipes and which are susceptible to dispersing, deteriorating or

suffering from damages, especially due to humidity, exposure to high thermal

excursions or other adverse weather conditions shall be suitably stored and protected.


Doc. No. 4985-PA-2022 Page 8 of 49

In particular, material for protective coatings, heat shrinkable sleeves, rock shields fall

within this class.

Pipe stringed along the construction right-of-way shall be protected by setting the pipe

on padded supports. No pipe shall be strung along the right-of-way before all clearing

and grading is completed. In order to maintain the spread within reasonable length,

the pipe stringing shall precede welding by a sufficiently short distance.

Pipe shall not be strung on the construction right-of-way in advance of trenching

where blasting will be necessary in rocky areas.

Pipe shall be strung in such a manner as to result in the least amount of interference to

the normal use of the land and/or other properties crossed, and gaps shall be left at

frequent intervals to permit the use of the land and the passage of farm animals,

equipment or other normal traffic across the construction right-of-way.

All materials shall be unloaded, stored if such is required, hauled to the site of the

work and assembled on the site in such a manner as to prevent damage, theft, etc.

Flammable materials such as paints, primers, volatile substances etc. shall be kept in

separate storage having proper ventilation until the final use and both inside and

outside of the storage all kind of preventive measures shall be taken against danger of

a possible fire.

The Contractor shall be fully responsible for all storage areas.

The Contractor shall prevent ingress of dirt or debris into the pipe during stringing.

The stock piling of coated pipes will be carried out on surfaces previously leveled and

coated with a layer of sieved earth or sand having sufficient thickness to prevent

coatings from being damaged or on wood wedges or sand bags.


Doc. No. 4985-PA-2022 Page 9 of 49

The Contractor shall carefully lower the pipe, within the right-of-way, on to sandbags.

Line pipe shall not be rolled off or dropped from the vehicles.

Lifting and handling of Factory Made large Radius Hot Bends and other materials

shall be accomplished without damage of any sort. Contractor shall adhere to all

lifting and handling instructions laid down by the Company/Engineering Consultant

in this specification.

The Contractor shall be fully liable for repair or replacement materials or equipment

damaged by Contractor.

For handling of coated pipes, equipment shall be selected carefully to avoid any

damage to the coating. Pads are recommended on forklifts and a spreader bar shall be

used when handling pipe with an overhead crane. These pipes shall be handled with

wide belt strips and not with chain or wire.

If the pipe is to be stored for long periods of time, the ends should be protected from

the elements to ensure cleanliness and to prevent deterioration of the coating. The

most common method of protection is to use a polyethylene bag securely taped over

the ends of each pipe, carefully stacked in a secured area to prevent damage from

other operations incidental to the job.

Pipes stacks shall be suitably secured against collapse and will consist of pipes having

the same diameter and thickness. Continuous pipes having different sizes, wall

thickness or coating thickness shall be clearly separated. 5.0 RIGHT-OF-WAY General The construction right-of-way shall be cleared and graded to a smooth surface for the

full width and prior to the stringing of pipe. In addition, fills or cuts may be indicated

on the plan and profile drawings in order to eliminate or lighten over bends or sags in

the pipeline.


Doc. No. 4985-PA-2022 Page 10 of 49

For the purpose of construction, 40 meter wide construction RoW to the right of

permanent Row (facing the direction of flow) shall be acquired by the Company. Any

requirement of land in addition to this, for construction, storage, access or residential

camps shall be arranged by the Contractor at its own cost.

The Contractor shall pay for all damages resulting from operations outside the

construction right-of-way.

The Contractor, at its own expense, shall verify by suitable means in advance of

actual construction, the precise location and actual depth of all existing pipelines,

utilities and subsurface structures that either cross or are in close proximity to the

proposed pipeline. Contractor shall avoid damages to and shall be liable for all

damages to all such structures.

Contractor shall restore all damaged property including but not limited to buildings,

fences, hedges, roads, bridges, culverts, drainage ditches, terraces, drainage, tile,

creeks, levees and rivers occupied or crossed in said construction. Any property

damaged in the prosecution of the work shall be put into as good condition as before

damage occurred and upto the satisfaction of concerned local authorities and as

agreed to by the Company/Engineering Consultant.

In rough or steep terrain the Contractor may be required to grade access roads into the

construction right-of-way for use in the moving in of materials, men and equipment.

Where such roads are required the Contractor shall obtain the necessary permission

from land owners and tenants involved and shall furnish the Company/Engineering

Consultant with a written copy of such permission. The Contractor shall be

responsible for all the damage caused by the construction and use of such roads.

Where the construction working area is shared or located on an existing pipeline

RoW, extreme caution shall be used at all times to avoid damage to existing facilities.


Doc. No. 4985-PA-2022 Page 11 of 49

Before any work can begin on shared RoW, the existing pipeline (if any) shall be

marked by the Contractor with red flags, for clear indication and Company will

inform the Contractor about pipe size, operating pressure, depth of pipeline and

product in the pipeline. Contractor shall take extreme care not to ply the equipment

over the existing pipeline.

Contractor shall cross its equipment only at the designated points over the existing

pipeline if deemed necessary. Earthen ramps shall be constructed/maintained at such

crossing points till completion of the pipeline construction. Site Marking The road and railway crossings shall be marked and the Contractor shall warn for

special operations.

If the right-of-way width is reduced, entrance to and exit from the narrow area shall

be clearly marked and stakes shall be placed if necessary.

A marker post shall be placed every 500 m along the right of way on the trench side

and it should be visible from the working track.

The Contractor shall maintain and possibly correct the marking during the

construction operations. Preparation of the RoW The Contractor, within the area made available to him by the Company shall at its

own cost perform the following:

Make all required arrangements (cleaning, leveling etc) permitting the delivery and

transfer of pipe, moving of vehicles, all operations required for the good performance

of work, traffic of vehicles belonging to any agent responsible for the supervision of

work, and if necessary installation of culverts, back-filling of ditches or reinforcing of

certain portions of natural ground which could be in poor condition.


Doc. No. 4985-PA-2022 Page 12 of 49

Remove or have removed all power line or telephone line poles. The Contractor shall

take all necessary steps to secure, in due time, the corresponding agreement from the

concerned governmental agencies. Cutting down of Trees Within the RoW made available by the Company, the Contractor shall proceed with

cutting down of trees, clearing of tree stumps and large roots.

Cutting down of trees shall be performed so as to avoid damages to other trees, plants,

crops and any construction.

Clearing and Grading operation shall not be more than 20 Km ahead of completed

trench unless approved by the Company.

All cut-down trees shall remain the sole property of the Company. Trimmed trunks

shall either be stacked along the R.O.W. or removed to a place specified by the

Company/Engineering Consultant.

The same shall be applied for bushes and branches resulting from the clearing

activity. 6.0 TRENCHING

Particular care shall be taken to locate all buried installation, crossing the pipe line

route in advance of grading and ditching.

The Contractor shall take centre-line of the pipeline as per relevant drawings to dig

and maintain the pipeline trench.

General In locations where the trench is cut across roads, paths, walkways, etc., the Contractor

shall provide temporary bridges of adequate strength and properly constructed to


Doc. No. 4985-PA-2022 Page 13 of 49

allow the passage of normal traffic with a minimum of inconvenience and interrup-

tion.

Proper warning signs shall be placed and maintained while such crossings are open. If

the crossings are open at night, the Contractor shall provide and use Warning Lights

or Lanterns, all as required by the agency having jurisdiction and/or the


The Contractor shall provide, at its cost, necessary pumps, de-watering equipment,

sheet piling, shorting well points, etc. as required to prepare trench in marshy and

high water table areas. Contractor shall ensure satisfactory disposal of water pumped

through the ground.

Where gravel, rock, and/or other hard materials are in the bottom of the trench in non

traffic areas and where in Company/Engineering Consultant opinion, such conditions

will result in damage to the pipe coating, the Contractor shall pad the bottom of the

trench with sand to a depth such as to give the pipe, in place, at least 150mm of

clearance from the hard materials. Depth Minimum depth of cover shall be measured from the top of the pipe coating, to the

top of the undisturbed surface of the soil. Fill material in the construction right-of-way

shall not be considered to add to the depth of cover.

The Contractor shall carry out deeper trenching at all parts of the RoW, where a

deeper cover is required by the Company/Engineering Consultant, or indicated on

drawings near roads, water course/Nala crossings, other pipeline crossings, and in

short sections of cultivated areas where special installations or surface arrangements

exist or are foreseen, or where this is required to avoid unnecessary bending of the

pipe.


Doc. No. 4985-PA-2022 Page 14 of 49

If, during performance of work, the minimum depth of cover cannot be achieved, the

Contractor shall submit for the Company/Engineering Consultant’s approval all

necessary provisions to ensure equivalent protection. Width The trench shall be wide enough to allow for lowering-in without damage to the pipe,

pipe coating. The trench shall be excavated so as to provide a minimum clearance of

200 mm on either side of pipeline. Each side of the pipe shall be measured from the

outside of any coating at the horizontal centerline of the pipe when it is placed in the

trench.

The Contractor may be required to excavate deeper than shown on the Drawings, or to

excavate a trench wider than required by the Specifications and Drawings, in order to

properly construct the pipeline at road, path, walkway, dike and stream crossings, and

other locations of a similar type. It is understood that the Contractor recognizes such

possibilities and that he has included such possible costs in the Contract Price. Ditches

Ditching operations, increase in width and depth, supply of back-filling material of

the ditch bottom shall be at the Contractor’s expense.

When required in locations where ditch walls shall be protected by shielding, the

Contractor shall perform the corresponding work at its own cost.

Ditch walls and bottom shall be free of damaging elements (stones, roots, etc.). Ditch

walls shall be as vertical as possible.

At points where trench is known to cross other pipelines or underground systems.

Excavation shall be performed manually.


Doc. No. 4985-PA-2022 Page 15 of 49

The bottom of the finished trench shall be adjusted in such a manner that the bottom

of pipe, bent according to the design, will fit on its whole length so that the pipe will

not be ovalized or overstressed in any way.

In rocky areas, the Contractor shall protect the ditch bottom with a padding of sieved

sand of 200 mm thick. Pipeline being backfilled in the rocky areas shall be provided

with the mechanical protection of a minimum of 10-mm thickness.

Top Soil

Top soil shall be conserved by removing one layer of top soil to a depth of between

100 mm and 150 mm. Removed top soil shall be stockpiled in a location that will

minimize any loss due to erosion or mixing with other materials.

Top soil conservation shall be carried out in all areas where excavation or leveling is

necessary including the trench line, graded pipeline route, temporary stock piles and

camp sites.

The excavated materials shall be stored within the RoW.

When required by concerned governmental agencies, the Contractor shall remove all

excavated materials and move them to locations chosen in agreement with the

Company/Engineering Consultant. The Contractor shall also supply and perform the

necessary back-filling.

Crossing of Unstable Areas

If the zones crossed by the line present any risk of settling and sliding, the Contractor

shall, immediately, inform the Company/Engineering Consultant of such risk.

In steep areas of hillside before starting the work, the Contractor shall provide for

suitable arrangements as per relevant drawings or other similar protections approved

by Company/Engineering Consultant in order to prevent the material removed from


Doc. No. 4985-PA-2022 Page 16 of 49

falling down the hill. The foregoing is particularly applicable where lines of

communication, houses, water courses and cultivations exist.

Temporary Crossings Wherever it is permissible to open cut a road with an improved surface to make a road

crossing, the Contractor shall remove the surface in accordance with the restrictions

and requirements of the national, provincial, municipal or other agency having

jurisdiction thereof.

Where possible the Contractor shall arrange to complete the trenching, laying and

back-filling of such crossings and to remove the temporary bridging before the end of

the regular work day in order to minimize the hazard to night traffic. Water Drainage

The Contractor shall be responsible for the protection of the Site against water of any

kind and origin.

The Contractor shall be responsible for maintaining surface or deep water drainage

under all circumstances.

The Contractor shall also be responsible for all consequences resulting from problems

caused by surface or deep water drainage and for any damage or accident likely to

occur.

The Contractor shall be responsible for drainage of water of any origin from the site

up to the adequate outlets. Such obligations cover the construction and maintenance

of water supply connections (drain-pits, drains, etc.), the supply of power and

equipment necessary for drainage, operational and supervisory personnel, the

restoration of the site etc. so that ditching operations and lowering-in of pipe into the

ditch be carried out under good conditions.


Doc. No. 4985-PA-2022 Page 17 of 49

When the back-filled trench making a drain effect is liable to cause damages to the

pipeline or to the nearby lands, the Contractor shall submit to the

Company/Engineering Consultant adequate measures to prevent damages from

occurring. Underground Drainage

Within drained areas or areas to be drained, the pipe shall be laid in order that the

distance between the top of pipe and the bottom of each drain is at least 300 mm.

The Contractor shall take similar measures for separate drain lines which may have

not been reported earlier and which is likely to be encountered during the

performance of Work. The Contractor shall immediately inform the

Company/Engineering Consultant of the existence of such drain lines.

As soon as the pipe has been laid down, the Contractor shall restore all drain lines in

such a way so as to obtain a draining system similar to the initial one.

Drain lines which are damaged by vehicles shall be replaced and restored to the

original conditions.

Special measures shall also be taken in order to prevent the ditch, after back filling,

from being used as drain line.

Within grounds drained by underground systems, the Contractor shall restore any cut

network, at its own cost, using a method satisfactory to the land owner and approved

by the Company/Engineering Consultant. Bell Holes

When pipe tie in is to be performed in the ditch, the Contractor shall provide, at its

own expense, bell holes having at least the following dimensions:

Depth: 60 Sixty cm below the lower part of pipe.


Doc. No. 4985-PA-2022 Page 18 of 49

Length: 70 (seventy) cm in excess of the outside diameter of the Pipe.

Width: 90 (ninety) cm between the outside of the pipe and the bell hole wall

on either side of the pipe.

7.0 BENDING Preformed Bends

Preformed bends shall be installed in the pipelines where the changes in direction are

larger than permissible with the elastic bends. Bends may require more cover than the

minimum cover at straight run of pipelines.

Preformed bends can be broadly classified into:

• Factory made preformed bends (for angles 16º and above)

• Site bends using bending machine (for angles between 3º and 16º)

• Site bends using bites (for angles less than 3º)

Factory Made Preformed Bends

The factory made preformed bends shall be installed where the changes in direction

are equal to or greater than 16º. Factory made preformed bends will be procured in

three sizes i.e. 22.5 º, 45º and 90º. Any other angle shall be achieved by fabricating

the 45º and 90º bend at site.

Site Bends Using Bending Machine

Preformed bends less than 16º but greater than 3º shall be made by welding into the

correct location of the string a length of pipe which has been bent with a smooth

stretch bending machine. The bending radius shall be minimum forty (40) times the

diameter of the pipe.


Doc. No. 4985-PA-2022 Page 19 of 49

Bends shall not be made closer than 2 ft. from a circumferential weld unless the weld

is back welded. The weld shall be X-rayed after the bend is made.

Site Bends Using Bites

Horizontal changes of direction which are larger than permissible with elastic bends

are to be made using preformed bends in 3º (maximum).

More specifically, when horizontal bends are to be made by using pipe bending

machine, the maximum permissible bend or `bite' at one place on the pipe shall be

zero degree thirty minutes (0º 30’) and the minimum spacing of such bites shall be 3

feet. The limitation of horizontal bend shall be 3º per 37 feet pipe length. Normally,

this means 6 each 1/2º bites spaced 3 feet with 11 feet straight tangent at the ends of

each pipe length.

