Method Statement Pipeline Repair [PDF]

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SHELL – IRAQ MAJNOON OIL FIELD – GENERAL

Method Statement for Pipeline Maintenance and Repair

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Contractor Approval

Company Approval

Company Identification

MAJNOON OIL FIELD DEVELOPMENT

000 Job No. 000

SHELL - IRAQ Contractor logo and business name

Contractor Identification

000

Engineering Contracting & Trading Contract No. 000 Vendor logo and business name

Vendor Identification

Order No. Facility Name

Location

MAJNOON OIL FIELD - GENERAL

OFF SHORE

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Method Statement for Pipeline Maintenance and Repair

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INDEX

1 2

SCOPE.......................................................................................................................................... 4 RESPONSIBILITY......................................................................................................................... 4 HEALTH AND SAFETY

3 4 5 6 7 8 9 10 11

DRAWINGS / REFERENCE DOCUMENTS..................................................................................6 ENVIRONMENTAL........................................................................................................................ 7 WORKING HOURS....................................................................................................................... 8 RESOURCES................................................................................................................................ 8 FACILITIES……………………………………………………………………………………………...…8 REQUIREMENT............................................................................................................................ 9 PROCEDURE SEQUENCE........................................................................................................... 9 Hydro Testing, Pre-Commissioning & Commissioning..................................................11 GRIT BLAST COATING AND WRAP WORKS 11

12 Back filling.................................................................................................................................. 11 13 Removal of isolations in sequence.......................................................................................... 12 14 Re Coating.................................................................................................................................. 12 15 Cathodic Protection and Corrosion Monitoring ………………………………………………12 16 IN-PROCESS EXAMINATION.................................................................................................... 13 17 NDT REQUIREMENTS................................................................................................................ 14 18 ATTACHEMNT............................................................................................................................ 15

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SCOPE The purpose of this Method is to define the minimum requirements of method adopted by AlKawther Engineering Contracting & Trading for the overall control of Pipeline Maintenance and Repair, complete excavation , cold cut , hot tapping , pipe works and the in process NDT examination for existing welds preferred both in plant Piping and infield Pipelines where fluid service is either sour or non-sour for the existing Majnoon flowlines.. API – 570 [ INSPECTION, REPAIR, ALTERATION, AND RERATING OF IN-SERVICE PIPING SYSTEMS ] defines a repair ' The work necessary to restore a piping system

to a condition suitable for safe operation at the design conditions. If any of the restorative changes result in a change of design temperature or pressure, the requirements for rerating also shall be satisfied. Any welding, cutting, or grinding operation on a pressure-containing piping component not specifically considered an alteration is considered a repair. The scope for ad hoc SERVICES includes but is not limited to - Sectional repair and replacement of defective pipeline - Sleeving of pipeline defects using approved propriety epoxy fillings - Installation of pressure rated clamps - Patch repair - Wrap repair - Draining, de-pressurizing, purging and cleaning of pipelines - Pipeline isolation - Flowline replacement and installation including commissioning and decommissioning - Maintenance and repair of pipeline integrity systems including but not limited to valves, flanges, cathodic protection systems and pig launchers and receivers. Please refer to the general welding procedure 000 xxxxxxxxxxxxxx – & NDT Procedure N0. 000xxxxxxxxxxxxxxx and coating control procedure 000xxxxxxxxxxxxxx for general information regarding activity to be carried out. SELL – Iraq as the COMPANY undertaking the redevelopment of Majnoon Oil Field in the south of the Republic of Iraq .

2 2.1

RESPONSIBILITY Site Manager (SM) Site Manager is responsible for the overall erection activities to be carried out during the project execution of scope of work and for implementation of this procedure. He shall be responsible for ensuring that all recommendations from any incident, Near misses are investigated and recommendations are implemented. General planning, giving instructions to area foremen to implement the safe and timely working operations and adherence to the Project Quality Plan.

2.2

Construction Manager (CM) Will report to SM and is responsible for overall construction activities, controlling, advising and supervision the erection crew to see the job on progress with proper quality, safe work environment and completion on time. He is responsible for preparation of Work Packs, field detailed designs, calculations, drawings related to Scope of WORK as required by COMPANY , and to verify that complete the general method of construction and detailing is satisfactory. and Approved by COMPANY

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Project Quality Manager QC Manager report to SM and shall be responsible for all Quality activities related to the Installation of any new brand materials including the administration of non-conformance management in close co-operation with various related departments. He is also responsible for the supervision of all related records / Reports and Quality Control. will require, check and manage, for properly filing in the Final Project Dossier, the required certification documents. Also within his responsibility to meet all requirements of the specifications, or, adequacy of construction method, quality of WORK

2.4

Site Field Engineer In cooperation with Site Manager, are responsible to verify the overall field welding works of Tie-in that all construction documents is in “updated” and in “Approved for construction” status. Moreover will verify that these documents are available on construction place to the operating personnel and/or subcontractor (if any). And responsible for the management of the resources to be provided management services as per the CONTRACT requirement. Provision of other general and administrative support, as may be required for the efficient performance of the WORK.

2.5

Supervisor Will give instruction to machine operators and workers to ensure implementation of the Quality Control Plan (QCP) and Inspection & Test Plan (ITP) applicable. Carry out on-going visual inspections on construction and working practices. Responsible for records, check sheets and time sheets and safe working operations.

2.6

HSE Manager Report to SM and is responsible for Ensuring compliance of Health, Safety and Environment during erection and including safety plan and direct safety training. He is responsible for ensuring that site management and supervisors correctly select and maintain safety and protective equipment within the requirements of the project. He is responsible for the investigation for all accidents and its causes and shall recommend preventive measures. Designated Supervisor for each activity will be assigned

2.7

HSE Supervisor HSE supervisor, reports to HSE Manager and is responsible for but not limited to the following: *Safety Policy

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Personal Protective Equipment(PPE) shall be issued to all workers such as safety shoes, helmets, working gloves, earplug, safety goggles(if required) and safety harness for workers who will be assigned in elevated places 1.8 meter and above

2.7.2

Personal Protective Equipment(PPE) shall be issued to all workers such as safety shoes, helmets, working gloves, earplug, safety goggles(if required) and safety harness for workers who will be assigned in elevated places 1.8 meter and above

2.7.3

All of work permit required for this working shall be applied and approved / issued by Owner and all members of the work party shall have a Tool Box Talk (TBT) outlining the requirements of the PTW and will sign their names on said TBT form prior to commence the work

2.7.4

The working area shall be cleared of non-essential personnel.

2.7.5

High standards of housekeeping are understood to be indicative of a safe workplace, during the course of all work activities workers shall continuously clear away any waste materials from the task including general waste to a designated place

2.7.6

Understand that the environment is an important issue for the project, and shall segregate the waste into the different waste streams generated by the work scope of this procedure, The working area shall be cleared to the satisfaction of company after work completed.

