Ras Gara 10" Oil Pipeline phase (2)

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GENERAL METHOD OF STATEMENT Date 04/10/2018

GENERAL METHOD STATEMENT

Project : Ras Gara 10" Oil Pipeline phase (2)

Company : PETROBEL

Contractor : PETROJET

TABLE OF CONTENTS

1. FIT UP AND WELDING PROCEDURE--------------------------------------------------------------------------

2. FIELD JOINT COATING , REPAIR AND HOLIDAY TEST PROCEDURES……………………………

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3. EXCAVITION TRENCHING PROCEDURE----------------------------------------------------------------------------

4. LOWERING OPERATION PROCEDURES----------------------------------------------------------------------------

5. BEDDING, PADDING AND BACKFILLING PROCEDURE--------------------------------------------------------

6. ROAD CROSSING METHOD OF STATEMENT……………………………………………………………..

7. PIGGING , CLEANING AND FLUSHING PROCEDURES …………………………………………………..

8. TIE IN'S………………………………………………………………………………………………………..

1- FIT UP AND WELDING PROCEDURE PROCEDURE

1. INTRODUCTION

1.1. Project Description

Ras Gara 10" Oil Pipe line phase (2) of carbon steel. Material specification is API 5L Grade X52.
Pipeline Diameter is 10" and wall thickness is (12.7 and 15.09) mm by long 20 km from valve room No: 3
to valve room No:4.
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2. DEFINITIONS

By assigned to them except where the content otherwise requires:

COMPANY : PETROPEL
CONTRACTOR: PETROJET

PMTC : Project Management Team Company ( PETROBEL)

3. PURPOSE OF THIS DOCUMENT

This Method Statement covers the requirement of API 1104, (Design General Specification for
Pipeline Welding) for welding of pipelines with dia. 10" Pipeline construction.

4. REFERENCE DOCUMENTS

4.1 American Welding Society (AWS)

ANSI/AWS A5.01: Filler Metal Procurement guide line.

4.2 American Petroleum Institute(API)

API 5L: Specification for Pipe
API 1104: Welding of Pipeline and Related Facilities

4.3 American Society of Testing and Materials

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

5. RESPONSIBILITY

The Welding inspector is responsible for monitoring and control welding operation to make sure that
the proper WPS is applied, also responsible for visual inspection before, during and after welding
operation

6. WELDING ACTIVITY

Welding activities shall be covered with the following:

6.1 Welding activity shall be carried out according to the approved welding procedures.

6.2 Only qualified welders or welding operators As API-1104 and PETROBEL spec's are be used to
perform the welding operation.

6.3 Pipe to pipe welding supervisor shall ensure that welding parameters and electrodes being used
comply with the approved welding procedures with special attention to clamp removal and pipe
lower off.
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6.4 All welders shall ensure that cleaning of previous weld pass is accepted before start welding.

6.5 Welding foreman to ensure that weld number and welder ID number are painted next to each
completed weld.

6.6 All passes shall be inspected visually for any defects or arc strike.

6.7 In case of in-trench welding, all safety measures will be taken to assure overall trench stability and
enough welding spacing.

7. RESOURCES

Personnel & Equipment required for welding crew shown in Table:-

Description Qty. Description Qty.

Forman (welding) 2 Side boom 5
Welder 16 Welding M/C 12
Pipe fitter 3 Tractor (for welding m/c) 4
Grinder 9 Internal Clamp 2
Brusher 9 External Clamp 2
Safety Supervisor 1 Excavator 3
Helper 5 Trolley 1
Laborer 5
Rigger 10
Mechanic 3
Electrician 3

8. SAFETY REQUIREMENT

8.1 PETROJET shall comply and shall be responsible for ensuring that all respects with client safety
regulations and rules which shall be strictly adhered to.

8.2 PETROJET shall provide and maintain all temporary lights, guards, fencing and warning signs
when and where necessary for protection of the work.

8.3 All vehicles & equipment used shall be equipped with fire extinguisher of suitable capacity.

8.4 PETROJET shall provide and maintain sufficient and adequate first aid equipment at the site and
ensure that a sufficient number of personnel are trained in the performance of first aid
techniques.

8.5 PETROJET shall be responsible for ensuring that personnel safety apparel (protective clothing,
hard hats, safety shoes, masks) is worn and used.

8.6 All equipment for use in the performance of the work shall be in a safe and proper condition and
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capable of performing the intended work.