Linear and Angular Tolerances

Bends shall be provided with a total angularity tolerance of ± .5 degrees as

determined by the intersection of the tangent centerlines measured by appropriate

equipment.

Contractor's Responsibility

Small sag and over-bends can be handled by careful trenching of the pipeline trench

and/or field bending the pipe.

Contractor shall submit for Company/Engineering Consultant’s approval the

procedure for field bending of line pipe and repair of coating of the pipeline in the

field.

Miter bends are not allowed.


Doc. No. 4985-PA-2022 Page 20 of 49

8.0 CLEANING & INSPECTION OF PIPES & BEVELS

• All pipes shall be internally cleaned prior to assembling.

• The means of cleaning shall be proposed by the Contractor for approval of the

Company/Engineering Consultant’s Representative.

• All operations performed later on shall be conducted so as to prevent any foreign

body, especially water and earth, from penetrating into the pipes.

• Any assembled section or part shall be carefully sealed closed at each interruption

of work by night caps agreed upon by the Company/Engineering Consultant, so as

to prevent water, dirt, animals and any foreign substance from entering the pipe.

• All Site personnel shall be fully aware to comply with the provisions and be

informed that equipment, tools or suits shall not be left in the pipe, for any reason.

• If, upon removal of night caps, it appears that some foreign bodies have

penetrated into the pipe, the contaminated portion shall be properly cleaned before

proceeding with further assembling operation.

• Immediately, prior to proceeding with alignment, each pipe end shall be carefully

cleaned, using metallic brushes.

• In the event such surfaces show rust, mill scales, grooves, burrs, etc. a grinding

machine of flexible disk type shall be used.

• Cleaning shall be performed on the inside and outside of the pipe and at least up to

ten (10) cm from the edge.

• When cleaning is performed by grinding, the bevel root face shall be

reconditioned using a file.

• Prior to welding, pipe diameter and thickness will be verified at each pipe end.

Bevel design shall comply with type of welding.


Doc. No. 4985-PA-2022 Page 21 of 49

9.0 WELDING

General

Welding and welding related requirements of the following codes and standards shall

be considered part of but subject to the more stringent provision of these

specifications:

• API 1104 latest edition (Standard for welding pipelines and related facilities).

• American National Standard Institute ANSI B31.8 (Latest edition).

• ASME Code - Section IX welding / brazing qualification.

No circumferential weld shall be located within 150 mm of the center of a support.

All welds shall be marked with waterproof crayon or paint stick by the welders

according to numbers assigned to them by Company/Engineering Consultant at the

time they qualify. Should any welder leave, his number will become void and it shall

not be duplicated on the project. No punch or steel stenciling will be permitted.

Except as otherwise required herein, all welding shall equal or exceed the

requirements of API 1104, Standard for welding pipelines and related facilities, latest

edition.

All welding machines, line-up clamps, machines, cutting torches, and other

equipment, tools, and supplies used in connection with the welding work shall be kept

in good mechanical condition so as to produce sound welds.

All welding electrodes furnished and used by Contractor shall be of an approved type

and quality suitable for pipeline welding acceptable to Company/Engineering

Consultant. All welding electrodes found to be deteriorated, defective, or otherwise

damaged shall be rejected and prohibited from use on the pipeline.


Doc. No. 4985-PA-2022 Page 22 of 49

No cutting or welding on the line pipe, other than that required for making the normal

circumferential joints will be allowed without written permission from


No welding electrode or grounding shall be permitted to arc the pipe except in the

actual bevel being welded.

Procedure & Qualification

Prior to starting of production welding, a welding procedure shall be established in

accordance with API 1104, Standard for welding of pipelines and related facilities,

latest edition, and shall be approved by the Company/Engineering Consultant.

Approved pipe welding procedure shall be recorded in detail as outlined in API

Standard 1104 and be adhered to during subsequent construction. The Contractor shall

obtain a certificate of qualification of welders, from the Company/Engineering

Consultant, before any welding is carried out on site.

Welding procedures which have been established approved and qualified shall not be

changed. Re-qualification shall be required for any change in welding procedure

already established approved and qualified. The entire welding procedure, qualifica-

tion tests shall be conducted in presence of the Company/Engineering Consultant.

Contractor shall organize the test at a fixed place on site to be intimated to the

Company/Engineering Consultant at least one week before the date fixed for these

tests.

Contractor shall, for the execution of welds, designate one or two welders to undergo

the procedure qualification tests to meet the code requirement and the welders

involved shall qualify for production welding on the qualification of procedure test.

The pipes welded at the time of the test shall be two job size nipples free from dirt,

paint, etc. and ends beveled with machine.


Doc. No. 4985-PA-2022 Page 23 of 49

For each procedure test, four specimens shall be removed from the completed joint as

per API Standard 1104 for carrying out necessary mechanical tests (destructive). Each

procedure test shall be macro-hardness tested using Vickers equipment with a 10kg

load. Hardness shall not exceed 300 HV10. All hardness surveys shall be witnessed

by the Company/Engineering Consultant. The procedure qualification shall be carried

out at Contractor's expense.

Welder Qualification

The qualification test of welders shall be conducted strictly in accordance with API

Standard 1104 (latest edition). Test shall be conducted in the presence of the

Company/Engineering Consultant.The welder(s) who have performed successful

procedure qualification test shall be automatically qualified in that procedure.

This qualification shall, in particular, enable to distinguish between welders capable

of executing any pass, root bead, hot pass, filler bead, capping in mainline,

fabrication, tie-ins and repairs.

All the qualified welders shall be given the identification tag consisting of following

information:

• Photographs

• Welder identification symbol

• Welder’s name

• Contractor’s name

Reports

The Contractor shall draw up a report of each qualification procedure which shall

contain the results of all inspections and tests performed on the corresponding welds.

This report shall be signed by the Contractor and the Company/Engineering


Doc. No. 4985-PA-2022 Page 24 of 49

Consultant representative and the Inspection Agency. These documents shall be

available on Site when the welding is performed.

A form of the API 1104 type or equivalent shall be used for recording test

performance conditions and results of the welding procedure qualification test.

Validity

The validity of qualification of a welder shall be maintained subject to the following

conditions:

The welder has worked on identical parts/procedure for total duration of at least 60

days and the partial or total inspection of welds which he has performed, proved the

work to be of high standard.

In case welder leaves the site his identification shall be cancelled.

A qualified welder whose production work is found to be repeatedly defective can be

replaced by other welder. The Company/Engineering Consultant reserves the right to

disqualify such elder.

Any welder who fails the qualification tests or who has lost his qualification during

the course of his work, may after a further training of a minimum of 15 days, take

another qualification test.

Electrode Specification

Welding electrodes shall be sealed in tin packing and only that number of tins opened

on each day that are likely to be consumed during the day. The electrodes/rods must

be free from any trace of oxidation.

Welding electrodes at the job site during construction and open electrodes overnight

shall be stored in ovens to keep the electrodes dry and in good condition.


Doc. No. 4985-PA-2022 Page 25 of 49

The electrodes for API 5L X-52 pipe shall conform to AWS-E-70XX specifications

except that the stringer bead may be made with E-6010 electrode. Different electrodes

may be used if approved in the welding procedure.

The size of electrodes shall be established in the welding procedure.

Welding electrodes should be of acceptable makes such as LINCOLN, ESAB,

PIPEWELD & PHILLIPS. Contractor would be required to obtain

Company/Engineering Consultant’s approval of the selected make.

Production Welding

General

Weld qualification procedure shall be provided to the Company/Engineering

Consultant for approval.

Production welding shall not begin until all the following qualifications have been

performed and found acceptable in accordance with this specification:

• Qualification of welding procedures.

• Qualification of weld repair procedures.

• Qualification of welders and welding operators.

• Qualification of radiographic procedures.

• Qualification of mechanical testing procedure.

The welding conditions that apply to production welding shall be those used for the

welding procedure qualification tests.

Preheating & Interpass Temperature

If preheating is found necessary, the required temperature shall be reached at the joint

and over a distance of a least 76 mm (3”) in all directions from the joint. This


Doc. No. 4985-PA-2022 Page 26 of 49

temperature shall be checked regularly (e.g. using temperature indicating crayons).

These requirements also apply to tack welds.

The interpass temperature is normally not to exceed the maximum temperature

recorded during the Welding Procedure Qualification Test, and restricted to 250 ° C

max.

Tack Welds

Tack welds shall be performed in accordance with a Company/Engineering

Consultant’s approved procedure and by qualified welders. They shall be 75 to 100

mm(3 to 4”) long for O.D. > 12 ¾” and minimum of 50 mm (2”) or 4 times the W.T.

(whichever is less) for OD. < 12 ¾”, to prevent any crack formation at the root of the

finished weld.

Welding Sequence

The second pass (hot pass) shall be made within five minutes (or less) after deposit of

the root pass.

No pass shall be commenced until the preceding pass is completed.

Alignment Clamp

Use of an alignment system inside the pipeline (internal clamp) is preferred.

Internal line up clamp shall not be released until the root bead is 100% complete and

pipe has been properly supported.

External line up clamp can only be removed when root bead is 50% completed in

equal segments uniformly spaced around the circumference of the pipe.

Cleaning

Before welding, the surfaces to be connected shall be cleaned of any trace of mill

scale, slag, rust, grease, paint etc.

Upon completion of each welding pass the weld run shall be cleaned of any trace of

slag and various deposits.

After completion of the welded joint, the surfaces next to the weld shall be cleaned of

any trace of slag, spatters and various deposits.


Doc. No. 4985-PA-2022 Page 27 of 49

Arc Strikes

No arc strikes shall be permitted outside the bevel area. Any accidental arc strikes

shall be ground out then submitted to magnetic particle or liquid penetrant inspections

in accordance with ASME SE-709 or ASME SE-165 respectively.

Post-weld Treatment

No heat treatment is required on completed production welds provided hardness

requirements are respected.

Protection against Rough Weather

The Contractor shall take all necessary measures for protecting the welds and welders

from bad weather conditions (rain, wind, etc.) for the duration of the work. Adequate

protective means and equipment shall be made available on the Site.

Welding Conditions Control

The following parameters shall be checked during welding:

• Preheating temperature (when required).

• Minimum and maximum interpass temperatures.

• Welding current amperage and voltage.

• Travel speed.

The Contractor shall provide all measuring instruments necessary for making these

checks to the satisfaction of the Inspector.

As far as possible, the instruments shall be the same or of the same type as those used

for the procedure qualification performance.

Identification of Welds

After execution and before the inspection, the welded joints are numbered by the

Contractor and furthermore, in the case of piping of pipeline installations, marked on

the drawing.


Doc. No. 4985-PA-2022 Page 28 of 49

In line, each welded number shall be written again over the coating material.

Welders are requested to stamp their identification number on the first in - line welds

they perform and also when a modification is brought in the composition of their

welding crew.

Marking on pipe shall never be made by punching.

Weld Inspection

General

The Contractor shall provide visual inspection of the set-up prior to welding and

whilst the welding is in progress. The Contractor shall provide non-destructive

testing (NDT) to test the finished welds.

The Contractor’s inspection personnel and equipment shall be submitted for prior

approval by the Inspector.

Non-Destructive Inspections

NDT inspector shall have certificate of NDT conforming to ASNT level II or level III

from a recognized institute and have adequate experience in the NDT inspection of

pipeline laying work.

a) Visual Examination

Weld preparations and completed welds shall be visually inspected by the Contractor

and the Inspector.

Once the welding is completed, all welds shall have a uniform outside appearance and

shall blend progressively and without undercut into the base metal. The adjacent

surface shall be cleaned of any spatters or other deposits.

b) Radiographic Inspection

Radiographic inspection using X-ray or gamma-ray methods shall be performed in

accordance with the requirements of API 1104 (radiographic procedure specification,

qualification test, etc.) taking into account the following specific requirements:


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• The Image Quality Indicator (IQI) shall be of the wire type as per DIN 54109

Standard or ISO Standard.

• The geometrical unsharpness shall not exceed 0.2 mm,

• The detection sensitivity shall not exceed 2% of the weld thickness.

• The image density shall be between 2.0 and 3.5.

Each film shall include a weld number as well as figures or letters corresponding to

the weld actual external marking.

All radiographs shall be submitted for examination and acceptance by the


The Contractor shall submit the radiographic inspection report to the

Company/Engineering Consultant that it may be approved as soon as possible.

c) Inspection Requirements

All welds shall be visually examined.

Visual examination of butt welds shall essentially be carried out whilst the weld is

still above the minimum interpass temperature recorded in the qualified welding

procedure, so that any remedial work necessary to the capping pass can be carried out

before non-destructive testing.

Radiograph of welds using X-ray or gamma-ray methods shall be carried out by the

Contractor in accordance with the following schedule:-

Non-Specific Welds

All double-joint butt welds and running field butt welds shall be 100% radiographed

whenever any one of the following conditions applies:-

1. The start or recommencement of each and every different welding procedure by a

welder or group of welding operators working together as a team.

2. Whenever a new root run welder is assigned to or within a team of welding

operators.


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3. When production welding by any operator or team of operators recommences

after a cessation of more than 72 hours for whatever reason.

This 100% radiography shall be maintained for 100 joints or two days work

performed at the normal rate, whichever is the greater.

If it is agreed by the Company/Engineering Consultant and the Contractor and the

Inspection Agency that sound welds are being consistently produced and any defects

are within the limits of acceptability, then the level of radiography may be reduced to

10%. The reduction shall be effected in the number of welds and the full length of

each weld chosen for examination shall be radiographed. The Company/Engineering

Consultant will select welds to be radiographed following visual inspection.

During operation of 10% radiography, if the radiograph of any weld joint shows a

defect requiring either a repair or a cut-out, then the whole of the adjacent weld joint

on each side of the defective weld joint shall be radiographed by the Contractor. If in

so doing, any additional defects necessitating either a repair or a cut-out are shown to

be subjected to full radiographic examination and 100% radiography shall be re-

imposed on further welds produced by the welding team concerned.

The period of 100% radiography shall continue until the Company/Engineering

Consultant. and Contractor again agree that sound welds are being consistently

produced by the welding team concerned.

Specific Welds

The following specific butt welds shall be subjected to 100% radiographic tests.

1. Within populated areas such as residential sub-divisions, shopping centres and

designated commercial and industrial areas.

2. River, lake and stream crossing within the area subject to frequent inundation; and

river, lake and stream crossing on bridges.


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3. Railway or public highway rights of way, including tunnels, auger bores, bridges

and overhead railway and road crossing.

4. Welded joints to valves, flanges or other fittings and specials, insulating flanges

and anchor flanges.

5. Connecting joints on pipes of different wall thickness.

6. Tie-in joints.

7. Welds which have been wholly or partially repaired.

8. Any weld performed to qualify a welding procedure or a welder.

The Company/Engineering Consultant reserves the right to carry out magnetic crack

detection or ultrasonic examination of any weld if this is considered necessary to

assist radiographic interpretation or to determine the soundness of the weld.

Ultrasonic testing shall be performed using written procedures, equipment and

operators approved by the Company/Engineering Consultant.

The Contractor shall perform a magnetic particle or liquid penetrant inspection at any

time upon the request of the Inspector. These inspections shall be performed

according to ASME SE-709 and ASME SE-165 respectively.