3 3.1

DRAWINGS / REFERENCE DOCUMENTS DOCUMENTS , CODES and STANDARDS

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SIPD-1496: -

03516-PLI-MEC-SPC

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ASME B31.3 Latest Edition ASME B31.4 : ASME Section V : API 5L Latest Edition API 1104 Latest Edition : 0000000XXXXXXXXXX : - API 570 Latest Edition

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ASME Sec. Ⅷ : 00XXXXXXXXXXXXXX : 00XXXXXXXXXXXXXX 000 XXXXXXXXXXXXXX 000 XXXXXXXXXXXXXX

:

Pipeline Maintenance and Repairs Sec IV Scope of Work Construction and installation of pipelines. Mechanical Works Process Piping Transportation System for Liquid Hydrocarbons Non-destructive Testing, Latest Edition. : Specification for Line Pipe Welding of Pipelines NDT Procedure Inspection, Repair, Alteration, and Rerating of In-service Piping Systems Rules for construction of pressure vessel Welding Consumable Control Procedure General Welding Procedure PROJECT QUALITY PLAN Health –Safety and Environment (HSE) Plan

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TERMS AND DEFINITIONS 2.2.1

Const

Abbreviations

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SHELL – Iraq Contract Administration: CONTRACTOR: Project Manager : Project Quality Manager Right of Way Scope of Work Personal protective equipment Quality Control Plan Job Safety Analysis

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Construction Manager

-

Site Manager

(COMPANY) (Engineering Contractor) Al-Kawther Engineering [ AKE ] ( PM ) (PQM) (ROW) (SOW) (PPE) (QCP)

(JSA) :

(CM)

:

- Inspection Test Plan - Explosives Reminisces of War Unexploded ordnance

(SM) :

( ITP) ;

(ERW) (UXO)

-Tool Box Talk

(TBT)

- Personal Protective Equipment - Majnoon Field Development - Right Of Way - Majnoon Operations Team

(PPE) (MFD) (ROW) (MOT)

2.2.2 - Site - Company : - Contractor :

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Definitions Mean the location where the project is to be constructed and thereof Shell - Iraq Alkawther Eng.

the vicinity

HEALTH AND SAFETY 4.1

RISK ASSESSMENT Refer to Project specific 00250600DFRC7402S – Risk Assessment the specific Risk Assessments apply: It is responsibility of the Site Manager, Project Engineer, Supervisor and HSE Project Manager to consider any concurrent risk or simultaneous operations when planning welding activities, in order to identify the need for further Risk Assessment of the Welding activities. It is responsibility of the Supervisor to assess, with the help of the HSE Officer in charge, to check the fully applicability of the above mentioned Risk Assessments. In case any of the activities to be carried out are not fully covered, because of concurrent operations and / or adjacent risk a specific Risk Assessment (Job Safety Analysis) shall be drafted and submitted to the HSE Project Manager. The JSA can refer to the above listed Risk Assessments and add only the identified additional risks.

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The JSA shall be discussed with all involved crew before activities commencing during the toolbox Talks. It is furthermore responsibility of the Supervisor to identify any change in the activities or incoming risk from adjacent environment and to take them into consideration in a specific JSA as described above.

4.2

SAFETY PRECAUTIONS All the new members of the contractor shall undergo a safety induction course in order to be aware of the work. Safety officer shall be available as and when required. HSE compliance shall be ensured as per contractor Management Plan – Workmen shall have all relevant PPE as required for the job. Only experienced technicians / skilled workmen shall be allowed to undertake the job. Necessary fire extinguishers & Personal H2S monitor shall be provided in the vicinity. A toolbox meeting shall be conducted to brief all concerned about Dos & Don’ts. Special coverage of salient points related to the job undertaken and risk involved, including course of action in case of emergency, shall be ensured during the session. After completion of the activities, the area shall be cleared of all equipment, Tools & tackles, surplus materials and debris generated from the works. CONTRACTOR shall have a developed HSSE Management System covering all activities under the CONTRACT that is compatible with COMPANY’s HSSE management system as described in Section VI – HSSE. As part of CONTRACTOR’s HSSE management system, CONTRACTOR shall develop a Contract HSSE Plan describing the specific actions, programs and procedures that will be implemented by CONTRACTOR to manage hazards associated with the execution of the Services. The HSSE Plan shall be developed in accordance with the COMPANY requirements. The Contract HSSE Plan shall cover all Contract phases from mobilisation through execution and demobilisation. CONTRACTOR shall ensure that any person, admitted to the Worksite by CONTRACTOR shall comply with COMPANY requirements. All persons engaged in the Services shall be conversant with and, at all times, strictly comply with the HSSE standards. CONTRACTOR shall be required to continuously maintain a system of hazard management so that HSSE lapses are quickly identified and corrected before they result in an accident. All equipment, including but not limited to vehicles, lifting equipment, accessories etc used in the execution of the Services are required to fully comply with COMPANY HSSE standards and any Iraqi law, regulation and/or approval process. Equipment must be correctly maintained, with a valid record of such maintenance available for audit and validation at COMPANY request. COMPANY reserves the right to restrict or reject the use of certain equipment, if in their opinion, any breach of standards has or likely to have occurred. CONTRACTOR shall ensure that all personnel involved in the execution of this CONTRACT will be issued with the appropriate Personal Protective Equipment (PPE)

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and shall ensure all personnel shall be adequately trained. PPE shall meet the standards of COMPANY PPE being used and is be approved by the COMPANY.

4.3 Emergency Response and Evacuation Plan CONTRACTOR shall make available the Core Team, Equipment and Temporary & Other Facilities above for an Emergency on a 24hr/7day call-out basis to deal with a pipeline emergency. Core Team shall be on site as per normal working hours in 2.1.1 above, and all team members must be available for call-out at any time to provide first line support in an emergency such as a pipeline leak. 3.4 Worksite Handover ERW CLEARANCE and Permit to Work The PROJECT SITE is characterized by local population and high level of unexploded ordnance (UXO) and Explosives Reminisces of War (ERW) from recent conflicts. COMPANY shall provide UXO and ERW clearance of the WORK SITE. Before commencement of the WORK, independent confirmation of ERW clearance must be received by CONTRACTOR from COMPANY complete with third party ERW QA/QC Documentation. CONTRACTOR shall comply with the ERW CERTIFICATES & ERW QA/QC limits and excavation WORK requirements. Where excavations are required deeper than the ERW permit clearance limits, then CONTRACTOR shall clearly define such locations and request additional ERW Clearance from COMPANY. CONTRACTOR shall obtain all permits issued under COMPANY’s Permit-to-Work System, required to perform the WORK, such as, but not limited to, access and excavation permits. CONTRACTOR shall keep and maintain record of all permits to Work and release of area by ERW clearance complete as per Section - VI (Health, Safety, Security and Environment) and where otherwise specified.

5 ENVIRONMENTAL The table below outlines the environmental risks associated with the pipeline and flowlines works at site. Environmental Risk

Description

Spill Control

ACTION/ MITIGATION

Re-fueling of the plant will not be

A designated re-fueling area will be established

undertaken within 30m of an existing

and spill kits will be provided on the trucks at all

surface water course

times to ensure they have the necessary equipment to deal with any hydrocarbon spill.

cleared vegetation Waste & contaminations

shall be disposed of in an environmentally friendly manner generated by the work scope of this procedure,

according to the approved environmental waste management procedures Shall be segregate the waste into the different waste streams waste

6 WORKING HOURS Working hours to be dictated as per programme of works and statutory norms requirements. AKE Eng. will erect localised task lighting if extended working hours are required. COMPANY will be informed if extended hours are required.