8.7 All persons engaged in the performance of the work are aware of and comply with client safety
regulations.

8.8 The necessary precautions shall be taken to prevent damage to the worksite and to property and
the environment adjoining the work site and to keep it clean, tidy and in good order at all times.

8.9 All side booms shall have a valid and current test certificate and to be checked regularly and re-
certified every 12 months, copies of test certificates to be handed over to client

8.10All operators of lifting equipment shall be trained and experienced in the use of the lifting
equipment they are operating.

8.11Side booms are not allowed to work in the vicinity of overhead power lines unless a safe
working distance is maintained.

8.12Welding sets and electrical equipment in use must be in safe, good and well maintained
condition.

8.13Special attention shall be given to the safe working condition of flexible cables (welding
machines) and equipment that may cause sparks if not properly maintained.

8.14Elec. operated hand tools shall meet the following requirement: 110/230 volts AC single phase
with double insulation.

All elec. operated hand tools shall be subject to constant inspection by the safety officer.

9. IN –TRENCH WELDING

For in-trench welding of tie-ins a welding pit to be made 3 m x 3 m wide with safe sloped sides
provided with a life rope and ladder inside the pit and a witness person outside.
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2- FIELD JOINTS COATING PROCEDURE

2.1 PURPOSE:
This the procedure that will be followed for applying the field joint coating system for the onshore girth weld
areas on the carbon steel pipeline, document describes during the installation phase to ensure providing
a sufficient protection of the steel substrate at the girth weld areas against corrosion. The field joint coating
operation shall be performed by “Coating applicator and shall be inspected by Certified Coating Inspector”.
The inspector will verify the shrinkable sleeve material for correctness by verifying the related
Documents / Manufacture's data sheets .he shall ensure the storage as per the recommendation of the
manufacturer.
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Certified Coating inspector to ensure the clearance of the join from QC mechanical to be released for
surface preparation .blast cleaning, Preheat requirements for sleeve application .if repair required he
shall follow the approved procedure, Certified coating inspector to witness or supervise the holiday
test, peel test and destructive tests to ensure the quality, Certified Coating Inspector to be guide all
the people who are involved
In the installation of shrink sleeve. All materials supplied by PETROJET shall be furnished with an appropriate
manufacture certification. This certification shall clearly defines the product, its specification, date of
manufacture and expiry date in addition to all the necessary information needed to ensure both the integrity
and high performance of the product approved by employer .

2.2 HANDLING AND STORAG OF COATING MATERIALS.

 Material used for coating shall be provided by Contractor clearly marked with the following details:
 Name of Manufacturer
 Material Identification
 Batch Number
 Date of Manufacture
 Quantity
 Manufacturing Standard
 Product life /Expiry Dade
 Materials shall be handled and stored in accordance with applicable safety regulations and the
material manufacturer's recommendations, and shall be used according to the manufacturer's batch
sequence.
 The containers or packages of materials to be used for coating shall be properly handled in order to
avoid any damage, scattering or pollution during loading, unloading and storage.
 All shrinkable sleeve material will be received with data sheet conformity from the supplier.
 Materials receiving at sit once arrival of any coating material (HSS) and its application material (Primer,
hardener) the material controller with QC inspection shall check and inspect the received material as
per material control procedure document.

 in a dry, ventilated area, such as warehouse or watertight shipping container, keep product
sealed in original cartons and avoid exposure to direct sunlight ,rain ,dust or other adverse
environmental elements, avoid prolonged storage at temperature above 35° C or below -20° C
as stated by Manufacturer.
 The coating materials shall be properly packed and clearly marked with the Manufactures name,
material approval, identification batch number, date of manufacture, Test Certificate, Test date, Storage
temperature and MSDS.
 The materials, at time of application shall not be older than the shelf life of 3 years from the date of
manufacturer, as stated by the manufacturers, epoxy primers have shelf life of 3 years from month of
manufacturer.
 The closure patch shall be smoothed with a gloved with a gloved hand to eliminate any entrapped
air and to ensure good bonding.
 The installed sleeve shall be undisturbed for 4 hours or until the adhesive has been solid field
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whichever is longer.
 Adhesive extended from the ends of the sleeve indicates proper application. The edges of the
sleeve shall be inspected to confirm firm bonding to the surface of the coated pipe. There shall be
no sign of punctures or pinholes and the external appearance of the sleeve shall be smooth, without
dimples.