Extent of Radiographic Inspection

Upon completion of the works, all radiographs shall be handed over to and become

the property of the Company/Engineering Consultant..


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Weld Acceptance Criteria

The weld acceptance standards of API 1104 (Latest Edition) shall apply to the visual

and non-destructive inspections (radiographic, etc.) for welding procedure

qualification tests, welder qualification tests and production welds.

The Inspector on Site shall be sole judge of weld acceptability and his decision is

final.

Repair & Removal of Defects

Welds which do not meet the acceptable standards of this specification, shall be cut

out at the Contractor's expense by removing a cylinder of pipe containing the weld, or

with the prior approval of the Company/Engineering Consultant..

Cutouts and repairs shall be made by the Contractor as soon as possible.

Repairs may normally be allowed, at Company/Engineering Consultant’s discretion,

under the following conditions:

• Where there are no cracks in the weld.

• Where the segment of weld to be repaired was not previously repaired.

• Where the weld is inspected after repairs by the method used to originally

inspect the weld.

Defect removal: Weld defects shall be removed by grinding. The repair cavity shall

be of sufficient size to allow adequate access for welding.

Cleaning: The requirements for cleaning of weld beads shall also apply for repairs.

Arc burns shall be removed by grinding. Grinding shall have a smooth contour. After

grinding, the remaining wall thickness in the area will be verified by the

Company/Engineering Consultant. and shall not be less than 90% of the nominal wall

thickness


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If the thickness is less than that acceptable, the Contractor shall cutout a cylinder of

pipe containing the arc burn and replaces it.

10.0 LOWERING IN

• Pipe shall not be lowered into the trench when, in Company/Engineering

Consultant’s opinion, the temperature is such that damage to coating may result.

• All skid marks and other possible places of damage to the coating shall be

checked with a holiday detector and damaged area properly repaired before the

pipe is finally lowered into the trench.

• The distance between two side booms shall not exceed then the

Company/Engineering Consultant procedures while lowering. The coated pipes

shall be lifted with non-abrasive nylon belts to prevent the coating damage.

• Coated pipe shall not be placed in the trench until bare field joints have been

coated as per by coating supplier recommended Practice and cave-ins, plugs, hard

clods, stones, skids, welding rods, etc., have been removed and padding has been

placed. Coated pipe shall not be dragged along the ground. If coating is damaged

due to mishandling it shall be repaired as per procedure recommended by coating

supplier recommended Practice.

• If water or mud is found in the ditch, whenever possible, proceed with pumping

out of water and cleaning of the ditch before lowering-in takes place.

• In case it is not possible to drain the water from the ditch, the Contractor shall

submit for the Company/Engineering Consultant’s approval, all necessary

measures in order to have the pipe normally rest on the bottom of the ditch.

Pigging and Air Testing

• All weld segments shall be air pigged and soap tested at 90 psig before lowering

into the trench. All weld repairs shall be completed and sections shall be cleared

radio graphically before pigging and air testing.


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11.0 TIE-INS

The pipe shall be cut so as to permit a good line-up and weld. Unless pipe has been

placed in the ditch and shaded, tie-ins shall not be made at the temperature less than

10ºC. Bell hole welding shall be done in bell holes which provide adequate clearance

to enable the welder to exercise normal welding skill and ability. The overlap of pipe

strings at tie-in shall be at least 2 meters.

• The weld seams of the adjoining pipes shall offset by 30% or 76 mm (which ever

is greater). If not possible, a spool piece of not less than 1.2 meters in length shall

be inserted.

The minimum length of pup that shall be used is 1 meter. All pups of 1 meter or over

shall be moved ahead and welded into the pipeline daily. Pups under 1 meter shall be

gathered up and delivered to the Company/Engineering Consultant's nearest storage

area.

12.0 BACK-FILLING OF THE TRENCH

The Contractor shall backfill the trench after the pipe is in place as set forth in the

following: The trench shall not be back-filled until Company/Engineering Consultant has

approved the fit and cover of the pipe in place in the trench and has approved starting

the back-filling operation.

The trench shall be back-filled to 0.2 meter initially. The backfilling shall be such

that initial back-filling shall be performed as soon as possible after the trench is

approved for back-filling.

After the initial backfill has been placed in the trench to the level of the surrounding

ground the Contractor shall compact the backfill by making as many passes as

necessary with a rubber tired compacting device or as per Company/Engineering

Consultant’s approved procedure.


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After the initial backfill, the remaining material excavated shall be neatly crowned

over the trench and lightly compacted. The crown remaining shall be large enough in

Company/Engineering Consultant’s opinion to prevent the formation of a depression

in the soil when the backfill has settled into its permanent position.

The backfill shall be crowned to a height of not less than 0.3 m, after the settlement.

Spoil that cannot be used in the backfill shall be considered as surplus and shall be

removed from the ROW by the Contractor. Contractor shall dispose off the spoil in a

manner and at locations satisfactory to Company/Engineering Consultant.

Where the trench has been dug through driveways, walkways, roads, dikes, etc. the

backfill shall be thoroughly compacted by mechanically tamping the fill material into

place in properly wetted layers not thicker than 150mm. The surface of such areas

shall be restored to their original condition in a manner satisfactory to

Company/Engineering Consultant and the responsible authorities.

Trenches crossing ditches shall be back-filled with the material excavated from the

trench at that location except that in locations where the excavated material in

Company/Engineering Consultant's opinion is not suitable for back-filling, the

Contractor shall provide and use suitable material from another source. Ditches with

lined or otherwise improved surfaces shall be resurfaced in a manner satisfactory to

and approved by the Company/Engineering Consultant and the responsible

authorities.

Where the excavated material is rock, gravel or other hard materials which in

Company/Engineering Consultant ‘s opinion, would damage the pipe or pipe

insulation the Contractor shall furnish and place sufficient sand or soft earth to give

the pipe protective cover before the trench is back-filled with the hard materials. Also

Rock shield is to be provided for the protection of the pipe and coating.

Rock boulders not larger than 1 cubic foot volume may be placed in ditch after the

padding is in place; however, in cultivated areas, no rocks shall be placed on top of


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the backfill which would interfere with ploughing or cultivating. All surplus rock

shall be disposed off to the satisfaction of the Company/Engineering Consultant, land

owner and/or tenant at no additional compensation.

When back-filling across irrigated fields, Contractor shall provide furrows across

pipeline right-of-way as required by the Company/Engineering Consultant, land

owner or tenant to direct the flow of water into normal irrigation furrows. Extra cover

is required at vertical, horizontal and composite preformed bends in some cases.

In areas where pipeline in land on sloping ground, the backfill/trench shall be

stabilized as per details shown in Alignment sheets.

The Contractor shall provide diversion ditches and/or culverts for floodwater in order

to keep the pipeline from acting as a dam and channel bank.

Spot back-filling is required to tie down, and restrain the pipe in the ditch after it has

been lowered in. Spot back-fills shall provide full-specified cover and shall cover all

preformed bends a distance of 6 meter to each side of the centres of the bends. The

maximum clear distance between spot back-fills shall be 20 meter. Spot back-fills

shall cover the pipe for at least 5 meters along the pipe. Completion of back-filling

shall follow spot back-filling as closely as practicable.

Backfilling shall be carried out immediately after lowering-in, within 48 hours, in

order to give the pipe a natural anchorage, avoiding long exposures of the coating to

significant variations of temperatures, harmful spells of adverse weather conditions

and caving-in of the trench walls.

13.0 SPECIAL MECHANICAL PROTECTION

The Contractor shall apply an additional mechanical protection around pipeline in

case where there is a danger of damage to pipeline or pipeline coating.


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These cases may originate due to pipeline laying in rocky areas and other concrete

works regarding pipelines.

Mechanical protection is also used to protect the pipeline coating from accidental

abrasion and from subsequent abrasion during lifetime of the pipeline.

Characteristics

• Mechanical protection shall be a flexible padding designed specially for the

protection of the corrosion coating on pipeline.

• Mechanical protection shall be flexible to shape and cut easily. It shall remain

flexible at lower temperatures and its application shall not be affected by colder

temperature.

• It shall be unaffected by wet or extreme weather conditions.

• Mechanical protection shall provide the padding required for pipe coatings

without the concern of blocking out cathodic protection or it must have zero

dielectric properties.

• It shall absorb impact of uneven backfill material and protect pipe from protruding

rock in trench. Also, it shall minimize abrasion of coating from pipe movement in

ground.

• The protection shall be lightweight and shall be available in appropriate sizes for

optimal match to pipe diameter.

• The protection shall be longer and wider than the set-on weight and any other

concrete works.

• In any case, its thickness shall be at least 10 mm.

• The Contractor shall specify the following properties of the protection along with

the sample, prior to the Company/Engineering Consultant’s approval:


Doc. No. 4985-PA-2022 Page 38 of 49

• Weight

• Tensile strength

• Toughness

• Impact resistance

• Roll width and length

• Elongation

14.0 CROSSINGS

• This section refers to all the details regarding Pipeline crossing roads, highways,

canals, distributaries etc. The details primarily reflect the minimum requirements

to ensure safe crossings of pipeline through the above-mentioned crossings.

Contractor shall use such equipment and procedures that shall not cause damage

to any structure or facility intercepted by or adjacent to the crossing.

• The trench on either side of the tunnel/bore shall be de-watered and the inside of

the tunnel shall be cleaned before the casing pipe (for Cased Crossing) and carrier

pipe are pulled or pushed into place.

• The pipe shall be pulled or pushed into the tunnel/bore in such a manner that the

pipe is centered in the tunnel/bore, the carrier pipe coating is not damaged, and the

rate of travel into the tunnel/bore is uniform.

• Crossing of all underground pipes, cables, etc. shall be Contractor’s responsibility.

The Contractor is responsible for obtaining necessary permission, if required, and

coordination with relevant authorities during construction.

• Carrier pipe, under metal roads, tracks and any water stream shall be installed

with minimum cover of 1.2 m for Track and 2m for the Nala Crossing, as

measured from the top of the pipe to the top of the surface.

• All crossings shall be as per relevant Drawings.


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Contractor’s scope shall include supply and installation of the Plastic Grating. Also,

Contractor shall provide detail engineering design for the Crossing Design which

includes detail design calculation, Design Analysis Reports and Drawings for

Construction and Installation.

15.0 SPECIAL ITEMS

Installation of the following equipment shall be included as a special item in pipeline

construction:

• Scraper Traps

• Fitting

• Insulating Flanges

• CP stations

They shall be installed in accordance with the applicable Drawings.

16.0 APPURTENANCES

Appurtenances include test lead assemblies for cathodic protection of pipeline,

abutment, markers, etc.

The Contractor shall supply the material and install the appurtenances in accordance

with the drawings.

In addition the Contractor shall be required to carryout pipeline protective works in

terrain liable to erosion which include but are not limited to, stone pitching,

abutments, bunds etc.

17.0 FINAL TESTING

The Contractor shall hydrostatically test each completed section of the pipeline as per

the requirements set forth in ANSI B.31.8, latest edition, except the test pressure


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which will be specified by the Company/Engineering Consultant. The Contractor

shall submit the test procedure to the Company/Engineering Consultant for approval

before starting hydrostatic test.

The Contractor shall hydrostatically test each segment according to the wall thickness

and pressure as per API 5LX-52, API/1110 and ANSI B31.8.

Test pressure for heavier wall thickness at crossing shall be the same as that for the

adjoining pipe and should be pre-tested.

All appurtenances, test headers and crossings shall be pre-tested prior to installation.

A minimum of two underground temperature measurement points shall be established

accurate to 0.1oC, two days prior to a test commencing, and read at 12 hour intervals.

In general, the length of each test section shall be specified by the

Company/Engineering Consultant’s Representative. Contractor may recommend

length of sections for company/engineering consultant’s approval.

Valves shall not be subjected to differential pressures greater than the maximum

operating pressure while in closed position. All permanently installed mainline and

bypass valves shall be in the open position during the test.

The test pressures for each section shall be specified by Company/Engineering

Consultant, but will not exceed 98%, nor be less than 90% of the specified minimum

yield strength of the pipe.

Before filling the line with water for hydrostatic test, the line shall be cleaned by

passing cleaning pig.

The line shall be cleaned by running of cleaning pigs, at least one pig with gauge

plate. The cleaning shall be done with water. The gauging pig shall be equipped with


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a metal “gauging flange”. The diameter of the gauging plate shall be 96% of the pipe

ID. The material of gauging flange shall be steel.

Each section shall be brought up to test pressure and stabilized. A calibrated and

certified (within the previous six months) recording pressure gauge, dead weight

tester and thermometers shall be furnished by the Contractor to verify the test. The

unit of pressure measurements shall be Bar or PSI and all pressure measuring

instruments calibrated in the same unit. The Contractor shall record all data required

by any or all Governmental Agencies, Acceptance Authorities and

Company/Engineering Consultant and shall prepare and submit records and reports in

as many copies as may be required to these organizations.

The Contractor shall furnish clean fresh water and all equipment, labor, materials,

services, supervision and supplies required for the hydrostatic test, except any

chemicals required treating the test water. All chemicals shall be provided by the

Contractor and not by the Company/Engineering Consultant. When so required, the

Contractor shall inject treating chemicals at the fill point in such amounts and at such

rates as specified by the Company/Engineering Consultant. All water shall be filtered

through a mechanical filter to remove all solids exceeding 250 microns in diameter.

The test pressure shall be attained and maintained for 24 hours and recorded every

hour by installing a deadweight tester and pressure recording instrument in the section

at both ends isolated for the test. Unexplainable pressure drops or increases during the

test period shall not be acceptable to the Company/Engineering Consultant. A test

shall be extended if necessary until such time that the section is proved leak-tight or

the evidence for a leak is established by comparison of pressure changes with those

anticipated due to underground temperature fluctuations. The Contractor shall be

responsible for providing pig launching and receiving traps and all necessary fittings

and equipment for testing purposes. Test segment shall be filled continuously until

clear water is obtained at the discharge end.


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Leaks, or breaks in the pipeline during the test which are a result of defective

materials furnished by the Company/Engineering Consultant shall be located and

repaired by the Contractor, but cost thereof shall be paid by the Company/Engineering

Consultant as extra cost.

After each section has been tested, it shall be tied into the previously tested section or

sections and the areas of damage cleaned up. Water removal from the completed

system will be done by the Contractor using compressed air as the propelling fluid for

running scrapers or spheres, until such time when no water comes out ahead of the

pigs and pipeline is reasonably clear of all water.

Leaks, or breaks in the pipeline during the test which are a result of defective

materials or workmanship furnished by the Contractor shall be located and repaired

by Contractor at its own cost.

The Contractor shall have the sole responsibility for disposing off the test water at tie-

ins leaks or breaks, and at the dewatering points. Tie-ins shall be done in such a

manner that the convenience and safety of the general public is protected and in a

manner satisfactory to the responsible authorities. Any damage resulting from careless

or improper disposal of water shall be rectified and paid for by the Contractor.

Continuous two way communication, preferably by voice, radio, shall be maintained

between filling pumps, test pumps, scraper traps, recording pressure gauges and all

other significant points along the portion of the line being filled or tested.

Communication equipment shall be made available for use by the Contractor.

The charts from the pressure-recording and temperature reading instruments during

the pressuring and test operations shall be preserved for Company/Engineering

Consultant as official record of tests. The charts shall be properly identified and

signed by the Contractor's Superintendent as being true records of the test involved.