Company Identification

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RESOURCES 7.1 PERSONNEL -

7.2

Contract Manager Site supervisor Planner HSE Supervisor (s) Foreman Pipe-fitter(s) Welding Engineer/Technician(s) Welding Inspector(s) Coating / Holiday Inspector(s) Welder(s) Pay welder operator(s) Side-boom operator(s) Excavator operator(s) Grinder(s) Unskilled Worker/Helper(s) Hiab Truck driver

EQUIPMENT’S

1 x 400 Amp Welding Set (Excluding Consumables) 1 x Welding Rectifier LTG 400 or equivalent 1 x Welding Generator KHG 500 P ESAB or equivalent 1 x Electrode Baking Oven 1 x Grinding Machine 1 x Air Operated Cold Cutting Machine 1 x Beveling Machine (4 Inch to 32 Inch) 1 x Hydraulic Torque Wrench (6 Inch to 32 Inch 600# Flange Wrench and above) 1 x Gas Tester (H2S, CO, MH4 etc) & Breathing Apparatus equipment 1 x Holiday Detector 1 x Mobile Generator Set 20 KVA - mobile Car(s) and 4WD truck(s) 60 tons Side-boom(s) 100-200 HP Excavator(s) External Clamp(s)

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Oxy-acetylene cutting machine(s) Technical gas (e.g. propane, etc.) Lifting devices (e.g. slings, etc.) Hessian bags

7.

Facilities

1 x Mobile Toilet Facility, including wash basin, soap dispenser, hand drying equipment 1 x Storage Container (Air Conditioned) - 20 foot - including shelving 1 x Storage Container - 20 foot (Non Air Conditioned) - including shelving 1 x Pick-Up Truck 4 x 4 (4 Seater/double cabin) (No.1)

1 x vehicles for transport of CONTRACTOR personnel to and from work-sites. Adequate communication means via GSM and Internet between CONTRACTOR Base, sites and COMPANY site representatives Utilities for office, ablutions block and the like (Electricity, water, etc...).

CONTRACTOR

Fabrication Workshop (minimum 10M x 10M) for Fabrication of Steel Structures, Testing and Calibration Site office, minimum 8m x 3m Cabin or similar, suitably equipped for four personnel

with

air conditioner, well stocked first aid box and

Secure Fenced area for storage of COMPANY’s equipment (min. 25M x 25M area with 2M high fence with barbed wired on top Daily Cleaning of Facilities and provision of all basic welfare supplies. lighting for the Temporary Base Location

8 8.1

.

REQUIREMENT DRAWINGS , ENGINEERING AND REPORTING

8.1.1 Pipeline shall have approved drawings by Engineering. Following steps shall be followed in accordance with this method statement Contractor shall make . preparation of Work Packs, field detailed designs, calculations, drawings related to Scope of WORK as required by COMPANY. The approval of the drawings/ documents and WORK etc. by COMPANY shall not be construed as a complete check but will indicate only that the general method of construction and detailing is satisfactory. Approval by COMPANY of CONTRACTOR’S drawing or other documents and WORK shall not relieve CONTRACTOR of its obligation and responsibility to meet all requirements of the specifications, or, adequacy of construction method, quality of WORK and HSE compliance

8.1.2 8.1.3

COMPANY shall review and approve the CV’s of all KEY Personnel CONTRACTOR shall coordinate with the COMPANY REPRESENTATIVE to ensure that interface with the

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8.1.4

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COMPANY and other Contractors are managed. CONTRACTOR in consultation with COMPANY shall develop and implement all the procedures and plans required by the CONTRACT for the performance of the WORK in a safe, secure and environmentally responsible way and in accordance to the CONTRACT. Where the CONTRACT does not specify particular procedures, plans or systems but such are necessary for the proper execution of the WORK, CONTRACTOR shall develop and implement such procedures, plans and systems.

8.1.5 CONTRACTOR shall be responsible to submit and carry out Welding Procedure Qualifications and Welder Qualifications, as applicable for the CONTRACT, which shall be subject to approval by COMPANY. 8.1.6 All relevant documentation shall be available in the work pack before it is issued to the Performer. 8.1.7

The Performer shall identify, select and offer for the QC review, the most suitable welder(s) to perform the welding. The welder selection shall be based on technical competency, historical performance records from recently performed welds, historical repair rate and current certification. Selected welder/s shall be approved by the company. 8.1.8 CONTRACTOR shall prepare and submit reports on the Work done as required by COMPANY and in a format acceptable to COMPANY. All such reports shall require approval of COMPANY prior to being issued formally. COMPANY reserves the right to reject any report, in part or in whole, which does not comply with the requirements stated. However, CONTRACTOR can agree with COMPANY, deviations on format and contents. CONTRACTOR shall prepare and submit the following reports on the Work done. The preparation and submission of these reports shall be considered a fundamental condition for satisfactory completion of the Work.

8.1.9

Daily Report CONTRACTOR shall submit a daily report detailing the availability of equipment and personnel working as Core Team during the previous 24 hours. During the SERVICE ORDER period, CONTRACTOR is required to submit a daily activity report every morning to the COMPANY representative which shall include details of the work performed, the activities undertaken, number of man-hours worked, all incidents and accidents (if any and as per Shell HSSE policy), time constraints and areas of concern for the previous 24 hours. The daily report shall be submitted to the COMPANY Site Representative no later than 17.00 hours on the day following the date of the report. CONTRACTOR shall prepare report format for COMPANY approval.

8.1.9

Weekly Progress Report During the SERVICE ORDER period, COMPANY may request CONTRACTOR to submit a weekly progress report (a week shall be from Saturday to Friday) to the COMPANY Representative in the form of a Gantt chart, the progress of each plan including actual progress versus planned progress. The weekly report shall be submitted to the COMPANY Site Representative no later than 09:00 hours on the Saturday of the following week. CONTRACTOR shall prepare report format for COMPANY approval.

8110

Monthly Report nd

CONTRACTOR shall submit a monthly report on the 2 day of every month which summarises the contents of daily and weekly reports. CONTRACTOR shall prepare report format for COMPANY approval. CONTRACTOR shall report KPI’s (refer Article 10 below)

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8.5

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RESOURSES & MATERIAL MANAGEMENT CONTRACTOR shall be responsible for the management of the resources to be provided. CONTRACTOR shall provide the personnel, systems, equipment, tools and facilities necessary to effectively perform the WORK. This shall include, but not limited, to: 8.5.1 WORKSITE management services as per the CONTRACT requirement. Provision of other general and administrative support, as may be required for the efficient performance of the WORK. 8.5.2

Receipt control, storage and handling of equipment and materials and maintenance of a Material Control Inventory system and procedure throughout the duration of the CONTRACT . Any material or equipment that CONTRACTOR wants to use for ad hoc SERVICES shall be pre- approved by COMPANY and non-propriety equipment shall be the most competitively priced selected from a minimum of three technical and commercial quotes .

8.5.3

Local government bodies’ clearance/approvals/permit etc. as required for performance

of Scope of WORK. 8.5.4

CONTRACTOR shall provide storage area for COMPANY supplied materials. CONTRACTOR’s scope includes the collection and inspection of COMPANY supplied materials including loading and transportation from COMPANY store/yard and subsequently taking responsibility/ ownership for such materials. Any defects found in such material/equipment following acceptance by CONTRACTOR shall be made good at CONTRACTOR’s account to the satisfaction of the COMPANY. All materials supplied by CONTRACTOR must be ordered, inspected and expedited by CONTRACTOR. CONTRACTOR is responsible for material tracking and providing all documentation needed for supplied goods. COMPANY shall perform pre-mobilisation inspections on equipment, tools and materials and issue to CONTRACTOR a premobilisation certificate prior to the mobilisation to the WORK site.