2.3 POLYETHYLENE MATERIAL.

The polyethylene shall be suitable for a supplier 3 layers coating system.

Contractor shall obtain from the Manufacturer the following certified data for each batch of material:
 Density
 Melt Flow Index
 Shore Hardness
 Elongation
 Tensile Strength
 Melting Point
 Dielectric Breakdown Voltage
 Environmental Stress Cracking Resistance
 Brittleness Temperature
 The Contractor shall test one batch in every ten for compliance with the Manufacturer's
Certificates described.
 The Contractor shall provide the information detailed for Company approval prior to the
start of coating operations.

 The heat shrinkable sleeve provide superior corrosion protection and excellent bonding on
pipelines operating onshore up to 65°C & 80°C respectively and have been designed with a
unique adhesive technology that remains “open” longer than traditional adhesives. Also,
special surface active agents allow bonding to energy lower surface coatings (such as
polypropylene). As a result, lower preheats are required and superior bonding to PE surfaces
is achieved.

 The heat shrinkable sleeve can be used as a 3-layer sleeve system at the same low pre-heat.
For added flexibility.

 Epoxy Primer is a specially formulated 100% volume solids (solvent less) two component
epoxy.
 Bulk Epoxy Primer Bulk epoxy components must be ordered separately. The mixing ratio for
the E primer is 4 parts base, 1 part cure by volume, Pot life at 23°C, Typical epoxy coated
thickness4 - 6 mils (100-150 microns). Shelf Life at 23°C, out of sunlight 3 years
 For the shrink sleeves, the thickness in the as-delivered state shall be as specified by the
Manufacturer of the shrink sleeve. The applied shrink sleeve shall be of even thickness over
the total sleeve surface Allowing for some variation on weld seams the minimum value
measured on top of the weld shall not be less than 75% of the nominal sleeve thickness.

2.4 STEEL SURFACE PREPARATION

 Oil, grease will be removed with detergent or solvent cleaning.
 Weld slag, spatter, fragments, and other foreign bodies shall be removed using suitable tools.
 Blasting operation must be with adequate pressure of air, which is free from impurities
contamination such as oil and water with pressure equivalent to 6 bars at the nozzle exit.
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 Blasting shall take place to reach near white metal grade SA 2½ according to ISO 8501-1, the
jet is passed over the surface long enough to remove all mill scale, rust and foreign matter
The abrasive material used shall give a surface profile 40-75 microns.
 Abrasive Size and Corresponding Profile as specified in Table-2
Table 2 Abrasive size

MESH SIZE PRODUCT EXPECT SURFACE PROFILS IN

ABRASIVE
DESIGNATION MICRON AT APPROX. 100 PSI

Abrasive very fine 80 40

Abrasive fine 40 50
Abrasive medium 18 65
Abrasive large 12 75

 The surface profile shall be measured by direct microscopic roughness profile gauge to
measure the roughness of the surface taken into a press 0 – film tape.
 Restrictions: blast cleaning shall not be conducted when the surface are less than 3° c above
dew point or temp. more than 50 C˚ when the relative humidity of the air is greater than 85%
Also when rains are falling down or when the weather is in a windy or dusty condition.
 Shall be such that Chloride contamination is less than 50 mg/m2 and shall be protected
from conditions of high humidity, rainfall or surface moisture and shall not be allowed to
rust before application of the sleeve. If rust occurs, the surface must be prepared again.
Any field joint not coated within 4 hours of abrasive blasting shall be re-blasted prior to the
application of the coating.

2.5 EPOXY PRIMER APPLICATION.

 The mixing ratio for the primer shall be according to data sheet instructions.
 Primer shall be applied immediately after the cleaning. The surface must be clean and dry.
Primer materials shall only be applied in accordance with primer manufacture recommended
method. Primer shall be uniformly applied without sags, spots, damage or contamination.
 Apply mixed epoxy to a uniform specified Thickness of 4-6 mils (100-150 microns) according
to data sheet.
 Prior to applying any heat shrinkable sleeve, the pipe surface must be uniformly.
preheated to the recommended temperature. Preheating times vary with pipe
diameter, Wall Thickness and ambient temperature conditions.
 The pipe must not be allowed to cool below the specified preheat temperature before
the sleeve is applied.
 As pre-heat temperature is less than 70° C, propane burners shall be used for pre
heating. Touches may be used for tie-in welds at Company's discretion. To check that
the required pre-heat temperature has been achieved, a digital contact thermometer
shall be used.
 PTJ shall ensure that adequate shielding of the field joint area shall be made during the joint
coating operations, so as to prevent air cooling of the surface due to environmentally windy
conditions.
 PTJ shall ensure that the pipe line shall be fully supported either side of the joint area (Fig 1)
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to allow the sleeve to be fitted. The supports shall be rigid and padded to prevent damage to
the surrounding parent coating material.
2 inch min.
Heat Shrinkable Sleeve Pipe20”or 10”

