INSTALLATION OF LP GAS RING HEADER AND

ASSOCIATED WORK AT SHUAIBA INDUSTRIAL

AREA
Project MK-KOC-PRO-001 Page 1 of 10

MARK TECHNOLOGIES COMPANY W.L.L

Pipeline Construction
Procedure

Rev Date Prepared Reviewed Approved

 INSTALLATION OF LP GAS RING HEADER AND
ASSOCIATED WORK AT SHUAIBA INDUSTRIAL
AREA
Project MK-KOC-PRO-001 Page 2 of 10

TABLE OF CONTENTS

1 Purpose.......................................................................................

2 Scope...........................................................................................

3 References..................................................................................

4 General Requirements................................................................

5 Storage and Handling.................................................................

6 Installation Of Buried Pipelines...................................................

7 Tie-In Temperatures....................................................................

8 Clean-Up, Records......................................................................
 INSTALLATION OF LP GAS RING HEADER AND
ASSOCIATED WORK AT SHUAIBA INDUSTRIAL
AREA
Project MK-KOC-PRO-001 Page 3 of 10

1 Purpose

This procedure describes the minimum requirements for Installation of LP gas

ring header and associated work at shuaiba industrial area-RFP-2045041.
2 Scope
This procedure defines pipeline codes and additional construction requirements
governing onshore pipelines for Installation of LP gas ring header and associated
work at shuaiba industrial area.
3 References
The selection of material and equipment, and the design, construction,
maintenance, and repair of equipment and facilities covered by this standard
shall comply with the latest edition of the references listed below,
API Standard 1104 Standard for Welding Pipelines and Related Facilities

API 5L – Specification for Line Pipe

ASME VIII Div 1 ASME Boiler and Pressure Vessel Code,
Section VIII Division I, Pressure Vessels
ASME IX Welding and Brazing Qualification
ASME B31.8 Gas Transmission and Distribution System
ASNT-SNT-TC-1A American Society for Non-destructive Testing
ASTM E747-87 Test Method for Controlling Quality of Radiographic Testing
Using Wire Penetrameters.
ASTM E-23 Standard Test Methods for Notched Bar Impact Testing of Metallic
Materials, 1994.
ASTM A370 Standard Test Methods and Definitions for Mechanical Testing of
Steel Products ,1994.
ASME V Non- Destructive examination
NACE MR 0175 Standard Material Requirements- Sulphide Stress Cracking
Resistant Metallic Materials for Oilfield Equipment
NACE RP 0472 Methods and Controls to Prevent In-Service Environmental
Cracking of Carbon Steel Weldments in Corrosive Petroleum Refining
Environments.
 INSTALLATION OF LP GAS RING HEADER AND
ASSOCIATED WORK AT SHUAIBA INDUSTRIAL
AREA
Project MK-KOC-PRO-001 Page 4 of 10

4 General Requirements

4.1 A route drawing, detailed plan drawings, hydrostatic test diagrams, and
other drawings required shall be the basis for installing the pipeline. The
end of the pipeline, Station 0 + 00, shall be stated in the Scope of Work,
and is normally the upstream end. A metric measurement shall be used
for the horizontal survey. Profile surveying shall be in meters and decimal
fractions of a meter.

4.2 The Contractor shall determine the vertical profile of the pipeline, the
amount of cover, the location and degree of elastic and preformed bends,
and the locations of vents and drains in accordance with this standard and
the construction drawings. The change in slope of the pipeline at normal
spacing of 30 m, and at intermediate stations as required, shall be
calculated.

4.3 The right-of-way shall be graded to a flat or smooth rolling surface and
shall be wide enough to drive a vehicle on at least one side of the line.
Irregularities shall not obstruct access of construction equipment. Fills
and cuts shall be made to reduce the number and/or magnitude of over
bends and sag bends in the pipeline. The width of such fills and cuts shall
not be less than the area to be stabilized, and the adjacent slopes shall
not be steeper than four to one.
The final finished right-of-way shall be completed in a manner which
permits routine operation and maintenance access with standard four
wheel drive vehicles.
4.4 If the pipeline construction changes the natural drainage pattern, either by
the grading of the right-of-way or by a bermed-over cover, provisions shall
be made to prevent wash-out of the pipeline cover by rain storms.

4.5 Elastic Bends

The maximum change in slope for elastic bends shall be in accordance
with the Project Specification or the Scope of Work. Larger changes of
slope shall be made with preformed bends.

4.6 Preformed Bends

 INSTALLATION OF LP GAS RING HEADER AND
ASSOCIATED WORK AT SHUAIBA INDUSTRIAL
AREA
Project MK-KOC-PRO-001 Page 5 of 10

Preformed bends shall be made by welding into the correct location of the
string a length of pipe which has been bent with a smooth stretch bending
machine. No wrinkle bends or hot bends shall be used. At any point
along a preformed bend, the pipe diameter shall not be reduced by more
than 2-1/2 percent of the nominal pipe diameter. Bends shall not be made
closer than 600 mm from a circumferential weld unless the weld is back
welded. The weld shall be radiographed after the bend is made.
A hydraulic bending mandrel and polyurethane-lined bending dies shall be
used for spiral-welded pipe.

