Volume3A Mech PDF

GAS PLANT FACILITY PROJECT
ISSUED FOR BIDDING
0 10-Apr-11 Issued For Bidding WRK MTZ MK FS

LOCAL PROJ.
REV DATE DESCRIPTION ORIG CHKD LE EM
REPR. MAN
CLIENT
REVISIONS APPROVAL
APPROVAL
TITLE :
DATA SHEET OF INSULATING GASKET FOR
RTJ FLANGES
ENAR PETROTECH SERVICES (PVT ) LTD
7-B, KORANGI INDUSTRIAL AREA,
KORANGI-KARACHI
DOCUMENT NO:
4985-DS-1808
PROJECT NO. TYPE LOCATION AREA CODE SEQ. NO. REV.
14-4985
PAGE 1 OF 2
DOC NO : 4985-DS-1808
OIL & GAS DEVELOPMENT COMPANY LIMITED PAGE : 2 0F 2
GAS PLANT FACILITY PROJECT
DATA SHEET OF INSULATING GASKET FOR RTJ FLANGES
1 Customer OIL & GAS DEVELOPMENT COMPANY LIMITED Job Number 4985
2 Project GAS PLANT FACILITY PROJECT Tag Number
3 Location Baluchistan Quantity: See Bid Price schedule Annexure-X
4 PROCESS FLUID AND CONDITIONS
5
6 Fluid: Untreated Natural Gas
7 Service: Sour
8 Design Pressure : 1440 psi(g)
9 Design Temperature : 82.00 C (Max)
10 -90 C (Min)
11 Installation: Above ground
12
13 SPECIFICATION COMPLIANCE
14
15 Each Insulating Gasket set shall comprise of the following items:
16 1) One central gasket consisting of a ring suitable for ring type joint flange that is
17 "snap in" fitted to inner and outer rings. The inner and the outer rings are
18 suitable for full face gasket.
19 2) One full length insulating sleeve per bolt.
20 3) Two insulating washers per bolt.
21 4) Two steel washers per bolt.
22 Each set shall be individually and securely packed in a reinforced corrugated cardboard box.
23
24 DESIGN DATA
25
26 Piping Design Code: ASME B31.3
27 Application: Electrical isolation of Cathodic Protection System
28 Flange Size: 8" NPS 5" NPS 5" NPS 3/4" NPS
29 Flange Type: RTJ RTJ RTJ RTJ
30 ASME Class: 900# 1500# 900# 1500#
Quantity : 18 NO 12 NO 6 NO 20 NO
31 Dimensional Standard: ASME B16.20

32 Gasket Material: Plain Phenolic (Uncoated) Central Ring
33 Virgin PTFE Inner and Outer Rings
34 Gasket Thickness: 5.6 mm Supplier to confirm
35 Sleeve Material: Plain Phenolic / Polyester Mylar
36 Insulating Washer Material: Plain Phenolic
37 Steel Washer Material: Carbon Steel Galvanised
38 NACE MR 0175 compliance: Required
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55 NOTES
56
57
58
59
60
61
62
63
Data Sheet No. 4985-DS-1809
DATA SHEET FOR Prep. By ANA Apr. By MK
CORROSION COUPONS Date 3/1/2012
Sheet 1 of 12 Rev. 0
Client: Oil & Gas Development Company Limited

Project: Gas Plant Facility Project Unit:
Req. No.: Order No.:
Vendor: Job No. : 4985
Vendor Dwg. No.: Model No.:
Tag No. 100-CC-001 101-CC-001 102-CC-001 103-CC-001

Quantity 01 (Note-1,2,3) 01 (Note-1,2,3) 01 (Note-1,2,3) 01 (Note-1,2,3)
P&ID No. 4985-PB-2103 4985-PB-2104 4985-PB-2105 4985-PB-2106
Service Process Fluid Process Fluid Process Fluid Process Fluid
SERVICE CONDITION
Type Corrosion Coupon Corrosion Coupon Corrosion Coupon Corrosion Coupon

Line No. 8"-PF-EC-0101A 8"-PF-EC-0201A 8"-PF-EC-0301A 8"-PF-EC-0401A
Pipe Size / Pipe Thickness 8"/ sch 80S 8"/ sch 80S 8"/ sch 80S 8"/ sch 80S
End Connection Flare weld Flare weld Flare weld Flare weld
Dimension from top of pipe to

Supplier to advice Supplier to advice Supplier to advice Supplier to advice
Protective cover
Maximum Pressure (psig) 1550 1550 1550 1550
Maximum Temperature (ºF) 180 180 180 180
Piping Material /Corrosion Allowance 0 mm 0 mm 0 mm 0 mm
Operating Temperature (ºF) 30 -130 30 -130 30 -130 30 -130
Operating Pressure (psig) 200 - 1300 200 - 1300 200 - 1300 200 - 1300
H2S 700 ppm 700 ppm 700 ppm 700 ppm
CO2 22.75 22.75 22.75 22.75
Nitrogen 8.41 8.41 8.41 8.41
M th
Methane
(Mole %))
65 37
65.37 65 37
65.37 65 37
65.37 65 37
65.37
Ethane 1.98 1.98 1.98 1.98
Propane 0.66 0.66 0.66 0.66
i-Butane 0.17 0.17 0.17 0.17
GASES & LIQUID COMPOSSITION
n-Butane 0.17 0.17 0.17 0.17

i-Pentane 0.06 0.06 0.06 0.06
n-Pentane 0.10 0.10 0.10 0.10
n-Hexane 0.04 0.04 0.04 0.04
Heptane+ 0.09 0.09 0.09 0.09
H2O 0.19 0.19 0.19 0.19
Material:
Flare weld Access Fitting Body ASTM A-182 F316L ASTM A-182 F316L ASTM A-182 F316L ASTM A-182 F316L
Solid Plug Assembly 316L 316L 316L 316L
Disc Coupon Holder 316L 316L 316L 316L
Disc Coupon 316SS 316SS 316SS 316SS
Heavy Duty Protective Cover 316SS 316SS 316SS 316SS
Primary Packing RPTFE RPTFE RPTFE RPTFE
O' Ring Seal BUNA 'N' 70 BUNA 'N' 70 BUNA 'N' 70 BUNA 'N' 70
NOTES:
1. Two inch (2'')High pressure access fitting assembly, comprising:
- Access fitting body, Flare weld.
- Solid plug assembly , complete with 'O' Ring Seal, Packing and retaining Nut.
-Disc Coupon Holder.
-Heavy duty protective cover.
2. Two nos of 2" Strip Corrosion Coupon, Retrievable.
3. Corrosion coupons shall be NACE MR0175/ISO15156 complaince.
4. MANUFACTURER TO SIZE FOR " BOTTOM " OF LINE MONITORING.

Tag No. 104-CC-001 105-CC-001 106-CC-001 107-CC-001

P&ID No. 4985-PB-2107 4985-PB-2108 4985-PB-2109 4985-PB-2110
SERVICE CONDITION

Protective cover
H2S 687ppm 540ppm 598 ppm 540 ppm
CO2 44.63 43.98 45.78 44.30
Nitrogen 24.64 25.80 24.80 26.68
(Mole %)
Methane 29.13 28.82 27.91 27.48

Ethane 0.63 0.54 0.55 0.62
Propane 0.26 0.26 0.27 0.26
i-Butane 0.08 0.08 0.09 0.09
n-Butane 0.03 0.07 0.07 0.07

i-Pentane 0.03 0.03 0.03 0.03
n-Pentane 0.04 0.04 0.05 0.05
n-Hexane 0.04 0.03 0.03 0.02
Heptane+ 0.08 0.07 0.05 0.06
H2O 0.34 0.23 0.31 0.29
Material:
NOTES:

Tag No. 108-CC-001 109-CC-001 110-CC-001 111-CC-001

P&ID No. 4985-PB-2111 4985-PB-2112 4985-PB-2113 4985-PB-2114
SERVICE CONDITION

Protective cover
CO2 45.69 45.48 40.22 45.33
Nitrogen 25 17
25.17 24 99
24.99 16 25
16.25 22 90
22.90
(Mole %)
Methane 27.80 28.04 41.17 30.04

Ethane 0.53 0.65 1.11 0.76
Propane 0.25 0.26 0.41 0.29
i-Butane 0.08 0.09 0.12 0.09
n-Butane 0.07 0.07 0.11 0.08

i-Pentane 0.02 0.03 0.04 0.03
n-Pentane 0.04 0.04 0.06 0.04
n-Hexane 0.02 0.01 0.06 0.05
Heptane+ 0.03 0.02 0.15 0.11
H2O 0.24 0.30 0.29 0.26
Material:
NOTE:

Tag No. 112-CC-001 113-CC-001 114-CC-001 100-CC-002

P&ID No. 4985-PB-2115 4985-PB-2116 4985-PB-2117 4985-PB-2103
SERVICE CONDITION

Line No. 8"-PF-EC-1301A 8"-PF-EC-1401A 8"-PF-EC-1501A 8"-PF-EA2-0102
Pipe Size / Pipe Thickness 8"/ sch 80S 8"/ sch 80S 8"/ sch 80S 8"/ sch 80

Protective cover
CO2 45.08 45.26 44.94 22.75
Nitrogen 21.39 21.74 23.56 8.41
Methane 31.76 31.08 29.79 65.37
(Mole %)
Ethane
th 0 79
0.79 0 82
0.82 0 69
0.69 1 98
1.98
Propane 0.31 0.30 0.27 0.66
i-Butane 0.10 0.10 0.08 0.17
n-Butane
GASES & LIQUID COMPOSITION
0.08 0.08 0.07 0.17

i-Pentane 0.03 0.03 0.03 0.06
n-Pentane 0.05 0.05 0.04 0.10
n-Hexane 0.06 0.06 0.06 0.04
Heptane+ 0.12 0.13 0.11 0.09
H2O 0.23 0.35 0.34 0.19
Material:
Flare weld Access Fitting Body ASTM A-182 F316L ASTM A-182 F316L ASTM A-182 F316L ASTM A-105N
Disc Coupon 316SS 316SS 316SS AISI 1018
Heavy Duty Protective Cover 316SS 316SS 316SS AISI 1018
NOTE:

Tag No. 101-CC-002 102-CC-002 103-CC-002 104-CC-002

P&ID No. 4985-PB-2104 4985-PB-2105 4985-PB-2106 4985-PB-2107
SERVICE CONDITION

Line No. 8"-PF-EA2-0202 8"-PF-EA2-0302 8"-PF-EA2-0402 8"-PF-EA2-0502
Pipe Size / Pipe Thickness 8"/ sch 80 8"/ sch 80 8"/ sch 80 8"/ sch 80

Protective cover
Piping Material /Corrosion Allowance 3mm 3mm 3mm 3mm
H2S 700 ppm 700 ppm 700 ppm 687ppm
CO2 22.75 22.75 22.75 44.63
Nitrogen 8.41 8.41 8.41 24.64
e %)
Methane 65.37 65.37 65.37 29.13

Ethane
th
(Mole
1 98
1.98 1 98
1.98 1 98
1.98 0 63
0.63
Propane 0.66 0.66 0.66 0.26
i-Butane 0.17 0.17 0.17 0.08
n-Butane 0.17 0.17 0.17 0.03

i-Pentane 0.06 0.06 0.06 0.03
n-Pentane 0.10 0.10 0.10 0.04
n-Hexane 0.04 0.04 0.04 0.04
Heptane+ 0.09 0.09 0.09 0.08
H2O 0.19 0.19 0.19 0.34
Material:
Flare weld Access Fitting Body ASTM A-105N ASTM A-105N ASTM A-105N ASTM A-105N
Disc Coupon AISI 1018 AISI 1018 AISI 1018 AISI 1018
Heavy Duty Protective Cover AISI 1018 AISI 1018 AISI 1018 AISI 1018
NOTE:

Tag No. 105-CC-002 106-CC-002 107-CC-002 108-CC-002

P&ID No. 4985-PB-2108 4985-PB-2109 4985-PB-2110 4985-PB-2111
SERVICE CONDITION


Protective cover
H2S 540ppm 598 ppm 540 ppm 608 ppm
CO2 43.98 45.78 44.30 45.69
Nitrogen 25.80 24.80 26.68 25.17
e %)
Methane 28.82 27.91 27.48 27.80

Ethane
th
(Mole
0 54
0.54 0 55
0.55 0 62
0.62 0 53
0.53
Propane 0.26 0.27 0.26 0.25
i-Butane 0.08 0.09 0.09 0.08
n-Butane 0.07 0.07 0.07 0.07

i-Pentane 0.03 0.03 0.03 0.02
n-Pentane 0.04 0.05 0.05 0.04
n-Hexane 0.03 0.03 0.02 0.02
Heptane+ 0.07 0.05 0.06 0.03
H2O 0.23 0.31 0.29 0.24
Material:
NOTE:

Tag No. 109-CC-002 110-CC-002 111-CC-002 112-CC-002

P&ID No. 4985-PB-2112 4985-PB-2113 4985-PB-2114 4985-PB-2115
SERVICE CONDITION


Protective cover
CO2 45.48 40.22 45.33 45.08
Nitrogen 24.99 16.25 22.90 21.39
Methane
(Molle %)
28.04 41.17 30.04 31.76

Ethane 0 65
0.65 1 11
1.11 0 76
0.76 0 79
0.79
Propane 0.26 0.41 0.29 0.31
i-Butane 0.09 0.12 0.09 0.10
n-Butane 0.07 0.11 0.08 0.08

i-Pentane 0.03 0.04 0.03 0.03
n-Pentane 0.04 0.06 0.04 0.05
n-Hexane 0.01 0.06 0.05 0.06
Heptane+ 0.02 0.15 0.11 0.12
H2O 0.30 0.29 0.26 0.23
Material:
NOTE:

Tag No. 113-CC-002 114-CC-002 200-CC-001 200-CC-002

P&ID No. 4985-PB-2116 4985-PB-2117 4985-PB-2118 4985-PB-2118
SERVICE CONDITION

Line No. 8"-PF-EA2-1402 8"-PF-EA2-1502 10"-PF-DA3-0108 10"-PF-DA3-0208
Pipe Size / Pipe Thickness 8"/ sch 80 8"/ sch 80 10"/ 12.7mm 10"/ 12.7mm

Protective cover
Operating Temperature (ºF) 30 -130 30 -130 30-130 30-130
Operating Pressure (psig) 200 - 1300 200 - 1300 200-1300 200-1300
CO2 45.26 44.94 22.75 22.75
Nitrogen 21.74 23.56 8.41 8.41
Methane 31.08 29.79 65.37 65.37
(Mole %)
Ethane
th 0 82
0.82 0 69
0.69 1 98
1.98 1 98
1.98
Propane 0.30 0.27 0.66 0.66
i-Butane 0.10 0.08 0.17 0.17
n-Butane
0.08 0.07 0.17 0.17

i-Pentane 0.03 0.03 0.06 0.06
n-Pentane 0.05 0.04 0.10 0.10
n-Hexane 0.06 0.06 0.04 0.04
Heptane+ 0.13 0.11 0.09 0.09
H2O 0.35 0.34 0.19 0.19
Material:
NOTE:

Tag No. 200-CC-003 200-CC-004 200-CC-005 200-CC-006

P&ID No. 4985-PB-2118 4985-PB-2118 4985-PB-2119 4985-PB-2119
SERVICE CONDITION

Line No. 10"-PF-DA3-0308 10"-PF-DA3-0408 10"-PF-DA3-1108 8"-PF-DA3-1208
Pipe Size / Pipe Thickness 10"/ 12.7mm 10"/ 12.7mm 10"/ 12.7mm 8"/ 11.1mm

Protective cover
Operating Temperature (ºF) 30-130 30-130 30-130 30-130
Operating Pressure (psig) 200-1300 200-1300 200-1300 200-1300
CO2 22.75 22.75 40.22 45.33
Nitrogen 8.41 8.41 16.25 22.90
Methane 65.37 65.37 41.17 30.04
(Mole %)
Ethane
th 1 98
1.98 1 98
1.98 1 11
1.11 0 76
0.76
Propane 0.66 0.66 0.41 0.29
i-Butane 0.17 0.17 0.12 0.09
n-Butane
0.17 0.17 0.11 0.08

i-Pentane 0.06 0.06 0.04 0.03
n-Pentane 0.10 0.10 0.06 0.04
n-Hexane 0.04 0.04 0.06 0.05
Heptane+ 0.09 0.09 0.15 0.11
H2O 0.19 0.19 0.29 0.26
Material:
NOTE:

Tag No. 200-CC-007 200-CC-008 200-CC-009 200-CC-010

P&ID No. 4985-PB-2119 4985-PB-2119 4985-PB-2119 4985-PB-2120(sh 1 of 2)
SERVICE CONDITION


Protective cover
CO2 45.08 45.26 44.94 44.63
Nitrogen 21.39 21.74 23.56 24.64
Methane 31.76 31.08 29.79 29.13
(Mole %)
Ethane
th 0 79
0.79 0 82
0.82 0 69
0.69 0 63
0.63
Propane 0.31 0.30 0.27 0.26
i-Butane 0.10 0.10 0.08 0.08
n-Butane
0.08 0.08 0.07 0.03

i-Pentane 0.03 0.03 0.03 0.03
n-Pentane 0.05 0.05 0.04 0.04
n-Hexane 0.06 0.06 0.06 0.04
Heptane+ 0.12 0.13 0.11 0.08
H2O 0.23 0.35 0.34 0.34
Material:
NOTE:

Tag No. 200-CC-011 200-CC-012 200-CC-013 200-CC-014

P&ID No. 4985-PB-2120(sh 1 of 2)4985-PB-2120(sh 1 of 2) 4985-PB-2120(sh 2 of 2) 4985-PB-2120(sh 2 of 2)
SERVICE CONDITION


Protective cover
H 2S 540ppm 598 ppm 540 ppm 608 ppm
CO2 43.98 45.78 44.30 45.69
Nitrogen 25.80 24.80 26.68 25.17
Methane 28.82 27.91 27.48 27.80
e %)
Ethane 0 54
0.54 0 55
0.55 0 62
0.62 0 53
0.53
(Mole
Propane 0.26 0.27 0.26 0.25

i-Butane 0.08 0.09 0.09 0.08
n-Butane
0.07 0.07 0.07 0.07

i-Pentane 0.03 0.03 0.03 0.02
n-Pentane 0.04 0.05 0.05 0.04
n-Hexane 0.03 0.03 0.02 0.02
Heptane+ 0.07 0.05 0.06 0.03
H 2O 0.23 0.31 0.29 0.24
Material:
NOTE:


Tag No. 200-CC-015

Quantity 01 (Note-1,2,3)
P&ID No. 4985-PB-2120(sh 2 of 2)
Service Process Fluid
SERVICE CONDITION
Type Corrosion Coupon