Supports
(Fig 1)

2.6 HEAT SHRINK SLEEVE FIELD JOINT.

 The field joint coating system shall be totally compatible with the pipeline coating systems and shall
provide corrosion & handling protection at least equal to the pipeline system.
 The pipe shall be uniformly heated within the temperature range recommended by the heat shrink
sleeve manufacturer.
 Preheat the joint area using the torch temperature
 The temperature advice to ensure that the corrected temperature is achieved on the steel surface and
50mm from the coated side.
 The heat shrink sleeves should have a minimum thickness of 2-mm, including over the high point of
the field weld.
 The minimum overlap over factory applied coating 75mm other side of the weld before heat is applied
to the sleeve and 50 mm after completion of the joint

2.7 INSTALL THE HEAT SHRINKABLE SLEEVE.

 Gently removes the release plastic about 150 mm from the end place center the sleeve over the joint
area on the right angel to the axis of the pipe.
 Wrap the sealer loosely around the pipe to ensure the overlap of100mm of both side heat the backing
under lap and adhesive side of the overlap center the sleeve over the joint area press the overlap area
into place and remove the remaining release plastic.
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 Using medium flame with yellow tip and keep it constant is moving in a paint
Brush motion around the sleeve at middle region of the sleeve if utilizing two Torch operators should
work
in opposite side of the pipe.
 Continuously heating in the paint brush motion from the center toward the end of the sleeve
Until shrink able is completed in a similar manner heat the shrink and the remaining circumference
of the Pipe.
 Roll out the bubbles in shrinking process by silicon roller while the sleeve is still hot and brush any
trapped air.

2.8 INSTALLED THE CLOSURE SEAL TAPE.

 Heat the adhesive surface of closure seal tape to melting then quickly center the closure on the
overlap region.
 Continuously heat the past closure seal to ensure that the adhesive layer fully melting using glove
hand smooth the closure patch firmly down with wrinkles roll out the closure area with roller to push
out the air voids.
 Material traceability records
 Manufactures certificates attached

2.9 SHRINKING PROCESS.

 Heat and shrink joint cover along the weld bead from the bottom to the top of the pipe and
press the shrunken part with gloved hands. Hand massage and/or application of a grooved
roller on the weld bead portions are effective means of removing possible entrapped air.

 Heat and shrink the longitudinal half of joint cover from the centre toward one edge of joint
cover by moving the torch up and down along the circumferential direction while holding
flame perpendicularly against the pipe surface. Proceed with the heat shrinking work
toward the end making sure that the shrunken parts are completely finished.

 Immediately after shrinking the longitudinal half of joint cover, massage the whole
shrunken part and the gap between the pipe and pipe coating with gloved hands. Also,
apply a flat roller on the flat surface of the pipe from the bottom to the top of the pipe where
the outer diameter of the pipe is more than 14 inches. Then, apply a profile roller from the
centre bead to the side edge of joint cover to remove the possible entrapped air in
between the pipe surface and joint cover. Also, apply the profile roller to heat seal tape and
the overlapping part in order to get rid of possible entrapped air while the adhesive is still
fluid.

 Apply the previous step to the other longitudinal half of joint cover.

 Heat shrinking process is completed when the adhesive flows out of all edges of joint
cover. If necessary, reheat and remove the possible entrapped air in between the pipe and
joint cover using a profile roller, etc.

2.10 QUALITY CONTROL DURING FIELD APPLICATION

2.10.1 PRELIMINARY INSPECTION

 Check Data sheet & batch identification for application material
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 Check storage condition.

 Confirm application method according to supplier.
 Calibration for instruments, equipment's with their certificates.

2.10.2 INSPECTION TEST DURING APPLICATION

 Visual inspection

 The visual inspection shall be the blast pipe surface is not contaminated with oil,
grease, or any other similar contaminant.