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The chart or charts shall cover the interval of the test from the time that the pressure

exceeds 1 Bar until a successful test has been completed and the pressure has been

reduced below 1 Bar.

All failures shall be numerically and chronologically dated and reported with

pertinent description and data.

The Contractor shall properly clean the pipeline after final tie-in by air pigging. All

the testing and cleaning procedure shall be done to the entire satisfaction of the


After the hydraulic testing is complete, Contractor will run magnetic bi-directional

disc pigs and or any other suitable cleaning pigs through the pipeline until such time

that all construction debris, mud, sand, stones and foreign material is completely

removed from the pipeline.

18.0 PAINTING

All exposed above ground metal surfaces on piping, structure, equipment, or attached

appurtenances shall be painted by the Contractor with equipment and labor supplied

by the Contractor as per the painting specification.

19.0 CONCRETE

All concrete works required for pipeline construction shall be carried out by the

contractor including supply of all material, labor, equipment and machinery. The

work shall be carried out in accordance with the project specification for concrete

works.

20.0 WET AREAS, SWAMPS DITCHES AND AREAS SUBJECT TO FLOODING

The Contractor shall perform all the work necessary to install the pipelines across wet

areas, swamps, ditches and areas subject to flooding.


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21.0 LINE MARKERS AND CATHODIC TEST ASSEMBLIES

Line markers shall be supplied and installed at every 500m, upstream of every road,

track, highway, nala, distributaries, and river crossings in accordance with the

requirements of drawings.

Cathodic Protection Test Assemblies shall be installed as per the relevant alignment

sheets along the buried pipeline sections in accordance with the relevant detail

drawings.

22.0 FINAL CLEAN-UP OF THE CONSTRUCTION RIGHT-OF-WAY AND

PERMANENT JEEPABLE TRACK.

The Contractor shall restore the construction right-of-way as near as practically

possible to its original condition.

All surplus and defective materials supplied by the Company/Engineering Consultant

shall be collected by the Contractor and delivered to the Company/Engineering

Consultant 's specified location.

All surplus and defective material supplied by the Contractor and all trash, refuse, and

spoiled materials shall be collected and disposed off by the Contractor.

All loose rock exposed by the construction operations, which is scattered over the

right-of-way and adjacent property shall be removed and hauled by the Contractor.

The permanent Jeepable track both in shared and non-shared section of RoW shall be

maintained and restored to Jeepable condition. All water courses, depression, etc.

shall be provided with proper crossings using appropriate size RCC flume pipes and

land filling/cutting so as to make the entire RoW Jeepable in one continuous stretch.


Doc. No. 4985-PA-2022 Page 45 of 49

23.0 COMMISSIONING AND START-UP

This part of the specification defines the various responsibilities of the Contractor for

the commissioning of the complete pipeline system and lists the preparatory work to

be performed and the requirements to be met before the pipeline system can be

commissioned.

The operations personnel of the Company/Engineering Consultant shall be involved in

pipeline commissioning within the framework of the specified training program

Contractor’s Responsibilities:

The Contractor shall prepare a commissioning plan for each part of the pipeline

system in consultation with the Company/Engineering Consultant. The Contractor

shall determine the work, services, equipment and personnel required for

commissioning and shall be responsible both for the co-ordination of commissioning

and for liaison with the Company/Engineering Consultant. The Contractor shall

instruct the personnel to be deployed for commissioning about the commissioning

procedures to be used and shall cause such personnel to give an undertaking to

comply with all safety regulations applicable to commissioning.

The Contractor shall provide all personnel and equipment required for the

performance of all work required for commissioning in accordance with the

commissioning plan. The services to be performed by the Contractor for

commissioning shall include without limitation:

• Take an active part in preparing the commissioning plan in accordance with sub-

section 26.2.1 above,

• Supply and provide any equipment, facilities, etc. which may be required for

commissioning, manage and co-ordinate commissioning work and monitor

compliance with safety regulations,


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• Install, test, inspect, calibrate and commission instruments, control system, panels,

supplies in strict accordance with specifications prior to commissioning of the

pipeline system,

• Install any additional lines and facilities which may be required for

commissioning including such lines and facilities which may be required for the

disposal of water or for the treatment of waste products,

• Procure and supply (if not provided by the Company/Engineering Consultant fill

and dispose off methanol and nitrogen, (if required) or any other drying agent

including the provision of any facilities which may be required for the handling

of methanol and nitrogen or any other drying agent and cause suitable safety

precautions to be taken in handling such products,

• Supply transport equipment and mobile lifting equipment with all accessories

required,

• Supply and install pressure indicators and pressure recorders required for the

works hereunder if required,

• Operate mechanical and electrical implements in accordance with the

commissioning plan,

• Provide personnel required for the works hereunder including personnel for the

observation and maintenance of the pipelines and for the recording, evaluation

and documentation of meter reading taken during the works hereunder,

• Provide a standby crew with suitable specialists and equipment to perform any

repairs or additional work which may become necessary during commissioning,

• Prior to the commencement of commissioning works, the Contractor shall:

- Install and level all mechanical equipment cold-aligned, subjected to no-load tests

and load tests (if practical), and make ready for operation. Fresh charges of


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lubricants, coolants and fuels shall have been installed according to

manufacturer's instructions,

- Ensure that all certificates required for commissioning are available,

- Check which environmental and other regulations must be complied with during

commissioning and obtain any necessary approvals from authorities,

- Select and name persons to contact for work on the pipelines and work on the

stations,

- Ensure ease of access to all plans, equipment, etc.,

- Ensure that adequate means of communication (telephone, radio) are available for

the commissioning work,

- Calculate, obtain and remove the methanol or nitrogen required as a safety batch

in front of product medium, separated by scrapers in pipelines,

- Train personnel for the commissioning operation, patrol the route and check the

effectiveness of radio communications,

- Provide all fire fighting and other safety equipment required for the

commissioning operation,

- Provide all explosion-proof equipment required for the commissioning operation.

- Supply all protective clothing which may be required for the works hereunder,

- Make a final clean-up after work is completed and accepted by the

Company/Engineering Consultant. All remaining scrap, debris, waste, surplus

materials, tools and equipment shall be removed from the job site, except for the

equipment required for maintenance in the guarantee period, in accordance with

the Contract. All surplus materials shall be returned to the Company/Engineering

Consultant 's warehouse,


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- Bear all costs of the works hereunder including the costs of the supply,

transportation, connection and erection of all equipment required therefore,

- Keep complete records of the works hereunder.

Before any pipeline section is commissioned, the following conditions shall be met

and the Contractor shall carry out a review to ensure that said conditions have been

met .A test of functions shall be made to ensure that all flow paths which may be set

on the pipeline including station inlet and outlet lines during commissioning can

effectively be set,

• Any installation, commissioning and operation instructions issued by the supplier

or manufacturer of any equipment or facilities installed in or in the pipeline

section shall be available on site and shall be complied with,

• Check shall be made to ensure that all equipment which must be installed in a

specific direction with reference to the direction of flow has been installed in the

correct direction,

• The electrical control installation and instrumentation shall have been tested and

accepted in accordance with specifications. Proper rotation of motors, polarity,

and circuit continuity and insulation resistance checks shall have been completed.

Functional checks of electrical and control circuits shall have been completed,

• Explosion-hazard areas shall be determined and marked with appropriate signs.

The Contractor shall ensure that all personnel comply with safety precautions laid

down for explosion-hazard areas including areas which are designated as

explosion-hazard areas temporarily (e.g. during methanol or any other drying

agent filling and disposal),

• An emergency plan shall be prepared detailing all immediate actions to be taken

in the case of a fire or an environmental pollution incident,


Doc. No. 4985-PA-2022 Page 49 of 49

• Functional checks of alarm and shut-down systems shall be completed and

accepted by Company/Engineering Consultant prior to commissioning.

General Start-up Conditions:

• Contractor shall provide a complete operating team, including necessary vendor

representatives capable of starting up and operating the plant under the

supervision of Company/Engineering Consultant's operating personnel. It is

required that Company/Engineering Consultant operations personnel grant prior

approval to Contractor before any operating decisions are implemented. It will be

Contractor's responsibility to not only prove the operation of the new facility, but

also to train Company/Engineering Consultant operating and maintenance

personnel in the proper procedures for safe, reliable facilities operation.

• Instrumentation shall have operated correctly in the manner intended by the

project specifications. It shall have maintained the plant operating at the required

set points, allowed safe start-up, running and shut-down. It shall have monitored

the plant in such a manner that it provided the plant operators with a clear

understanding of the plants condition at all times. Emergency shut- down systems

shall be tested for proper operation.

SCOPE & SPECIFICATION VALVE INSTALLATION Project: UCH-II Development Project Owner: Oil & Gas Development Co. Ltd. Prepared by: IN Checked by: MMM Approved by: TH Revised by: -



Job No. 14 – 4985

Spec. No. 4985-PA-2023

Sheet 1 of 3 Rev. 0

TABLE OF CONTENTS

1.0 VALVE INSTALLATION ...................................................................................... 3

Specification for Valve Installation UCH-II Development Project

Spec. No. 4985-PA-2023 Page 3 of 3

1.0 VALVE INSTALLATION 1) The valves shall be kept closed at all times before installation for protection purpose of the valve seats.

2) During welding operations of butt-welded end valves, the valves shall be opened and their seats properly protected.

3) Valves flanges or screwed connections shall be protected by proper means before erection.

4) During installation undue stresses shall be avoided by proper alignment of piping section, so that the free moving of gate or ball between the seats will be preserved.

SPECIFICATION FOR APPLICATION OF UNDERGROUND PIPE & FITTINGS ANTI-CORROSION FIELD WRAPPING

Project: UCH-II DEVELOPMENT PROJECT

Client: OIL & GAS DEVELOPMENT COMPANY Prepared by: NJ Checked by: MK Approved by: FS Revised by: -



Job No. 14 – 4985

Spec. No. 4985-PA-2024 Sheet 1 of 8 Rev. 0

Specification for Application of Underground Pipe and Fittings Anti Corrosive Field Wrapping


Spec. No. 4985-PA-2024 Rev. 0 Sheet 2 of 8

TABLE OF CONTENTS

SECTION NO.

DESCRIPTION SHEET NO.

1.0 SCOPE ............................................................................................3

2.0 REFERENCE CODES AND STANDARDS ...............................4

3.0 APPLICATION REQUIREMENTS ............................................5

4.0 INSPECTION .................................................................................8




1.0 SCOPE This Specification contains the general requirements applicable to the application and testing of exterior anti-corrosion wrapping, in field, to the fittings, bends, joints, flanges and any un-coated pipe lengths of underground piping for the UCH-II Development Project.




2.0 REFERENCE CODES AND STANDARDS This specification should be read in conjunction with the following specifications: 4985-PA-2000 Specification for Piping Fabrication and Installation ISO 8501 Pictorial Cleanliness Standard In case of deviations from this Specification or any referenced specification the contractor shall bring the matter to the Company's attention for resolution and approval in writing.




3.0 APPLICATION REQUIREMENTS

3.1 General Application Requirements

The responsibility for dry storage and handling of coating and wrapping materials for protective coating shall lie with the contractor. Material which becomes wet and unusable shall be replaced by the contractor at no expense to the Company. The completed coating shall be solid, free of wrinkles, buckles, pockets and tears and thoroughly bonded to the pipe throughout.

3.2 Specific Application Requirements The Densolen S-40 and Denso Mastic system in conjunction with the Densolen HT primer, or an equivalent system approved by the Company may be used.

3.2.1 Surface Preparation The Densolen coatings specified require the removal of all loose deleterious surface materials and surface grease in accordance with Class St 1, I.S.O. 8501. This can normally be achieved by mechanical wire brushing followed by a solvent wash.

3.2.2 Primer Application

The Densolen Primer HT shall be used in conjunction with both the Densolen S-40 Tape as well as the Denso Butyl Mastic Strip. Application shall be made by brush, or roller to a dry film thickness of 60 microns to 10 microns. Primer shall be allowed to tack dry prior to application of the S-40 tape or Butyl Mastic.

3.2.3 Welded Joint-Tape Application The weld and surface of the pipe shall be cleaned as specified in Section 3.2.1, to 150mm each side of the weld, where the edge of the shop coating will be encountered. The surface of the shop coating shall then be cleaned back a further 100mm from the edge of the coating, making a total of 500mm along the pipe to which the field wrapping shall be applied. The edges of the existing shop coating shall be feather trimmed so as to make a smooth transition from the shop coating to the pipe.




A single coat of the Densolen HT Primer shall be applied as specified in Section 3.2.2. The Densolen S-40 Tape shall be applied in a spiral fashion incorporating a minimum of 55% overlap to ensure a double tape thickness at all times. End laps occurring at the end of individual rolls shall be a minimum of 1/3 of a turn. The Densolen S-40 Tape system should be applied by use of a Densomat 1 wrapping machine which shall ensure that the coating is applied free of creases and air bubbles and has sufficient tension to enable full amalgamation between the butyl layers.

3.2.4 Fittings and Appurtenances - Mastic Application The surface of the pipe shall be cleaned, as described in Section 3.2.1, to 150mm from the weld or appurtenance. The existing coating shall be feather trimmed end cleaned a further 100mm back from the edge of the shop coating, as described in 3.2.3. Primer shall be applied as specified in Section 3.2.2. The Denso Butyl Mastic Strip is a mouldable material, supplied :s: 95mm wide x 3mm thick x 1 Om long rolls. The mastic shall be wrapped or placed in strip form allowing a 25mm overlap onto itself to ensure no missed areas, as well as a minimum 100mm overlap onto the neighboring coating system. The mastic shall be applied in a method to provide 100% contact with the substrate requiring protection ensuring that all overlap areas are pressed firmly into place.

3.2.5 Field Repairs Any holes, defects, discontinuities, pinholes, torn, abraded or mutilated spots found at site in the original coating shall be repaired. Refer to Section 4 for the Inspection Procedure. If the damaged area is large, the original coating shall be removed back 50 to 100mm. The pipe shall then be cleaned to the coating limits in accordance with 3.2.1. The remaining coating shall then be feather trimmed and cleaned a further 100mm back




from the related circumference. The Densolen S-40 Tape and Primer HT shall be applied as described in Section 3.2.3.




4.0 INSPECTION

Taping and mastic coating over the entire length of each field joint, field repair, underground appurtenances and fittings shall be inspected by means of a Holiday Detector (electrical inspection device), which shall be approved by the C All holes or defective coating discovered shall be repaired and tested again. The calibration of the Holiday Detector shall be carried out regularly to the satisfaction of the Contractor. The Detector shall be a Contractor approved 8 to 10 kilovolt DC Holiday Detector. The Holiday Detector Probe shall be a brass bristle brush. All phases of the work covered by this Specification shall be subject to the approval of an Inspector to be appointed by the Company. The Company's Inspector shall be free to visit the site when and where ever any work to which this Specification applies is in progress. Any faults found in the application of the wrapping shall be rectified by the contractor at his expense.