8.5.6

8.5.7

Supply of manpower, equipment, tools, materials, etc in the capacity as listed in Schedule B of section III complete with management and administration etc

CONTRACTOR shall develop and implement a Materials Management System and procedures to ensure the safe and secure handling of all materials.

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8.5.8

8.9

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CONTRACTOR shall hand over all the surplus COMPANY Free Issued materials to COMPANY in good condition suitable for future use and complete with all associated certification, permits and licenses. All surplus COMPANY Free Issue Material shall be fully documented in accordance with a Materials Management procedure to be developed and implemented by CONTRACOR.

CO-ORDINATIONS WITH OTHERS CONTRACTOR shall, at all times coordinate with the COMPANY REPRESENTATIVE to ensure that interfaces with COMPANY and other contractors are managed correctly. CONTRACTOR shall coordinate with COMPANY Operations authority for all related construction activity requisites by: 8,9.1

Attending coordination meetings with COMPANY

8.9.2

Planning and shifting resources to meet specific Project/operational needs

8.9.3

Enhancing resources and working with COMPANY and other contractors to meet operational constraint in WORK areas without impacting SERVICE ORDER schedule as far as can be reasonably accomplished.

8.9.4

RFI Request for Inspection shall be issued by the Contractor to Company with prior 24 hours’ notice after Preliminary verifications in process examination during the entire preparation and execution phases of the repairing activity .

. . 8.10 EARTH-WORK MATERIALS 8.11.1

CONTRACTOR shall be responsible for obtaining and importing suitable materials for earthworks filling. CONTRACTOR shall supply plant, equipment and labour to extract and excavate materials and load into vehicles at the borrow pits/quarries. The borrow pits and quarries are to be approved by COMPANY. CONTRACTOR shall also be responsible for obtaining licenses and approvals from relevant authorities. The costs for obtaining licences/approvals and acquiring soil/gravel material resources shall be deemed to be included in the CONTRACT rates and prices.

8.1.1 All material to be supplied by CONTRACTOR is subject to inspection and approval by COMPANY. Wherever possible CONTRACTOR shall comply with COMPANY approved Vendor Lists. CONTRACTOR shall submit the required documentation and certificates of compliance before start of WORK, which shall confirm that all materials provided by CONTRACTOR, meet COMPANY requirements.

8.1.2

CONTRACTOR shall provide sufficient and suitable vehicles to transport the quantities of soil and gravel to the sites in accordance with the schedule. CONTRACTOR will be responsible for all traffic management including the direction and control of vehicles importing material to WORKSITE in full compliance with COMPANY Journey Management Policy.PROCEDURE SEQUENCE

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9 PROCEDURE SEQUENCE

9.1 Site preparation. 9.1.1

Conduct site survey with the Company’s representative and confirm plant specifications 9.1.2.The site specifications should be recorded and cross-checked with the Company.

9.1.1

All discrepancies should be noted and discussed with the Company’s representative .

9.1.2

Conduct pre-work risk assessment.

9.1.3

Minutes of the risk assessment should be recorded and attached to the worksite permit.

9.1.4

Contractor senior representative on site will conduct a toolbox talk with all personnel affected by the operation.

9.1.5

Minutes of the toolbox talk should be recorded and attached to the worksite permit.

9.1.6 9.2

Raise appropriate work permits.

FREEZE PLUG & PIG ISOLATIONS Site field Engineer and Pipe supervisor should coordinate with Construction manager to ask company/MOT that isolation valve on existing pipeline line should be closed and verified. Also they should check whether pressure release on existing pipe or not after valve closed. Verification of process and mechanical isolations by CONTRACTOR/COMPANY/MOT Confirm identified isolations and spades are cross referenced onto PTW and isolation certificates CONTRACTOR shall, when required, mobilize a specialist Contractor for the Freeze Plug Isolation of pipeline sections. CONTRACTOR shall provide full assistance to COMPANY to complete and maintain the freeze plug isolation for the period required for flushing, cold- cutting and welding of the new line section, in order to complete the required pipeline repair. CONTRACTOR shall, when required, mobilize a specialist Contractor for pipeline isolation using friction or smart pigs. CONTRACTOR shall provide full assistance to COMPANY to complete and maintain the line isolation for the period required for flushing, cold-cutting and welding of the new line section in order to complete the required pipeline repair.

9.3

EXCAVATION Excavation is a temporary civil work on which persons work and which provides support for the materials used in construction, maintenance, repair or demolition work. It can also be used to obtain access to certain areas of equipment and pipelines to proceed the required inspection . CONTRACTOR shall use pipe detectors for identifying the pipeline location and route. All

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excavation and back filling/padding shall be carried out as per specification to be specified in the SERVICE ORDER. CONTRACTOR shall submit a detailed method statement for each excavation. All pipe exposing activities shall be carried out manually unless specified otherwise in the Permit to Work. 9.4 . COFFERDAM CONSTRUCTION CONTRACTOR when required shall construct cofferdams to provide an all season work environment for emergency pipeline repairs in areas with high water table and water canals. CONTRACTOR shall provide all materials and equipment required for the construction of the cofferdam. All cofferdam construction materials (H-beams, sheet piles etc.) shall be retrieved and WORKSITE re-instated to the original condition after the pipeline repairs. CONTRACTOR shall submit a detailed method statement for each coffer-dam application.Coating Removal Paint, Coating or Wrapping material shall be carefully removed from the existing pipeline area to be subjected to inspection . Before coating removal, where applicable, disconnect cathodes protection from the buried sections of pipes. 9.5

WATER & OIL DRAIN Contractor piping supervisor should provide Truck pump to evacuate oil and water out from the pipe line or flow line if required. For Draining, depressurising, purging and cleaning of pipelines

9.6

SURFACE CLEANING , WALL THICK. & VISUAL INSPECTION CONTRACTOR shall survey and re-establish COMPANY ROW boundaries prior to clearing the ROW for pipeline repair. All clearing shall be restricted within COMPANY ROW and as per the SERVICE ORDER scope. All cleared vegetation shall be disposed of in an environmentally friendly manner according to the approved environmental waste management procedures. The CONTRACTOR shall obtain COMPANY approval for additional temporary ROW required for the execution of Scope of WORK. The additional soil fill materials, where required, shall be from COMPANY approved borrow pits. CONTRACTOR when required and by instruction of COMPANY, shall expose and prepare for inspection, sections of flowlines and pipelines in accordance with the applicable documents within the CONTRACT. The identified pipeline flowlines sections shall be exposed, de-coated and UT inspected by COMPANY approved inspection CONTRACTOR. Based upon the inspection results, CONTRACTOR shall execute the COMPANY preferred pipeline repair method. The section of existing run pipe to which the repair and maintenance to be carried out shall be thoroughly cleaned properly with grit blasting , power brush for a distance extending 150O mm either side of the location of the specified area. After cleaning, the pipe shall be visually examined externally for laps, cracks, pitting and other signs of mechanical damage or general corrosion . defect and leak locations to be identified . The minimum actual wall thickness to be checked and comparison with the design data respected with corrosion allowance to be verified / Company approval to be taken on thickness readings reports and visual in spection reports with recommendations.