Line No. 8"-PF-DA3-1008
Pipe Size / Pipe Thickness 8"/ 11.1 mm
End Connection Flare weld

Supplier to advice
Protective cover
Maximum Pressure (psig) 1400
Maximum Temperature (ºF) 180
Piping Material /Corrosion Allowance 3mm
Operating Temperature (ºF) 30-130
Operating Pressure (psig) 200-1300
H 2S 197 ppm
CO2 45.48
Nitrogen 24.99
Methane 28.04
e %)
Ethane 0 65
0.65
(Mole
Propane 0.26
i-Butane 0.09
n-Butane
0.07
i-Pentane 0.03
n-Pentane 0.04
n-Hexane 0.01
Heptane+ 0.02
H 2O 0.30
Material:
Flare weld Access Fitting Body ASTM A-105N
Solid Plug Assembly 316L
Disc Coupon Holder 316L
Disc Coupon AISI 1018
Heavy Duty Protective Cover AISI 1018
Primary Packing RPTFE
O' Ring Seal BUNA 'N' 70
NOTE:

CORROSION PROBES Date 3/1/2012

Tag No. 100-CP-001 101-CP-001 102-CP-001 103-CP-001

Quantity 01 01 01 01
P&ID No. 4985-PB-2103 4985-PB-2104 4985-PB-2105 4985-PB-2106
SERVICE CONDITION
Type Corrosion Probe Corrosion Probe Corrosion Probe Corrosion Probe


Protector
Piping Material/ Corrosion Allowance 0 mm 0mm 0mm 0mm
CO2 22.75 22.75 22.75 22.75
Nitrogen 8.41 8.41 8.41 8.41
Methane 65.37 65.37 65.37 65.37
e %)
Ethane 1.98 1.98 1.98 1.98

(Mole
Propane 0.66 0.66 0.66 0.66

i-Butane 0.17 0.17 0.17 0.17
n-Butane 0.17 0.17 0.17 0.17
i-Pentane 0.06 0.06 0.06 0.06

n-Pentane 0.10 0.10 0.10 0.10
n-Hexane 0.04 0.04 0.04 0.04
Heptane+ 0.09 0.09 0.09 0.09
H2O 0.19 0.19 0.19 0.19
Material:
Hollow Plug Assembly 316L 316L 316L 316L
316L Body with 316L Body with 316L Body with 316L Body with
Probe Material
Carbon steel element. Carbon steel element. Carbon steel element. Carbon steel element.
Thread Protector AISI 1018 AISI 1018 AISI 1018 AISI 1018
Probe Packing RPTFE RPTFE RPTFE RPTFE
NOTE:
1. Two inch (2'') High pressure access fitting assembly to be welded on SA-312 TP316L for EC spec comprising:
- Hollow plug assembly , complete with Seals, Packing and retaining and sealing Nut.
-Electrical Resistance probe Retrievable type, incorporating a metal element , compatible with the pipe, suitable for the
continuous monitoring of internal corrosion rates and for installation and retrieval under full line pressure.
-Probe to instrument adaptor.
-Protective cover with hole for instrument adaptor.
2.Corrosion Probes shall be NACE MR0175/ISO15156 complaince.


Tag No. 104-CP-001 105-CP-001 106-CP-001 107-CP-001

P&ID No. 4985-PB-2107 4985-PB-2108 4985-PB-2109 4985-PB-2110
SERVICE CONDITION

Protector
Piping Material/ Corrosion Allowance 0mm 0mm 0mm 0mm
H2S 687ppm 540ppm 598 ppm 540 ppm
CO2 44.63 43.98 45.78 44.30
Nitrogen 24.64 25.80 24.80 26.68
Methane 29.13 28.82 27.91 27.48
(Mole %)
Ethane 0 63
0.63 0 54
0.54 0 55
0.55 0 62
0.62
Propane 0.26 0.26 0.27 0.26
i-Butane 0.08 0.08 0.09 0.09
n-Butane 0.03 0.07 0.07 0.07
i-Pentane 0.03 0.03 0.03 0.03

n-Pentane 0.04 0.04 0.05 0.05
n-Hexane 0.04 0.03 0.03 0.02
Heptane+ 0.08 0.07 0.05 0.06
H2O 0.34 0.23 0.31 0.29
Material:
Probe Material
NOTE:


Tag No. 108-CP-001 109-CP-001 110-CP-001 111-CP-001

P&ID No. 4985-PB-2111 4985-PB-2112 4985-PB-2113 4985-PB-2114
SERVICE CONDITION


Protector
CO2 45.69 45.48 40.22 45.33
Nitrogen 25.17 24.99 16.25 22.90
Methane 27.80 28.04 41.17 30.04
e %)
Ethane
a e 0.53 0.65 1.11 0.76
(Mole
Propane 0.25 0.26 0.41 0.29

i-Butane 0.08 0.09 0.12 0.09
n-Butane 0.07 0.07 0.11 0.08
i-Pentane 0.02 0.03 0.04 0.03

n-Pentane 0.04 0.04 0.06 0.04
n-Hexane 0.02 0.01 0.06 0.05
Heptane+ 0.03 0.02 0.15 0.11
H2O 0.24 0.30 0.29 0.26
Material:
Probe Material
NOTE:


Tag No. 112-CP-001 113-CP-001 114-CP-001 100-CP-002

P&ID No. 4985-PB-2115 4985-PB-2116 4985-PB-2117 4985-PB-2103
SERVICE CONDITION
Type Corrosion Probe Corrosion Probe Corrosion Probe Corrosion Coupon

Line No. 8"-PF-EC-1301A 8"-PF-EC-1401A 8"-PF-EC-1501A 8"-PF-EA2-0102
Pipe Size / Pipe Thickness 8"/ sch 80S 8"/ sch 80S 8"/ sch 80S 8"/ sch 80

Protector
CO2 45.08 45.26 44.94 22.75
Nitrogen 21.39 21.74 23.56 8.41
Methane 31.76 31.08 29.79 65.37
(Mole %)
Eth
Ethane 0 79
0.79 0 82
0.82 0 69
0.69 1 98
1.98
Propane 0.31 0.30 0.27 0.66
i-Butane 0.10 0.10 0.08 0.17
n-Butane 0.08 0.08 0.07 0.17
i-Pentane 0.03 0.03 0.03 0.06

n-Pentane 0.05 0.05 0.04 0.10
n-Hexane 0.06 0.06 0.06 0.04
Heptane+ 0.12 0.13 0.11 0.09
H2O 0.23 0.35 0.34 0.19
Material:
Flare weld Access Fitting Body ASTM A-182 F316L ASTM A-182 F316L ASTM A-182 F316L ASTM A-105N
Probe Material
NOTE:
1. Two inch (2'') High pressure access fitting assembly to be welded on pipe SA-312 TP 316L for EC spec & on SA-106
Gr.B for EA2 spec comprising:
-Protective cover with hole for instrument adaptor

Tag No. 101-CP-002 102-CP-002 103-CP-002 104-CP-002

P&ID No. 4985-PB-2104 4985-PB-2105 4985-PB-2106 4985-PB-2107
SERVICE CONDITION


Protector
CO2 22.75 22.75 22.75 44.63
Nitrogen 8.41 8.41 8.41 24.64
Methane 65.37 65.37 65.37 29.13
(Mole %)
Eth
Ethane 1 98
1.98 1 98
1.98 1 98
1.98 0 63
0.63
Propane 0.66 0.66 0.66 0.26
i-Butane 0.17 0.17 0.17 0.08
n-Butane
0.17 0.17 0.17 0.03

i-Pentane 0.06 0.06 0.06 0.03
n-Pentane 0.10 0.10 0.10 0.04
n-Hexane 0.04 0.04 0.04 0.04
Heptane+ 0.09 0.09 0.09 0.08
H2O 0.19 0.19 0.19 0.34
Material:
Probe Material
NOTE:
1. Two inch (2'') High pressure access fitting assembly to be welded on SA-106 Gr.B for EA2 spec comprising:


Tag No. 105-CP-002 106-CP-002 107-CP-002 108-CP-002

P&ID No. 4985-PB-2108 4985-PB-2109 4985-PB-2110 4985-PB-2111
SERVICE CONDITION


Protector
CO2 43.98 45.78 44.30 45.69
Nitrogen 25.80 24.80 26.68 25.17
Methane 28.82 27.91 27.48 27.80
(Mole %)
Eth
Ethane 0 54
0.54 0 55
0.55 0 62
0.62 0 53
0.53
Propane 0.26 0.27 0.26 0.25
i-Butane 0.08 0.09 0.09 0.08
n-Butane
0.07 0.07 0.07 0.07

i-Pentane 0.03 0.03 0.03 0.02
n-Pentane 0.04 0.05 0.05 0.04
n-Hexane 0.03 0.03 0.02 0.02
Heptane+ 0.07 0.05 0.06 0.03
H2O 0.23 0.31 0.29 0.24
Material:
Probe Material
NOTE:


Tag No. 109-CP-002 110-CP-002 111-CP-002 112-CP-002

P&ID No. 4985-PB-2112 4985-PB-2113 4985-PB-2114 4985-PB-2115
SERVICE CONDITION


Protector
CO2 45.48 40.22 45.33 45.08
Nitrogen 24.99 16.25 22.90 21.39
ole %)
Methane 28.04 41.17 30.04 31.76

Eth
Ethane 0 65
0.65 1 11
1.11 0 76
0.76 0 79
0.79
(Mo
Propane 0.26 0.41 0.29 0.31

i-Butane 0.09 0.12 0.09 0.10
n-Butane 0.07 0.11 0.08 0.08

i-Pentane 0.03 0.04 0.03 0.03
n-Pentane 0.04 0.06 0.04 0.05
n-Hexane 0.01 0.06 0.05 0.06
Heptane+ 0.02 0.15 0.11 0.12
H2O 0.30 0.29 0.26 0.23
Material:
Probe Material 316L Body with 316L Body with 316L Body with 316L Body with
NOTE:


Tag No. 113-CP-002 114-CP-002 200-CP-001 200-CP-002

P&ID No. 4985-PB-2116 4985-PB-2117 4985-PB-2118 4985-PB-2118
SERVICE CONDITION

Line No. 8"-PF-EA2-1402 8"-PF-EA2-1502 10"-PF-DA3-0108 10"-PF-DA3-0208
Pipe Size / Pipe Thickness 8"/ sch 80 8"/ sch 80 10"/ 12.7mm 10"/ 12.7mm

Protector
Operating Temperature (ºF) 30 -130 30 -130 30-130 30-130
Operating Pressure (psig) 200 - 1300 200 - 1300 200-1300 200-1300
CO2 45.26 44.94 22.75 22.75
Nitrogen 21.74 23.56 8.41 8.41
Methane 31.08 29.79 65.37 65.37
(Mole %)
Eth
Ethane 0 82
0.82 0 69
0.69 1 98
1.98 1 98
1.98
Propane 0.30 0.27 0.66 0.66
i-Butane 0.10 0.08 0.17 0.17
n-Butane 0.08 0.07 0.17 0.17
i-Pentane 0.03 0.03 0.06 0.06

n-Pentane 0.05 0.04 0.10 0.10
n-Hexane 0.06 0.06 0.04 0.04
Heptane+ 0.13 0.11 0.09 0.09
H2O 0.35 0.34 0.19 0.19
Material:
Probe Material
NOTE:
1. Two inch (2'') High pressure access fitting assembly to be welded on API-5L X-52 (PSL2) Pipe for DA3 spec, and SA-
106 Gr.B for EA2 spec comprising:
-Protective cover with hole for instrument adaptor

Tag No. 200-CP-003 200-CP-004 200-CP-005 200-CP-006

P&ID No. 4985-PB-2118 4985-PB-2118 4985-PB-2119 4985-PB-2119
SERVICE CONDITION


Protector
CO2 22.75 22.75 40.22 45.33
Nitrogen 8.41 8.41 16.25 22.90
Methane 65.37 65.37 41.17 30.04
%)
(Mole %
Eth
Ethane 1 98
1.98 1 98
1.98 1 11
1.11 0 76
0.76
Propane 0.66 0.66 0.41 0.29
i-Butane 0.17 0.17 0.12 0.09
n-Butane 0.17 0.17 0.11 0.08
i-Pentane 0.06 0.06 0.04 0.03

n-Pentane 0.10 0.10 0.06 0.04
n-Hexane 0.04 0.04 0.06 0.05
Heptane+ 0.09 0.09 0.15 0.11
H2O 0.19 0.19 0.29 0.26
Material:
Probe Material
NOTE:
1. Two inch (2'') High pressure access fitting assembly to be welded on API-5L X-52 (PSL2) Pipe, comprising:


Tag No. 200-CP-007 200-CP-008 200-CP-009 200-CP-010

P&ID No. 4985-PB-2119 4985-PB-2119 4985-PB-2119 985-PB-2120(sh 1 of 2
SERVICE CONDITION


Protector
CO2 45.08 45.26 44.94 44.63
Nitrogen 21.39 21.74 23.56 24.64
Methane 31.76 31.08 29.79 29.13
%)
(Mole %
Eth
Ethane 0 79
0.79 0 82
0.82 0 69
0.69 0 63
0.63
Propane 0.31 0.30 0.27 0.26
i-Butane 0.10 0.10 0.08 0.08
n-Butane 0.08 0.08 0.07 0.03
i-Pentane 0.03 0.03 0.03 0.03

n-Pentane 0.05 0.05 0.04 0.04
n-Hexane 0.06 0.06 0.06 0.04
Heptane+ 0.12 0.13 0.11 0.08
H2O 0.23 0.35 0.34 0.34
Material:
Probe Material
NOTE:


Tag No. 200-CP-011 200-CP-012 200-CP-013 200-CP-014

P&ID No. 985-PB-2120(sh 1 of 2985-PB-2120(sh 1 of 2985-PB-2120(sh 2 of 2985-PB-2120(sh 2 of 2
SERVICE CONDITION


Protector
CO2 43.98 45.78 44.30 45.69
Nitrogen 25.80 24.80 26.68 25.17
Methane 28.82 27.91 27.48 27.80
(Mole %)
Eth
Ethane 0 54
0.54 0 55
0.55 0 62
0.62 0 53
0.53
Propane 0.26 0.27 0.26 0.25
i-Butane 0.08 0.09 0.09 0.08
n-Butane
0.07 0.07 0.07 0.07

i-Pentane 0.03 0.03 0.03 0.02
n-Pentane 0.04 0.05 0.05 0.04
n-Hexane 0.03 0.03 0.02 0.02
Heptane+ 0.07 0.05 0.06 0.03
H2O 0.23 0.31 0.29 0.24
Material:
Probe Material
NOTE:


Tag No. 200-CP-015

Quantity 01
P&ID No. 4985-PB-2120(sh 2 of 2)
Service Process Fluid
SERVICE CONDITION
Type Corrosion Coupon

Line No. 8"-PF-DA3-1008
Pipe Size / Pipe Thickness 8"/ 11.1 mm
End Connection Flare weld
Supplier to advice
Protector
Maximum Pressure (psig) 1400
Maximum Temperature (ºF) 180
Piping Material/ Corrosion Allowance 3mm
Operating Temperature (ºF) 30-130
Operating Pressure (psig) 200-1300
H2S 197 ppm
CO2 45.48
Nitrogen 24.99
ole %)
Methane 28.04
Ethane 0.65
(Mo
Propane 0.26
i-Butane 0.09
n-Butane 0.07
i-Pentane 0.03
n-Pentane 0.04
n-Hexane 0.01
Heptane+ 0.02
H2O 0.30
Material:
Flare weld Access Fitting Body ASTM A-105N
Hollow Plug Assembly 316L
316L Body with
Probe Material
Carbon steel element.
Thread Protector AISI 1018
Primary Packing RPTFE
Probe Packing RPTFE
NOTE:

Client: OGDCL Job No 14-4985
ENAR
Project Gas Project Doc No 4985-DS-1804
Data Sheet
Item Anchor Flanges Sheet 1 of 1
Revision 0
Issued for Bidding
Date 20/12/11
By WRK
Checked MK
Approved FS
Client
1 Process Data
2 Fluid Untreated natural gas
3 Pressure (psig) Min 142 Max 178
o
4 Temperature ( F) Min -30o Normal 100 o
Max 180o
5 Flow lb/hr Min 18880 Max 93005
6 Design Data See Note 2 Construction
7 Pressure Design (psig) 1400 Type -
o o o
8 Temperature ( F) 30 - 180 Seals -
9 Flow m3/h 93005
10 Design Code ASME VIII
11 Design Factor Note 2
12 Location WT (mm) 11.1 9.5
13 Design Load (Axial KN) 1135 730
14 Quantity 30 6
15 Size 10” 8”
16 Pup Material API 5L X52
17 Pup Length Note 2
18 Pup WT Note 2
19
20 End Connections BW/BW to ANSI 16.25
21 Corr’n Allowance (mm) 0
22 Suppl’y Requirements
23 Materials
24 Hubs ASTM A-694 Grade F52
25 Flanges and Forgings -
26 Plate -
27 Inspection and Testing
28 Mechanical Tests NDT to ASME VIII (See Note 1)
29 Hydrostatic Tests -
30 Electrical Tests -
31 Surface Treatment
32 External Removable Skin for Corrosion Protection
33 Internal Approved Rust Inhibitor
34 Remarks
35 Note 1 Supplier shall refer to 4985-PA-2010 for full Technical Requirements
36 Note 2 Flanges to be designed and calculations furnished by supplier, using design
loads given.
4985-DS-1804

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Job No. 14 – 4985
Spec. No. 4985-GS-9504
SPECIFICATION FOR
ERECTION & INSTALLATION OF SKID MOUNTED/
FIELD ERECTED EQUIPMENT
Project: UCH-II Development Project
Owner: Oil & Gas Development Co. Ltd.
Prepared by: NJ
Checked by: Mk
Approved by: FS
Revised by: FAS
0 ISSUED FOR BIDDING 04/12/2012

Rev. Description of Revision Date Revised Page Nos.
Specification for Erection/Installation of Skid Mounted/Field Erected Equipment
UCH-II Development Project
TABLE OF CONTENTS
SECTION DESCRIPTION SHEET

NO. NO.
1.0 SCOPE .............................................................................................3
2.0 REFERENCE CODES AND STANDARDS ..................................4
3.0 GENERAL .......................................................................................5
4.0 STATIC EQUIPMENT ERECTION...............................................6
5.0 ROTARY EQUIPMENT ERECTION ............................................9
6.0 GROUTING...................................................................................12
7.0 PREPARATION OF LUBE OIL PIPING SYSTEMS ..................19
Spec. No. 4985-GS-9504

Rev. 0 Sheet 2 of 20
1.0 SCOPE
The specification covers the care and procedures to install the mechanical equipment
belonging to UCH-II Development Project.
Spec. No. 4985-GS-9504