SPECIFICATION FOR FIELD CALLIBRATION AND PRESSURE SAFETY VALVE



Job No. 14 – 4985

Spec. No. 4985-PA-2026

Page 1 of 4 Rev. 0

UCH-II Development Project Specification for field calibration and pressure safety valve


TABLE OF CONTENTS

1.0 SCOPE .......................................................................................................................... 3



1.0 SCOPE This document covers the procedure for the field-testing and calibration of pressure safety valves and thermal relief valves. These valves shall be tested in the field or in the contractor workshop prior to installation on their permanent places. All tests on Safety Relief Valves shall be recorded on the test sheet and the signature of witness shall be obtained. The Relief Valves shall be tested in two stages: 1) Popping & Reseating 2) Seat Leakage Test

1.1 Popping & Reseating a) Before popping the Relief Valve the outlet flange cover shall be removed.

b) The Inlet Nozzle shall be wiped clean prior to testing.

c) The Relief Valve “Cold Set Pressure” shall be ascertained and entered on the

Test Record Sheet. This pressure should be found on the valve data plate or on the Valve Data Sheet.

d) The Test Pressure shall be increased slowly until the Relief Valve is observed to

pop and the pressure (as indicated on the test gauge) shall be noted on the test record sheet. If the difference between the measured popping pressure and the cold set pressure is outside acceptable tolerances, the valve setting shall be adjusted in accordance with the manufactures instructions.

e) The test pressure shall then be lowered and the reseating pressure noted and

checked that it agrees with the manufactures instructions.



1.2 Seat Leakage Test

This test procedure is summarized as follows: a) Immediately after the popping test the test pressure shall be lowered and held at

10% below the set pressure (or 0.35 bar g minimum).

b) The body cavity shall then thoroughly dried with instrument air.

c) The valve outlet shall be observed for 10 minutes for leakage.

d) Failure of leakage test shall be corrected by dismantling the valve and lapping the disc and seat in accordance with the manufacturers instructions. Then retesting as per Section – 1.

e) After testing the valve shall be identified by a suitable colored sticker.

SPECIFICATION FOR CHEMICAL CLEANING


0 ISSUED FOR BID 28/11/12 R Description of Revision Date Revised Page

Nos.

Job No. 14 – 4985

Spec. No. 4985-PA-2027

Page 1 of 8 Rev. 0

UCH-II Development Project Specification for Chemical Cleaning


TABLE OF CONTENTS

1.0 SCOPE .....................................................................................................3 2.0 PURPOSE ................................................................................................4 3.0 RESPONSIBILITY OF THE PC CONTRACTOR .................................5 4.0 GENERAL CONDITIONS FOR CHEMICAL CLEANING .................6



1.0 SCOPE

This specification covers the requirements for chemical cleaning of equipment & piping for UCH II Development Project.

This specification is general and gets forth the basic guidelines and conditions for chemical cleaning; however, the PC Contractor has the responsibility of developing a detailed procedure and of supervising and monitoring its use.



2.0 PURPOSE

• Certain pieces of equipment & pipes must be chemically cleaned to remove mill scale, dirt, greases used as rust preventatives.

• Chemical cleaning will generally be done after completion of unit construction.

If cleaning is done prior to completion of construction, the cleaned equipment must be protected from atmospheric exposure and entry of any outside debris or dirt.

• The PC Contractor shall be responsible for the selection of the chemicals, which

selecting the chemicals, the Contractor shall consider material of the piping and the equipment to the cleaned. Such chemicals shall not be used which has negative effects on the piping and equipment material to be cleaned. The PC Contractor shall be responsible to demonstrate the suitability of chemical to be used by appropriate tests.

• If hydrocarbon feed is not to be charged to the unit within a few hours after the equipment & pipes is cleaned, the cleaned equipment & piping should be filled with nitrogen and blinded off. If startup is to be delayed longer than two weeks, the nitrogen purge may be continued, provided the system is monitored daily to maintain a positive nitrogen pressure. As an alternate, the system may be filled with water containing a passivating material, which shall be drained before startup. CAUTION: The effects of the passivating solution on the equipment and specific requirements of the process must be carefully considered and the selection of such chemicals shall be done after getting approval from the OGDCL/Engineering Consultant.



3.0 RESPONSIBILITY OF THE PC CONTRACTOR 3.1 The PC Contractor shall accept the responsibility of proposing and carrying out an

acceptable and proven procedure for the entire cleaning operation. This shall cover all applicable steps in detail, such as flushing, degreasing, chemical cleaning, neutralizing, passivating, dean water flushing, draining, and safety. A copy of the procedure shall be submitted to OGDCL/Engineering Consultant.

3.2 The PC Contractor shall use inhibitor, detergent, emulsifier, or other addition agents in accordance with accepted practice and experience, and to suit the equipment layout and metallurgy, of the unit.

3.3 The PC Contractor shall be responsible for the arrangement of equipment considering

pumps, chemical storage tanks, temporary piping connection blinds etc necessary for the job completion. The PC Contractor shall inform the OGDCL/Engineering Consultant about chemical or trade names and required quantities of all chemical cleaning, degreasing, neutralizing, inhibiting, and passivating agents (also the nitrogen to be used for agitation and blanketing) in time for these materials to be made: available at the job site before the cleaning operation is to start.

3.4 After the completion of chemical cleaning the PC Contractor shall be responsible for the safe disposal of chemical (acids, degreaser and neutralizer etc) and drying of equipment and piping to the entire satisfaction of OGDCL/Engineering Consultant given at site.



4.0 GENERAL CONDITIONS FOR CHEMICAL CLEANING

• Control valves shall be replaced by a spool assembly during chemical cleaning.

• All instruments shall be protected from the chemical cleaning solution.

1. Orifice plates shall not be in place in the lines. 2. Spool assemblies shall be substituted for all inline turbine meters. 3. The valve in the pressure taps adjacent to the line or vessel of all

instruments shall be closed and the drain valve on the instrument opened. 4. Externally mounted liquid level instruments, such as displacement type

level transmitters and gage glasses, shall have block valves adjacent to the vessel closed and drain valves opened. Internal displacement type level instruments shall not be in place and the nozzle through which they are inserted shall be blinded off.

5. Thermo wells shall not be in place and their connections shall be blinded

off. 6. Piping strainer screens shall not be in place.

• All relief valves shall be removed and nozzles blanked off. • Temporary valves, 3/4" minimum size, shall be installed at the high points of

the systems to be circulated. • Re-boilers or exchangers that are part of the process unit shall not be used as

a means of heating any of the chemical solutions. All heating is to be external to the systems being cleaned, and by equipment furnished by the chemical cleaning PC Contractor. Steam should never be introduced into any part of the system. Overheating must be avoided.

• Process pumps shall not be used to circulate the chemical cleaning solution.

All process reciprocating and rotating equipment and their ancillary systems shall be disconnected and blinded off, and jumper lines or spools furnished as required to complete piping circuits. All transfer and circulating pumps for



handling chemical cleaning, degreasing, neutralizing, and passivating solutions are to be furnished by the PC Contractor and should operate from a dependable power source. In order to reduce the time required for filling and circulation, the pumping rates shall be the maximum consistent with good practice and proper protection of the base metals.

• The chemical cleaning solution must not be allowed to stand undisturbed in

any part of the equipment at any time. The filling, circulating, draining, flushing, and neutralizing operations are to be continuous for each of the systems to be treated.

SPECIFICATION FOR CORROSION PROBES & COUPONS

Project: UCH-II DEVELOPMENT PROJECT

Client: Oil & Gas Development Company Limited

Prepared by: FAS Checked by: MK Approved by: FS Revised by: -



Job No. 14-4985

Doc. No. 4985-PA-2028

Page 1 of 9 Rev. 0

Specification for Corrosion Probes & Coupons UCH II Development Project

Spec. No 4985-PA-2028 Page 2 of 9

TABLE OF CONTENTS

1.0 SCOPE .......................................................................................................................... 3 2.0 HAZARDOUS AREA REQUIREMENTS ................................................................ 4 3.0 TROPICALIZATION ................................................................................................. 5 4.0 PAINTING AND PREPARATION FOR SHIPMENT ............................................ 6 5.0 SPARE PARTS ............................................................................................................ 7 6.0 DEVIATIONS/EXCEPTION ..................................................................................... 8 7.0 TESTING ...................................................................................................................... 9



1.0 SCOPE This specification covers the minimum requirements but not necessary limited to the design, testing, site testing and commissioning of the Corrosion Probes and Coupons to be installed at UCH II Development Project. The system will be complete of corrosion coupons and probes as specified in the attached data sheets and all auxiliary equipments for the correct working of the system. The system will be designed by the PC Contractor to operate at the specified line conditions and fluids composition indicated in the attached data sheets.

The PC Contractor shall calculate the length of corrometers in accordance with specified data. The PC Contractor shall select and specify the system only from renowned and reputed manufacturers in the corrosion protection industry. All material, labor, etc. shall be provided by the PC Contractor at his own cost and responsibility, which shall be considered included in the rates quoted by the PC Contractor. The PC Contactor shall be responsible for testing and commissioning of the items in accordance with the requirements of this specification.



2.0 HAZARDOUS AREA REQUIREMENTS

• Electrical Classification Exia II CTS/T4 • Area Classification Zone -2 II BT3



3.0 TROPICALIZATION All electrical components shall be tropicalized by means of hermetically sealed units, protective coating on circuit boards, gold plated edge connectors etc.



4.0 PAINTING AND PREPARATION FOR SHIPMENT After test and inspection, all corrosion probe non-mechanical exterior surface shall be prepared and painted in accordance with the Project Painting Spec. 4985-GS-9523. Any approval of an alternative paint finish does not reduce the responsibility of the PC Contractor to satisfy the quality requirements of the Project Painting specification.



5.0 SPARE PARTS Spare parts required for commissioning/startup and two years operation shall be included.



6.0 DEVIATIONS/EXCEPTION Equipment provided in accordance with this specification shall have to be protected, manufactured, inspected, tested and warranted in full accordance with requirements defined in this specification and attached documents. Any deviation from what above required shall have to be submitted from PC Contractor to OGDCL for approval.



7.0 TESTING The PC Contractor shall propose necessary test procedures for review and approval by OGDCL/Engineering Consultant, prior to conducting any test. The procedure shall fully detail all the testing that will be carried out by the PC Contractor to demonstrate to the satisfaction of OGDCL that the equipment supplied functions in accordance with the requirements specifications. The PC Contractor shall provide all equipment, test material, including any required to meet the codes and standards specified. OGDCL/Engineering Consultant shall witness all testing.

The results of tests of each instrument shall be recorded in the form of an inspection dossier, signed copies of which shall be submitted to OGDCL.

SITE, ENVIRONMENT & UTILITY DESIGN DATA

Project: UCH‐II Development Project

Client: Oil & Gas Development Company Limited Prepared by: MAM Checked by: FHR Approved by: FS Revised by: ‐

0 ISSUED FOR BIDDING October 5, 2011


Job No. 14 – 4985

Doc. No. 4985‐A‐1000

Page 1 of 7 Rev. 0

Doc. No. 4985‐A‐1000 Sheet 2 of 7 Rev. 0

UCH II DEVELOPMENT PROJECT Site, Environment & Utility Design Data

TABLE OF CONTENTS

1 Introduction ................................................................................................................................................ 3

2 Environmental Conditions............................................................................................................................ 4

2.1 AMBIENT PRESSURE DATA............................................................................................................................... 4 2.2 AMBIENT TEMPERATURE DATA.........................................................................................................................4 2.3 RAINFALL DATA ............................................................................................................................................4 2.4 WIND DATA.................................................................................................................................................4 2.5 HUMIDITY....................................................................................................................................................4 2.6 ICE/FROST DATA...........................................................................................................................................4 2.7 ELEVATION...................................................................................................................................................4 2.8 EARTHQUAKE DESIGN DATA ............................................................................................................................4

3 Utility information....................................................................................................................................... 5

3.1 HOT OIL......................................................................................................................................................5 3.2 FUEL GAS ....................................................................................................................................................5 3.3 INSTRUMENT AIR...........................................................................................................................................5 3.4 PLANT AIR ...................................................................................................................................................5 3.5 NITROGEN ...................................................................................................................................................6 3.6 ELECTRICAL POWER .......................................................................................................................................6 3.7 WATER ANALYSIS ..........................................................................................................................................6

4 National Environmental Quality Standards (NEQS):...................................................................................... 7



1 Introduction

The UCH gas field owned by Oil & Gas Development Company Limited (OGDCL)

is located in Tribal Dera Bugti Agency District of Baluchistan Province. OGDCL

has been operating the UCH gas field and supplying gas to UCH Power Plant,

located at 50 Kms distance from UCH gas field. The UCH Power Plant has

586MW per day power production capacity.

OGDCL intends to develop the UCH field by installing UCH‐II Plant comprising

surface facilities, flow lines, commingling system and gas purification plant. The

gas purification plant unit will be capable of to processing on an average 300

MMSCFD raw gas stream.

OGDCL has engaged ENAR Petrotech Services (Pvt.) Limited (ENAR) for the Basic & detailed Engineering of the UCH‐II Gas Processing Plant. This document covers the Site, Environment & Utility Design Data for the UCH‐II Development Project.



2 Environmental Conditions 2.1 Ambient Pressure Data

Maximum Monthly Normal Pressure 14.689 psia Minimum Monthly Normal Pressure 14.337 psia

2.2 Ambient Temperature Data

Description January June

Mean Daily Maximum (°F) 73 113

Mean Monthly Maximum (°F) 79 121

Record Maximum (°F) 83 131

Mean Daily Minimum (°F) 44 85

Mean Monthly Minimum (°F) 38 79

Record Minimum (°F) 30 72

Maximum Wet bulb Temperature (°F) 83

2.3 Rainfall Data

Maximum Daily Rainfall (24 hours) 124.5mm Highest Average Monthly Rainfall 59mm

2.4 Wind Data

Maximum Velocity 100mph Design Velocity 120mph

2.5 Humidity Relative Humidity (Monthly Normal) 18% to 76%

2.6 Ice/Frost Data

Not applicable.

2.7 Elevation

The UCH Field has a mean elevation of 250 feet MSL.

2.8 Earthquake Design Data

The region in which the UCH Field is located does not experience earthquakes. However, the recommended earthquake factor for structural design is g/10.



3 Utility information

3.1 Hot Oil

Properties of Hot Oil Inlet Outlet

Temperature (ºF) 250 300

Heat capacity “Cp” (BTU/lb °F) 0.4313 0.457

Viscosity “μ” (Lbs./ft. hr) 4.991 1.477

Thermal Conductivity “K” (BTU/hr. °F) 0.095 .0918

Specific Gravity 0.9347 0.915 * Hot oil of similar properties shall be utilized; to be finalized during detailed engineering phase.

3.2 Fuel Gas

Fuel gas conditions and composition are presented in Table 1 below.

Table 1: Fuel Gas Composition

HP fuel Gas LP Fuel Gas Raw Gas **Raw Gas Components

Winter Summer Winter Summer Sales Gas

Conditions Pressure (Psig) 400 (max) 100 (max)

Temperature (°F) 75‐110 60‐100

Composition (Mole%) H2S (ppmv) 214 ‐ 750 214 ‐ 750 214 ‐ 750 214 ‐ 750 5

CO2 22.80 22.73 22.80 22.73 34.17

N2 8.44 8.41 8.44 8.41 22.39

C1 65.56 65.32 65.57 65.32 41.50 C2 1.98 1.97 1.98 1.97 1.066 C3 0.66 0.66 0.66 0.66 0.400 iC4 0.17 0.17 0.17 0.17 0.102 nC4 0.17 0.17 0.16 0.17 0.118 iC5 0.09 0.10 0.09 0.10 0.063 nC5 0.05 0.06 0.05 0.06 0.040 C6+ 0.02 0.13 0.04 0.13 0.14

H2O 0.01 0.26 0.01 0.26 0.009 * Fuel gas composition based on available composition of single well of Eastern Lobe (i.e. UCH‐28); to be updated during detailed engineering phase.