 Oil, grease, and other contaminants shall be removed by wiping the contaminated area
with a suitable solvent, detergent or potable water
.
 The pipe surface shall be checked to ensure that there is no moisture present on the
pipe surface and that there are no major steel defects

 Check for degree of surface cleaning

The blast cleaned surface shall be visually inspected after the blast cleaning in order to
determine the steel surface cleanliness degree.
The minimum surface cleanliness grade shall be SA 2 ½ Very Thorough Blast Cleaning
in accordance with ISO 8501-1.

 Check atmospheric ambient condition

 The ambient conditions shall be measured before the commencement of the pipe
surface blast cleaning
o Ambient temperature
o Ambient relative humidity
o Ambient dew point

 The pipe surface temperature shall be measured before the blast cleaning on the
incoming rack of the blast station. The steel surface temperature shall be a
minimum of 3°C above the ambient dew point.

2.10.3 INSPECTION AFTER APPLICTION

 Visual inspection (100%)

The coating shall be inspected 100% to ensure that the coating is free from blisters,
wrinkles, voids and disbandment

 Porosity test (holiday detector) in accordance with NACE RP-02-74 (100%)

 100% of the coating system shall be holiday detected in accordance with the
method defined test voltage set at 5 kv per millimetre of nominal thickness of
coating and not to exceed 25 kv.
 Each field joint coating shall be 100% tested for holidays with full encirclement
contact electrode.
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 The detector shall be switched on, with the voltage set at 25 kv, and the
electrode set to pass the test holes

 A spark discharge must correspond with every hole

 Adjust the test voltage to 25 kv.

 The conductive scanning electrode (brushes or rings) shall be maintained in

good contact with the tested pipe.

 With a maximum travel speed of the scanned pipe at 300mm/s, the coating
system shall be holiday detected 100 %.

 Peel strength (according to ASTEM d1000) one per shift

 This test method covers the procedure of evaluating the adhesion of applied 3L
PE coatings on steel substrates using the hanging weights method.
 Utility knife (sharp cutter)

 The test shall be performed at temperatures as agreed by client

.
o For test at elevated temperature C(according to data sheet ), the back side
of the steel shall be heated to the test temperature, which shall be
measured at the root of the peeled strip by means of optical pyrometer
.
o A strip of coating of minimum length of 160 mm shall be cut in
circumferential direction and 50 mm wide, perpendicular to the axis of the
pipe, and shall be isolated from the coated pipe

o Manually peel off the coating strip at an angle of 45  to the pipe surface
as the (fig 2).

o The test weight shall be suspended from the coating strip.

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(Fig 2)

2.11 REPAIR SYSTEM

 If the field joint coating does not pass inspection, the sleeve shall be removed while being hot and a
new sleeve shall immediately being applied.
 The repair procedure will be defined on site according to the type of defect and company's Site
representative will approve such procedure; otherwise, the sleeve will be removed and a new one shall
applied.
 Contractor shall submit detailed coating repair procedures for approval by Company.
 These shall detail minimum/ maximum areas for which each type of repair is applicable. Contractor
shall incorporate manufacturer data sheets and test data for materials to be used.
 The maximum defect allowable before the joint shall be classed as reject and re-coated shall not
exceed 5 percent joint (inclusive of damage caused by testing).
 Repairs shall provide a finished coating equal in effectiveness to that of the parent coating.
 Each repaired area shall be holiday inspected in accordance with this specification.
 Shrink sleeves may be considered an acceptable repair.
 Contractor shall submit coating stripping procedure for pipes selected for coating quality.
 Repair patch records at repair inspection report.

2.12 Equipment:

Certificates and calibration for all equipment submit at sit before start work, the equipment

Controller with QC inspection shall

check and inspect No. Of Items with H.S.E before
start work.
Compressor
Blast pot
Cylinder gas , Regulator , Hose , Flam torch
Hand Tool ,Knife , putty knife , Roller Rage ,
Marker
Air filter
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2.13. HSE REQUIREMENTS