5 Storage And Handling

5.1 Pipe stacking shall be made in a manner which will not damage the pipe
or coating.
5.2 End protectors shall remain on pipes and fittings while in storage.
5.3 Slings for lifting pipe shall be nylon or similar material to prevent damage
to the pipe surface. Wire rope slings shall not be used.
5.4 Pipe shall not be rolled or dropped off trucks.
5.5 Storage, handling, and installation of pipe that are externally coated with
fusion bonded epoxy or polyethylene shall be done with extreme care.
5.6 When a length of pipe is cut from a longer joint of pipe, all vendor
markings and other identifying information shall be transferred to each
length of pipe.

6 Installation Of Buried Pipelines

6.1 Each length of pipe shall be examined to make sure it is free from internal
obstructions. Any obstructions shall be removed before the pipe is welded
into a string.

6.2 Pipe joints shall be welded to form strings of 900 to 1000 m. Pipe strings or
portions thereof shall not be moved until all joints have been fully welded
and inspected.

6.3 When open ends of pipeline strings are not attended, they shall be capped
to prevent entry of debris. Each string of the pipeline shall be cleaned to
remove all debris.
 INSTALLATION OF LP GAS RING HEADER AND
ASSOCIATED WORK AT SHUAIBA INDUSTRIAL
AREA
Project MK-KOC-PRO-001 Page 6 of 10

6.4 The as-built drawings shall indicate any buried installations and bonding
stations.

6.5 Buried installations crossing the pipeline route shall be located in advance
of grading and trenching. The trench bottom shall be surveyed to
establish the elastic bends and required preformed bends in rolling terrain
or when passing through dunes. When the pipe is lowered into the trench,
the pipe shall conform to the trench bottom and shall be supported at all
points. The maximum allowable unsupported length before backfilling is 3
m. Any such voids shall be carefully backfilled. The minimum clearance
between pipelines or between a pipeline and an obstruction shall be as
specified, unless additional clearance is specified on the pipeline
drawings.

6.6 Spot backfilling shall be used to restrain the pipe after it has been lowered
into the trench. Spot backfill shall have full specified cover and shall cover
all preformed bends a distance of 6 m to each side of the centers of the
bends. The maximum clear distance between spot backfills shall be as
specified by the project design. Spot backfills shall cover the pipe for at
least 4.5 m along the pipe.

6.7 LPG lines, gas lines, and oil well flow lines shall have a minimum cover of
900 mm. Other lines shall have a minimum cover of 600 mm. Original
grade shall be restored over the pipeline unless otherwise specified below.
Additional cover required at road or rail crossings shall be as noted on the
drawings.

6.8 Project specifications shall specify where extra cover is required at

vertical, horizontal, and composite preformed bends based on bend radius
and tie-in temperature, to adequately restrain the buried pipeline. Such
extra cover shall extend a minimum of 6 m beyond a bent portion of pipe.

6.9 Installation In Sand Areas

6.9.1 The trench shall be wide enough to allow lowering the pipe without
damaging the pipe or the coating and shall be excavated to the depth
required to provide the specified depth of cover below finished grade
 INSTALLATION OF LP GAS RING HEADER AND
ASSOCIATED WORK AT SHUAIBA INDUSTRIAL
AREA
Project MK-KOC-PRO-001 Page 7 of 10

6.9.2 The bottom of the trench shall be free of rock or other material that could
damage the pipe coating.
6.9.3 The pipe shall be embedded in an annulus of clean sand not less than 200
mm thick in a manner which shall not damage the coating. The sand shall
not contain stones larger than
6.35 mm. size.
6.9.4 The remainder of the backfill shall be placed in a manner which shall not
disturb the annulus of clean sand around the pipe (sand pad). Backfill
shall not contain rock larger than 50 mm size.