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9.7

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ABANDONMENT OF PIPELINE CONTRACTOR when required shall assist in the execution of abandonment of pipeline. The main activities consist of the excavation of the applicable pipeline section and this section needs to be cut and removed by the CONTRACTOR. All recovered sections shall be cut into 3m pieces and returned to COMPANY yard. In case a section of the line is not fully accessible for recovery, CONTRACTOR shall drain the section from oil and apply a cleaning programme under COMPANY direction. CONTRACTOR shall ensure that no spills occur during cut-out and removal of pipeline section / pieces. All recovered crude shall be discharged at COMPANY nominated flow station.

9.1 HOT TAP & STOPPLING CONTRACTOR when required shall mobilize a specialized Hot Tapping Contractor to provide hot tapping and stoppling activities. CONTRACTOR shall provide full assistance to COMPANY for completion of this activity. . 9.8

REPAIR METHOD CONTRACTOR shall suggest the recommended repair method for each pipeline section according to site survey , visual inspection and thickness measurement readings . The proposed repair and maintenance method to be submitted to COMPANY should do Assessment and identification of repair method for approval prior to implementation. These methods should be one of the following :

9.1

Sleeving of Pipeline Defects CONTRACTOR shall, when required, execute the sleeving of defective pipeline sections in accordance with the responsibility matrix and other documents within the CONTRACT. This work shall include the excavation to expose the defective pipeline section. In addition the work includes de-coating and full NDT inspections to confirm the areas to be sleeved. Where metal sleeves are specified, DPT, MPT or X-ray tests shall be carried out by CONTRACTOR to determine the quality of welds. CONTRACTOR shall, when required, provide sleeving repair with epoxy filling which may require using a specialist service provider. The service provider and repair procedure shall be pre-approved by COMPANY. metal sleeves are specified, DPT, MPT or X-ray tests shall be carried out by CONTRACTOR to determine the quality of welds. CONTRACTOR shall, when required, provide sleeving repair with epoxy filling which may require using a specialist service provider. The service provider and repair procedure shall be pre-approved by COMPANY. The longitudinal seam welds of full encirclement sleeves should be tested in accordance with 5.6. The backing material, if used, should be removed and the specimens may be flattened at room temperature before testing.

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Appropriate gasket material

Figure C-1—Encirclement Repair Sleeve

Fluid in

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Note: T = tensile; RB = root bend; FB = face bend; NB = Nick-break; SB = side bend; MT = macro test.

Figure B-3—Location of Test Specimens—In-service Welding Procedure Qualification Test

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The face-bend specimens (see Figure B-5) should be

approximately 9 in. (230 mm) long and approximately 1 in. (25 mm) wide. They may be machine cut, or oxygen cut oversized and machined by a non-thermal process to remove at least 1/8 in. (3 mm) from each side. The sides should be smooth and parallel, and the long edges rounded. The sleeve or branch and reinforcements should be removed flush with the surface, but not below the surface of the test specimen Any undercut should not be removed. Note: In lieu of taking separate specimens for the face-bend test, the remaining portion of the nick-break specimens may be used. SLEEVE WELD

Note: This test position qualifies the procedure for all positions. Tests may be performed in other positions which will qualify the procedure for that position only.

Figure B-2—Suggested Procedure and Welder Qualification Test Assembly

1/ " 2

(13 mm)

Attachment wall thickness

Pipe wall thickness

Note: Smooth and etch at least one face of each weld specimen cross section with a suitable etchant to give a clear definition to the weld structure.

Figure B-4—Macro Test Specimen—In-service Welds

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Wall thickness Weld ground flush

(see Note 2) Wall thickness BRANCH WELD

(see Note 3)

SLEEVE WELD Test specimen

See Note 1

Approximately 1" (25 mm)

Approximately 9" (230 mm) SLEEVE/ BRANCH REMOVED 1/ " 8

(3 mm) max. R all corners

Notes: 1. Test specimens may be machine cut or oxygen cut oversized and machined (see B.2.4.5.1). 2. The sleeve or branch weld reinforcement should be removed flush with the surface of the test specimen. The branch weld test specimen is shown in the axial direction; specimens in the other direction are curved. Test specimens should not be flattened prior to testing. 3. Where wall thickness is greater than 0.500 in. (12.7 mm), it may be reduced to 0.500 in. (12.7 mm) by machining the inside surface. 4. In lieu of taking separate specimens for the face bend test, the remaining portion of the nick-break specimens may be used.

Figure B-5—Face-bend Test Specimen Sleeve Fit-up For sleeve and saddle welds, the gap between the sleeve or saddle and the carrier pipe should not be excessive. Clamping devices should be used to obtain proper fit-up. When necessary, weld metal build-up on the carrier pipe can be used to minimize the gap.

9.2 Pipeline Clamping CONTRACTOR, when required, shall carry out pipe clamping using pressure rated clamps and in accordance with COMPANY Specifications.

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Temporary repairs of locally thinned sections or circumferential linear defects may be made on-stream by installing a properly designed and fabricated bolted leak clamp. The design shall include control of axial thrust loads if the piping component being clamped is (or may become) insufficient to control pressure thrust. The effect of clamping (crushing) forces on the component also shall be considered. During turnarounds or other appropriate opportunities, temporary leak sealing and leak dissipating devices, including valves, shall be removed and appropriate actions taken to restore the original integrity of the piping system. The inspector and/or piping engineer shall be involved in determining repair methods and procedures. Procedures that include leak sealing fluids (“pumping”) for process piping should be reviewed for acceptance by the inspector or piping engineer. The review should take into consideration the compatibility of the sealant with the leaking material; the pumping pressure on the clamp (especially when repumping); the risk of sealant affecting downstream flow meters, relief valves, or machinery; the risk of subsequent leakage at bolt threads causing corrosion or stress corrosion cracking of bolts; and the number of times the seal area is repumped 9.3 Patch repair Fillet-welded patches require special design considerations, especially relating to weld-joint efficiency and crevice corrosion. Fillet-welded patches shall be designed by the piping engineer. A patch may be applied to the external surfaces of piping, provided it is in accordance with 8.1.3 and meets either of the following requirements: a. The proposed patch provides design strength equivalent to a reinforced opening designed according to the applicable code. b. The proposed patch is designed to absorb the membrane strain of the part in a manner that is in accordance with the principles of the applicable code, if the following criteria are met: 1. The allowable membrane stress is not exceeded in the piping part or the patch. 2. The strain in the patch does not result in fillet weld stresses exceeding allowable stresses for such welds. 3. An overlay patch shall have rounded corners (see Appendix C). Size of the patch should not exceed 1/2 the pipe diameter. A full encirclement sleeve should be used if the corroded area exceeds 1/2 the diameter

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9.1 . Flowlines Construction (New and Replacement) 10

9.3.1

10

9.3.2

During the life of CONTRACT it may be necessary to replace existing or install brand new flowlines. CONTRACTOR shall, when required by COMPANY, replace part of, or install a completely new flowline, which will typically be no more than 7 km long. Scope of flowlines, repair or installation will be described in a SERVICE ORDER and include but not be limited to: Receiving handling, storage, transportation of line pipe material to yard or Work Site 9.3.3 Stringing, bending, lining up, swabbing, bevelling, alignment, preheating as required, cField testing & installation of valves and any other ancillary

9.3.4 9.3.5

WPQR, WQT and welding of field joints Installation of fittings/induction bends/inline items applicable), lowering, tie-in welds, repair of weld joints,

etc, NDT, heat

treatment

(if

9.3.6 Application of shrink sleeves, coating & coating repair, holiday inspection coating qualification including supply of material, 9.3.7

Clearing trench, installation of temporary & permanent pipeline markers, cleaning etc

9.3.8

CONTRACTOR shall submit method statements and resources to complete the work safely. CONTRACTOR shall prepare and qualify proposed welding procedure specifications according to the requirements of COMPANY Standard Specification DEP 31.40.60.12, API RP 2200 and latest edition of API 1104.