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

installation are:
• Local laws or decrees on safety during working.
• OSHA (Occupational Safety and Health Administration) to back up the previous

ones, for special duties.
• Manufacturer's instructions.
• Enclosed specifications.
Spec. No. 4985-GS-9504

3.0 GENERAL
As a general rule, all mechanical equipments shall be installed strictly following the
manufacturer's instructions. Said instructions are a part of Technical Documentation
to be supplied to OGDCL/Engineering Consultant.
Spec. No. 4985-GS-9504

4.0 STATIC EQUIPMENT ERECTION
4.1 This section refers to all static equipments e.g. vessels, columns, re-boilers, flare
stacks, tubular heat exchangers, oil water separator packages, skid mounted
equipments, filters, etc., to be erected/installed by the Contractor.
The erection work should conform in each specific case to the following codes,
standards and relevant Specifications:
• ASME Section VIII Div. I.
• Instructions and drawings issued by Manufacturer.
• Layout of each equipment and orientation for correct positioning, shown in the
piping drawings.
4.2 Handling of each equipment or part should be performed such as to eliminate over-
stressing.
4.3 Use of slings, where indicated in the equipment drawings shall be used.
4.4 Wherever the equipment is provided with lifting lugs they shall be used as the only
main points for lifting.
4.5 The nozzles and/or the man ways may be used as lifting points only if specifically
indicated so.
4.6 All stiffeners, protection covers, temporary supports and all other facilities provided
by the equipment manufacturer should be left in their places until erection time.
4.7 Before placing the equipment on foundations, the top of concrete should be chipped
by hammering to remove the surface layer, which has low strength and to ensure a
suitable bond between the foundation concrete and grouting.
4.8 The equipment should be laid on blocks of steel wedges and/or shims to ensure a
grouting space as specified in the drawing, if not, than 25 to 35mm, to be maintained.
Spec. No. 4985-GS-9504

4.9 Minimum two blocks of wedges and/or packages of shims should be considered for
each foundation bolt (one on each side of each bolt).
4.10 The sliding supports of the horizontal equipment should rest on intermediate
bedplates of steel and the necessary blocks of wedges and/or shims should be installed
under such bedplates only.
4.11 The two nuts of each foundation bolt shall be tightened to each other above the base
plates of the sliding supports such as to ensure free spaces of 1.5 to 3mm.
4.12 No welding shall be permitted on the equipment supplied as completely shop

assembled. Site welding of certain external attachments may be considered when
specifically ordered only.
4.13 All welding procedure test and welders qualification should be done as per ASME
Section IX & other Specification prepared by OGDCL/Engineering Consultant.
4.14 Preheat and post weld heat treatments (stress relieving) when required, should be
done using electric induction equipment provided with temperature recorders.
4.15 Nozzle of the equipment should be checked for tension/stresses. All the piping
attached with the equipment should be free of tension/stresses.
4.16 The telltale hole is to be used to pneumatically test attachment welds on reinforcing
pads. The telltale hole shall be plugged after hydrotest with non-hardening sealant or
grease.
4.17 The final tightening of all the studs should be done uniformly and in the proper
diametric sequence to impose equal pressure on the gasket and to avoid distortion or
over-stressing of equipment.
4.18 Colloidal molybdenum disulfide or other approved lubricants shall be applied to all
studs before the joints are assembled.
4.19 All equipment components shall be sorted separately as per PC Contractor's

instructions and stored on wooden sleepers above the ground.
Spec. No. 4985-GS-9504

4.20 Access and service platforms which affect the erection of equipment and sub-
assemblies should be erected after box-up of equipment.
4.21 Field hydrostatic pressure testing of all equipments shall be conducted in accordance
with the equipment manufacturer's instructions.
4.22 Test records shall be maintained for all tests conducted. Format for test record shall be
provided by the Contractor for OGDCL’s/Engineering Consultant’s approval, which
would include the following:
a) Date of test
b) Equipment number
c) Test medium
d) Inspector's name and signature
e) Duration of test
f) Pressure records
g) Ambient Temperature
4.23 The following inspection should be made in the presence of representative of

OGDCL/Engineering Consultant and a certificate must be signed for each inspection:
a) Correct leveling and orientation of equipment

b) Hydrostatic testing
c) Stress relieving and hardness testing
d) Refractory drying if required/applicable
e) Mechanical completion
f) Box-up
g) Equipment Acceptance Certificate
Spec. No. 4985-GS-9504

5.0 ROTARY EQUIPMENT ERECTION
5.1 This section refers to all compressors (centrifugal and reciprocating), centrifugal
blowers, pumps (centrifugal pumps), screw pump, gear pumps, proportioning (meter-
ing) pumps, reciprocating pumps with or without gear-box driven by electric motors,
gas turbines, stream turbines, or diesel engines single stage or multistage, air coolers,
etc. Steel structure attached with air cooler is also part of equipment. It also includes
assembly and installation of packaged skid mounted rotary equipment like chemical
injection packages, air generation unit and packaged reciprocating compressor.
5.2 Handling of each unit should be performed by placing the slings such as to eliminate
over-stressing.
The eye bolts on the top of the drivers or driven casings (if such eye bolts are
provided by manufacturers) shall be used when lifting those parts separately and not
when lifting the complete unit.
5.3 Storage conditions before erection on foundations and preservations after erection on
foundations should conform in all respects to the instructions issued by
manufacturers. Suction and discharge flange covers as well as all the protection plugs
provided by manufacturers to the other openings must be left in their places until the
piping is connected with them. If no covers or protection plugs have been provided by
manufacturers or if such covers or plugs are not suitable for protection after removing
the units from their boxes, they should be replaced by sub-contractor with the suitable
ones.
Each equipment should be inspected periodically and additional steps should be

considered when necessary (periodic cleaning, filling with oil, etc.).
5.4 Before placing the units on foundations, the top of concrete should be chipped by
hammering to remove the surface layer, which has low strength and to ensure a
suitable bond between the foundation concrete and grout.
5.5 The equipment should be laid on blocks of wedges and/or shims to ensure a grouting
space as specified in the drawing between the concrete top and base plate bottom. The
blocks of wedges and/or shims should be placed near each foundation bolt and
Spec. No. 4985-GS-9504

adjusted as necessary to ensure a correct level (horizontality) in all directions. After
leveling, the nuts of the foundation bolts should be lightly tightened. Grouting should
be performed as per Section 6.0 of this specification.
5.6 Alignment of the unit (a) driver and speed reducer unit, (b) speed reducer unit and
driven (if any) should be performed to conform strictly to the accuracy indicated by
the manufacturers using dial “Laser alignment tool”.
Use of dial indicator straight edges and sensor gauges cannot be considered unless
approved by OGDCL/Engineering Consultant.
Each alignment should include accurate checking of radial and axial deviations fas-
tening the dial indicator bracket, sequentially to each half of the coupling.
Alignment should be checked:
• Before grouting
• After grouting and
• After connection of piping to the equipment
5.7 Lubrication, installation of auxiliary piping and accessories installation of packing or

mechanical seals (if the mechanical seals have not been installed by the Manufacturer)
as well as all operations on the equipment itself like dismantling and reassembling (if
required) must conform strictly to the instructions given by the Manufacturer for each
equipment.
5.8 The piping attached to the compressor should be cleaned chemically before com-
missioning.
5.9 Flanged connections to pumps, compressors, turbines and all other machines shall be
left un-tightened and protected by suitable covers until the machines are made
available for final connections.
5.10 The suction and discharge nozzle flange faces and piping flange faces shall match
within the tolerances stated herein and following the Manufacturer's requirement.
5.11 No additional stresses shall appear when flange bolts are tightened.
Spec. No. 4985-GS-9504

5.12 After piping is connected onto pumps and before starting-up of said machinery, a final
check of coupling(s) lining-up will be performed, using a dial type indicator. This
check shall show the same values, which have been read before piping was connected.
This will allow checking that no additional stresses have been induced by piping
connection. After agreed-upon operation time, a final check of the shaft lining-up
shall take place.
5.13 The erection of auxiliary equipment like coolers, pulsation bottles, dampeners, separa-
tors, etc. should also include inspection and pressure tests.
Running test of each item should be performed after all necessary facilities are
available to check for proper operation. Temporary provisions may be considered if
safe enough only.
5.14 All fabrication and erection of steel structure shall comply with American Institute of
Steel Construction (AISC).
5.15 All welding procedure tests and welders qualification should be done as per ASME
Section IX.
5.16 The following inspection should be made by representative of OGDCL/Engineering

Consultant and a certificate must be signed for each inspection:
a) Correct leveling and orientation of equipment.
b) Alignment:
– Before grouting
– After grouting
– After connecting the pipe to the equipment
c) Mechanical completion certificate.
d) Test run certificate/acceptance certificate.
5.17 No spare parts should be used for replacing the defective ones during erection work,
unless specifically agreed upon.
Spec. No. 4985-GS-9504

6.0 GROUTING
6.1 Scope
This section defines the materials and workmanship related to grouting for the
following applications:
i) Bonding of new concrete to existing concrete
ii) Grouting of base plates and equipment bases
Materials include - regular cement grout, no shrink cement-based grout, epoxy grout
and bonding mixtures.
6.2 Reference Codes and Standards
The standards to be taken into consideration in addition to the terms of the present
specification are:
ASTM-C33-79 Standard Specification for Concrete Aggregates
ASTM-C109-77 Standard Test Method for Compressive Strength of Hydraulic

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

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

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

Thermal Expansion of Chemical-Resistant Mortars, Grouts and
Monolithic Surfacing
ASTM-C579-75 Standard Test Methods for Compressive Strength Surfacing.
Spec. No. 4985-GS-9504

ASTM-C827-78 Standard Test Method for Early Volume Change of Cementi-
tious Mixtures
CRD-C588-79 Specification for Nonshrink Grout

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

Work
6.3 Delivery, Storage & Handling
a) Nonshrink Cement-Based Grout and Epoxy Grout aggregate shall be delivered

to the site in sound dry bags and Epoxy Grout liquid components in sealed
hardener and resin containers. The Contractor shall be responsible for storing
the grout in a dry, weatherproof area and within the temperature range of 4ºC to
32ºC.
b) The total job storage time for non-shrink grout shall be limited to ten months.
6.4 Materials
a) General
Sand-cement grouts shall be proportioned at the site. All non-shrink grouts shall
consist of pre-measured, prepackaged materials, supplied by the Manufacturer,
except water.
All grouts shall be non-corrosive, non-staining and resistant to effects of

moisture.
b) Water, Sand and Cement

Water shall conform to AASHTO T26. When conforming water is not available,
mortar test cubes shall be made with non-conforming water in accordance with
the requirements of ASTM C109. Tested cubes shall have a minimum of 90% of
the 28 day specified strength.
Spec. No. 4985-GS-9504

Sand shall be used as defined by ASTM C125 and shall conform to ASTM C33,
grading for fine aggregates (No. 4 to 100). Sand for bonding mixture shall pass a
No. 16 sieve.
Cement shall be Portland Cement Type I or Type II, ASTM C150.
c) Cement Grouts
Plain Cement Grout shall be two parts sand for every part cement, by weight;
with a minimum 28 days compressive stress of 20 MPa (3000 psi) in accordance
with ASTM C109.
d) Non-shrink Cement-Based Grout shall meet the following requirements:
Plastic Volume Change: No shrinkage (0.0%) and a maximum of 4.0%

expansion at any time before initial set when tested according to ASTM C827.
Hardened Volume Change: No shrinkage (0.0%) and a maximum of 0.1%

expansion in the hardened state when tested according to CRD C588.
Compressive Strength: Minimum allowable compressive strength at 28 days to

be 40 MPa (6000 psi) as measured by ASTM C109.
Initial Set Time: Not less than 60 minutes when tested according to ASTM
C191.
Soundness: No grout shall contain metallic substances (catalyzed or non-

catalyzed), aluminum powder, water reducing agents, fluidifiers, accelerators,
super plasticizers, or other materials known to increase drying shrinkage and/or
compromise long-term durability.
e) Non-shrink Epoxy Grout shall meet the following requirements:
Volume Change: No shrinkage and a maximum of 4.0% expansion when

tested according to ASTM C827 (modified).
Compressive Strength: Minimum allowable compressive strength at 7 days to

be 40 MPa (6000 psi) as measured by ASTM C579.
Spec. No. 4985-GS-9504

Heat Development: The peak exothermal temp of a 50 mm (2") diameter by
100 mm (4") high cylinder of grout not to exceed 35ºC (95ºF) when tested at
24ºC (75ºF) material and laboratory temperatures.
Thermal Expansion: Not to exceed a coefficient of thermal expansion of 54 x

10-6 mm/mm/ºC (30 x 10-6 in/in/ºF) when tested according to ASTM C531.
f) Bonding Mixtures and Adhesives

The following bonding mixture or adhesive can be used to create cohesion or
water tightness between new concrete and existing concrete:
– Cement Bonding Mixture - Neat cement and water mixed to the consistency
of creamy paint.
– Epoxy Adhesive - Mixture consists of a proprietary epoxy adhesive, mixed

and applied in accordance with manufacturer's instructions. Epoxy adhesive
to be approved by Client\Company.
6.5 Applications
Grout to be provided between the top of foundation concrete and the bottom of
bearing plates. Thickness of grout shall be as specified in drawing, if not, than to be a
nominal thickness of 25 mm (1") with a minimum thickness of 12 mm (½") in order
to avoid feather edging.
Non-shrink grout or epoxy grout to be used for the following applications. Nonshrink
grout to be used unless epoxy grout is specified by equipment Contractor or
OGDCL/Engineering Consultant.
• All compressors.
• Reciprocating pumps greater than 75 kW (100 HP) and centrifugal pumps
greater than 375 kW (500 HP).
• Structures with a height to width ratio over 2, or with large vibrating equipment,
if one column load is over 500 kN (110 kips).
• Normal structures if one column load is in excess of 1000 kN (220 kips)
Spec. No. 4985-GS-9504

Drawings to indicate where non-shrink grout is to be used.
For grouts that will experience temperatures above those listed below, high tempera-
ture grouts to be used.
Maximum Temp.
Cement based grout – 200ºC
Epoxy grout – 135ºC
High temperature cement-based grout sets faster than normal temperature grout.
Because of the difference in thermal coefficient of expansion between epoxy grout

and concrete, stresses are formed at grout edges. Grout details to allow for expansion
joints, grout cut back, corner reinforcing or added epoxy depth at corners
6.6 Execution
a) Surface Preparation
Surface of the existing concrete of grease shall be cleaned from oil, paint and
other coatings. The surface shall be roughened to expose the aggregate and
thoroughly flushed with clean water.
Before grouting, equipment bases and base plates shall be leveled and aligned in
accordance with recommendations of equipment manufacturer and drawings.
When any cement-based grout or bonding mixture is used, the concrete surface
shall be thoroughly soaked until absorption stops. Excess water shall be
removed just before grouting of bonding.
When epoxy grouts or adhesives are used, all surfaces shall be kept dry before
application.
b) Form work
Forms or back braces used shall be securely anchored to withstand the forces of
the placement of grout.
Spec. No. 4985-GS-9504

For nonshrink cement based grout tight forms shall be provided with tape sealed
joints. Form oil to be applied for easy form release.
For nonshrink epoxy grout, watertight forms shall be provided with chamfer
strips in place where chamfer edge is required. Forms to be lined with
polyethylene or heavy wax for easy form release.
c) Placement
Grout placement shall be done in a manner that will assure the filling of all
surfaces and the intimate contact of grouting materials with surfaces grouted.
Grout to be placed rapidly and continuously to avoid cold joints under the
baseplate. Grouting to be done from one side to the other in one direction with
tamping or rodding to eliminate voids.
d) Finishing
Cement-based grout shall be trimmed back to the level indicated on the

drawings after the grout has reached an initial set. Surfaces to be sloped away
from base plate and protruding edges cut back.
Epoxy grout cannot be trimmed after set. Top surfaces shall be finished to
proper slope prior to initial set.
Finish coating shall be applied over grout holes and vent holes after grout has
set.
e) Curing
Immediately after placement, cement-based grout shall be protected from

premature drying, excessively hot or cold temperatures and mechanical injury.
Grout to be maintained with minimal moisture loss by implying proper
methodology at relatively constant temperature for the period necessary for
hydration of cement and hardening of concrete.
Epoxy grout shall be cured in accordance with manufacturer's instructions.
Spec. No. 4985-GS-9504

f) Shims and Wedges
Removal of shims and wedges is not required unless specified by equipment
manufacturer. All shims or wedges left in place shall be completely encased in
grout.
g) Anchor Bolts and Pipe Sleeves

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

The bonding mixture shall be applied by working it into the surface with a stiff
brush. New concrete to be placed before bonding mixture dries out.
Epoxy adhesive shall be applied in accordance with manufacturer's instructions.
i) Testing
Cement-based grout shall be tested under ASTM C109 and epoxy grout under
ASTM C579. Cubes shall be prepared for each type of grout and tested for
required compressive strength according to the following schedule.
Grout Type 24 Hrs. 2 Days 7 Days 28 Days

Plain Cement Grout – 2 2 2
Nonshrink Cement Grout 3 – 3 3
Epoxy Grout 3 3 3 –
Spec. No. 4985-GS-9504

7.0 PREPARATION OF LUBE OIL PIPING SYSTEMS
7.1 General
Prior to testing of rotating main machinery fitted with lubricating oil piping, the
preparation works defined hereunder shall be undertaken.
7.2 Pickling of Oil Piping

After all welding, fabrication and erection of oil piping has been completed, the
piping shall be dismantled in suitable sections configuration, so that efficient flow of
liquids could be performed through said piping sections.
• Cleaning
Before pickling procedure performance, all oil equipment shall be opened
inspected, to determine condition of internal parts. When deemed necessary,
such material shall be cleaned, using a solvent previously agreed upon by the
equipment Manufacturers.
• Pickling
After proper and careful preparation every pipe section will be flushed, using hot
caustic soda. This will be performed until perfect cleanliness has been reached.
Then the pipe sections shall be flushed with fresh clean water up to elimination
of caustic soda.
After performance of this operation flushing with hot muriatic will take place.
Pickling shall be repeated until the system is completely clean and to
OGDCL’s/Engineering Consultant’s satisfaction.
• Rinsing
The piping shall then be rinsed by flushing with fresh clean water, until all traces
of acid are removed.
• Drying
The piping shall, after that procedure, be dried by blowing air or gas, until
complete removal of all water and humidity.
Spec. No. 4985-GS-9504

• Miscellaneous
After drying the piping shall receive a coat of clean engine oil to prevent
oxidation.
As an alternative, the system may be filled with approved oil, run for 6 hours and
kept as it is, up to test operation until the final oil will be filled.
After flushing has been performed, the oil will be drained from the system and
the filters’ cartridges replaced by new ones.
All new cartridges cost will be borne by the Contractor.
For lube oil flush, the tube bundle shall be removed from coolers and stored with
care to prevent damage. Upon completion of flushing operations, the bundle
shall be thoroughly cleaned using same solvent used (in para cleaning above). It
shall then be reinstalled in the oil coolers.
Spec. No. 4985-GS-9504