6.10 Installation in Rock Areas

Normally, aboveground construction shall be used in rock areas where

blasting would be required for trenching. When there is economic
justification, a "half trenching" alternative may be used as follows:
a) The minimum trench depth shall be such that the top of the pipe is below
the original ground surface or the pipe centerline is 150 mm below the top
of the rock.
b) The minimum width of the bottom of the trench in rock areas shall be 600
mm wider than the pipe. The pipe shall be centered in the trench.
c) Selected bedding material shall be placed in the bottom of the trench and
made level. The bedding material shall be clean sand or soil and shall not
cause damage to the coating. The bedding material shall not contain
stones larger than 6.35 mm. In addition, sand pads shall be placed at
approximately every 9 m to support the pipe 200 mm off the prepared
bottom. The bottom of the trench shall be inspected to insure that no
rocks will protrude anywhere to within 100 mm of the pipe.
d) After lowering the pipe into the trench, the Contractor shall use surveying
sticks to establish dimensional controls to satisfy the inspector that the
final cover will be sufficient and centered over the pipeline.
e) A pad of selected bedding material shall be placed under and around the
pipe to provide a minimum cover of 200 mm around the entire
circumference of the pipe. The sand pile remaining above the 200 mm
cover shall be shaped to its natural angle of repose, approximately 35
degrees from the horizontal.
 INSTALLATION OF LP GAS RING HEADER AND
ASSOCIATED WORK AT SHUAIBA INDUSTRIAL
AREA
Project MK-KOC-PRO-001 Page 8 of 10

f) The remaining backfill and berm shall be placed in a manner to avoid

disturbing the sand pad. Other material shall be pushed up from the
sides, or new material shall be placed adjacent to the sand pad. Coarse
material shall not be placed on top of the sand pad and be allowed to roll
down. Backfill shall not contain rock larger than 150 mm size.

g) The width of the flat top (berm) of the dike shall be at least twice the pipe
diameter along the overall minimum cover above the top of the pipe. For
every 300 mm of additional cover required at vertical or horizontal bends,
the berm width shall be increased 600 mm. The ramped sides of the dike
shall not be steeper than 35 degrees.

i) Diversion ditches and/or culverts for flood water shall be provided to keep
the pipeline cover from acting as a dam or a channel bank.

7 Tie-In Temperatures

7.1 A tie-in weld is a weld that connects a pipeline string to another string, or
to the pipeline under construction, or to an anchor. The segment of the
pipeline between tie-in points remains fully restrained at the tie-in
temperature if shrinkage of the segment is prevented by adequate
anchorage at both ends.

7.2 The Construction Engineer shall determine the highest practical tie-in
temperature for each tie-in weld of a buried pipeline, including any
intervening road crossings. The tie-in temperature shall be within the
range stated in the Project Specification.

7.3 The actual tie-in temperature shall be the average of two readings, one at
the top and one at the bottom of the pipe. The temperature measuring
device shall contact the pipe and shall be shielded from direct sunlight.

7.4 The Contractor shall record all tie-in temperatures and the pipeline
stations of the tie-ins.

7.5 Method of Tie-in for Buried Pipelines

 INSTALLATION OF LP GAS RING HEADER AND
ASSOCIATED WORK AT SHUAIBA INDUSTRIAL
AREA
Project MK-KOC-PRO-001 Page 9 of 10

When a sufficient number of strings have been completed, the first string
of a buried pipeline shall be placed in the trench and spot backfilled (or
tied into an anchor) during the hottest part of the day. The subsequent
strings shall be connected to the starting end by tie-in welds. Each new
string must be kept free of movement to prevent cracks in the tie-in weld.
The portion of the pipeline between the trench and the bank shall be
supported by side booms/ cranes holding the line in a gentle S-curve.
During the night and the cool periods of the day, there should be at least
900 to 1200 m of pipe on the bank to keep the S-curve in sufficient tension
to restrain the pipe in the trench.
If the S-curve cannot fully restrain the line during the cool periods, the
curve will develop slack as the line becomes warm. This will require the
lifting of the tail to move the slack towards the free end of the line when
the temperature is high.
Alternatively, the tie-in weld may be made in the trench (at tie-in
temperature) and the tail may be resting in the trench.
The spot-backfilling to tie down the line up to a point 1200 m from the free
end of the tail may be done at any temperature of the pipe. Backfilling
closer to the free end may be carried out only during the hottest part of the
day.

8 Clean-Up, Records

8.1 Construction waste materials shall be removed from the right-of-way as

the construction progresses.
8.2 Record books shall be sent to the Contractor Design Office.
Documentation shall describe and locate all repairs and tie-in
temperatures.
All survey data and as-built drawings shall be sent to the Contractor
Design Office. The following information shall be included:
a) Bottom-of-line elevations and ground elevations at all 30 m stations and at
all preformed bends;
b) The location and degree of all horizontal bends;
c) The location and degree of all preformed sag bends and over bends;
d) The location of all vents and drains;
e) The identification, station, elevation and size of all pipes which cross the
pipeline and of any other buried steel installations within 30 m;
 INSTALLATION OF LP GAS RING HEADER AND
ASSOCIATED WORK AT SHUAIBA INDUSTRIAL
AREA
Project MK-KOC-PRO-001 Page 10 of 10

f) The stations of all markers, appurtenances and cathodic protection

facilities;
g) All other data which should be included on a maintenance record profile,
including the stations of block valves, anchors, road crossing, and
changes in the grade of the pipe, wall thickness, and diameter;
h) Safety Instruction Sheets