10

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Grinding and welding for repaired pipelines . The production welding shall be performed in accordance with the approved Welding Procedure Specification The welder and welding operator shall be qualified in accordance with welder and welding operator performance qualification procedure Welding consumable control shall be as per approved Welding Consumable Control Procedure

9.10 WELD INSPECTION CONTRACTOR shall be responsible for carrying out all the tests, inspections and all QA/QC WORK required, demonstrating the quality of the WORK as per section VII. This shall include all test and inspection equipment and trained personnel such as Radiographic inspection of welds (X-ray) developing and Interpretation, reporting etc. These activities shall be carried out by a licensed company to be approved by COMPANY. All butt welded joints after visual inspections, shall be subjected to 100% radiographic examination. For fillet welded attachments, weld examinations shall be by magnetic particle inspection (MPI) or Dye Penetrate Test (DPT) as specified by COMPANY. CONTRACTOR shall provide all equipment and certified experienced personnel complete with standard well equipped air conditioned darkroom for all NDT tests. All NDT test procedures and NDT tests results shall be reviewed and approved by COMPANY 9.11.1

Visual Inspection of Welds Regardless of any other method of examination used, the welds shall be subjected to visual examination and be free from injurious defects

9.11.2.

Radiography All weld joints shall be examined by the Radiographic test in accordance with ASME Code and approved procedure, and the acceptance criteria shall be in accordance with the specification, which covers the run pipe. Radiography works shall be carried out in accordance with approved procedure

. 10 Hydro Testing, Pre-Commissioning & Commissioning CONTRACTOR scope during hydro-testing, pre-commissioning and commissioning includes but is not limited to: 10.1

Submit a general approval

pressure

testing

procedure

for COMPANY’s

review

and

10.2 - Prepare detailed test procedures for COMPANY’s review and approval, before actual tests are carried out 10.3 Provide certification for all test equipment for use in hazardous areas dObtain approval from COMPANY for all test instruments 10.4 Carry out witnessed calibration tests at COMPANY’s sole discretion

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10.5 Carry out pressure testing in the presence of COMPANY’s Site Team and CONTRACTOR’S QA/QC personnel of the affected section in accordance with COMPANY Specifications 10.6 Record, compile and retain copies of the test clearance sheets, pressure test records and charts. Originals of these documents to be submitted to COMPANY as part of the as-built package immediately after the pressure test operation. 10.7 Request from COMPANY a certificate of “Complete and ready for commissioning” which shall be issued by COMPANY if the work for the said part is performed to satisfaction Testing and Pre-commissioning of all pipelines includes but is not limited to; supply & filling suitable quality water with chemical inhibitors (if required), supply & install all temporary connections, hydro testing, pressurization for required duration, dewatering, disposal of hydro test water including temporary connections as required, flushing, drying, all pigging (except intelligent pigging), nitrogen purging, etc. in accordance with the CONTRACT. CONTRACTOR shall de-water all pipelines after repairs, testing but prior to commissioning. All equipment and fittings required for de-watering shall be supplied by CONTRACTOR. All pipeline contents shall be retrieved into CONTRACTOR supplied tanks or excavated lined containment pits. CONTRACTOR shall submit method statement for hydro testing and pipe cleaning clarifying water source used for hydro test and disposal of hydro test water, complete with equipment list and arrangement, in accordance with COMPANY HSSE requirements .

10

GRIT BLAST COATING AND WRAP WORKS All material surface of pipe shall be cleaned with power tool before coating and wrap works at sites. Damaged coating and wrap tape surface shall be repaired in accordance with appoved procedure after pressure test

11

Back filling Back filling and compaction will be carried out on completion of works and in accordance with procedure No:0000000 xxxxxxxx

12

Removal of isolations in sequence On satisfactory completion, in accordance with the MOT PTW procedure, CONTRACTOR shall inform Company in order for process and mechanical isolations to be removed. Removal of isolations by MOT shall be in sequence and verified by CONTRACTOR and Company.

13

Re Coating Coating and wrapping shall be carried out in accordance (00XXXXXXXXXXXXX_EXDE00_00 Coating Control Procedure). 14.1 HOLIDAY DETECTION

with

procedure

No:

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The whole surface will be inspected with a holiday pulse-type detector. The detector voltage for wrap will be: MAX . 25 KV – (to be confirmed by the Manufacturer Spc.) The detector voltage for coating will be 8.0 KV /1000 µ ( max 20 KV ) The electrode used for locating holidays shall be designed to ensure direct contact with the coating (with no visible gaps) and must provide complete coverage of the whole coated surface. Holiday detection shall not be conducted if the surface temperature of the pipe is above 90°C. The travel rate of the detector's electrode shall not exceed 0.3 m/s and shall not be allowed to remain stationary while the power is on. The holiday detector output voltage shall be calibrated twice per ten (10) hour shift. 11 . Cathodic Protection and Corrosion Monitoring 15.1 CONTRACTOR shall, when required by COMPANY, use an approved specialist service provider to carry out cathodic protection survey, design and troubleshooting services. SERVICES include but not limited to: 15.2 Installation and maintenance of transformer rectifier units b- Installation and replacement of ground bed material 15.3 Installation, replacement and commissioning of sacrificial anodes 15.4 Installation and maintenance of junction boxes, reference electrodes and test posts e- Installation of spark gap arrestors and isolation kits 15.5 Cable laying and splicing g-Cad welding Pre-commissioning and commissioning of impressed current and sacrificial anode systems 15.6 Support COMPANY Corrosion Engineer in execution of routine Cathodic Protection and 15.7

16

Corrosion Monitoring activities.

IN-PROCESS EXAMINATION In-process examinations shall be performed by Performer JV QC and witnessed by the company in accordance to the requirements of ASME B31.3 Section 344.7. All phases of the process shall be documented on approved by company forms. The following items and parameters shall be witnessed, verified and recorded:

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Material certification and traceability verification. This shall be performed prior to the commencement of the job.

13.1

WPS applicability. This shall be performed prior to the commencement of the job.

13.2

Welding equipment availability and quality verification. This shall be performed prior to the commencement of the job.

13.3 Welders’ certification. Welders selected shall be the most qualified contract welder(s). 13.4 The welder selection shall be based on technical competency, number of previous repairs and current certification. This shall be performed prior to the commencement of the job. 13.5 Verify NDE personnel by company that have demonstrated the test. This shall be demonstrated prior to the commencement of the job. 13.6 Verify NDE equipment meets the requirements of the applicable NDE procedure. This shall be performed prior to the commencement of the job.