Job No. 14 – 4985
Spec. No. 4985-GS-9523
Page 1 of 23 Rev. 0
SPECIFICATION FOR PAINTING & PROTECTIVE

COATING
Prepared by: FAS

Checked by: AJ
Approved by: FS
Revised by: -
0 ISSUED FOR BID 28/11/12

Specification for Painting & Protective Coating
TABLE OF CONTENTS
1.0 INTRODUCTION....................................................................................................... 3
2.0 CODES AND STANDARDS...................................................................................... 4
3.0 SCOPE OF SUPPLY .................................................................................................. 5
4.0 ENVIRONMENTAL DESIGN CRITERIA ............................................................. 6
5.0 APPLICATION PROCEDURE ................................................................................ 7
6.0 GALVANISING ........................................................................................................ 13
7.0 PREPARATION OF NON FERROUS SURFACES............................................. 14
8.0 SURFACES NOT TO BE COATED ...................................................................... 15
9.0 DEVIATIONS ........................................................................................................... 16
10.0 COATINGS REPAIR PROCEDURE .................................................................... 17
11.0 APPROVED PAINT MANUFACTURERS ........................................................... 19
12.0 PAINT SYSTESM .................................................................................................... 20
13.0 COLOUR CODING.................................................................................................. 23
Spec. No.4985-GS-9523-0 Page 2 of 23

1.0 INTRODUCTION
1.1 General
This specification covers Company's requirements for the surface preparation,

selection of material, and material application procedures for Protective Coating
systems to be used on steel structures, equipment and production facilities for the
UCH-II Development Project during fabrication, construction and/or operation.
1.2 Terminology
Company Oil and Gas Development Company Limited

Company Representative A Company designated Engineer, Party/Parties duly
authorized by the company to act on behalf of the
company with whom the Supplier shall consult at all
reasonable times and whose instructions, request and
decision shall be binding on Supplier.
Supplier Entity with whom the Company will execute a
Contract for supply of equipment/material as per this
document
Project UCH-II Development Project
Spec. No.4985-GS-9523-0 Page 3 of 23

2.0 CODES AND STANDARDS
2.1 Codes, Standards and Regulations
The surface preparation and coatings shall be in accordance with this specification,
the latest editions of the following Codes and Standards and Statutory Regulations
(where applicable):
"Steel Structures Painting Steel Structures Painting Council

Manual Vol. 1" "Good Painting 4440 Fifth Avenue
Practice". Pittsburgh, PA 15212, U.S.A.
"Steel Structures Painting Steel Structures Painting Council
Manual Vol. 2 "Systems and 4440 Fifth Avenue
Specifications". Pittsburgh, PA 15212, U.S.A.
"Swedish Standard S.I.-05.5900" Swedish Stds. Inst.
"Pictorial Surface Preparation Box 3295
Standards for Painting Steel S-10366 Stockholm 3,
Surfaces". Sweden
"Echelle European de Degres European Committee of Paint and

D'Enrouillement pour Peintures Printing Ink manufacturers Association
Antirouille" ("European Scale obtainable from:
of Rusting for Anti Corrosive Paint Manufacturers Assn. of Great
Paints"). Britain,
Alembic House, Albert Embankment, London
A.S.T.M. A123 American Society for Testing and Materials

"Zinc (Hot Galvanized) Coatings on 1916 Race Street
Products from Rolled, Pressed and Philadelphia, PA 19103
Forged Steel Shapes, Plates, U.S.A.
Bars and Strip".
2.2 Order of Precedence
In case of conflict between this specification and its associated specifications and the
above codes and standards, the Application Supplier shall bring the matter to the
Company’s attention for resolution and approval in writing. In all cases the most
stringent requirement shall apply.
Should any conflict occur as a result of applying paint manufacturers data sheets and
specifications, the order of precedence shall be as follows:
Data Sheets
This Specification
Other reference Project Specifications
Codes and Standards referred to within this specification and its attachments.
Spec. No.4985-GS-9523-0 Page 4 of 23

3.0 SCOPE OF SUPPLY
3.1 General
The overall scope of supply for the preparation and painting shall be as indicated
within this specification.
3.2 Scope of Supply
The application Supplier appointed to carry out surface preparation and painting shall
provide the following as a minimum:
Supply of all labor sufficient to complete the work
Supply of all equipment, special tools and power
Supply of suitable grit/sand
Supply of all coating materials
Responsibility for safe storage of consumable materials ambient conditions
during operations
Inspection and testing in accordance with this specification and its attachments
All documentation as required by this specification and its attachments.
Spec. No.4985-GS-9523-0 Page 5 of 23

4.0 ENVIRONMENTAL DESIGN CRITERIA
4.1 General
Unless otherwise stated on the data sheets, all equipments and structures will be
located in an open exposed area.
4.2 Site Environmental Data
Environmental conditions for all equipments and structures covered by this

specification will be listed in the Project Specification on Site Data and Utilities
Spec. No. 4985-A-1000.
Spec. No.4985-GS-9523-0 Page 6 of 23

5.0 APPLICATION PROCEDURE
5.1 General
5.1.1 Supplier's Representative/Guarantee
The Application Supplier shall arrange for the services of a technical representative
of the selected coating manufacturer to visit the worksite before the beginning of
cleaning and coating operations to advise the Application Suppliers personnel
regarding proper equipment, surface preparation and coating procedures. The
technical representative shall thereafter make periodic visits to assist the Application
Supplier in applying and curing the products and systems at the recommended dry
film thickness.
Coating manufacturer and Application Supplier shall give a joint 5 year guarantee as
follows:
All coatings will be 'sound' and giving a degree of paint protection efficiency' similar
to scale 8 of the European Scale of Degree of Rusting for Anti Corrosive Paints" - for
a period of five years.
The guarantee period will start from the provisional acceptance of the completed
work.
5.1.2 Inspection
The Company's representatives and the Paint manufacturer's representative shall have
access to the Application Suppliers worksites at all times during blasting and coating
application and shall be permitted to inspect the work at will. Both representatives
shall be given at least two days' notice prior to initial starting of any work covered by
the specification. The Company's representatives shall have the authority to reject
any work that does not conform to the specification.
5.1.3 Supplier's Personnel
The Application Supplier shall select only competent and fully skilled personnel and
shall keep an experienced foreman on the job at all times when work is in progress.
Spec. No.4985-GS-9523-0 Page 7 of 23

5.2 Surface Application - General
5.2.1 Cleaning
All steel surfaces to be coated shall be cleaned by abrasive blasting.
Blasting abrasives shall be dry, clean and free from contaminations.
Preliminary blasting may be done at night with the prior consent of the Company's
representatives provided that all surfaces so blasted shall again be blasted to within
the specified tolerances before any coating materials are applied.
Final blast cleaning shall be permitted only during daylight hours and in the presence
of the Company’s representative.
All blast cleaned surfaces shall be coated with the specific primer within four hours
after blasting, prior to sundown on the same day before rusting occurs. All dust and
abrasive particles shall be thoroughly removed from surfaces before the application
of any coating. A minimum of 50mm around the edges of blast cleaned surfaces shall
be left uncoated unless joining a coated surface. No acid washes or other cleaning
solutions or solvents shall be used on metal surfaces after they are blasted. This
includes inhibitive washes intended to prevent rusting.
Blast cleaning shall not be done on surfaces that are moist or that may become moist
before the application primer.
All N.D.T. of components and surfaces to be coated must be ascertained to have been
completed prior to preparation and coating. Any steel not primed on the same day as
it was blasted or any steel wet by rain or moisture shall be reblasted.
No blasting shall be permitted when metal surface temperatures are less than 3°C
above the dew point, or when the relative humidity of the air is greater than 80%.
Temperatures and humidity shall be recorded twice a day.
Blast cleaning shall not be done in proximity to surface coating operations or near
other surfaces susceptible to dust and particle contamination.
Any portion of the fabrication to be blast cleaned, including the drilling of bolt holes,
shall be complete and in final condition before blasting is started, unless otherwise
authorized by the Company. All welded areas shall be given special attention for
removal of weld flux slag, weld metal spatter, weld heat oxides, weld flux fumes,
slivers and other foreign objects before blasting. Any oil or grease contamination
shall be removed by solvent cleaning and the area re-blasted. Blasting shall continue
a minimum of 20mm into adjacent coated surfaces.
Spec. No.4985-GS-9523-0 Page 8 of 23

5.3 Blast Cleaning Requirements
5.3.1 As a minimum, all cleaning shall be to a NEAR-WHITE-BLAST CLEANING in

accordance with and as illustrated by Swedish Standard SIS 05 5900 Grade SA 2½.
A Near-White-Blast Cleaned Surface Finish is defined as 'one from which all oil,
grease, dirt, mill scale, rust, corrosion products, oxides, paint and other foreign
matter have been completely removed from the, surface except for the very light
shadows, very slight streaks or slight discolorations caused by rust stain, mill scale
oxides, or slight residues of paint or coating that may remain. At least 95 per cent of
each 5 sq. cm. of surface area shall be free of all visible residues, and the remainder
shall be limited to the light discoloration mentioned above".
Size of abrasive particles shall be such that anchor profile achieved is a maximum of
50 microns unless otherwise approved by Company. The abrasive selected for use,
which will be angular in nature, shall be in accordance with the recommendations of
the coating manufacturer. The anchor profile shall be measured and recorded or
replicated with: -
• The "Testex Press-O-Film" system or equivalent

• The "Rugotest LCA-CFA No. 3" or equivalent
Sand blasting equipment is to be inspected in respect of discharge rate and pressure,

hose sizes and air drying.
Sand/grit is to be stored under cover and shall be "DRY" for feeding into the spray
hopper.
After blasting, all grit/sand shall be removed by dry air blowing or vacuum.
5.4 Coating
5.4.1 Supply of Materials
All coating materials and thinners shall be furnished by the Application Supplier in
original, unopened containers bearing the manufacturer' label and instructions. For
materials having a limited shelf life, the date of manufacture and the length of life
shall be shown.
5.4.2 Preparation of Materials
All coating materials shall be stirred in a pot with a power mixer before use to,
thoroughly remix the pigments and thinners. Only thinners specified by the coating
manufacturer shall be used. Mixing and thinning directions as furnished by the
coating manufacturer shall be followed.
Spec. No.4985-GS-9523-0 Page 9 of 23

5.4.3 Use of Materials
If the coating material requires the addition of a catalyst, the pot life under
application conditions shall be clearly stated on the container label and this pot life
shall not be exceeded. When the pot life limit is reached, the spray pot shall be
emptied, remaining material discarded, the equipment cleaned and new material
catalyzed.
Coating materials which have livered, gelled or otherwise deteriorated during storage
shall not be used. Thixotropic materials which may be stirred to obtain normal
consistency are not subject to this restriction.
Depending upon location, the Application Supplier shall employ the suitable system
as listed in this Specification.
Coating systems shall be supplied by one manufacturer who shall assure the
Application Supplier that the various components of the coating system are
compatible.
5.5 Coating Application
5.5.1 Surface Defects
All surface defects including cracks, surface laminations and deep pitting, likely to
be detrimental to the protective painting system shall be removed in accordance with
the relevant equipment, vessel, piping or structural code or specification covering
surface defects. All fins at saw cuts, barbs and sharp edges shall be similarly
removed. Where extensive grinding has been necessary, the dressed areas shall be
reblasted to remove all rust and provide an adequate paint key.
5.5.2 Weather
No coating shall be applied during fog, mist, rain, frost, or when the metal surface
temperatures are less than 3°C above the air dew point or when the relative humidity
of the air is greater than 85% (95% for application of inorganic zinc silicate paints).
The Company or his representative may suspend application of coating when, in their
opinion, damage to the coating may result from actual or impending weather
conditions.
5.5.3 Coating
Each coat shall be applied uniformly over the entire surface. Skips, runs, sags and
drips shall be avoided. When these occur they shall be brushed out immediately or
the material shall be removed and the surface recoated. On beams and irregular
surfaces, edges shall be coated first and an extra pass made later.
Spec. No.4985-GS-9523-0 Page 10 of 23

Each coat shall be allowed to dry for the time specified by the coating manufacturer.
Paint rollers shall not be used.
5.5.4 Film Thickness
Specified film thickness for coating materials shall be strictly observed. Film
thickness shall be checked with appropriate film thickness gauges furnished by the
Application Supplier. The Application Supplier shall calibrate gauges for the
thickness range to be checked, over the type of surface to be coated. When dry film
thicknesses are less than those specified, additional coats shall be applied as required
at no additional cost to the Company.
5.5.5 Integrity of Coating
Coating shall be free from pin holes, voids, bubbles and other discontinuities. Any
such defects shall be repaired at the Application Supplier's expense. Prior to the
application of a coating, any damage to the previous coating shall be repaired with
the specified material. Upon completion, any damage of fault to the coating system
shall be repaired to the satisfaction of the Company at no additional cost.
5.5.6 Contaminations
Precautions shall be taken to prevent the deposition of dust, moisture or other foreign
matters on the surface after coating. Any coated surface that becomes contaminated
with dirt etc. shall be air blasted or washed down and allowed to dry. If the
contamination still exists the affected surfaces shall be reblasted.
5.5.7 Spray Application
The Company reserves the right to inspect all equipment for spray application prior
to commencement of spraying. Spray guns, lines and pressure pots shall be clean
before adding new material. An adequate moisture trap shall be installed between the
air supply and each pressure pot. Suitable pressure regulators and gauges shall be
provided for both the air supply to the pressure pot and the air supply to the spray
gun. Spray equipment and operating pressure shall comply with the
recommendations of the coating manufacturer.
The length of the material hose between pressure pot and spray gun shall not exceed
15 meters. Pressure pot, material hose and spray gun shall all be kept at as nearly the
same elevation as possible. The spray gun shall be held at right angles to the surface
and each pass shall overlap the previous pass by 50%.
Spec. No.4985-GS-9523-0 Page 11 of 23

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

his selection and use of paint spray equipment, and any specific instructions for
application.
5.5.8 Brush Application
When coatings are to be applied by brushing, brushes shall be of a style and quality
that will permit proper application of material. Round or oval brushes are generally
most suitable for bolts, irregular surfaces and rough or pitted steel. Flat brushes are
suitable for flat area. Flat brushes shall not be more than 100mm wide. No extending
handles shall be used on brushes. Brushing shall be done so that a smooth coat, as
nearly uniform in thickness as possible, is obtained. There shall be no detrimental
brush marks. Paint shall be worked into all corners and crevices. When applying
solvent type coatings, care shall be taken to prevent lifting of previous coats.
Adhesion tests shall be made at the discretion of the Supplier or his representative.
5.6 Protection
The Application Supplier shall protect buildings, structures and equipment from
droppings and spray, and shall be solely responsible for all damage to other
equipment and facilities as a result of coating operations.
5.7 Field Welds
No coating shall be placed on edges or surfaces prepared for field welds or within
50mm of these areas.
5.8 Bolt Holes
Care should be taken to ensure that bolt holes receive the required coatings.
Spec. No.4985-GS-9523-0 Page 12 of 23

6.0 GALVANISING
6.1 General
All grating, and other items so specified dipped on the Project Drawings, shall be
hot-dipped galvanized in accordance with ASTM A.123.
6.2 Repair of Galvanized Surfaces
All galvanized surface that require welding, cutting, drilling or other preparation and
any galvanized surface that has been damaged shall be repaired with the specified
coating repair system.
Before application of repair coating, surface shall be washed with fresh water; rust
and other deposits shall be removed by power sanding and the area thoroughly
cleaned with solvent and / or grease removing agent. Coating material shall be
applied immediately after completion of surface preparation.
Spec. No.4985-GS-9523-0 Page 13 of 23

7.0 PREPARATION OF NON FERROUS SURFACES
7.1 General
Prior to applying coating material, surfaces shall be degreased using an emulsifying

agent and then washed thoroughly in fresh water and allowed to dry. All surfaces
shall be given a 'sweet blast' immediately before coating.
7.2 Stainless Steel Parts
Stainless steel parts shall not be painted.
Spec. No.4985-GS-9523-0 Page 14 of 23

8.0 SURFACES NOT TO BE COATED
Equipment and component drawings will indicate areas that do not require coatings,
which will generally include:
Flanged faces
Tapped holes
Machined parts
Stainless steel parts
Plastic or PVC based materials
Cupro-nickel parts
Grit or sand blasting is NOT to be carried out local to:
Machined surfaces
Running bushes or bearings
Instrument glasses
Cables
Or any other items of equipment that will incur damage without adequate
covering or protection
All openings in mechanical equipment and process piping are to be adequately

plugged or covered prior to blasting to prevent the ingress of sand or grit.
Any coatings, drips, runs or streaks that go accidentally onto the above listed
surfaces, are to be removed without the use of power tools.
All tapped holes are to be re-tapped after painting of equipment.
Name plates and "Tag" identifications shall not be painted so obliterating markings
thereon.
Prefabricated parts that require welding shall not be painted local to the weld
preparation.
A strip 50mm wide from the weld bevel is to be left unpainted.
Spec. No.4985-GS-9523-0 Page 15 of 23

9.0 DEVIATIONS
"Small" items of proprietary equipment can be supplied with a preparation and

protective coating system and finish to the equipment Vendors "own standard";
provided that the Vendor confirms to the Company or his representative, in writing,
that the Vendor's "own standard" is "as good as" or "better than" the preparation and
finish as required by this Specification inclusive of the "five year" guarantee
specified in Para. 5.1.1. of this specification.
Upon request, the Vendor will be supplied with details of climatic and environmental
conditions applicable.
Vendors who 'choose' the above deviation are required to provide.
A written data sheet of "own standard" paint system and top coat color to, be
included in the Vendors data book or installation maintenance manual.
A written data sheet of a 'Repair Procedure' for the paint system to be, included in
the Vendors data book or installation/maintenance manual.
A quantity of 'primer - tie coat' and 'top coat' (matching color), for making good
by others. The paint is to be included as part of the equipment.
THE SUPPLIER PAINT SYSTEM MUST BE COMPATIBLE WITH THE PAINT

SYSTEMS (FOR SPECIFIC AREAS) AS LISTED IN THIS SPECIFICATION.
Spec. No.4985-GS-9523-0 Page 16 of 23

10.0 COATINGS REPAIR PROCEDURE
10.1 General
This Repair Procedure is to be used for repairing 'small' areas of coating damage
incurred:
During fabrication in equipment supplier works
During fabrication/construction of steelwork
During hook-up work
During pre-commissioning and start up
During full on stream operation, up to a five year period from start up.
10.2 Exclusions
This Repair Procedure does not cover:
Major or extensive areas of repair