 All safety aspects of the heat shrink work shall be the responsibility of the crew supervisor and shall be
in accordance with HSE manual.
 The labor force shall wear safety shoes, helmets, glasses and gloves at all times on site.
 Blasters shall wear protective helmets supplied with fresh air when operating abrasive materials
blasting equipment. Compressor used for blasting unit shall be properly earthed. During blasting
operation, entry for the unauthorized persons shall be restricted. Safety signboards shall be in place.
 Propane bottles shall always be placed in the upright position in suitable racks.
 All heating activities shall be in a controlled way. Fire extinguishers shall be kept nearby the heating
place. Propane cylinder shall be kept at safe distance from the heating place.
 Wind shields shall be used as and when required in order to protect the joint from depositing heating
joint area on a windy day.
 Manufacturer’s recommendation for safe handling and use of paints shall be complied with.
 All necessary precautions to meet local / Client requirements including working conditions, clothing, fire
and explosion hazards, safety equipment, solvents, lighting, venting and grounding of vessels shall be
complied with.
 Rags and other waste material soiled with paints, mixing shall be kept in tightly closed metal storage
while on the job or not in use.

3- EXCAVITION TRENCHING PROCEDURE

General: Contractor shall provide site “housekeeping” on a daily and continuous basis to ensure that the

site is free from scrap, debris, and rubbish at all times. Tools and equipment shall be properly stored and

set.

3.1 Trenching shall be completed by hydraulic excavators, assisted in hard ground by hammers (as

Necessary) to a depth & width to accommodate the pipeline sections in accordance with the alignment

sheets and typical trench details.

3.2 Trench sides shall be battered / tapered to 30 degree or angle of repose, where necessary, to allow
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personnel to enter the trench for cleaning if from loose rock or any foreign material and for leveling

an bedding purposes.

3.3 Care shall be taken to ensure that fresh material recovered from the trenching operation and which is

intended to be used for backfilling, over the pipe, in the trench or for the windrow (BERM), is not mixed up

with loose debris or foreign materials

3.4 Trenching shall be executed following the completion of survey and right of way grading

3.5 The trench shall be excavated before welding work or parallel welding work.

3.6 The pipeline to be laid shall be graded to contour to the right of way at the specified minimum cover

according to approved drawings and procedures.

3.7 The trench shall be surveyed following completion of excavation to ensure the trench bottom
conforms.

To the profile detailed in the bending schedule.

3.8 The trench shall be excavated to provide a minimum lateral clearance of 200 mm around the Pipe

3.9 The minimum depth of cover must comply with the values shown on the approved typical drawings.

3.10 Trench width in the sand dune areas shall be sufficient to allow the trench to be opened during the

construction period.

3.11 Excavation of trench shall be done in accordance with approved pipeline alignment sheets. Prior to

trenching approval shall be taken from COMPANY for pipeline centerline.

3.12 Where there is a change in direction, the trench shall be curved to accommodate the specified radius

of the pipe bend with 30 cm clearance left between the bended pipes’ wall and the trench edges.

3.13 Machine excavation is not allowed and only manual (hand) excavation shall be carried out within 5m

of an existing service, excavating by hand shall be carried out because mechanical excavation is

dangerous to the existing ground services. However, the trench must be free of stones, rocks and any

hard objects to avoid any damage to either the pipe or pipe coating.

3.14 If the trench is over depth, the trench shall be filled with suitable material until it reaches the required

depth and good consolidation.

3.15 Alignment during excavation shall be controlled by the surveyor.

3.16 The surveyor shall check the trench depth and ditch profile; if it is not within the limits and specs, the
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back end supervisor shall give the required instructions to carry out remedial work and the revised trench

shall be re-checked by the surveyor.

3.17 There shall be no free spans of pipes when laid, except those shown on the approved drawings.

3.18 Alignment of centerline stacks should be properly checked by Surveyor and Foreman prior to start

trench excavation and to be as per approved alignment sheets.

3.19 Trenching in sand dunes, where the pipeline is to be laid in sand dunes, the trench shall be cut to

ensure the minimum width at the trench bottom is in accordance with the typical drawings.

3.20 Crossings trench, where the trench is cut across existing access roads or tracks etc., temporary

bridges or diversions shall be made. The temporary bridges shall be of adequate strength and properly

constructed to ensure public safety and allow passage of normal traffic with minimum inconvenience and

interruption. Wherever deemed necessary by the Company, Contractor shall arrange to complete the

trenching, laying and backfilling of such crossings and to remove the temporary bridging before the end of

the regular work day in order to minimize the potential hazard to night traffic. Necessary permission from

relevant authorities will be obtained in writing, as applicable, before commencing any work and shall be

ensured that all regulations and requirements of that authority are complied with. Required warning signs

shall be provided at the crossings location.