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13.7 Verify if a temporary shelter needs to be erected to provide weather protection as the weld is being made. 13.8 Hydrogen bake-out. Witness band setup and verify temperature if applicable. 13.9 Witness bevel, parent metal preparation and NDE of the beveled face. 13.10 Witness joint fit-up. Verify root gap and ensure that any inside miss match are within required specifications. 13.11 Verify pre-heat temperature. 13.12 Verify welding parameters are within those specified in the WPS. These include Amperage, Voltage, inter pass temperature and travel speed. If the parameters do not meet the requirements of the WPS, the weld shall be cut out. 13.13 Witness the MPI or DP inspection of the root and hot pass. 13.14 Perform visual inspections on all filler passes and cap. 13.15 Witness setup for PWHT if applicable. Verify number of thermocouples. Sign PWHT chart at the beginning and at the end of the heat cycle. 13.16 Verify that the appropriate hardness tests have been performed. 13.17 Witness required NDE, i.e. UT, RT and MPI (DP). Ensure the approved procedures are followed and the required forms are completed.

17

NDT REQUIREMENTS

17.1

17.2

13.18

Hardness testing shall be required on all “closure welds in sour service”. (This does not apply to austenitic materials). JV Hardness Testing Procedure as per 00250600DBQR7215 – NDT Procedure shall be used. All hardness values shall be below 237 HB/250 HV10. Visual inspection of all welding passes shall be performed. This includes root tacks. No evident visual imperfections shall be allowed.

MPI (DP for austenitic welds) shall be performed on the root and hot pass of carbon steel welds while the pre-heat temperature is being maintained. The use of permanent magnetic yokes is prohibited. No linear indications are allowed. Note: Additional care and safety precautions shall be taken while working around hot surfaces. 13.19 MPI/UT shall be performed on all completed carbon steel welds after PWHT (DP for austenitic materials). No linear indications are allowed. 13.20 Each closure welds shall be examined with a combination of NDE methods & techniques as to ensure that the entire weld volume is scanned in different directions in order to ensure any detection of linear defects located within different weld planes. This will be primarily achieved by examining the welds with volumetric NDE (i.e. RT or UT) methods. This shall be in addition to MPI/UT performed during in-process examination and after PWHT (points 3 and 4 as above). Whenever the weld joint thickness or other technical difficulties will affect the feasibility of performing RT or UT, a specific method/technique shall be developed by Performer. These specific cases will be submitted to the company for approval.

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13.21 Welded joints with thickness < 35 mm shall be inspected by radiography utilizing D4 film. Any existing provisions for radiography on partially completed thick wall welds shall apply. The acceptance criteria for Severe Cyclic Service shall apply except no evidence of under cutting or concave root is allowed. Note: An ultrasonic critical root scan (as defined in the referenced JV UT procedure - as per – NDT Procedure) is required for all “closure welds” in sour service and 10,000 psi systems. 13.22 An ultrasonic inspection shall be performed on all welds > 35 mm (except for austenitic materials if any-dedicated NDE procedure to be qualified). The acceptance criteria listed in ASME Section VIII Appendix 12 shall apply. Imperfections which produce a response greater than 20% of reference level shall be investigated. Indications characterized as cracks, lack of fusion or incomplete penetration are unacceptable regardless of length. Other imperfections are unacceptable if the indications response exceeds the primary reference level and have lengths which exceed:

Length of imperfections 6 mm (1/4 in.) 1/3t

Thickness of the weld Thk up to 19 mm (3/4 in.) Thk from 19 mm to 57 mm (3/4 to 2 ¼ in.)

19 mm (3/4 in.)

Thk over 57 mm (2 ¼ in.)

Note: A sensitive ultrasonic root scan is required for all “Welds” in sour service and 10,000 psi systems. 13.23 1At the welding contractor’s option, NDE may be performed on a weld before PWHT for informational purposes only. One of the two required volumetric methods can be performed before PWHT but only the one performed after PWHT shall be selected as method as per section 7 points 6 and 7. Weld acceptance shall be performed after PWHT and shall meet the requirements of sections 10 points 5 and 6.

13.24 Dye penetrant inspections shall be performed on the root bead and hot pass for all welds. No linear indications are allowed. 13.25 Dye penetrant inspections shall be performed on small carbon steel welds that cannot be inspected by other techniques. No linear indications are allowed.

14

DOCUMENTATION The inspection reports for structural steel works will be the verification documents for meeting the requirements of the Project specification. QC inspectors shall be responsible for completing Inspection Reports for these activities. -

Risk Assessment Report Forms for NTD Procedure –

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APPENDIX A CURRENT LIST OF COMPANY PIPELINES

Dia of the PL / FL

15

length (m)

6" Dia

28810

8" Dia

83290

10" Dia

5850

12" Dia

2050

16" Dia

12350

20" Dia

17300

28" Dia

38000

32" Dia

24000

ATTACHEMNT

RA - Radiography Revision Number: 0

Assessed by:

Date:

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Task/operation and location [including any tools/equipment in use] Exposure to radiation Hazards Risk ratings Without controls With controls Exposure to ionizing radiation High Medium Unsealed sources of radiation can be inhalation, ingestion, High Low absorption through broken skin or injection. Other: Harm Cancer Dermatitis Radiation Poisoning Persons in danger NDT workers Other workers Member of the public Control measures Employees working with the radiation source should be competent and fully trained. Employees to wear appropriate personnel protective equipment supplied. Warning signs must be erected at each entrance of where work is being carried out to prevent other employees entering area. Appropriate warning signs will be displayed and restrictive bunting tape will be erected to cordon off the area where work is being carried out. Keeping as far back as possible from the radiation source and constantly monitoring the restricted area to prevent other employees entering. Any employees working with ionising radiation sources must be equipped with personnel film badges (dosimeter badges) which record the amount of exposure an employee has received over a given amount of time. Prior to use the radiography equipment must be checked. Flashing lights and acoustic warning alarm shall be used during night work if required. Care must be taken to ensure maximum distance between the operator and X-ray tube and no unauthorised personnel is within the controlled area before work starts. When work is ended, all equipment shall be collected and taken back to the store. Personal protective equipment Safety helmet, safety boots and hi-visibility vest Light eye protection Personal Dosimeter Specific Job Safety Analysis required? Yes, to be developed together with the subcontractor actually carrying out the Radiography activities: Radiation Safety, Emergency procedure, Recovery procedure, etc. Information, instruction and training Workers informed of the control measures and instructed to wear the required PPE Refresher training undertaken in the form of toolbox talks Emergency procedures Recovery and Emergency procedure to be developed with Radiation Site Representative. Monitoring procedures It is responsible of the NDT crew supervisor to check that at all times the effectiveness of the barriers in place (barricade, lights, and alarms). Regular reviews of control measures undertaken to ensure that they are effective and that workers are adhering to them; where necessary, procedures should be updated Inspections of all equipment before use During site radiography the appropriate personnel protective equipment must be worn, including dosimeter Other items

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APPENDIX – B – INSPECTION AND TESTING PLAN FOR PIPELINE CONSTRUCTION H - Hold point W – Witness R – Review A – Approval S – xxxxx Sl no