Major or extensive repair/maintenance of areas after start up
In such cases, the remaining 'undamaged' coatings are to be removed back to base
metal and the applicable preparation and coating system is to be applied anew.
The Company or his representative is to be informed of any major damage to

coatings during all stages of fabrication and/or construction.
10.3 Small Areas
Repairs to 'small,' areas of coatings will apply to two separate standards:
10.3.1 The Standard Coating Systems as listed in this Specification.
10.3.2 The Standard Coating System as used by a Vendor of some small items of
equipment.
Repairs covered by (10.3.1) are to be as per systems shown.
Repairs covered by (10.3.2) are to be as per the specific 'Coatings Repair Procedure'
which will be located within the equipment Vendors installation/maintenance
manual, for the item of equipment requiring repair. The Vendor will have also
included for quantities of 'primer' 'tie coat' of mating color in his 'spares' supply.
Spec. No.4985-GS-9523-0 Page 17 of 23

10.4 Dressing Back
For all small repairs, the damaged coating is to be removed back to base metal and to
an area that overlaps into 'sound' undamaged coating. Damaged areas of coatings are
to be removed with hand tools or power tools and not 'grit or sand blasting'. The
preparation (prior to coating) shall be as per this Specification (10.3.1) or Supplier
specification (10.3.2) whichever is applicable.
Spec. No.4985-GS-9523-0 Page 18 of 23

11.0 APPROVED PAINT MANUFACTURERS
Coating systems listed in this specification are to be applied with suitable materials
from the following approved list of paint manufacturers available in Pakistan:
ICI
BERGER
SIGMA COATINGS
Any deviation from this list shall be subject to prior approval by the Company.
Spec. No.4985-GS-9523-0 Page 19 of 23

12.0 PAINT SYSTESM
12.1 Key List
Code Work Location

1A Shop or Field Surface preparation – Blast clean SA-3
1B Shop or Field Surface Preparation – Blast clean SA 2 ½
2 Field Surface Preparation – needle gun, water wash and scrub,
power tool clean ST-3
5 Shop Primer – 75 microns DFT zinc phosphate (high build)
8 Shop or Field Primer 40 microns DFT urethane zinc rich (moisture
tolerant)
9 Shop or Field Primer 50 microns DFT urethane zinc rich (moisture
tolerant)
10 Field Intermediate – 75 microns DFT urethane M10 (moisture
tolerant)
11 Shop or Field Top Coat – 75 microns DFT modified Alkyd gloss (high
build)
12 Shop or Field Top Coat – 150 microns DFT urethane pitch (moisture
tolerant)
13 Shop or Field Top Coat – 50 microns DFT urethane gloss (moisture
tolerant)
14 Shop or Field Undercoat – 30 microns DFT urethane undercoat
(moisture tolerant)
15 Shop Primer – Inorganic zinc silicate 75 microns DFT
16 Field Top Coat – Aluminum silicone 25 microns DFT
17 Field Tough up – Inorganic zinc silicate 75 microns DFT
12.2 Application
Details of paint systems and the applications are listed below:
System 1 - Structural steel for Buildings

System 2 - Structural supports, tank internals
System 3 - External roofs, tank externals
System 4 - Structural steel, piping and vessels below 100°C
System 5 - Piping and Vessels above 100°C
Spec. No.4985-GS-9523-0 Page 20 of 23

System System System System System
1 2 3 4 5
Surface preparation 1B 1B 1B 1A 1A
Primer 5-AS 9-AS 8-AS 5-AS 15-B
Undercoat 14-AS 10-AS 10-AS 14-AS -
Top Coat 13-AS 12-AS 13-B 13-AS 16-AS
TOUCH UP 13- 12- 13- 13- 17-
Brush Brush Brush Brush Brush
Minimum DFT 150 250 130 150 90

(microns)
Maximum DFT 170 280 160 170 100
(microns
Legend: AS - Airless spray application

B - Brush application
12.3 Pumps, Machinery and Electrical Equipment
12.3.1 Surface Preparation and Painting at manufacturer's Works for Equipment Installed
Outside Buildings.
Manufacturers shall specify their standard painting system for the site conditions, and
shall specify surface preparation, type of coating, number of coats, dry film thickness
and color. Should this system be unacceptable to the Company, the requirements of
this specification shall govern.
Painting at Site
No painting is permitted but the shop finish shall be made good if damaged.
Color matching
If required by the Company, finish painted items shall be painted for color matching.
12.4 Instruments, Instrument Panels, Consoles and Cabinets
12.4.1 Surface Preparation and Painting at Manufacturer's Works for Equipment Installed
Inside Fully Enclosed Buildings.
This equipment shall have its surface prepared, primed and finished in accordance
with Manufacturer's standards. In general this shall consist of:
Spec. No.4985-GS-9523-0 Page 21 of 23

One coat of primer and

two coats of enamel
12.4.2 Surface Preparation and Painting at Manufacturer's Works for Equipment Installed
outside Buildings this equipment manufacturer shall specify their standard system for
the site conditions and shall specify surface preparation, type of coating, number of
coats, dry film thickness and color. Should this system be unacceptable to the
Company, the requirements of this specification shall govern.
Painting at Site
No painting is permitted but the shop finish shall be made good if damaged.
Colon Matching
If required by the Company, finish painted items shall be painted for color matching.
12.5 Protective Coatings for Valves
12.5.1 Scope
This specification covers the preparation and external coating requirements for
assembled valves.
12.5.2 Surface Preparation and Application
Following complete assembly of valves, all oil and grease shall be completely
removed and surface thoroughly wire brushed to remove all loose and friable
material.
Apply one coat of System No. 2 (a Zinc Dust Filled Primer) to a dry film thickness of
75 microns. All valve stems and stuffing box guides shall be suitably protected with
grease after coating has been completed.
This does not apply if the Supplier's standard practice of preparation is by grit or shot
blasting either before assembly or, with proper masking precautions, after assembly.
If abrasive blasting is carried out, the use of an inorganic primer (System No. 1) is to
be applied.
Spec. No.4985-GS-9523-0 Page 22 of 23

13.0 COLOUR CODING
Fire water piping shall be painted solid red in a suitable weather resistant paint
available in Pakistan.
Pipe work shall generally be painted silver with color coding as below.
Color coding of pipe work shall be as per the Piping Service Designations. Each pipe
shall be color coded with three painted bands (with the exception of Fire Water
piping) identifying
Product Medium
ANSI Piping Class
Piping Material
Color coding shall be prepared by Supplier and agreed by Company/Company

representative from the appropriate range of suitable paints available in Pakistan.
Spec. No.4985-GS-9523-0 Page 23 of 23

Job No. 14 – 4985
Spec. No. 4985-GS-9524
Page 1 of 25 Rev. 0
SPECIFICATION FOR PACKING & PROTECTION OF

MATERIAL AND EQUIPMENT
Prepared by: FAS

Checked by: AJ
Approved by: FS
Revised by: -
December 1,
0 ISSUED FOR BID
2012
Specification of Packing & Protection of Material & Equipment
TABLE OF CONTENTS
1.0 GENERAL…………………………………………………03
2.0 TYPES OF PACKING & PROTECTION
RECOMMENDED ACCORDING TO TYPE OF
MATERIAL………………………………………………05
3.0 PACKING FOR AIR TRANSPORT…………………….18
APPENDICES
Spec. No.4985-GS-9524-0 Page 2 of 25

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

single packing.
It shall be mandatory to pack the spare parts in separate packing. The spare parts
packages may be included in the main equipment packing.
1.2 Definitions
Company Oil and Gas Development Company Limited

Company Representative A Company designated Engineer, Party/Parties duly
authorized by the company to act on behalf of the
company with whom the Supplier shall consult at all
reasonable times and whose instructions, request and
decision shall be binding on Supplier.
Supplier Entity with whom the Company will execute a
Contract for supply of equipment/material as per this
document
Project UCH-II Development Project
Spec. No.4985-GS-9524-0 Page 3 of 25

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

• Transshipment, handling and lifting
• Storage, for more or less long periods, in the open air.
• Every packing should stay reliable for duration of one year minimum.
Spec. No.4985-GS-9524-0 Page 4 of 25

2.0 TYPES OF PACKING & PROTECTION RECOMMENDED ACCORDING
TO TYPE OF MATERIAL
2.1 Sea Packing

The packing shall be strong enough to support without damage during transportation
as well as long duration storage in harbor facilities and/or site.
2.1.1 Pallets
Every material delivered in pallets such as certain products in bags, bricks, etc.
a) Protection
i Against Humidity: plastic coating

ii Mechanical:
– Corners reinforcement through metallic or iron angles
– Face protection to be insured by bituminous paper or cardboard.
The whole being secured by stainless steel strips.
2.1.2 Bundles (Appendix – A)

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

• Or by U bars tied together by threaded rods with nuts and lock nuts
• Or by wedges, intermediate or circular wooden pieces to ensure protection
against sharp edges and rigidity of the sets, the wedges being tied together by
nails, bolts or strips.
a) Concerned Materials
• Straight pipes of ¼", 20′ - 43′ long
• Steel bars
• Plain sheets
• Structural steel
• Structures
Spec. No.4985-GS-9524-0 Page 5 of 25

b) Protection
Protection against Corrosion

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

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

tive devices, bevel protectors/companion flanges
• When handling stainless steel pipes:
– Do not use steel slings

– Do not hook up pipes by their ends
– Use leather straps
2.1.3 Reels
( fig. attached as Appendix – A)
Metallic or electric cables, ropes, flexible pipes, etc.
b) Protection
i Against corrosion: ends to be enveloped or lambed, steel metallic cables

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

protected by a wooden stave.
Spec. No.4985-GS-9524-0 Page 6 of 25

2.1.4 Cradles
(fig attached as Appendix – B)
Materials of great dimensions, heavy weight, neither fragile nor needing me-
chanical or physicochemical protection such as oily water separators, corrosion
inhibitor packages, drag reducer packages etc.
b) Protection
• Against Corrosion
Cleaning and coating are to be made in accordance with the particular
conditions of the order. A good protection of nozzles, nozzle flanges and
machined pars shall be done by plugging or by applying coating process.
Utilization of a corrosion inhibitor will be recommended in certain cases.
• Protection Against Mechanical Items

Wooden or metallic cradles with belts made of flat steel bars attached
through turnbuckles to the cradles.
In every case, Supplier shall provide lifting devices (rings, lugs or hooks) in
definite and easily spotted points for sling lifting.
When belting by flat steel bar or by cradle, it is necessary to place another

material avoiding friction such as felt, rubber or plastic in between the
material and the belt. Moreover if it is not possible to use a crane hook for
handling, Supplier shall supply for the transportation duration, the
necessary accessories such as spreader bars, slings, ropes, etc.
2.1.5 Frames for Shaped Steel Sheets

(fig. attached as Appendix – C)
In order to avoid shaped steel sheets deformation/twisting during transportation and
handling, they are layed on top of the other with intermediate shims inside a rigid
frame. Such frame shall have pad eyes for easy handling by hooks and slings.
Spec. No.4985-GS-9524-0 Page 7 of 25

2.1.6 Crates
(fig. attached as Appendix – D)
Vessels with external elements/equipment not allowing the utilization of cradles
or the barge transportation such as piping, air coolers, steel structures, etc.
b) Protection
Protection against corrosion is to be made in accordance with the particular
conditions of the order and in every case:
• Machined parts shall be wrapped with adhesive plastic tape

• Contact surfaces of metallic structural parts shall be protected by a
rustproof material.
• Pipe ends shall be coated with kraft paper or jute cloth or fitted with proper
protective devices.
Protection for Mechanical items (anti-shocks): material shall be steadied either

directly on the crate bottom tray or by means of cradles. Another wedging shall
be made on the cove tray for complete immobilization.
2.1.7 Full Packing Cases
Sets requesting mechanical protection against shocks and eventually physico-
chemical protection such as machined pieces, small fragile piping, mechanical
parts, valves, fittings, bolts, hand tools, insulation material, glass parts etc.
b) Protection
Against corrosion:
• Machined parts shall be wrapped with an adhesive plastic coating

• Tools, valves accessories shall be wrapped in paper with corrosive
inhibitor.
• Bolts and nuts shall be greased and wrapped in jute bags according to size.
Spec. No.4985-GS-9524-0 Page 8 of 25

Mechanical Protection shall be by wooden case with one face planed; joined
edge, with bituminous kraft paper for internal with an overlapping coating. The
cover shall be made of 2 layers of wood bituminous kraft paper in between the 2
layers.
2.1.8 Groove & Tongue Wooden Package
Those requiring physicochemical protection such as electric material (motors,
panels, equipment) electro-mechanical generators, electronics, electro-pumps,
control valves, motorized reducing gears.
b) Protection
• Protection against corrosion is such that material shall be placed inside

plastic bags with dehydrating products. Machined parts shall be protected
by a waterproof plastic film.
• Protection for Mechanical items: wooden case with both faces planed and
grooved, with waterproof paper for internal coating. The cover shall be
made of 2 layers of planed and grooved wood with an overlapping
bituminous kraft paper in between the two layers. Mobile pieces inside the
equipment shall be tightly fixed to structures.
2.1.9 Protective Packing
Fragile materials such as:
• Pressure gauges, vacuum meters, thermometers
• Measuring and control equipment
• Control panels, electronic equipment, laboratory equipment, electric mate-

rial, and glass equipment.
Spec. No.4985-GS-9524-0 Page 9 of 25

b) Protection
• Protection against corrosion and humidity shall be plastic bags and de-
hydrating products. Cases are to be coated internally with bituminous kraft
paper.
• Protection for Mechanical items: material shall be fixed on shock absorbers

or in an internal case placed on shock absorbers. Shock absorbers may be
springs, wedges, mats, expanded plastics, etc. Mobile pieces and delicate
components shall be blocked before packing.
Cases shall be planed, grooved and tongued: cover shall be made of two layers
of wood with an overlapping bituminous kraft paper in between the two layers.
2.1.10 Steel Barrels
Chemical products, coal tar, catalysts, powders, chemical reactive, coils, etc.
b) Protection
Sealed closure in order to avoid any loss or moisture penetration
Containers
Containers used for grouping parcels shall be in accordance with ISO 668 standards.
2.1.11 Special Containers

Valuable turbine rotors shall be packed in pressurized hermetic sealed containers
filled with low pressure dry air or nitrogen.
2.2 Types of Packing Case Fabrication
2.2.1 Quality of Wood

Compact and dry fir wood or any similar wood available in the country shall be used
or even phenolic Douglas fir wood reinforced by fir boards.
Spec. No.4985-GS-9524-0 Page 10 of 25

Wood shall have the following essential characteristics:
• Dyness: about 20%
• Diameter of vicious or unstable knots shall be less than half of the board width
• Free of cracks longer than 12".
• Flaws accepted on condition they do not include bark and within the following
limits:
– Length: 1/5 of the length of the wooden piece

– Width: ½ of the width of the wooden piece
– Thickness: ¼ of the thickness of the wooden piece.
• board thickness and rail thickness shall be in accordance with the case weight
and dimensions. It shall be in accordance with the type of material packed and
the way it is straddled inside the packing.
In accordance with these parameters, the following parameters are given as guidance:
BOARD THICKNESS RAIL THICKNESS

GROSS WEIGHT
BEFORE PLANNING BEFORE PLANNING
Up to 1100 lbs ¾" to ⅞" ¾" to ⅞"
From 1100 to 4400 lbs ¾" to ⅞" ⅞" to 11/16"
From 4400 to 11000 lbs ⅞" to 11/16" 11/16" to 1¼"
From 11000 to 22000 lbs 11/16" 11/16" to 1¼" or 1½"
From 22000 to 48500 lbs 11/16" to 1¼" 1¼" to 1½"
From 48500 lbs and over 1¼" or 1½" 1½"
2.2.2 Case Fabrication
a) Crates
(fig. attached as Appendix – D)
Crates shall be erected in such a way that empty surfaces shall match filled
surfaces.
Spec. No.4985-GS-9524-0 Page 11 of 25

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

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

slings insertion.
Spec. No.4985-GS-9524-0 Page 12 of 25

Beneath the case, small rails 1½" to 2" thick shall be placed as spacing pieces to
protect the case against the lifting slings.
Position and length of such rails shall be established in accordance with the case
length and its center of gravity.
c) Cases for More Than 11,000 lbs

For cases weighing more than 11,000 lbs net weight, it is recommended to place
angle irons where the lifting slings are to be applied.
The walls and the cover may also be made out of Douglas fir phenolic marine
plywood but shall have a fir structure of 1½" × 5" minimum.
Cases shall always be internally coated with bituminous paper of high imper-
meability and capable of withstanding strong temperature variation, whatever be
the protection adopted for the contained material.
d) Plywood Utilization
Plywood panels may be used for pickings instead of sawn wood. Panel
thickness will depend on the cases dimensions and weight and will depend also
on the density of the goods, the structure of the case and the way it is steadied.
Plywood quality shall be that one which can withstand humidity. In accordance,
following data is given as guidance:
– Gross weight up to 1100 lbs thickness ¼" to 5/16"

– From 1100 lbs to 11000 lbs thickness ⅜"
– From 11000 lbs to 33000 lbs thickness ½"
– Over 33000 lbs thickness ⅝"
2.3 Modules/Packages/Assemblies
2.3.1 Weight & Dimensions of a Module
a) Available Transportation Capacities
Spec. No.4985-GS-9524-0 Page 13 of 25

b) Available Lifting Capacities

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

A module constitutes a lift able and transportable assembly. Bearing structures will,
therefore, be made up of standard rolled sections or box girders.
Structure calculation basis shall take into account the whole module life, especially
the very short and stressful periods that constitute transshipment.
Module shall be provided with the necessary slings, lifting beams, shackles, etc. for
crane handling.
a) Close Modules
These modules shall be closed by simple wind cutter partitions of fireproof
separators according to request.
They shall be mechanically ventilated and even air conditioned if requested for
safety reasons or weather conditions.
b) Cage modules
Cage modules shall be adopted when modules have to be piled up.
c) Skids
Skids shall be used preferably for mechanical equipment such as diesel generat-
ing sets, motor pumps, filters, separators, etc.
Spec. No.4985-GS-9524-0 Page 14 of 25