** Only available during plant startup operation. 3.3 Instrument Air

Instrument Air Normal Operating Pressure: 120 psig Dew point: ‐20 ºF

3.4 Plant Air Plant Air Normal Operating Pressure 120 psig



3.5 Nitrogen Normal Header Operating Pressure 88 psig

3.6 Electrical Power

Power Generation / Main Distribution 6.6KV, 3 Phase, 50Hz Power for Motor Control 400 V, 3 Phase, 50Hz 6.6KV, 3 Phase, 50Hz Lighting 230 V Instrumentation 24 V DC

3.7 Water Analysis Table 2: Water Analysis

Specifications Raw Water Potable Water* Demin Water

Taste ‐ Unobjectionable ‐

Appearance ‐ Clear & Odorless ‐

pH @ 25 °C 8.73 6.5‐8.5 6.5‐7.5

Conductivity µs/cm 265 < 10 < 10

Total Hardness ppm 54 < 500 Nil

Calcium Hardness ppm 33 ‐ Nil

Magnesium Hardness ppm 21 ‐ ‐

Turbidity NTU 02 < 5 ‐

Total Suspended Solids ppm 02 < 5 ‐

Total Dissolved Solids (TDS) ppm 127 < 500 5.0

Chlorides (Cl) ppm 24 < 250 Nil

Sulphate (SO4) ppm 38 < 250 ‐

Iron (Fe) ppm 0.006 < 0.3 Nil

Total Silica ppm 0.5 ‐ ‐

Alkalinity ppm 80 < 500 Nil * As per WHO standards



4 National Environmental Quality Standards (NEQS):

National environmental quality standards (NEQS) are attached as Annexure‐I

ENAR Petrotech Services (Pvt.) Limited

NATIONAL ENVIRONMENTAL QUALITY STANDARDS

REGISTERED No. M-302 L. 7646

The Gazette of Pakistan EXTRAORDINARY

PUBLISHED BY AUTHORITY

ISLAMABD, THURSDAY, AUGUST 10, 2000 PART-II

Statutory Notification (S.R.O)

GOVERNMENT OF PAKISTAN

MINISTRY OF ENVIRONMENT, LOCAL GOVERNMENT AND RURAL DEVELOPMENT

NOTIFICATION

Islamabad, the 8th August 2000

S.R.O. 549 (I)/2000.___ In exercise of the powers conferred under clause (c) of sub-section (1) of section of 6 of the Pakistan environmental Protection Act. 1997 (XXXIV of 1997), the Pakistan Environmental Protection Agency, with the prior approval of the Pakistan Environmental Protection Council, is pleased to direct that the following further amendments shall be made in its Notification No. S.R.O. 742(I)/93, dated the 24th August, 1993, namely: ___

In the aforesaid Notification, in paragraph 2._____

(1289) [4138(2000)/Ex.GAZ]

Price : Rs. 5.00

1290 THE GAZETTE OF PAKISTAN, EXTRA, AUGUST 10, 2000 [PART-II]

(1) for Annex, I the following shall be substituted, namely:_____ Annex-I

“NATIONAL ENVIRONMENTAL QUALITY STANDARDS FOR MUNICIPAL AND LIQUID INDUSTRIAL EFFLUENTS (mg/I,

UNLESS OTHERWISE DEFINED) S. No. Parameter Revised

Standards Existing Into Into Into

Standards Inland Sewage Sea ( ) Waters Treatment (5)

1 2 3 4 5 6

1. Temperature or 400C δ3oC δ3oC δ3oC Temperature Increase *

2. pH value (H+) . 6-10 6-9 6-9 6-9 3. Biochemical Oxygen

Demand (BOD)5 at 200C (1) 80 80 250 80** 4. Chemical Oxygen Demand

(COD) (1) .. . 150 150 400 400 5. Total Suspended Solids

(TSS) .. . 150 200 400 200 6. Total Dissolved Solids 3500 3500 3500 3500

(TDS) 7. Oil and Grease 10 10 10 10 8. Phenolic compounds (as

phenol) 0.1 0.1 0.3 0.3 9. Chloride (as C1- ) 1000 1000 1000 SC***

10. Fluoride (as F- ) 20 10 10 10 11. Cyanide (as CN-) total .. 2 1.0 1.0 1.0 12. An-ionic detergents (as 20 20 20 20

MBAS) (2)

13. Sulphate (SO42-) 600 600 1000 SC*** 14. Sulphide (S2-) 1.0 1.0 1.0 1.0 15. Ammonia (NH3) 40 40 40 40 16. Pesticides (3) 0.15 0.15 0.15 0.15

PART-II] THE GAZETTE OF PAKISTAN, EXTRA, AUGUST 10, 2000 1291

1 2 3 4 5 6

17. Cadmium (4) .. . 0.1 0.1 0.1 0.1 18. Chromium (trivalent 1.0 1.0 1.0 1.0

and hexavalent (4).. . 19. Cooper (4) .. . 1.0 1.0 1.0 1.0 20. Lead (4) .. . 0.5 0.5 0.5 0.5 21. Mercury (4) .. . 0.01 0.01 0.01 0.01 22. Selenium (4) 0.5 0.5 0.5 0.5 23. Nickel (4) .. . 1.0 1.0 1.0 1.0 24. Silver (4) 1.0 1.0 1.0 1.0 25. Total toxic metals .. . 2.0 2.0 2.0 2.0 26. Zinc .. . 5.0 5.0 5.0 5.0 27. Arsenic (4) .. . 1.0 1.0 1.0 1.0 28. Barium (4) .. . 1.5 1.5 1.5 1.5 29. Iron .. . 2.0 8.0 8.0 8.0 30. Manganese .. . 1.5 1.5 1.5 1.5 31. Boron (4) .. . 6.0 6.0 6.0 6.0 32. Chlorine .. . 1.0 1.0 1.0 1.0

Explanations: 1. Assuming minimum dilution 1:10 on discharge, lower ratio would attract progressively stringent standards to be determined by the Federal Environmental Protection Agency. By 1:10 dilution means, for example that for each one cubic meter of treated effluent, the recipient water body should have 10 cubic meter of water for dilution of this effluent. 2. Methylene Blue Active Substances; assuming surfactant as biodegradable.

3. Pesticides include herbicides, fungicides, and insecticides.

4. Subject to total toxic metals discharge should not exceed level given at S. N. 25. 5. Applicable only when and where sewage treatment is operational and BOD5=80mg/I is achieved by the sewage treatment system.

PART-II] THE GAZETTE OF PAKISTAN, EXTRA, AUGUST 10, 2000 1292 6. Provided discharge is not at shore and not within 10 miles of mangrove or other

important estuaries. * The effluent should not result in temperature increase of more than 30C at the edge of the zone where initial mixing and dilution take place in the receiving body. In case zone is not defined, use 100 meters from the point of discharge.

** The value for industry is 200 mg/I

Discharge concentration at or below sea concentration (SC). Note:______ 1. Dilution of liquid effluents to bring them to the NEQS limiting values is not permissible through fresh water mixing with the effluent before discharging into the environment.

2. The concentration of pollutants in water being used will be substracted from the effluent for calculating the NEQS limits” and

(2) for Annex-II the following shall be substituted, namely:____ Annex-II

“NATIONAL ENVIRONMENTAL QUALITY STANDARDS FOR INDUSTRIAL GASEOUS EMISSION (mg/Nm3, UNLESS OTHERWISE DEFINED).”

S. No. Parameter Source of Emission Existing Revised

Standards Standards

1 2 3 4 5 1. Smoke Smoke opacity not to 40% or 2 40% or 2

exceed Ringlemann Scale Ringlemann Scale or equivalent smoke number

2. Particulate malter (a) Boilers and Furnaces

(1) (i) Oil fired 300 300

(ii) Coal fired 500 500 (iii) Cement Kilns 200 300

(b) Grinding, crushing, Clinker coolers and Related processes,

Metallurgical 500 500 Processes, converter, blast furnaces and cupolas.

3. Hydrogen Any 400 400 Chloride

PART-II] THE GAZETTE OF PAKISTAN, EXTRA, AUGUST 10, 2000 1293 1 2 3 4 5

4. Chlorine Any 150 150 5. Hydrogen Fluoride Any 150 150 6. Hydrogen Sulphide Any 10 10 7. Sulphur Oxides (2) (3) Sulfuric

acid/Sulphonic acid plants

Other Plants except power 400 1700 Plants operating on oil and coal

8. Carbon Monoxide Any 800 800 9. Lead Any 50 50 10. Mercury Any 10 10 11. Cadmium Any 20 20 12. Arsenic Any 20 20 13. Copper Any 50 50 14. Antimony Any 20 20 15. Zinc Any 200 200 16. Oxides of Nitrogen Nitric acid

manufacturing 400 3000 unit.

(3) Other plants except power

plants operating on oil or coal:

Gas fired 400 400 Oil fired - 600

Coal fired - 1200 Explanations:-

1. Based on the assumption that the size of the particulate is 10 micron or more.

2. Based on 1 percent Sulphur content in fuel oil. Higher content of Sulphur will case standards to be pro-rated.

3. In respect of emissions of Sulphur dioxide and Nitrogen oxides, the power plants operating on oil and coal as fuel shall in addition to National Environmental Quality Standards (NEQS) specified above, comply with the following standards:-

1294 THE GAZETTE OF PAKISTAN, EXTRA, AUGUST 10, 2000 PART-II]

A. Sulphur Dioxide

Sulphur Dioxide Background levels Micro-gram per cubic meter (ug/m3) Standards.

Background Air Annual Max. Criterion I Criterion II Quality (SO2 Average 24-hours Max. SO2 Max. Allowable Basis) Interval Emission ground level

(Tons per Day increment to Per Plant) ambient (ug/m3)

(One year Average) Unpolluted <50 <200 500 50 Moderately Polluted* Low 50 200 500 50 High 100 400 100 10 Very Polluted** >100 >400 100 10

* For intermediate values between 50 and 100 ug/m3 linear interpolations should be used. **

No projects with Sulphur dioxide emissions will be recommended.

B. Nitrogen Oxide

Ambient air concentrations of Nitrogen oxides, expressed as NOx should not be exceed the following:-

Annual Arithmetic Mean 100ug/m3

(0.05 ppm)

Emission level for stationary source discharge before missing with the atmosphere, should be maintained as follows:-

For fuel fired steam generators as Nanogram (100-gram) per joule of heat input:

Liquid fossil fuel 130 Solid fossil fuel .. 300 Lignite fossil fuel 260

Note:- Dilution of gaseous emissions to bring them to the NEQS limiting value is not

permissible through excess air mixing blowing before emitting into the environment.

[File No. 14(3)/98-TO-PEPC.]

HAFIZ ABDULAH AWAN DEPUTY SECRETARY (ADMN)

PRINTED BY THE MANAGER, PRINTING CORPORATION OF PAKISTAN, PRESS ISLAMABAD. PUBLISHED BY THE MANAGER OF PUBLICATIONS, KARACHI.

COMPANY

OIL & GAS DEVELOPMENT COMPANY LTD

UCH-II DEVELOPMENT PROJECT

ENGINEERING CONSULTANT

Document Title: SPECIFICATION FOR FABRICATION, ERRECTION

AND TESTING OF ATMOSPHERIC STORAGE TANKS

Date: 02-OCT-2012 Document No: 4985-SA-7507 Rev :0 Sheet 1 of 28

SPECIFICATION FOR FABRICATION, ERECTION

AND TESTING OF ATMOSPHERIC STORAGE TANK

0 Issued For Approval 01-Oct-2012 WRK MYA FS

Rev Description Date Prepared Checked Approved

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TABLE OF CONTENT

1 GENERAL ............................................................................................................... 4

1.1 Scope ................................................................................................................ 4

1.2 Abbreviations and Definitions ............................................................................ 5

2 CODES AND STANDARDS .................................................................................... 6

3 REFERENCED DOCUMENTS ................................................................................ 6

4 AMBIENT CONDITIONS ......................................................................................... 6

5 DOCUMENTATION ................................................................................................. 6

6 scope of supply ..................................................................................................... 7

7 FABRICATION ........................................................................................................ 8

7.1 General ............................................................................................................. 8

7.2 Plate Preparation .............................................................................................. 9

8 ERECTION ............................................................................................................ 10

8.1 General ........................................................................................................... 10

8.2 Reception and Storage of Materials ................................................................ 11

8.3 Preparation of Materials .................................................................................. 11

8.4 Workmanship .................................................................................................. 11

8.5 Wind Bracing ................................................................................................... 12

8.6 Erection Holes and Attachments ..................................................................... 12

8.7 Setting Out Bottom Course of Shell Plates ..................................................... 12

8.8 Checking of Alignment .................................................................................... 12

8.9 Roof Framing .................................................................................................. 13

8.10 Shell Tolerances .......................................................................................... 13

8.11 Welding ........................................................................................................ 14

9 FOUNDATIONS .................................................................................................... 20

9.1 Checking of Foundations ................................................................................ 20

10 INSPECTION ..................................................................................................... 20

10.1 General ........................................................................................................ 20

10.2 Initial Weld Inspection .................................................................................. 21

10.3 Finished Weld Inspection ............................................................................. 21

10.4 Visual Inspection .......................................................................................... 22

10.5 Weld Defects ............................................................................................... 23

10.6 Retention and Recording of Radiographs .................................................... 23

11 TESTING ............................................................................................................ 23

11.1 General ........................................................................................................ 23

11.2 Testing Tank Bottom .................................................................................... 24

11.3 Testing Reinforcing Pads ............................................................................. 24

11.4 Tank Shells .................................................................................................. 24

11.5 Initial Filling .................................................................................................. 25

11.6 Fixed Roofs .................................................................................................. 25

11.7 Repair of Leaks ............................................................................................ 26

11.8 Retesting ...................................................................................................... 26

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12 SAFETY PRECAUTIONS .................................................................................. 27

13 PAINTING .......................................................................................................... 27

14 PREPARATION FOR SHIPMENT ..................................................................... 28

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1 GENERAL

OGDCL intends to develop UCH field by installing UCH-II Plant comprising surface

facilities, flow lines, commingling system and gas purification plant. The gas purification

plant unit will be capable of processing 300 MMSCFD (Avg.) raw gas stream. For

implementation of the project four (04) no’s storage tanks are required including one

(01) fire water tank, one (01) raw water tank, one (01) diesel storage tank and one (01)

demin water tank.

In this connection, ENAR prepared tender document for the procurement, fabrication,

erection, inspection and testing of atmospheric storage tank.

1.1 Scope

This Specification covers the requirements for the fabrication, erection,

inspection and testing of field erected Welded Steel Atmospheric Storage Tanks

and their appurtenances to be used for UCH-II Development Project.

This specification details the requirements of the code under which the tanks are

to be fabricated.

Storage Tanks made to this specification shall be fabricated according to the

requirements of this specification, of the CONSULTANT’s detailed drawings and

the Codes, standards and specifications as listed in Chapter 2.

This specification is applicable to tanks with the following characteristics:

Vertical, cylindrical shell tanks of all welded steel construction.