4- LOWERING OPERATION PROCEDURE

4.1 GENERAL REQUIREMENTS

4.1.1 Document review for release for lowering and previous activities (welding, NDT, coating, etc.)

4.1.2 The pipe cradles used to lift the pipeline shall be smooth and suitable to hold the pipes

4.1.3 Cradles shall be recovered carefully to protect pipes and pipe coating from any damage

4.1.4 Laying in the trench shall be on fine sand bags at the trench bottom with 20cm at least.

4.1.5 Laying in shall be carried out using adequate equipment that is in the proper position in order

To avoid stress which may damage the pipes or pipe coating.

4.1.6 Laid pipeline shall rest fully on the trench bottom without touching its walls or being stressed.

4.2 PREPARATION AND TRENCH INSPECTION

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4.2.1 Before Lowering-in, the trench depth / width shall be checked and recorded to ensure that the trench

Is in accordance with the approved drawings and the trench section where the pipeline is to be lowered

Shall be checked thoroughly to ensure that they are free from pipe off cuts, skid supports, stones, debris,

Stakes, rock projections and any other rigid materials, which, if left under the pipe, could damage or tear

the coating of the pipe.

4.2.2 The bedding sand bags shall be located to ensure pipeline supporting prior to sand padding.

4.2.3 Padding material shall be soft soil containing no gravel, rock or lumps of hard material and shall be

placed in the trench bottom prior to lowering-in Operation. In case where the rock, gravel or hard material

is encountered on the trench bottom, sand-Padding thickness shall not be less than 200 mm.

4.3 FINAL CHECKING OF COMPLETED PIPELINE BEFORE LOWERING

4.3.1 Lowering of pipeline section shall start after acceptance of Pipe Book (Up to Field Joint Coating)

The pipeline section shall be released for lowering-in after completion of all NDT and field joint coating

activities.

4.3.2 Immediately prior to lowering a complete checking by a full circle holiday detector (spring type) shall

be carried out on the pipeline coating and the field joint coating, to ensure the integrity of the completed

pipeline coating system. Damages, if any, shall be repaired and cleared after holiday check as

per the approved pipeline coating repair procedure and ensure 100% holiday free pipeline. Each repair

shall be holiday detected to COMPANY satisfaction.

4.3.3 While carrying out of the above full circle holiday testing, special efforts shall be taken to check the

places / area where the pipeline had been in contact with the skids or with lifting equipment's during

laying. Holiday if any, shall be repaired, re-checked and cleared.

4.3.4 Holiday testing and coating repair shall be carried out in accordance with the COMPANY

Specification and approved coating repair procedure.

4.4 LOWERING

4.4.1 Three side-booms shall be used for the lowering in operation, equipped with proper pipe cradles

4.4.2 Side-booms shall work from the ROW side of the trench and be positioned 3m from the trench
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centerline.

4.4.3 The portion of pipeline between the trench and the bank shall be supported by side booms holding

the line in a gentle ‘S’ curve.

4.4.4 The vertical and horizontal alignment of the pipe shall conform to the contour of the trench and there

shall be no undue sag, twist or bend.

4.4.5 The 1st side-boom shall position its boom over the trench centerline while the 2nd and 3rd side-

booms shall position their booms to suit.

4.4.6 The 1st side-boom shall lower the line into the trench carefully, the 2nd and 3rd side-booms

shall lower in sequence to maintain a smooth line ‘S’ curve.

4.4.7 The lowering-in Forman shall be the person with sole responsibility for controlling the movement of

the equipment.

4.4.8 Following lowering-in, a surveyor shall take the level of the top of the pipe and the ground level in

order to check the cover and installed profile of the pipe. If any of the measurements are unsatisfactory,

the pipe shall be raised and the trench bottom re-leveled to overcome the problem. The pipe shall be

lowered again and the level re-checked.

4.4.9 Immediately after lowering-in and survey, a sand plug shall be placed in order to anchor the pipeline

against thermal movement until backfill is carried out. Use a loader or a backhoe in a suitable distance to

accomplish this.

4.4.10 The section lowered on the trench shall be in the center of the trench with the minimum distance

from the walls. In case there are bended sections, the pipeline shall be laid free of stress.

4.4.11 The Company representative has the right at any time to perform inspections to verify the pipeline

configuration.

4.4.12 Suspended section of pipeline between trench bottom and skids shall be supported using sufficient

side booms to hold the pipeline in a gentle S curve. Side booms shall be deployed with the lowering crew

consisting of lowering foreman, riggers and side boom operators.