2.3.3 Shipping Preparation

Mobile elements (spring supports, etc.) shall be immobilized. Equipment shall be
protected as follows:
a) Measuring and control equipment, which are too fragile for transportation, shall
be dismounted, packed separately, carefully marked and shipped with the
module.
b) Valves, control valves and other equipment, dismounted for the hydraulic tests
and replaced by plugs, shall stay dismounted but will be packed separately,
carefully marked and shipped with the module.
c) Tanks and pipes shall be emptied and dried.
d) Stainless steel elements shall be coated with a coating which shall be in

accordance with the steel grade.
e) All the openings shall be closed.
f) Flanges and screwed fittings shall be mechanically protected and also rust proof
protected.
g) Equipment such as electric motors, relay, panels, MCC shall be heated by their
own equipment or by provisional means.
h) If the internal equipment request an inert atmosphere, this atmosphere shall be

introduced and maintained in the module or in the compartment of the module
where these equipment are housed.
i) In the same way, if the equipment inside the module requests air conditioning,
this air conditioning shall be maintained through an external source of energy.
j) Enough desiccant material shall be placed inside certain equipment such as

motors, pumps, valves, etc.
2.3.4 Slings & Lifting Accessories

As soon as the module get a certain weight (over a few tens of tons), it is
recommended to fit the module with its slings, shackles, with the pins blocked or
even welded and eventually with the lifting beam as soon as it leaves for the field.
Spec. No.4985-GS-9524-0 Page 15 of 25

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

It will be determined through calculation but verified through weighing. In certain
cases the lifting ears will be welded only after the practical determination of the
center of gravity.
2.3.6 Orientation
In order to facilitate handling operations on the job site, the orientations marks North
South or East West shall be marked, when possible, on the module, in the
manufacturing plant, in accordance with the layout drawing.
2.4 Special Regulations
2.4.1 Steadying
All packed material shall be internally steadied in an adequate manner in order to
avoid any displacement during transportation.
2.4.2 Protective Products

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

Hot sealed plastic bags, composed of cloth, aluminum and a double layer of
polyethylene, shall be used for material such as panels, electric gears, hydraulic gears
and similar ones which are much affected by humidity. Introduction of dehydrating
products shall maintain above mentioned material in an atmosphere having less than
35% humidity. Polyethylene bags must not be used.
Spec. No.4985-GS-9524-0 Page 16 of 25

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

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

As far as possible and particularly for parcels uneasy to handle manually, trimming
points shall be provided preferably at the higher angles of the parcels in order to
avoid damage to the pickings when trimming operations are carried out for
transportation.
Spec. No.4985-GS-9524-0 Page 17 of 25

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

transpallets, etc)
• Extended storage (at least one year) in the open air, sea environment, tropical
climate.
Consequently, cases or packages shall be conditioned accordingly.
Each part contained in the said package shall be protected to take the above
conditions into account so as to allow partial unpacking of cases or packages.
Spec. No.4985-GS-9524-0 Page 18 of 25

APPENDICES
Spec. No.4985-GS-9524-0 Page 19 of 25

APPENDIX – A
Spec. No.4985-GS-9524-0 Page 20 of 25

APPENDIX – B
Spec. No.4985-GS-9524-0 Page 21 of 25

APPENDIX – C
Spec. No.4985-GS-9524-0 Page 22 of 25

APPENDIX – D
Spec. No.4985-GS-9524-0 Page 23 of 25

APPENDIX – E
Spec. No.4985-GS-9524-0 Page 24 of 25

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

Job No. 14 – 4985
Spec. No. 4985-STA-4002
Page 1 of 21 Rev. 0
General Specification for Supply, Construction and

Installation of Steel structure
Prepared by: FAS

Checked by: AJ
Approved by: FS
Revised by: -

General specification for supply, construction and installation of Steel structure
TABLE OF CONTENTS
1.0 SCOPE .......................................................................................................................... 3
2.0 CODES AND STANDARDS....................................................................................... 4
3.0 EXTENT OF SUPPLY ................................................................................................ 5
4.0 MATERIALS ............................................................................................................... 7
4.1 Structural Steel......................................................................................................... 7
4.2 Bolts ........................................................................................................................... 7
4.3 Steel Flooring............................................................................................................ 7
4.4 Roof & Wall Cladding ............................................................................................. 7
5.0 MATERIAL QUALITY AND CHARACTERISTICS ............................................ 8
6.0 ROOFING AND SIDING ........................................................................................... 9
7.0 FABRICATION ......................................................................................................... 10
8.0 WELDING .................................................................................................................. 11
8.1 Quality..................................................................................................................... 11
8.2 Qualifications of Welders ...................................................................................... 11
9.0 ERECTION ................................................................................................................ 12
9.1 Erection Generally ................................................................................................. 12
9.2 Erection Tolerance ................................................................................................. 14
10.0 PROTECTION OF STEEL SURFACES ................................................................ 16
10.1 Equipment & Materials......................................................................................... 16
10.2 Surface Preparation & Painting ........................................................................... 16
10.2 Coating System ....................................................................................................... 18
11.0 INSPECTION ............................................................................................................. 19
12.0 TRANSPORTATION ................................................................................................ 20
13.0 RUNWAY BEAMS .................................................................................................... 21
Spec. No. 0105-STA-4002 Page 2 of 21

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

2.0 CODES AND STANDARDS
All steel structural work shall, as a minimum, comply with the requirements of this
specification and the latest editions of the following codes, standards and regulations
(where applicable).
BS 499: Part 1 Welding Terms & Symbols
BS 639 Specification for Covered Carbon & Carbon Manganese Steel

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

Weld Metal in Steel.
BS 729 Specification for Hot Dip Galvanized Coatings on Iron & Steel
Articles
BS 1706 Specification for Electroplated Coatings of Cadmium & Zinc

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

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

3.0 EXTENT OF SUPPLY
3.1 Supply shall include the following:
a) supply of material
b) prefabrication and pre-assembly
c) primerizing
d) packing
e) transportation
f) erection
3.2 Characteristics and quality of materials shall be:
– structural steel: grade Fe 430C or equivalent (BS EN 10025)

– high strength bolts: grade 8.8 (BS 3692)
3.3 Operating floors, conform to BS 4592, shall be grating panels shaped as detailed on
drawings and bordered. Each panel shall be hot dip galvanized as per BS after
fabrication.
Grating shall be electro-forged, 25×50 meshes, 25×5 bearing plates with an antis lip
serrated top surface. The grating panels shall be fixed on structure by galvanized ties
included in supply.
3.4 Roofing and siding (according to BS5427 and 5950) shall be made by galvanized
ribbed steel sheet with the following characteristic:
– thickness: 7/10 mm
– corrugation pitch: 170mm or similar
– corrugation height: 50mm or similar
3.5 Supply includes all sheets fixing pieces as hooks, screws, nuts, washers and every
other steel fitting of section and type useful to ensure the sheets and the finishing
pieces on the structure or to complete the work.

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

4.0 MATERIALS
4.1 Structural Steel

Structural steel shall comply with BS EN 10025. Grade Fe 430 C (BS EN 10025 Fe
580C) or equivalent. All steel shall be from a source approved by the OGDCL/
Engineering Consultant
4.2 Bolts
High tensile structural bolts and nuts shall comply with BS 3692 Strength Grade 8.8.
ISO Metric black bolts; screws and nuts shall comply with BS 4190.
Bolts and washers shall be zinc plated in accordance with BS 1706. Class Zn2. Nuts
may also be plated to the same specification, or may, alternatively, be supplied with a
cadmium finish in accordance with BS 1706 Class Cd 2 in order to facilitate
tightening.
Holding down bolts shall normally be supplied black with a light coating of oil. Each
bolt shall be supplied with hexagonal nut(s) and washer.
4.3 Steel Flooring

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

Roof and wall cladding shall be profiled sheeting as defined in BS 5427 and shall be
either aluminum to BS 4868 or steel.
Steel sheeting shall be in accordance with the structural design rules of BS5950 Part6.
Aluminum sheeting shall not be less than 1.2mm (18 SWG) thick unless otherwise
directed or approved by the OGDCL/ Engineering Consultant.
Cladding shall be supplied complete with all necessary purpose made accessories
including rigid pieces, aprons, flashings and filler pieces, brackets and fixings.
The complete roof and wall cladding system and accessories shall be from one
manufacturer and to the approval of the OGDCL/ Engineering Consultant

5.0 MATERIAL QUALITY AND CHARACTERISTICS
5.1 PC Contractor shall use materials specified in the relevant specifications and
drawings.
5.2 The technological characteristics of the steel used shall be confirmed by the mill
certificates and/or by certificates related to the mechanical tests carried out, in
accordance with the applicable laws.
Such certificates are issued by the official laboratories pursuant to local law for test
pieces previously selected and punched by OGDCL.
5.3 All materials shall be new and free from any defects both basic material and
workmanship.
5.4 Galvanized ribbed steel sheets for roofing and siding shall have an allowable stress of
1400 kg /cm2 minimum. For painted elements, steel sheets shall be galvanized with
275 gr/m2 of zinc for each face. Galvanized steel sheets shall be prepared for painting
by means of phosphating.
A test of bending shall be carried out. Certificates of origin, conformity and test shall
be delivered to OGDCL.

6.0 ROOFING AND SIDING
6.1 All panels roofing and siding with relevant accessories (flashing, gutters, etc.) will be
supplied with spare parts not less than 2%. That is that for each mark the PC
Contractor shall provide the 2% spare for each building, with a minimum of one
element each 50 elements of fraction.
Fixing elements and gaskets shall be supplied with 10% spare, while sealing material
with 20% spare.
6.2 If the supply foresees metal elements painted, the PC Contractor shall provide a
quantity of paint necessary to cover a surface equal to 2% of total painted surface.
Paint shall be same color of that of panels, recent production. Manufacturer
instructions for employ and storage shall be provided.

7.0 FABRICATION
7.1 Connections shall be welded or bolted according to drawing requirements.
7.2 If the structure calls for welded connections, the PC Contractor shall, prior to start of
work, qualify the welders by testing in the presence of OGDCL/ Engineering
Consultant. In addition PC Contractor shall be responsible for the type of electrodes
used, for the careful execution of welding as well as for welder's qualification.
7.3 Checkered plate and floor grating shall be properly shaped and cut to required size.
Grating and hold down fittings shall be galvanized.
7.4 All connections shall be made in a preliminary form by tacking with bolts or gudgeon
pins to assure the correct positioning of all elements thus avoiding the necessity for
measurements or markings on the jobsite for erection purposes. Sizing of tacking
elements shall be for PC Contractor’s account. Location and diameter of erection
holes shall be such as to allow assembling and to avoid the need for additional work
on the jobsite (i.e. piercing, reaming, etc.) 12mm (min.) diameter erection bolts shall
be supplied with 52 spares.

8.0 WELDING
8.1 Quality
Welding shall be carried out only under the direction of an experienced and compe-
tent supervisor. Unless otherwise agreed by the OGDCL/Engineering Consultant a
record shall be kept to enable major welds to be identified with the welders responsi-
ble for the work.
Electrodes and fluxes shall be used in accordance with the manufacturer's instructions
and shall be so chosen that the properties of the deposited metal are not inferior to
those of the parent metal.
The use of welding processes other than those covered by BS 5135 shall be subject to
the approval of the OGDCL/Engineering Consultant
The general welding program for shop and site welds, including particulars of the
preparation of fusion faces, the method of preheating where required, the methods of
making the welds, and the type of electrodes shall be submitted to the OGDCL/
Engineering Consultant for their approval.
The position of welds required for temporary fabrication attachments shall be subject
to approval by the OGDCL/Engineering Consultant.
8.2 Qualifications of Welders

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

9.0 ERECTION
9.1 Erection Generally
Erection on concrete foundations shall not commence unless the concrete has
acquired sufficient strength.
The PC Contractor shall properly align each part of the structure before making field
connections. The steel frames shall be true and plumb. Temporary bracing shall be
introduced to prevent instability due to lateral loads acting on the structure during
construction, including loading from erection or operating of equipment.
Minor misfits which can be remedied by a moderate amount of reaming and slight
cutting and chipping may be corrected by the PC Contractor when in the OGDCL/En-
gineering Consultant opinion it will not be detrimental to the strength or appearance
of the structure.
All errors shall be reported without delay to the OGDCL/Engineering Consultant.

Fitting-up bolts and drift pins shall not be used to bring improperly fabricated mem-
bers and parts into place, thus causing a strain on bolts in finished work. Drift pins
shall not be driven with such force as to injure adjacent metal.
No packing, shimming or wedging will be permitted to correct imperfect work unless

specifically approved by the OGDCL/Engineering Consultant. No welded connection
shall be made until the member or structure has been properly aligned.
All members in completed frames shall be true to line and free from bends, twists and
open joints.
Field connections shall be welded or bolted as shown on the drawings. Permanently

bolted connections of primary construction members shall be made with the use of
bolts as shown on the drawings and in conformity with all Local, National, Provincial
and Municipal Laws and Regulations and the OGDCL/Engineering Consultant safety
ordinances.

Holes, cutouts, etc., shall be provided only where indicated on the drawings and any
additional holes, cutouts, etc., made at site will require prior approval from the
OGDCL/Engineering Consultant. Bolt holes shall only be drilled.
Any damage to materials on the site due to inadequate precautions being taken during
the erection of the steel work shall be made good to the satisfaction of the OGDCL/
Engineering Consultant at the PC Contractor's expense.
For major structures, the PC Contractor shall submit to the OGDCL/Engineering

Consultant an erection plan complete with data on heaviest lift, weights and
calculations involved. Approval of this erection plan by the OGDCL/Engineering
Consultant shall not relieve the PC Contractor of his responsibility for the erection of
the structure.
Before setting bases and bearing plates for structural steel, concrete surfaces to
receive grout shall be chipped to a minimum depth of 6mm to remove laitance and to
expose aggregate. Bottom surface of base and bearing plates shall be cleaned then
supported on steel wedges, shims, or other adjustable devices.
After the supporting members have been properly positioned and plumbed, the
holding down bolts shall be tightened. The entire bearing area under the base or
bearing plate shall be packed with grout. The grout shall be thoroughly worked to
eliminate voids and provide a uniform bearing surface. After the grout has cured for
72 hours, the shims and wedges shall be removed, the voids packed with grout, and
the holding down bolts re tightened.
After erection, the various members forming part of a completed frame or structure
shall be aligned and adjusted before being permanently fastened. The finished
structure shall conform to the lines and elevations shown on the drawings.
Splicing of structural members where not detailed on the drawings is not permitted,
without prior approval of the OGDCL/Engineering Consultant as to the location and
type of splice to be used.

9.2 Erection Tolerance

Erection tolerances shall generally be in accordance with BS 5950: Part 2.
• Beams
The maximum tolerance for level and alignment shall be ±5mm across any
particular floor of the structure. Maximum differential between connecting
beams or adjacent beams shall not exceed 2 mm.
• Stanchions
Plan Position
The distance between the centers of adjacent stanchions at any one-floor level
shall not exceed ±5 mm.
The cumulative tolerances over three or more bays shall not exceed the following:
Upto and including 30m ±10 mm

Over 30m ±15 mm
9.3 PC Contractor Duties

PC Contractor shall provide following services:
– he shall provide personnel and means to check correctness of structures installa-

tion;
– supply of means of transportation and lifting;
– organization of material storage according to OGDCL/Engineering Consultant;
– material unloading at site arrival;
– erection works including adjustments, execution of holes for pipe crossing and
any other accessory work to give the work complete and usable;
– restoration of primer and surface protection damaged;

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

– Before the arrival at site of materials. PC Contractor shall define storage areas
according to OGDCL/Engineering Consultant.
– Open storage shall be provided on wood sleepers to avoid contact with soil and
prevent a damage of painting.
– Each element of supply shall be examined at sight during unloading.
– Damaged elements shall be storage separately to permit the restoration.

10.0 PROTECTION OF STEEL SURFACES
10.1 Equipment & Materials

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

– The PC Contractor shall paint all new equipment, structure materials, as
appropriate, together with any existing paint work, damaged during execution of
the Works in accordance with this Specification.
– All new steel surfaces requiring to be painted shall be grit blasted.
– If heavy scale is present it must be removed by hammering or scraping. Any

heavy scale contaminated by oil must be removed using non-sparking tools.
Grease or oil shall be removed by swabbing the affected surface area with a
solvent or cleaning agent specified by the OGDCL/Engineering Consultant, and
dried using clean cloths.
– Any seams, welds, sharp edges and laminations shall be ground smooth prior to
blasting. Any area not requiring to be blasted shall be masked with suitable
masking material.
– The surface shall be blasted to Swedish Standard SIS 055900, Grade S.A. 2.5
using commercially available grit (type to be approved by the
OGDCL/Engineering Consultant and a source of dry compressed air at a
minimum of 250 cfm at 100 psi. Pitted areas shall be blasted such that there is no
residual scale in the bottom of the pits. On certain occasions other forms of
surface preparation may be accepted at the discretion of the

– Blasting must not be carried out if the relative humidity is greater than 80% or
the temperature of the steel is within 2ºC or Dew Point. Care should be taken to
ensure that no water contacts the blasted surface.
– After blasting, the surface should be "blown down" with compressed air to
enable an inspection to be made; unsatisfactory areas are to be marked with
chalk and re blasted. When the surface preparation has been approved by the
OGDCL/Engineering Consultant all surfaces should be cleaned of residual dust
by, thorough "blowing down" or brushing with clean nylon brushes or preferably
with an industrial vacuum cleaner. Grit blasting shall be removed and disposed
of by the OGDCL/Engineering Consultant.
– Airless spray (using correctly sized spray nozzles) is the preferred method of
application. Application by brush and/or roller may be acceptable. In all cases
the minimum film thickness specified for each individual paint coat must be
achieved prior to final approval of the coating. Over coating intervals
recommended by the paint manufacturer must be adhered to unless the OGDCL/
Engineering Consultant advise otherwise.
– When over coating, the relative humidity must be less than 80% and comply
with paint manufacturer's data sheets. The steel temperature must not be within
2ºC of the Dew Point. The previously applied paint coating must be free of any
grease or oil, dust or water before over coating and each coat must be inspected
and approved by the OGDCL/Engineering Consultant before over coating is
permitted.
– Final color shall be specified later stage on the drawings; or Particular

Specification; or as determined by the chemistry of the paint system specified.
– All seams welds and sharp edges shall be stripe coated before spraying
commences.
– Painting shall only be undertaken upon satisfactory completion of all NDT and
hydro testing.

10.3 Coating System
• Surface Preparation
Cleaning with proprietary degreasing agent, flush with fresh (sweet) water and
allow to dry. Grit blast with one way abrasive to SiS Grade Sa 2.5 (SIS refers to
Swedish International Specification 05-59-00).
• Primer Coat
1 coat, 2 Component Epoxy Polyamide to DFT 50 pm.
Color - as specified by OGDCL/Engineering Consultant.
• Intermediate Coat
2 coats, 2 component Epoxy Polyamide high build to 100 pm DFT.

11.0 INSPECTION
During fabrication following shall be checked by OGDCL for:
– material compliance to the required mechanical characteristics
– size of the single structural elements
– size of the structure as a whole
– fitness of welders assigned to the work, by means of qualification tests
– correctness of welded and/or bolted connections
– easy erection of structural elements
– correctness of preparation for painting
– correctness of item marking.
The OGDCL reserves the right to check the compliance of fabrication with present
specification, relevant and a good engineering practice.