Fixed coned type roof either self-supported or structurally supported.

Should details or requirements in referenced codes or specifications be

contradictory or deviate from the listed codes and standards, the CONSULTANT

shall be notified, preferably at the bidding stage but, in any case, before any

costs may arise due to an alternative decision. No deviations from

CONSULTANT documents shall be allowed if not approved previously by the

CONSULTANT.

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Should any conflict occur as a result of applying Specifications, the order of

precedence shall be as follows;

This specification and applicable detailed drawing

Referenced codes and standards

Compliance by the PC CONTRACTOR (here in referred to as contractor in the

rest of the document) with the provisions of this Specification does not relieve

him of his responsibility to furnish equipment and accessories of a proper

mechanical design suited to meet the specified service conditions and/or local

codes governing health and safety.

The CONTRACTOR shall indicate in his offer all deviations of his standard

design from the inquiry documents. The CONTRACTOR carries the sole

responsibility for the correctness of his equipment.

1.2 Abbreviations and Definitions

COMPANY Oil & Gas Development Company Limited

(OGDCL)

ENGINEERING CONSULTANT ENAR PETROTECH SERVICES (PVT) LTD.

PC CONTRACTOR A party which manufactures and/or supplies

equipment, and services to perform the duties

specified by the COMPANY / CONSULTANT

PROJECT UCH-II Development Project

API American Petroleum Institute

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2 CODES AND STANDARDS

API 650 Welded Steel Tanks for Oil Storage

API 12D Specification for Field Welded Tank for Storage of

Production

ASME Section-IX Welding and Brazing qualifications (Only where refer-

enced in API 650)

ANSI B16.5 Steel Pipe Flanges. Flanged Valves and Fittings

ANSI B16.21 Non-metallic Flat Gaskets for Pipe Flanges

ASME Boiler and Pressure Vessel Code Section V, Non-destructive Examination

(only where referenced in API 650)

3 REFERENCED DOCUMENTS

4985-A-1000 Site, Environment & Utility Design Data

4985-STA-4002 Specification for Steel Structure

4985-GS-9523 Specification for Painting

4985-GS-9524 Specification for Packing and Protection of Material

& Equipment

4 AMBIENT CONDITIONS

Ambient Conditions are outlined in document # 4985-A-1000 .

5 DOCUMENTATION

All contractual documents shall be in the English language unless specified

otherwise in the project specification and dimensions shall be in Metric System

except lengths in millimeters.

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CONTRACTOR shall provide to the CONSULTANT following Documents for

Approval.

Detailed Construction Plan (including Construction Method Statement)

Construction and Fabrication sequence plans

CONTRACTOR schedule / progress (updated weekly)

Welding Procedures Specification and Qualification Records

Heat Treatment Procedures, Charts and Certificates

CONTRACTOR Test Procedures

Inspection and Test Procedures (including, but not limited to, NDE, Painting/

Coating)

Hydraulic Testing Procedures

Hydraulic Test Certificates

Test Reports (including NDE, Painting/Coating)

Mill certificates

Material Certificates

6 SCOPE OF SUPPLY

CONTRATORS's scope includes supply of all materials and accessories,

manufacture, and assembly - at shop or field, inspection, non-destructive

examination; testing, painting and delivery of shop fabricated tank accessories

(as applicable) at site.

CONTRACTOR shall ensure compliance with the codes, listed in section 2, and

all authority regulations and shall obtain local authority approval (if applicable).

This includes delivery of all documents required to satisfy the codes.

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Any deviations from the specifications or standards after purchase order award

must be submitted to COMPANY / ENGINEERING CONSULTANT in writing for

approval prior to implementing the changes.

CONSULTANT's approval of CONTRACTOR’s documents does not relieve

CONTRACTOR of their responsibilities.

The tanks shall be supplied complete including, but not limited to, the following:-

All accessories as specified on the tank detailed drawings.

All welded on internal and external attachments

Stairway, ladder and platform support clips.

Stairways, ladders and platforms.

Pipe support and guide clips

Pipe supports and guides.

Earthing lugs.

Nameplate.

Internal/external coating or painting as required.

Mechanical Guarantees.

7 FABRICATION

7.1 General

Field erected tanks shall be fabricated in accordance with API Standard 650.

Workmanship and finish shall be first class throughout and all work shall be

subject to the closest inspection by CONTRACTOR's inspection department

whether or not any inspection by the COMPANY / CONSULTANT is executed.

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No fabrication shall begin until the CONTRACTOR has received approval of

proper material certification, weld procedures specification (WPS) and procedure

qualification record (PQR) from the COMPANY/ CONSULTANT.

To minimize the amount of field work, for field fabricated tank, tank components

and appurtenances shall be prepared and prefabricated in the CONTRACTOR's

shop to the greatest practicable extent. In addition, shop trial assembly checks

shall be utilized as appropriate to ensure accurate fit-up for subsequent field

erection.

All welds and weld preparations shall be detailed and annotated to the relevant

weld procedure specification.

Rolled fabricated plate necks shall be butt welded and fully radio graphed to

100% joint efficiency for all tanks.

Plates, structural members and other material shall not be made up to the

required length by splicing together shorter lengths.

7.2 Plate Preparation

7.2.1 General

Plate preparation shall be carried out in accordance with API 650.

The preparation of plate edges and in particular the edges of shell plates, shall

be carried out carefully in a well equipped workshop.

After preparation all edges shall be examined and all plates showing laminations,

slag inclusions, edge cracks or other faults shall be rejected.

Curved edges of roof or bottom sketch plates or annular plates (if required) shall

be cut to shape in the workshop by mechanized gas cutting or machining.

Handling of plates and sections shall be done using suitable plate clamps or

other methods approved by the COMPANY / CONSULTANT to avoid damage of

any plate materials.

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7.2.2 Tolerances

The profile of all shell plates shall be accurate within a tolerance of ± 2mm in

length and ± 1 mm in width. In addition, to ensure that plates are truly

rectangular, the length of the diagonals measured across the rectangle formed

by scribing lines 50mm from each edge shall not differ by more than 3mm.

For roof and bottom plates with lapped seams, normal mill tolerances are

acceptable.

7.2.3 Rolling and Pressing

All shell plates shall be rolled to the correct tank curvature in a well equipped

workshop. Shell plates shall have their ends pre-set to the proper curvature.

Attention shall be given to prevent bending over the width of the shell plates

during the rolling process.

8 ERECTION

8.1 General

Erection of field erected tanks covered by this Specification shall be in

accordance with API Standard 650.

CONTRACTOR shall submit full details of sequence of erection including site

welding for COMPANY / CONSULTANT’S review and approval.

CONTRACTOR shall inform the COMPANY / CONSULTANT least six (6) weeks

prior to commencement of erection, of the site facilities and equipment required

for erection.

The CONTRACTOR shall furnish all labor, tools, welding equipment and cables,

scaffolding, and other equipment necessary for erecting tanks that are complete

and ready for use.

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8.2 Reception and Storage of Materials

The CONTRACTOR shall inspect and keep stock of all materials delivered at

site and be fully responsible for their safekeeping.

All fittings, plates, etc. shall be properly laid out on wooden supports clear of the

soil. Special care shall be taken that damage does not occur to faces of flanges

or to beveled ends of fittings.

8.3 Preparation of Materials

All materials shall be examined and repaired as necessary at the site before

being erected, to ensure that any damage incurred in transit is made good to the

satisfaction of the COMPANY / CONSULTANT. Particular attention shall be paid

to the removal of the buckles and distortions in the shell and bottom plates.

8.4 Workmanship

All workmanship shall be of a quality to ensure that the requirements of API

Standard 650 and this Specification are met. Only appropriate and standard

erection practices shall be used throughout the tank erection program and they

shall be applied only by skilled personnel. All work shall be subjected to close

quality control by the COMPANY / CONSULTANT, whether or not the

COMPANY / CONSULTANT waives any part of his own inspection. Bolt holes in

plates, structural members and other items shall be drilled, not punched. The

burning of such holes will not be permitted.

Manual gas cutting may be used for trimming the corners of bottom or roof plates

where two lapped joints intersect and for cutting openings for fittings positioned

on site.

Manual gas cutting shall not be used for any other purpose without the approval

of COMPANY / CONSULTANT's representative.

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8.5 Wind Bracing

During erection, tanks shall be safeguarded adequately against distortion or

damage due to wind pressure, by the provision of suitable steel wire guys or

braces.

A minimum of one guy every 8m of circumference is recommended. These shall

remain in place until welding of the shell plates and erection of the roof framing

has been completed, or with open top tanks (as applicable), until the wind girder

has been completed. Particular attention shall be given to the reliability of the

anchor blocks for the guys especially in weak, muddy soils.

8.6 Erection Holes and Attachments

Holes in plate work, to assist in erection, shall not be permitted.

Lugs, nuts, clamps and other devices to assist in erection may be attached to the

tank plates by welding, but all such attachments required only for the purposes

of erection shall ultimately be removed and any noticeable projections of weld

metal remaining shall be carefully ground or chipped away. Plates shall not be

gouged or torn in the process of removing attachments and any indentations

caused thereby shall be filled with weld metal and ground flush with the plate

surface.

8.7 Setting Out Bottom Course of Shell Plates

In setting out the bottom course of shell plates, allowance shall be made for the

contraction of the vertical joints during welding. While the plates are being

plumbed and checked for circularity and before they are tack-welded to the

bottom, they shall be held in position by metal clamps or other devices attached

to the bottom plates.

8.8 Checking of Alignment

Before final welding of the bottom course of shell plates begins, a check shall be

made to ensure that the alignment of the plates and the width of the gaps

between them are correct and that any inaccuracies after welding will be within

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the tolerances mentioned below. If the tolerances are expected to be exceeded,

the plates shall be re-aligned before final welding begins.

After the first course has been erected and welded, the internal radius,

measured horizontally from the centre of the tank to any point on the inside of

the tank shell, shall not vary from the nominal internal radius by more 13mm for

tank diameter less than 12.5m and 19mm for tanks with a diameter greater than

12.5m and less than 45m.

8.9 Roof Framing

Before erection of the roof framing begins, the tank shell shall be carefully

checked for uneven settlement and any misalignment of the top of the shell shall

be corrected before the roof members are positioned.

The strength of erection poles used for temporary support of the roof structure

shall be CONTRACTOR’s responsibility.

Roof plates shall not be welded to supporting structural elements unless

otherwise shown on the drawings.

8.10 Shell Tolerances

8.10.1 Verticality of the Tank Shell

After completion, the maximum out of plumbness of top of the shell relative to

the bottom of the shell shall not exceed 1/200 of the total height.

These tolerances are mandatory for the tank shell as a whole and should also be

used as guidance for each individual course.

8.10.2 Local Departures from the Design Form

Local departures from the design form for the shell horizontally and vertically

should not exceed 16 mm for a plate thickness less than 12.5mm when

measured over a gauge length of 2.5m remote from weld seams.

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Such departure from the design form shall be gradual over the gauge length,

sharp changes in form are not permitted.

8.10.3 Tolerances at Horizontal and Vertical Shell Seams

At horizontal and vertical shell seams, the shell profile should not deviate from its

design form by more than 12 mm for plate thickness less than 12.5mm,

measured over a gauge length of 1m.

8.10.4 Tolerances for Misalignment of Plates at Butt Welded Joints

Plates to be joined by butt welding shall be matched accurately and retained in

position during the welding operation. Misalignment of the centre line of the

plates shall not exceed the following:

In completed vertical joints, 10% of the plate thickness, or 1.5mm for plates

16mm thick and under.

In completed horizontal joints, 20% of the upper plate thickness, or 1.5mm for –

plates 8 mm thick and under and 3mm for plates over 8mm thick; whichever is

the smaller.

8.10.5 Top of Tank Shell

The tank shell shall be carefully checked for circularity, dimensions and level

before the roof members.

8.11 Welding

8.11.1 General

This part of specification covers the minimum requirements and procedures for

welding and does not relieve the CONTRACTOR from his responsibilities and

guarantees with respect to welding results.

The layout of all welded seams shall permit both internal and external inspection

of all main tank seams where possible.

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All butt welds shall be full penetration and full fusion welds as shown in the

applicable code or specified in this Specification. No lap joints are permitted on

shells.

Bottom plates of all tanks shall be lap welded throughout.

All welds of lugs, brackets, structural steel, etc., shall be located so as to miss all

tank welds by a minimum distance between the edges of the welds of 100mm, or

3 times the thickness of the thicker part being welded, whichever is greater.

Where tanks are to be internally lined, weld joints shall be smooth and free from

sharp edges and corners.

No welding shall be performed when the metal temperature is 5ºC and below

without the application of preheat.

All fillet welds shall be continuous.

8.11.2 Welding Processes

The scope of application of welding processes shall require the approval of the

COMPANY / CONSULTANT. High heat input processes such as electro slag

welding is prohibited. In all cases the heat input of the welding process shall be

limited to a maximum of 5KJ/mm.

8.11.3 Welder Qualification

All welders and welding machine operators shall be qualified in accordance with

ASME IX. Those welders and operators shall only be allowed to weld using the

approved process and in the position for which they are qualified. Welders shall

wear a personnel identification badge showing name and welder qualification.

8.11.4 Welding Procedure Qualification

The CONTRACTOR shall submit weld procedures, qualifications and weld

details in accordance with API Standard 650 for all weld types utilized for

COMPANY / CONSULTANT’s review and approval prior to commencing any

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production welding. Welds not made in accordance with the approved qualified

procedure shall be subject to rejection

Each procedure shall be qualified in accordance with procedures previously

approved by the COMPANY / CONSULTANT.

The CONTRACTOR shall weld test plates using his procedures to demonstrate

to the CONSULTANT that these procedures are suitable for making welds which

conform to the specified requirements. Each welding procedure shall be qualified

in accordance with the latest practice as given in the applicable rules of Section

IX of the ASME Boiler and Pressure Vessel Code.

The CONSULTANT shall be notified of any proposed changes to the applicable

welding procedure. Repair welding shall be performed using qualified

procedures and welders/operators.

8.11.5 Sequence of Welding

The sequence employed both for the tack welding and final welding of the

bottom shell and roof plates shall be arranged to minimize the distortion due to

weld shrinkage. The sequences shall be approved by the COMPANY /

CONSULTANT before erection starts.

8.11.6 Weather Conditions

Welding shall not be carried out when the surfaces to be welded are wet; nor

when rain or hail is falling or high winds are blowing, unless the welder or

welding operator and the work are properly shielded.

When the air temperature is below 0°C, the base metal at either side of the joint

shall be preheated before welding is started. For carbon steel the metal shall be

a temperature warm to the hand for a distance of not less than four times the

plate thickness, or 75mm whichever is the greater, in any direction from the joint

to be welded.

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8.11.7 Electrodes and Welding Wires

Welding materials shall be in accordance with the current list of approved

welding consumables published by Lloyds Register of Shipping or other

internationally acknowledged bodies.

Electrodes shall be stored in their original packets or cartons in a dry place

adequately protected from weather effects.

Low hydrogen electrodes shall be dried or baked at the temperature level and

times specified by the manufacturer and shall be used within 8 hours when

stored in quivers. Electrodes stored in quivers, but not used within the specified

times, shall be restored in ovens.

All consumables shall be stored and handled in accordance with manufacturer's

recommendations. Any unidentifiable consumable or those showing signs of

damage or deterioration shall be discarded.