4.4.13 The completed pipeline on supports/skids at the right of way will be lifted off, handled and laid
inside

the trench without any interruption for the whole length of the available section.
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4.4.14 Removal of pipe cradles shall be done in a manner, which shall avoid damage to the pipe coating.

5- BEDDING, PADDING AND BACKFILLING PROCEDURE

5.1 BEDDING

5.1.1 In soft ground, bedding is not required when existing soil at the bottom of the trench meets the requirements

indicated below.

5.1.2 When the trench is excavated in rocky or stony ground, EPC contractor shall provide the material required

for bedding. The bedding shall consist of fine graded soil with a particle size not more than 5 mm in 75%

corresponding proportion, 5-15mm in 15% corresponding proportion and 15-20mm in 10% corresponding proper

bedding material shall be spread at least 150 mm thick along the length of the trench bottom.

5.1.3 Bedding material shall be obtained from excavated material or from borrow pits approved by Company. The

excavated material shall be screened with suitable sieves.

5.1.4 The material used for the bedding shall be free of salt, organic material, hard bodies and approved by

company. Under no circumstances shall material used for bedding be contaminated by petroleum products, solvents,

concentrated acids or alkalis, or corrosive chemical compounds.

5.1.5 The suitable bedding material shall be transported close to the edges of the ditch with loaders, trucks or other

conveyance, spread evenly along the ditch bottom, and leveled off either manually or with special tools to guarantee

that the pipelines are in complete contact with the ditch bottom.

5.2 PADDING AND BACKFILLING

5.2.1 GENERAL

 Contractor shall pad and backfill the ditch after the pipe is in place as set forth in the approved construction

drawings. Before padding and backfilling, the ditch shall be inspected and any extraneous material shall be

removed. Before padding and backfilling, Contractor shall survey and record as-built measurements which shall

include location and record of the pipe joint number and welds. After the pipes have been lowered in the trenches

spanning about 4Km, Contractor shall finish the relevant padding.

 Padding material shall consist of fine graded material that meets the same requirements of paragraph.9.1 of this

procedure.

 Padding material shall be obtained from excavated material or from borrow pits approved by Company. In case the

pipeline is installed in a rocky area, excavated material shall be screened with suitable sieves or supply from sand
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quarries.

 Contractor shall place padding material over and around the pipe in a depth of at least 200 mm in such a manner

as to cause no damage to the pipe coating. The Contractor shall uniformly compact it to the required degree. (For

detail, see typical drawings of bedding, padding and backfilling of trench.) The depth of the padding shall be such as

to give the pipe in place the specified clearance from the hard material in accordance with typical drawings of

bedding, padding and backfilling. After the laying of the (Fiber Optical Cable) FOC padding is completed, an FOC

warning tape shall be installed for FOC. Remaining backfilling shall then be completed with excavated material free

from organic and aggressive soil and not containing stones larger than 150 mm in diameter.

 After the padding and backfilling operations are completed, resolved material shall be formed over the ditch line

and shall be neatly rounded to form a crown above the normal ground level. A crown shall not be created with

resolved material through cultivated land where the backfilling shall be completed with the removed and set aside

topsoil and subsequently leveled with the surrounding ground.

 Contractor shall remove and dispose of all soil materials from the ROW not used for backfilling in an acceptable

manner.

 Tie-in and FOC joints splicing:

A minimum number of three pipes at each side of the tie-in joint shall be exposed for convenience of operation,

which shall be padded and backfilled after completion of tie-in.

Fifteen meters of cables at each side of FOC joint shall be exposed for convenience of operation, which shall be

padded and backfilled after completion of FOC joint.

 Where the trench has been excavated through road / tracks, etc., all backfill shall be thoroughly compacted to 95

percent Proctor density. In certain cases, the COMPANY may require special compaction methods to be used

during backfilling of the trench to avoid settlement. The backfill surface shall be stabilized with crushed rock or other

suitable material as approved by relevant authorities. In all such cases, CONTRACTOR shall comply with the

requirements of the relevant Authorities as part of his scope of work for all operations up to reinstatement.

 Underground drainage that has been interrupted by trenching operations shall be carefully reinstated and any

damaged sections replaced. Backfilling shall be carried out without the use of mechanical equipment in locations

where, in the opinion of the COMPANY, damage may occur to any existing service or structure in the vicinity.