12.0 TRANSPORTATION
– Loading on transportation means shall be carried out with the necessary care to
prevent any deformation and damage to the machined material.
– Nuts and bolts shall be packed in boxes. The boxes shall be marked on the
outside at 2 points using water resistant paint, as follows, job number and
drawing number, type and quality of bolts. Each box shall contain only one type
bolt.
– Roofing and siding elements shall be separated on the basis of marks and
separately packed.
– For short distance truck transportation galvanized steel panels shall be provided
packed with metallic strap and with wood spacer (3 cm min.) interposed.
Prepainted steel panels in addition shall be wrapped in bituminized Kraft paper.
– For short distance railway transportation material shall be provided in wood

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

13.0 RUNWAY BEAMS
– The testing of all runway beams shall be carried out in accordance with BS 2853
and such statutory requirements as may be specified.
– Runway beams shall be erected free from twist and the bottom flange shall be
horizontal.

Job No. 14 – 4985
Spec. No. 4989-PA-2004
Scope & Specification Hydrostatic Testing
Project: UCH-II DEVELOPMENT PROJECT
Prepared by: IN
Checked by: MMM
Approved by: TH
Revised by: -

Specification for Hydrotesting
TABLE OF CONTENTS
1.0 SCOPE ............................................................................................................................. 3
2.0 GENERAL ....................................................................................................................... 4
3.0 CODES & STANDARDS ............................................................................................... 5
4.0 PROCEDURE ................................................................................................................. 6
5.0 SAFETY ........................................................................................................................... 7
6.0 MATERIALS AND EQUIPMENT ............................................................................... 8
7.0 FILLING THE PIPES .................................................................................................... 9
8.0 TEST PRESSURE ........................................................................................................ 10
9.0 FAILURES .................................................................................................................... 11
10.0 TEST RECORDS .......................................................................................................... 12
11.0 DEWATERING ............................................................................................................ 13
12.0 DRYING ........................................................................................................................ 14
13.0 TREATING ................................................................................................................... 15
Spec. No.0105-PA-2004 Page 2 of 15

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

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

• Preparing Piping profiles and test procedure for approval by the
• Filling the test section with water including addition of required chemicals.
• Performing the leak test at the specified pressure.
• Investigating for leaks or breaks, making any necessary repairs and retesting.
• Displacing and disposing of test water.
• Cleaning, flushing, drying, treating and capping off the tested Piping.
• Recording of all test data.
PC Contractor shall assign and designate a construction crew, with equipment, to the
testing operations. The testing operations shall be conducted diligently, thoroughly and
in a safe manner in accordance with accepted Piping Testing Practices. Any work by
PC Contractor or existing conditions, which in the opinion of OGDCL/Engineering
Consultant are deemed to be unsafe shall be corrected. The testing operations shall not
continue until the unsafe conditions have been corrected to the satisfaction of
OGDCL/Engineering Consultant. PC Contractor may not receive additional
compensation for time lost caused by unsafe conditions.
PC Contractor shall furnish a representative who shall be responsible for supervising all
testing operations. OGDCL/Engineering Consultant will witness and accept all tests.

3.0 CODES & STANDARDS
PC Contractor shall conduct the testing operations in accordance with ASME B31.3,
Section 345.4, “Hydrostatic Leak Test”.
Where there is a conflict between any Code and these specifications, the Code shall
govern over the portions or sections of these specifications, which contain the
confliction. When a Code covers same requirements as these specifications, the most
demanding requirements shall be complied with.
PC Contractor shall review inform employees of and abide by safety standards of

OGDCL/Engineering Consultant. Also, best industry standards will apply to the work
defined.
PC Contractor shall notify the OGDCL/Engineering Consultant as to the individual

within his organization who is responsible for the safety practices of the PC Contractor.

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

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

6.0 MATERIALS AND EQUIPMENT
PC Contractor shall furnish and install all test-header pipes, valves, fittings, test
instruments, water, chemicals, strainers and filters, fill and pressuring pumps, meters
and all piping incidental to filling, sectionalizing, transferring and disposing water.
PC Contractor shall also furnish adequate materials for capping off both ends of
completed test sections.
PC Contractor shall furnish an enclosed weatherproof, properly lighted, temporary

shelter of sufficient size to house the pressure recorders, calibration equipment and test
personnel at the data collection site of each test section during the testing operations.
PC Contractor shall also furnish sufficient lighting in the pump and test header areas
during periods of darkness when testing operations are in progress. Calibration of all
test instruments shall be performed by the PC Contractor and witnessed by the
The equipment furnished by the PC Contractor shall meet the following requirements:
• The filter shall be of a quality to remove 95 percent of all particles 40 microns in

diameter and larger. The filter shall be provided with a means of cleaning either
side without disconnecting the piping or interrupting the flow of testing media.
• The pumping system used for filling the test section shall be capable of filling the
pipe test sections at the rates specified in this section.
• The pumping system used for pressurization of the sections shaft' be capable of
attaining the test pressure required at a slow and steady rate of pressure increase.

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

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

for acceptance/rejection of all hydrostatic test operations ties with the
OGDCL/Engineering Consultant

9.0 FAILURES
Failures in the piping disclosed by the loss of pressure not attributable to temperature
changes shall be located and repaired by PC Contractor. If the failure is in the seam of
the pipe, the entire joint in which the seam failure exists shall be removed. A minimum
of one pipe diameter each side of the failure will be removed on all other failures. The
piece(s) removed shall be marked for orientation with respect to the position in the.
Piping and with the approximate location of the failure. PC Contractor' shall not cut on
or damage the failed edge of the pipe during removal, transit or unloading at the storage
location. All portions are to be retained. The failure shall be photographed prior to and
after removal from the Piping, if possible.
Care must be taken to ensure that external coating and backfilling at repair sites is
carried out in accordance with these specifications.
All welds in pipe repairs shall be 100 percent inspected by radiography. Upon
completion of a pipe repair.
PC Contractor shall at his expense, repair all defects found resulting from inferior
workmanship or defective materials furnished by the PC Contractor.

10.0 TEST RECORDS
The Piping pressure and temperature for the test period shall be continuously recorded
with recording instruments. The pressure recording shall serve only as information data
and may not be used to determine pressure drop for piping leakage. Test sections will
not be accepted until a predetermined test period can be recorded without pressure loss
unless the loss can be attributed to temperature change. All data and charts shall be
clearly marked with the following information:
• OGDCL/Engineering Consultant name and authorized representative.

• Testing PC Contractor's name and authorized representative.
• Description of facilities tested.
• Date and time of test.
• Test: pressure and duration.
• Test medium used.
• Explanation of any pressure discontinuities that appear on any chart.
• Signature of OGDCL/Engineering Consultant and Testing PC Contractor's
authorized representatives
All permanent records shall become property of the OGDCL/Engineering Consultant.
Fabricated assemblies and piping for tie-ins to existing Piping shall be tested in
accordance with this Specification. All data and charts shall be clearly marked in the
same manner the Piping test records are marked.

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

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

13.0 TREATING
Depending on the schedule for commissioning the Piping, the OGDCL/Engineering

Consultant may require the PC Contractor to fill the Piping with Inert Gas after drying
is complete.

Job No. 14 – 4985
Spec. No. 4985-PA-2021
SPECIFICATION FOR FABRICATION &

INSTALLATION OF PIPING
Prepared by: NJ
Checked by: MK
Approved by: FS
Revised by: -

TABLE OF CONTENTS
1.0 SCOPE .......................................................................................................................... 3

2.0 APPLICABLE CODES AND SPECIFICATIONS .................................................. 4
3.0 TYPICAL LINE AND VALVE CODE...................................................................... 7
4.0 MATERIALS ............................................................................................................... 8
5.0 STORAGE AND HANDLING ................................................................................... 9
6.0 WELDING APPROVALS ........................................................................................ 10
7.0 WELDING REQUIREMENTS ................................................................................ 13
8.0 FABRICATION ......................................................................................................... 20
9.0 INSPECTION AND TESTING ................................................................................ 26
10.0 CORROSION PROTECTION ................................................................................. 34
11.0 MARKING ................................................................................................................. 36
12.0 INSTALLATION OF PIPEWORK ......................................................................... 38
FIGURE 1: BRANCH REINFORCEMENT DESIGN

FIGURE 2: DIMENSIONAL TOLERANCES FOR FINISHED PIPEWORK
FIGURE 3: PROXIMITY OF WELDS
FIGURE 4: EFFECT OF ALLOYING OF THE WELD PREFERENTIAL CORROSION
TABLE 1: TYPE AND NUMBER OF MECHANICAL TEST SPECIMENS AND NDE

REQUIREMENTS FOR WELDING PROCEDURE QUALIFICATIONS
TESTS
TABLE 2: PRE-HEAT REQUIREMENTS FOR CARBON STEEL
TABLE 3: WELDING INSPECTION REQUIREMENTS APPLICABLE FOR DESIGN,
SUPPLY & COMMISSIONING
APPENDIX A - ADDITIONAL REQUIREMENTS FOR LOW TEMPERATURE

SERVICE
APPENDIX B - ADDITIONAL REQUIREMENTS FOR 300 SERIES STAINLESS
STEEL PIPING
Specification for Fabrication & Installation of Piping
1.0 SCOPE
This Specification covers the minimum requirements for the fabrication, installation,
inspection and testing of piping works for UCH-II Development Project.
This Specification shall be used in conjunction with the ASME B31.3, Process Piping
Code. The additional requirements for specific materials and/ or service conditions, in
the Appendices to this Specification, shall be applied as appropriate to each particular
piping class.
The PC Contractor shall bring his own consumable equipment/machinery and other
material and provide all services, skilled and unskilled labor including supervisory
and testing personnel needed during construction.

2.0 APPLICABLE CODES AND SPECIFICATIONS
Work shall be carried out according to the requirements of this specification and will
conform to the technical specifications, data sheets and fabrication/ installation
drawings.
Where specific details about the execution of any items of work are not included,
work shall be carried out according to the requirements of the latest editions of the
following standards and Engineering's general specifications described below:
American Society of Mechanical Engineers (ASME)
Section I Power Boilers
Section II (Part C) Welding Rods, Electrodes and Filler Metals
Section V Non Destructive Examination
Section VIII Pressure Vessels
Section IX Welding and Brazing Qualifications
B31.3 Process Piping (Latest Edition)

B31.8 Gas Transmission and Distribution Piping Systems
B.1.20.1 Pipe Threads General Purpose (Inch).
B.16.5 Pipe Flanges and Flanged Finings.
B.16.9 Wrought Steel Butt Weld Fittings.
B.16.11 Forged Steel Fittings. Socket Weld and Threaded.
B.16.20 Ring Joint Gaskets and Groves, for Steel Pipe Flanges.
B.16.25 Butt Welding Ends
B.36.10 Welded and Seamless Wrought Steel Pipe.
B.36.19 Stainless Steel Pipe

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

El 10 Test Method for Indentation Hardness of Metallic Materials
E146 Hardness Conversion Tables for Metals
E380 Metric Practice
E562 Practice for Determining Volume Fraction by Systematic Manual
point count
British Standards & Project Specifications
BS 427(Part 1) Testing of Metals

BS 709 Destructive testing fusion welded joints and weld metal in steel
BS 4870 Specification for Approved Testing of Welding Procedures
BS 5555 Specification for SI Units
BS 5750 Quality Systems
International Organization for Standardization
ISO R 148 Beam Impact Test V-notch for steel
Manufacturers Standardization Society
MSS SP44 Steel Pipe Line Flanges
National Association of Corrosion Engineers/ International Organization for

Standardization
NACE MR-0175/ Sulfide Stress Cracking Resistant Metallic Materials

ISO 15156
In case of conflict between this specification and its associated specifications and the
above codes and standards, the PC Contractor shall bring the matter to the OGDCL’s/
Engineering Consultant’s attention for resolution and approval in writing. In all cases
the most stringent requirements shall apply.

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

3.0 TYPICAL LINE AND VALVE CODE

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

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

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

A1 - Carbon Steel (C.A 1.5mm)


B - Carbon Steel Low Temperature (C.A. 3.0mm)
C - Stainless Steel Type 304L (C.A. 0.0mm)
G - Carbon Steel Galvanized (C.A 1.5mm)
P - Glass Fiber Reinforced Plastic (C.A. 0.0mm)
3.2 Valve Code
A five digit code is provided for each valve coded as follows:
First and Second digit: Valve type (VG= Valve Gate etc)
Third digit: Specification Number e.g 100, 101 etc.
For valves additional requirement refer document#4985-PA-2003.
4.0 MATERIALS
4.1 Piping materials shall be as specified in the piping detailed fabrication drawings
(isometrics). Alternative materials may only be substituted subject to specific
approval of OGDCL/ Engineering Consultant.
4.2 Materials for non-pressure items, or for reinforcing pads or saddles, which are welded
to a pressure part, shall be of the same type and quality of material as for the pressure
part.
4.3 All pressure parts and attachments shall comply with the requirements of ASME
B31.3.

5.0 STORAGE AND HANDLING
5.1 All piping material shall be stored by the PC Contractor in areas demarcated for this
purpose.
5.2 Pipes and fittings shall be stored in a roofed area on dry wooden platforms.
5.3 Valves, Control valves, instruments, steam traps, strainers, stud bolts & nuts, small
fittings and gaskets shall be stored in a covered, locked premise. In no case shall the
marking on the equipment be removed. Valves and other equipment provided with
protective caps shall be stored with the caps up to the moment they are installed.
5.4 PC Contractor shall be entirely responsible for safekeeping of all the material and
equipment. If any item is lost or damaged, the PC Contractor shall be required to
replace it at his own expense.
5.5 Handling of material shall be done with suitable mechanical equipment and safety of
workers shall be given top priority.
5.6 Unless indicated otherwise, covered space for storage of material shall be considered
as PC Contractor's responsibility.
5.7 All material stored shall be distinctly marked. Especially for NACE compliance
material.
5.8 PC Contractor shall maintain at all times, the record of material received as
“Free Issue” from the OGDCL/ Engineering Consultant. OGDCL/Engineering
Consultant shall be at liberty to check such record any time without prior notice.
5.9 Upon project completion the PC Contractor shall hand-over all records of all material
after reconciliation.
5.10 Material of one specification shall not be placed with different kind of material. Care
must be taken to ensure that alloy piping materials, such as stainless steel and similar,
are not contaminated by contact with carbon steel.

6.0 WELDING APPROVALS
6.1 Welding Procedure Specifications (WPS)
6.1.1 Every WPS and supporting PQR's shall be compiled and submitted for OGDCL’s/
Engineering Consultant’s approval, in accordance with the Submission of Procedures
Specification.
6.2 Procedure Qualification
6.2.1 Each welding procedure shall be qualified in accordance with the Code and ASME
IX. Care shall be taken to ensure that restraint and thermal conditions are at least as
severe as production welds represented.
6.2.2 The validity of a welding procedure qualification test certificate is restricted to the site
at which the test weld was conducted.
6.2.3 All mechanical testing and inspection shall be conducted after any post-weld
treatment that may be required. The procedure qualification test assembly shall be
subjected to the same inspection and NDE as required for production welds.
6.2.4 The extent of examination and mechanical testing shall be as defined in Table 3,
unless otherwise specified.
6.2.5 In addition to mechanical testing required by the code, the following tests shall be
undertaken on each procedure qualification test assembly:
− Bend Tests
Full thickness root and face specimens are required for thicknesses below 19 mm.
For material thicknesses 19 mm and above side bend test specimens shall be used.
− Macro-etch Test
Macro-specimens shall be prepared to a 600 grit finish or better and then etched to
show the fusion boundary clearly. For 5G and 6G test positions, the specimens
shall be extracted at the 12 o'clock and 6 o'clock positions.

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

minimum x3.
The macro specimens shall be free of unacceptable defects. A macrograph shall

be prepared for each specimen, and submitted as part of the test report, for
OGDCL’s/ Engineering Consultant’s approval.
− Hardness Survey
For all procedures which cover the welding of a pressure part, a hardness survey
shall be carried out on the macro-etch test section. The Vickers hardness test
method shall be used in accordance with BS 709. For carbon steel, the hardness
value shall not exceed 325 HV. For other materials, hardness requirements shall
be approved prior to testing.
Hardness traverses using Vickers test equipment with 22.05 lb load shall be
carried out where applicable at the locations detailed below. In the weld metal, 5
indentations evenly spaced along each traverse are to be made. In the HAZ,
indentations shall be made along the traverse, starting as close to the fusion line as
possible, with a spacing of 0.5 mm. A minimum of two indentations is also
required in the parent metal either side of the HAZ. The traverses shall be located
2 mm from both the inner and outer surfaces
− Notch-toughness Testing
For ferritic steel and duplex steel items which operate below 32 °F, austenitic
steels operating below minus 158°F and any instances when impact tested base
materials are specified, Charpy V-notch impact tests are required. Unless specified
in other applicable specifications, the requirements shall be as detailed in
Appendix A.
Procedure qualification tests in accordance with BS 4870: or other national

standard may be approved in place of those required by the Code.
6.3 Essential Variables
6.3.1 A welding procedure shall be re-qualified when any of the essential variables change
from the values used for qualification.

6.3.2 The essential variables shall be:
− Any of applicable essential variables listed in the Code and given in ASME IX.
− Joint Design
Change from single sided to double sided weld or vice versa. Change in root
alignment beyond the range of qualified. An increase of more than 2 mm in root
gap.
− Welding Process
Change in welding process or in combination of welding processes. Change in

polarity or from AC to DC or vice versa.
− Material
Any increase in carbon equivalent of carbon steels greater than 0.04% above that
qualified.
− Welding Consumables
A change in electrode diameter used for root runs. Change in type of shielding gas
or type of 'bare’ filler metal. Change in brand name of flux or flux coated filler
metal or filler metal which incorporates flux.
− Pre-heat/ Interpass Temperatures
Increase of more than 212°F or any decrease in the margin applied to the pre-heat
temperature required by Table 4. Any increase in interpass temperature.
− Heat-Input Energy
Decrease in heat input by more than 10%.
− Post-weld Heat Treatment

Change in heat treatment temperature beyond the range qualified, or change in

holding time by more than a factor of two. Any increase in cooling rate.
− Positions
Change in welding position beyond qualified positions indicated in ASME IX.
6.3.3 For procedures subject to impact testing, the additional essential variables shall be:
− An increase in the specified current range. An increase in the maximum electrode

diameter.
− An increase in the width of bead or a change from string to weave bead technique.
− An increase in maximum interpass temperature above 482 °F. Any change in

consumables.
6.4 Welders (Including Welding Operators)
6.4.1 Welders shall be qualified in accordance with the applicable Code, ASME IX or BS
4871 Part 1.
6.4.2 Welder qualifications in accordance with other recognized national standards may be
substituted subject to OGDCL’s/ Engineering Consultant’s approval.
6.4.3 All Procedures Qualification Record (PQR) & Welders Qualification Test (WQT) are
subject to the OGDCL’s/ Engineering Consultant’s witness and approval.
7.0 WELDING REQUIREMENTS
7.1 General
7.1.1 This section defines the general requirements for all materials and those specific to
carbon steel and low alloys steels. For materials other than carbon steel, welding and
fabrication shall also comply with the requirements of the appropriate Appendix to
this Specification.