1

2

3

4

Activity Description

Preliminary survey & site preparation including the requirement of Permit, ERW clearance certificate 1.1) Co-ordinates & initial level: Transfer /Protection of bench Marks

Responsibility Supplier’s Reference Acceptance Verifying Extent of verification Documents Document inspection CONTR COMP criteria Personnel ACTOR ANY

H

H

1.2) Point of intersection

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Right of way 2.1) Clearance / Width of Right of Way (ROW) and access road

H

H

2.2) Soil stripping

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2.3) Right of way

H

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2.4) Filling and Grading Excavation /Earth works for trenching

H

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3.1) Excavation Permit

H

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3.2)Dimension & location 3.3) Pipeline Routing & Chain age 3.4) Trail Excavation to detect underground utilities 3.4.1) Cable /Road /Pipeline

H

W

H

W

H

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H

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3.4.2) Road Crossing

H

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3.4.3) Pipeline Crossing 3.4.4) Pipeline characteristics

H

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3.5)Trenching

H

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3.6) Back Filling 3.6.1) Soft & Bedding ( Before Pipe laying ) 3.6.2) Soft & Padding ( After Pipe laying)

H

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H

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3.6.3) Back filling

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3.7) Berm Construction

H

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Materials Pipes ( Dia, Thickness & Grade) Fittings ( Size, Class and identification stamp)

W

W

W

W

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Gaskets( Size, Class and Serration Protection)

5

6 7 8

9

10

Valves ( Type ,Class and adequate Protection of Valve ends) Pipe line sectional replacement 5.1) Marking of Heat no., Pipe no. & length Arresting of leak by clamping Coating removal and recoating of pipes

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W

W

W

W

H

R

H

W

H

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Line up/Main line Welding 8.1) Line pipe traceability ( Pipe book) and weld map

H

W

8.2) WPS/PQR Approval

H

H

8.3) Qualification of welder 8.4) Electrode & dry condition inspection

H

W

H

S

8.5) Weld joint Fit-up 8.6) Pre-heating ( If required) 8.7) Marking for welder ID no./Joint no. 8.8) Visual inspection for surface defect 8.9)NDE- Radiographic testing, UT, MPT, PT 8.10) Hardness Testing

H

S

H

S

H

S

H

S

H

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H

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H

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8.11) Lamination check & Thickness check & PT /MPT on the cut-back. Weld Repair 9.1) WPS/PQR

H

H

9.2) Qualification of Welder

H

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9.3) Electrode & dry condition Inspection 9.4) Weld Joint Fit-up (For Cutout joints)

H

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H

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9.5) Pre heating(If required)

H

S

9.6) Visual Inspection for surface defect 9.7) Radiographic Testing

H

S

H

R

9.8) Hardness Testing

H

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H

A

H

w

Field joint Heat Shrink sleeve Application 10.1) Approval of Coating Application Procedure, Field Repair Procedure, Coating applicator & Site trial qualification 10.2) Heat shrink sleeve material, primer

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10.3) Weather conditions Relative Humidity, Dew point, substrate Temperature, Air temperature, Dry Bulb, Wet Bulb etc. 10.4) Surface preparation Checking Grit material, Degree of Cleanliness, Roughness, chloride test once on everyday production 10.5) Heat Shrink sleeve Application Preheating

H

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H

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H

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Primer application

H

S

Tape to overlap

H

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Overlap to PE Coating

H

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H

W

H

H

H

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H

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H

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H

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H

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12.1) Line pipe Traceability(Pipe book) 12.2) WPS/PQR

H

W

H

H

12.3) Qualification of welder

H

W

12.4) Electrode & dry condition Inspection 12.5) Weld joint Fit up

H

W

H

W

Visual Inspection of applied Heat shrink sleeve 10.6) Heat shrink sleeve repair Defective sleeves shall be removed, replaced or repaired and then reexamined 10.7) Repair on supplied coated pipes For surface defect without Holiday (by polyethylene sticks) For surface defect with holiday For holes about 1/2" dia (by polyethylene sticks) For holes above 1/2" dia (by patch work)

11

10.8) Heat shrink sleeve Testing Peel Test(once per working shift) Lowering and Laying

12

11.1) Holiday testing of Lowering section 11.2) Lowering of Pipeline section Tie-in of Pipeline sections

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12.6) Pre heating & PWHT (If required) 12.7) Marking of welder ID

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H

H

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W

12.8) Visual Inspection for surface defect 12.9) Radiographic Testing

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12.10) Hardness Testing

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13.6) NDE & Hydro-testing.

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13.7) Field joint HSS Application 13.8) Holiday testing

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13.9)

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H

H

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H

W

H

W

H

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no./Joint No.

13

12.11) Field joint Heat shrink sleeve application 12.12) Holiday test of Tie in joint Heat shrink sleeve All crossings : 13.1) Crossing of existing facilities Road Crossing 13.2) Survey works including the Permission & authorisation 13.3) installation of diversion Roads. 13.4) Excavation of crossings 13.5) Welding Inspection

14

Lowering

13.10) Spacer Installation, insertion, vent pipe 13.11)Backfilling & Reinstatement 13.12) Installation of diversion Roads. Pipeline Pigging 14.1) Cleaning Pig inspection 14.2) Cleaning operation

15

Inspect the Pig before loading Inspect the Pig After Removal Pipeline Gauging 15.1)Gauging Plate inspection 15.2) Gauging Plate outside Dia. Gauging plate material

16

H

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Gauging Plate thickness

H

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15.3) Gauging Operation

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16.1) Water analysis

H

R

16.2) Inhibitor Inspection

H

R

Pipe line Filling & inhibition

Company Identification

000

16.3) Test Equipment inspection Pumps , Valves,

Owner Identification

000

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16.4) Pigs inspection Bidirectional Pig

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16.5) Pipeline Flooding Operation

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Instruments ,Dead Weight tester, Pressure & temperature ,Recorder etc.

17

Hydrostatic Test 17.1) Pressurisation up to 50 % test pressure 17.2) Measurement of air content after reaching 50% test

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Pressure 17.3) Pressurisation up to 100 % test pressure 17.4) Temperature stabilization

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17.5) Pressure Monitoring

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Bi directional Pig

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18.3) Dewatering operation 18.4) Inhibited Water Disposal

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19

Swabbing

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Drying Air Drying & Nitrogen Purging (If applicable) Temporary Cathodic Protection System 21.1) Material Receiving Inspection 21.2) Installation of Sacrificial Anodes & Testing Permanent Cathodic Protection System 22.1) Material Receiving Inspection

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17.6) Readings Pressure & temperature recorder Dead weight tester & pressure gauge ( Maximum ,Minimum & average values) Ambient temperature readings Water temperature readings 17.7)Acceptance of test 18

Dewatering 18.1) De-Pressurisation 18.2) Dewatering Pigs

21

22

Company Identification

000

22.2) Bore well /Cashing Pipe Installation 22.3) Installation of Cathodic Protection Rectifiers 22.4) Installation of Lead Junction Boxes 22.5) Installation of Wires & Cable, Negative cable and test lead attachment 22.6) Permanent Reference CELL 22.6.1) Placement

24

Owner Identification

000

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22.6.2) Backfill

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22.6.3) Wiring

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22.7) Post Installation Testing of CP System Review /Compile Documentation