Similar precautions shall be taken in the storage of flux and wire for submerged

arc welding.

If the electrodes become damp but are not otherwise damaged they may be

used only after being dried out in a manner approved by the electrode

manufacturers. Any electrodes which have areas of the coating broken away or

damaged shall be discarded.

No electrodes shall be left lying about the site or in workshops. Electrodes so left

shall be discarded.

Welders and welding operators shall be experienced in the manipulation of the

electrodes and wires used before proceeding with the tank welding. Basic or low-

hydrogen electrodes are recommended for sealing runs and root layers. For low-

hydrogen electrodes, an oven shall be available at the welding site to ensure the

use of dry electrodes in accordance with the recommendations of the electrode

manufacturer.

For manual welding of shell plates of medium high-tensile steel, low-hydrogen

electrodes only shall be used.

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8.11.8 Tack Welds

Tack welds used in the vertical joints between shell plates and in the horizontal

Joint between the bottom course of shell plates and the bottom plates, during the

assembly of the tank, shall be removed prior to welding and shall not remain in

the finished joints.

Tack welds in the horizontal joints between shell plates and in the joints between

roof plates and bottom plates, need not be removed provided that they are

sound and free from cracks, that the covering beads are thoroughly fused into

them and that the quality of the welding is to the satisfaction of the

CONSULTANT’s representative.

8.11.9 Plate Edge Joints

If the CONTRACTOR requests for different plate edge preparations details shall

be submitted as soon as possible together with the proposed weld procedures

for the review and approval by the CONSULTANT.

8.11.10 Welding Procedure

The welding procedures shall be as follows:

In multi-layer welding each layer of weld metal shall be thoroughly cleaned of

slag and other deposits before the next layer is applied. All completed welds

shall be freed from slag, brushed and thoroughly cleaned before final

inspection and subsequent painting.

There shall not be any undercutting of the base metal.

The weld metal on both sides of all butt joints, except offset faces of

horizontal joints of unequal plate thickness, shall be built up in the form of an

overlay so that all the finished face in the area of fusion shall extend above

the surface of the adjoining plates to a height of preferably not more than

1.5mm.

The edges of the welds shall merge with the surface of the adjoining plates

without a sharp angle.

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Welds shall be left as welded and not be modified with a gas torch or by any

mechanical means which may change their appearance.

Where applicable, post weld heat treatment shall be carried out as required

by and in accordance with API Standard 650.

8.11.11 Bottom Plate Joints

All bottom plate joints shall be welded in accordance with the detail drawings.

It shall be checked that all locations where supports for accessories (e.g. roof

supports, roof drains, vacuum breakers, etc.) are welded to the bottom or will be

touching the bottom are provided with a suitable pad plate to prevent leakage.

The pad plates to be round or at least have rounded corners.

8.11.12 Bottom to Shell Plate Joint

The shell plates shall be continuously welded on both sides to the bottom sketch

plates or annular plates in accordance with the detail in drawings.

8.11.13 Shell Butt Joints

Shell butt joints shall be made as follows:

All seams shall be single-vee butt-welded.

All vertical butt joints shall have complete weld penetration and fusion

through the full thickness of the parent plate.

All horizontal single-bevel butt joints shall have complete penetration and

fusion through the full thickness of the parent plate.

In single-vee or single-bevel butt joints the vee or bevel shall be made on the

outside of the tank.

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9 FOUNDATIONS

9.1 Checking of Foundations

For a tank to have a shell which is truly circular and free from buckles and flat

spots, the foundation must remain flat and level as the tank shell is erected. For

this reason the foundation shall be checked, not only at the commencement of

operations, but several times during the various stages of tank erection. The

measurements shall be stated in a report. This final report shall be handed to the

CONSULTANT for maintenance purposes.

An indication that the tank is settling unevenly is the appearance of gaps in the

circumferential seams, and departure of the shell from the perpendicular. If these

signs appear, no attempt should be made to close the gap by pulling with the key

plates and wedges or cutting of plates.

The tank level shall be checked and corrected by leveling, if necessary. If the

gap is due to inaccurate fabrication, plate edges shall be built up with weld

metal, and the joint welded.

10 INSPECTION

10.1 General

CONSULTANT's inspector may engage in the inspection of the tank. The

inspectors shall have free access to CONTRACTOR's work at both shop and

erection site at all reasonable times and during all tests.

The CONTRACTOR shall supply all reasonable facilities for ensuring that the

work is being carried out in accordance with the requirements of this

Specification.

The CONTRACTOR shall provide inspection in accordance with API

Specification 12F together with API Standard 650 as a minimum.

The CONTRACTOR shall submit for the approval by the CONSULTANT his

Inspection and Test plan prior to commencement of any field activities. The

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CONTRACTOR shall inform the CONSULTANT at the time of placing the order

of any tests which cannot be adequately performed.

All heat numbers shall be marked by paint or other legible means in such a way

that these can easily be noted and read after erection. For bottom plates these

shall be on the inside, for all other parts, on the outside.

10.2 Initial Weld Inspection

All shop and/or site welding shall be subjected to close visual inspection by an

approved welding inspector of the CONSULTANT as the welding progresses,

and any faults or bad practices shall be corrected as soon as possible.

Particular attention shall be paid to the vertical and horizontal joints in the shell

plates, lap joints in bottom annular plates and other joints that pass under the

shell plates.

All these joints shall be thoroughly de-slagged by chipped and brushing, and

examined between each run of weld metal for faults such as lack of fusion,

surface cracks, slag inclusions and undercutting.

10.3 Finished Weld Inspection

All welds shall be inspected visually in accordance with (10.4). The use of

destructive methods of testing welds shall not be permitted.

In addition to visual inspection, butt welds in the tank shell shall be

radiographically inspected in accordance with API Standard 650.

The acceptance criteria for all non-destructive examinations of the tank parts

shall be in accordance with the requirements of API Standard 650. All

radiography shall be performed using X-ray radiation except where it is

impractical, in which case the CONSULTANT shall nominate a suitable

alternative method of the examination for the approval of CONSULTANT.

At CONSULTANT's discretion, ultrasonic examination may be substituted for

radiographic, magnetic particle and/or liquid penetrant examinations. However, if

the shell plate vertical joints have been welded by an automatic welding process,

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the completed welds shall be fully ultrasonically examined, unless they are to be

fully radiographed.

All compliance examination procedures as described herein shall be at the

expense of the CONTRACTOR. The cost of additional non-destructive

examinations which may be requested by the CONSULTANT will be borne by

CONTRACTOR except where defects are revealed. The cost of such

examinations revealing defects and the cost of further examinations proving the

acceptability of the associated repairs shall be borne by the CONTRACTOR.

All inspection shall be conducted and interpreted by qualified persons utilizing

proven techniques and equipment. The inspection results shall be substantiated

by charts, photographs and reports, which shall be submitted to the

CONSULTANT. The CONSULTANT shall be notified in advance of all these

tests to enable him or his appointed Agency to witness the tests.

10.4 Visual Inspection

All welds shall be visually inspected.

Visual inspection shall show that the following requirements are met:

The weld is made in accordance with the design requirements.

The profile of fillet welds is such that leg lengths are equal within 1.5mm and

the surface of the weld is slightly convex and free from overlap at the toes of

the weld.

The profile of butt welds is uniform, slightly convex and free from overlap the

toes of the weld

The height and spacing of ripples are uniform

The weld is free from undercutting

There are no pronounced lumps or cavities caused by starting or finishing a

weld bead

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The surface of the weld is free from cavities and trapped slag, and does not

display any porosity.

10.5 Weld Defects

Welds that are shown by radiography to have any of the defects or imperfections

as defined in API Standard 650 shall be judged to be unacceptable, and the

CONSULTANT’s welding inspector or representative shall decide to what extent

the welds shall be repaired in accordance with API Standard 650.

Imperfection revealed by other non destructive tests where applicable shall be

repaired at the discretion of the CONSULTANT and in accordance with API 650.

10.6 Retention and Recording of Radiographs

The CONTRACTOR shall record all films with their identification marks, on a

diagrammatically developed elevation of the shell plates and floor plates. The

defects shown on the radiographs shall be indicated on this diagram.

Finished radiographs shall be retained by the CONTRACTOR for a minimum

period of 3 years from the completion of site erection.

All radiographs shall be stored in such a manner as to prevent deterioration over

time as a result of light, pressure, excessive heat, excessive humidity, fumes or

ionizing radiation as appropriate. Reference should be made to the radiographic

film manufacturer's recommendations on storage.

The CONTRACTOR shall allow free access to radiographs at all times during the

3 years storage period by the CONSULTANT.

11 TESTING

11.1 General

As a minimum requirement, field fabricated tank shall be tested in accordance

with API Standard. As a minimum requirement, the testing of field erected tanks

shall be in accordance with API Standard 650.

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11.2 Testing Tank Bottom

The bottom of the tank shall be tested after installation by applying a vacuum to

the plate welded joints and checking for leaks, using a suitable soap film

solution. There shall be no air leakage.

This can be done using a vacuum box, which enables any leaks in the seams to

be positively located by visual examination.

The test shall preferably be made as soon as possible after welding of the

bottom, removal of slag, and wire brushing, but before any surface coating is

applied. The bottom plates shall in any case be tested before water is let into the

tank for hydrostatic testing.

11.3 Testing Reinforcing Pads

Reinforcing pads for manholes, nozzles and similar openings shall be tested

after installation by applying air pressure via each telltale hole and checking for

leaks, using a suitable soap film solution. There shall be no air leakage. Suitable

precautions shall be taken to ensure that excessive pneumatic pressure is not

applied during the test. Test pressure shall not exceed (15psi).

11.4 Tank Shells

The shells of fixed roof tanks shall be tested after completion of the roof.

For fixed roof tanks, testing shall be done by filling the tanks with, fresh water to

the level of the top leg of the top curb angle, and noting any leaks over a period

of at least 24 hours.

For field tests, the filling rate, holding time and drainage shall be as per API 650.

CONTRACTOR shall, for all field-fabricated tanks, submit a test procedure for

approval by CONTSULTANT.

CONTRACTOR shall notify CONSULTANT at least five days before the actual

test begins, and unless agree otherwise it shall not take place in the absence of

CONSULTANT or without CONSULTANT’s prior approval.

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The tank shall not have been previously hydrostatically tested. Prior to testing, it

shall be thoroughly cleaned internally of all dirt, oil, grease and other foreign

materials.

The CONTRACTOR shall be responsible for furnishing all apparatus and items

normally required for such testing, including fill and drain lines, blanking plates,

gaskets and associated bolting. However, service bolts and gaskets to be

furnished by the CONTRACTOR as spare parts shall not be used during the test.

Test gaskets shall be used on nozzles and gasketted joints which are to be

broken after the test (e.g. for draining, venting and drying the tank).

11.5 Initial Filling

The initial filling of a tank with water, shall be done slowly and a continuous

inspection shall be maintained for the whole of the filling period. The filling

procedure shall be established taking soil conditions into account. The filling

procedure shall be described in detail in a specification agreed by the

CONSULTANT strictly.

Uneven settlement of the tank on its foundation shall be reported immediately to

CONSULTANT, and filling shall be stopped at any signs of excessive settlement

pending a decision by CONSULTANT on the action to be taken.

On completion of the test, the tank shall be completely drained and all residual

water, silt and dirt shall be removed so that it is left in a ‘broom-clean’ condition inside.

11.6 Fixed Roofs

When the tank shell is tested with water, the roof shall be tested by pumping air

under the roof plates while the tank is still full of water. The influence of sudden

barometric changes and possible condensation during the night shall be

considered.

Fixed roof tightness testing shall be done in strict accordance with the

requirements of the API 650.

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The pressure shall be strictly controlled using a very accurate pressure gauge

during the entire period of the test.

Non-pressure tank roofs shall be tested to a pressure at pressure specified in

detailed drawings.

For the detection of leaks, soap suds or some alternative substance shall be

applied to all joints.

Alternatively, the roof weld seams may be tested by the vacuum box method.

11.7 Repair of Leaks

All leaks detected during testing shall be repaired to the satisfaction of

CONSULTANT, and on completion the entire tank shall be tight and free from

leaks.

In the joints between shell plates or bottom plates, or both, the defective part

shall first be cut out and repaired by welding. Isolated pinhole leaks in joints

between roof plates or indication of porosity in the joints, or of cracking, repair

welds shall be made for the affected parts of the joint. Mechanical caulking is not

permitted for any repair.

When the tank is filled with water for testing, defects in the shell joints shall be

repaired with the water level at least 0.3m below the work.

11.8 Retesting

After all defects have been repaired the repaired weld shall be retested by the

methods previously described.

If it is impractical to use these methods a second time, extra care shall be taken

in the inspection of welded repairs, and all defects which have been repaired

shall be tested with dye penetrants.

If further leaks are discovered when the tank is first filled with product, repairs

shall not be made until the tank has been rendered safe in accordance with

section 10.

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12 SAFETY PRECAUTIONS

The following safety precautions shall be taken:

Product connections shall not be made to any tank for any purpose until the

tank is accepted to be filled with product by CONSULTANT.

Once product connections have been made to a tank, welding or other hot-

work shall not be carried out until all lines connected to the tank have been

disconnected, the open ends of the pipelines blanked off, and the tank and its

vicinity tested and rendered safe to the satisfaction of the CONSULTANT.

Once a tank has contained product, welding or other hot-work is prohibited

before, in addition to the requirements above, the tank has been completely

emptied and rendered safe in accordance with the local safety regulations,

and written authority for the work has been issued by CONSULTANT.

Roof manholes shall be open while filling or emptying a fixed roof tank for

purposes, so that the tank is not damaged by excessive vacuum or pressure

loading.

CONTRACTOR shall provide adequate lighting/venting for work carried out

inside tanks.

CONTRACTOR shall submit for approval air pressure test procedure for fixed

roof tanks.

13 PAINTING

For external Painting and protective coating and the procedures for preparation

for painting shall be in accordance with the requirements having document no’s 4985-GS-9523, 4985-GA-9524, and 4985-STA-4002. Internal coating of the tank

shall be specified in the applicable detailed drawings of the tank.

All the tanks shall be cleaned inside and outside of weld spatter, weld slag, flux

deposits, burrs and splinters, loose mill scale and all other foreign matter.

Steel plates stored, pending for erection, shall be suitably protected against

oxidation.

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For field-erected tanks, all plates shall be primed prior to delivery to erection site.

Heat numbers shall in this case be left unpainted.

Before erection, the outside surface of bottom plates shall be brushed,

degreased, and then coated with hot applied bitumen paint.

14 PREPARATION FOR SHIPMENT

The CONTRACTOR shall be responsible for the adequacy of packing and

protection employed to ensure that the parts are delivered in an as new and

undamaged condition.

All pre-fabricated parts for field erected tanks shall be thoroughly cleaned, match

marked and beveled for welding at site prior to shipment.

Carbon-steel flange facings (except on nozzles shipped with gaskets in place),

shall be coated with an easily removable rust preventative. All flange facings

must be protected with temporary shipping covers.

CONTRACTOR must ensure that equipment and / or all parts thereof is properly

loaded and secured to the carrier to avoid damage by the use of suitable support

/ transport cradles, hold-down devices or otherwise.

CONTRACTOR shall also ensure that road transport clearance requirements are

met.

Date post:	18-Jan-2016
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