7.2 Weld Bevels and Preparations
7.2.1 Weld bevels and preparations, including those necessary for repair welding may be
prepared by machining, arc-air gouging, chipping, grinding or guided gas torch
cutting. Thermal cutting or arc-air gouging shall be carried out using the same pre-
heat as required on the approved welding procedure. Items cut from bulk material
shall be identified to material type.
7.2.2 Where the method of preparation is other than machining or grinding, cut surfaces
shall be finally prepared by grinding or machining to clean, bright, sound metal.
7.2.3 The finished weld preparation shall conform with the geometry specified in the
approved welding procedure and shall be visually inspected to confirm that the
preparation is smooth, uniform and free from tears, cracks, gouges, scale, or any
discontinuities which might affect weld quality.
7.2.4 Before thermal cutting or welding of galvanized steel, the galvanizing shall be
removed from immediate work area by grinding or pickling, such that molten zinc
does not contact work piece during cutting or welding.
7.2.5 Welding onto surfaces painted with a weldable primer may be carried out, when
Approved.
7.3 Care and Protection
7.3.1 Welding areas shall be protected from adverse weather conditions at all times during
pre-heating, welding, post-weld heat treatment and non-destructive examination. For
gas shielded welding, special precautions shall be taken to protect the welding area
from draughts.
7.3.2 When the base metal temperature falls below 41 °F, and to remove dampness, the
weld preparation and surrounding metal for a distance of three times the wall
thickness or 25 mm whichever is greater shall be pre-heated to 86°F prior to welding.
7.3.3 Contamination of one material by another shall be avoided by segregation of materials

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

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

required.
7.3.5 Weld metal shall be deposited in a controlled sequence to minimize distortion and
prevent the build up of excessive internal stresses.
7.3.6 Pipes shall not be moved (except for rotation on rollers) or lifted until at least 50% of
the final weld depth has been deposited in circumferential seams.
7.4 Alignment and Fit-Up
7.4.1 Root alignment of butt-welds shall be within the limits of the qualified WPS.
Tolerances of ±0.75 mm for GTAW and ±1.5 mm for other fusion welding processes
shall apply, unless wider tolerances are approved subject to qualification
7.4.2 When misalignment cannot be overcome by repositioning of work pieces one of the
following methods shall be employed:
Grinding or machining, provided that minimum design thicknesses are maintained

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

taper of 1 in 4 (or 14°).
7.4.3 Hammering shall not be used to achieve fit-up or overcome misalignment.
7.4.4 Other methods of overcoming misalignment, such as heating or working with jacks
shall not be used unless specifically Approved, after the Contractor has demonstrated
that the mechanical properties of the material will subsequently meet the relevant
requirements.
7.4.5 Where clamps or other methods of support are used to achieve fit-up, they shall not be
removed until at least 10% of the final volume of weld metal has been deposited.
7.4.6 Dimensions shall conform to those shown on the drawing.
7.4.7 Parts to be welded shall be securely held by clamps or tack welds to maintain the
required alignment and geometry.

7.5 Welding Process
7.5.1 The following welding processes are generally permitted:
Manual shielded metal-arc welding (SMAW)

Gas tungsten arc welding (GTAW)
Flux cored arc welding (FCAW)
Submerged arc welding (SAW)
7.5.2 Other processes may also be permitted, subject to Company’s approval.
7.5.3 When GMAW process is used, deposition shall be in the spray mode. The dip-
transfer mode is not permitted, except, if specifically, approved, for root runs in
carbon steel.
7.5.4 When GTAW process is used, the welding current shall be either alternating (AC) or
direct with the tungsten electrode connected to the negative supply terminal (DC-)
the arc shall be initiated by a high frequency device and terminated by a current decay
(crater fill) device. Electrodes shall be 2% thoriated tungsten. Shielding gases shall be
oxygen-free and shall flow at 11-21 ft3/hour. This process shall be used with the
addition of filler metal. At each weld interruption, the hot end of the filler metal shall
be cooled in the gas shield or shall be discarded. The torch shall have a gas lens.
7.5.5 Complete GTAW Process shall be used for butt / fillet-welds in pipe of diameter
2”and less, also root and hot passes of all welds except utility piping shall be GTAW
Process. Filling, caping in pipe diameter greater than 2” can be done by SMAW
Process.
7.5.6 All welds shall be multipass, with a minimum of two runs.
7.5.7 Peening is prohibited on all passes.
7.5.8 All pressure-containing butt-welds, including branch welds, shall be full penetration
welds. This shall be achieved by the following means:
For carbon steel, a single sided weld with a SMAW, GTAW root run. SMAW
electrodes for utilities service lines the root pass in pipe of 3" NB or larger shall not

exceed 2.5 mm wire size. GTAW shall be used for the root pass in less than 3" NB
pipe.
For non ferrous metals, a single sided weld with a GTAW root run using an inert gas
back purge.
7.6 Welding Consumables
7.6.1 Welding consumables shall conform to ASME II, Part C or a recognized national or
industry standard, unless otherwise approved. When two or more brands of
consumable are in use, they shall be positively identified and segregated to avoid
confusion.
7.6.2 All welding consumables shall be identifiable & compatible with base materials being
welded. Deposited weld metal shall be of similar chemical composition to base
material (except for dissimilar metal joints) and shall exhibit mechanical properties at
least equal to those of the base material. When different grades of material are joined,
weld metal shall not significantly overmatch the lower grade material.
7.6.3 Alloying elements shall be introduced to the weld pool primarily from the filler wire,
not from flux. Bare filler wires shall be free from grease and oil before use.
7.6.4 Welding consumables shall be supplied and stored in sealed, dirt-proof and moisture-
proof containers or bags.
7.6.5 Welding electrodes and fluxes shall be stored and dried in accordance with
consumable Manufacturer's recommendations. Low hydrogen electrodes shall be
segregated from other types during storage, and shall be baked to produce a weld
metal hydrogen content of 10 ml H2/l00g maximum.
7.6.6 Submerged arc flux may be reclaimed for recycling after use, only according to the
Approved procedure. Recycled flux shall be mixed with new flux in accordance with
Manufacturer's recommendations, but at a maximum of 40% of the total volume.
7.6.7 Consumables for dissimilar metal combinations shall be subject to OGDCL’s/

Engineering Consultant’s approval

7.7 Tack Welds
7.7.1 Tack welds shall be made by qualified Welders on 5G / 6G, using Approved
consumables as specified in the Approved WPS. Tack welds shall only be made
within V or groove and not outside.
7.7.2 When tack welds are to be incorporated into the final weld, they shall be ground and
feathered and visually inspected to be crack free.
7.7.3 Defective tack welds and tack welds which are not to be incorporated into the final
weld shall be carefully removed by grinding, to leave a correct weld preparation.
7.8 Pre-Heat
7.8.1 The pre-heat temperature for welding and thermal cutting shall be specified in the
WPS and shall meet the requirements of the Code.
For carbon steel, pre-heat shall be as indicated in Table 2, unless alternative pre-heat
levels are justified by the PC Contractor on the basis of an appropriate national
standard or recognized calculation method. If the pre-heat temperature used in the
qualification test exceeds the level determined, the same margin shall be applied in
calculating pre-heat temperatures for all combined thicknesses applicable to the
relevant weld procedure.
7.8.2 Pre-heat shall be applied by electrical resistance heating or by oxy-gas torch or by

other Approved means. Deposition of carbon or direct flame impingement shall be
avoided. Cutting torches shall not be used for pre-heating.
7.8.3 Pre-heat shall be applied in a gradual and uniform manner to the entire length of the
joint and shall be maintained throughout the welding operation or as required in the
Approved WPS.
7.8.4 The pre-heat temperature shall be established throughout the joint and surrounding
parent metal for a distance of three times the parent metal thickness or 50 mm
whichever is the greater from the joint.
7.8.5 The pre-heat shall be measured, using a contact pyrometer or temperature indicating
crayons, at representative positions including the extremities of the required heated

zone and both root-side and face-side of the joint. Where access to only one face is
possible, the heat source shall be removed for a period of one minute per 25 mm of
parent metal thickness to allow for temperature equalization prior to measuring the
pre-heat temperature.
7.8.6 For tack welds and welds involving high restraint or severe stress concentrations, such
as patch welds, cruciform joints, partial penetration welds or where misalignment
exceeds 3 mm, the required pre-heat shall be raised by at least 77°F above that
required by Item 5.8.1.
7.8.7 Pre-heat is not required for stainless steel except when joined to ferritic steel.
7.9 Temporary Attachments
7.9.1 Temporary attachments which are welded to the work piece shall be of the same
quality material as the work piece. Such attachments include cleats, bridges, backing
strips, etc.
7.9.2 Temporary attachments shall be welded to the work piece by qualified Welders using
the same consumables and pre-heat as specified on the Approved WPS for permanent
attachments.
7.9.3 Temporary attachments shall be removed, prior to post weld heat treatment, by
grinding, machining or thermal methods, not by hammering. When thermal cutting is
used, the attachment shall be cut 3 mm from the work piece surface and the remnants
shall then be removed by grinding or machining.
7.9.4 After removal of any attachment, the work piece surface shall be ground and
examined by magnetic particle or dye penetrate method.
7.9.5 Carbon steel attachments shall not be welded to stainless steel or other non-ferritic
materials.
7.10 Precaution against Preferential Weld Corrosion
7.10.1 Any mill-scale present shall be removed by abrasive blasting.

7.10.2 Weld metal nominal composition shall be selected to avoid preferential weld
corrosion with any particular parent material. For carbon steel in the absence of
specific test data or specific recommendations, Figure 4 may be used to determine
optimum nickel and/or copper contents.
8.0 FABRICATION
Fabrication of all piping shall be in accordance with the requirements of piping

drawings and specifications. Where specific details of fabrication are not included,
work shall be carried out in accordance with the latest edition of ASME B31.3,
Process Piping.
8.1 General
8.1.1 Piping shall be fabricated by the method stated in this specification; i.e. welded,
screwed or flanged.
8.1.2 Internals of valves and other in-line equipment, which may be damaged due to heat
from welding, shall be removed prior to welding.
8.2 Butt-Welded Piping
8.2.1 Permanent backing strips shall not be used. Temporary backing strips shall be used
only with OGDCL’s/ Engineering Consultant’s prior approval.
8.3 Socket Welded Piping
8.3.1 All material entering this type of piping specification shall comply with the relevant
piping specification.
8.3.2 Pipe ends shall be cut square and deburred prior to being located in the fitting.
8.3.3 Minimum rating of socket welded fittings shall be class 3000#. When socket welding
fittings or valves are used, pipe shall be spaced approximately 1.5 mm to avoid
“bottoming” which could result in excessive weld stress.

8.4 Screwed Piping
8.4.1 The PC Contractor shall use thread cutting lubricant of an approved type.
8.4.2 The correct number of threads shall be cut on pipes to comply with standard for
threads.
8.4.3 Minimum rating of screwed fittings shall be class 3000#.
8.4.4 Jointing compounds and thread sealing tapes shall be approved by the Company and
shall be used for all threaded joints except those requiring seal welding.
8.4.5 Generally seal welding is not allowed. When seal welding is required, jointing
compounds or tapes shall not be used; all exposed threads shall be covered by seal
weld. Seal welding shall be performed by qualified Welders, in accordance with the
Approved WPS.
8.4.6 Excessive wrench markings on pipe and fittings due to joint making shall be avoided
and cause for rejection.
8.5 Flanged Joints
8.5.1 Flanges shall preferably be welding neck with bore matching pipe internal diameter
(ID) unless otherwise specified and / or authorized.
8.5.2 Flange bolt holes shall straddle horizontal and vertical centre-lines, except when
otherwise specified on approved drawings, and shall match the orientation of mating
flanges.
8.5.3 Internal weld surfaces at orifice flanges and other flow measuring devices shall be
ground flush. The length over which this requirement applies will be specified
elsewhere.
8.5.4 All loose weld neck flanges to be field welded shall be tacked in position for shipping.
Alternatively, they may be bolted to fixed, mating flanges or shipped in hessian sacks
which are securely attached to the spool.

8.6 Bending
8.6.1 Unless specified otherwise on drawings and specifications or unless Approved, bends
in pipes shall be affected using proprietary manufactured elbows.
8.6.2 Bends shall be free of cracks, wrinkles, bulges, kinks and other serious defects and
shall not be excessively scaled. 'Cut and shut', creased or corrugated bends are not
permitted. Weld repair of defective bends is not permitted.
8.6.3 When permitted, 'cold' bends shall be made at or below 1202°F for carbon steel.
8.6.4 After bending, cold bends shall be suitably heat treated, unless it can be demonstrated
that the strength, hardness, ductility and notch toughness conform to specified
requirements, in the "as-bent" condition.
8.6.5 All traces of bending filler materials and other contaminants shall be removed prior to
heat treatment. No lead-or sulphur-containing materials shall be used as fillers.
8.6.6 When permitted, 'hot' bends shall be made as per procedure approved by the
Company.
8.6.7 All heating and heat treatments shall be performed in a uniform and controlled
manner using an enclosed furnace, electrical resistance heaters or electrical induction
methods. The use of hand held gas torches is permitted only on low pressure, utilities
(stream trace, drain & cooling water etc.) and small bore piping of less than 1½” ∅
pipes.
Any bending, hot or cold and any post-bending heat treatment shall be performed in
accordance with a written procedure that has been approved.
8.6.8 After bending, the pipe wall thickness at the thinnest point shall not be less than the
nominal wall thickness minus tolerance and corrosion-and erosion-allowance. Bends
intended for use in lines which will require pigging shall be gauge tested to ensure
true bore and radius, prior to installation.
8.6.9 Mechanical properties after bending shall be determined for bends of Inspection
Classes 1 and 2. One production test bend shall be made for each cast of pipe, with

bend radius and pipe diameter representative of minimum bend radius/pipe diameter
ratio to be used in production. One tensile test and one set of notch toughness
specimens (when impact testing is required) shall be removed from the extrados of
each test bend. Transverse samples shall be used when the pipe size permits and are
mandatory for pipe diameters of 12 inches NB and larger.
8.6.10 When bending is performed on longitudinally welded pipe, the weld shall be
positioned at the neutral axis and test bends shall additionally be tested in the weld
zone by taking tensile tests and notch-toughness test samples as required for weld
procedure qualification testing. Welds shall be subjected to 100% crack detection
after bending. Girth welds shall not be incorporated into bends.
8.6.11 All production tests shall meet the requirements for yield strength and elongation of
parent metal, ultimate tensile strength and notch-toughness energy at appropriate
temperature.
8.7 Prefabricated Pipework
8.7.1 Proposed maximum sizes of prefabricated spools shall be submitted for Company’s
approval.
8.7.2 When piping spools are fabricated for free issue to site, spool ends may be identified
as 'cut to fit' (CTF) on the approved drawings.
8.7.3 When 'CTF' spools are specified, a minimum of 100 mm additional length to that
dimensioned on drawings shall be left for cutting at the installation stage. 'CTF' ends
shall be Left Square and plain.
8.8 Post Weld Heat Treatment (PWHT)
8.8.1 PWHT shall be carried out according to a heat treatment procedure which shall meet
the requirements of the Submission of Procedures Specification.
8.8.2 PWHT shall be achieved by one of the following methods:
− In an enclosed furnace
− By local electrical resistance heating
− By local inductive heating.

8.8.3 Manual gas torches or exothermic chemical heating packs shall not be used for
PWHT.
8.8.4 When local PWHT is used, the work piece shall be heated symmetrically. For butt-
welds and branch/attachment welds, a full circumferential band around each pipe
extending a distance, 1.5 x e on either side of the weld centre-line shall be heated to
the minimum soaking temperature, and at least half the soak temperature shall be
reached at a distance of L either side of the weld,
Where L = 2.5 √Re

R = internal radius of tubular component e = wall thickness.
8.8.5 To avoid adverse thermal gradients, thermal insulation shall be applied over the
heated band to a distance 2 x L either side of the weld centre-line.
8.8.6 When heating is by gas burners, direct flame impingement on the work piece shall not
occur. The furnace atmosphere shall be controlled to avoid excessive oxidation.
8.8.7 The temperature of the work piece shall be measured by pyrometers or attached
thermocouples. Sufficient pyrometers/thermocouples shall be used to ensure an even
distribution of temperature throughout the heated zone.
8.8.8 Pipe ends, flange faces, threads and any other machined surfaces shall be suitably
protected against oxidation during the heat treatment cycle.
8.8.9 The temperature of the work piece shall not exceed the upper limit of the holding
temperature specified on the approved heat treatment procedure.
8.8.10 The temperature of the work piece throughout its heated portion shall be continuously
and automatically recorded on a chart. PWHT records shall be retained as part of the
documentation required by the Company.
8.8.11 All temperature measuring and recording equipment, including thermocouples, shall
be suitably calibrated. Calibration records will be subject to scrutiny by the Company.

8.8.12 Welding on to a part which has been heat treated is not permitted, except by
Company’s approval, when the requirement for further PWHT shall be as indicated in
the applicable code.
8.9 Dismantled Piping Fabrication
8.9.1 For connecting every cut at relocated dismantled piping spool, a 200mm long pipe
spool shall be welded after beveling of relocated pipe. PC Contractor shall adjust and
prepare the relocated pipe as per site requirement.
8.9.2 For every Tee connection at relocated piping which will not be useful for further
connection shall be replaced with piping spool of same length as respective Tee
length.

9.0 INSPECTION AND TESTING
9.1 General
9.1.1 Inspection and non- destructive examination shall be carried out in accordance with
procedures which have been approved.
9.1.2 NDE Operators shall be qualified in accordance with a recognized standard and shall
be approved prior to commencement of NDE work. As a minimum requirement, NDE
shall be supervised by an Operator qualified to ASNT-TC-1A Level II or suitable
equivalent.
9.1.3 The Company shall be given the opportunity of witnessing all inspection, NDE and
testing.
9.2 Fabrication Tolerances
9.2.1 All fabricated piping shall meet the tolerances shown in Figure 2.
9.3 Extent Of Non-Destructive Examination
9.3.1 Inspection classes for welding procedure qualifications tests are shown in Table 1.
9.3.2 The extent of examination to be carried out for each inspection class shall be as
shown in Table 2. All fabricated piping shall be examined to the extent shown.
9.3.3 Welding Inspection requirements applicable for design, supply and commissioning
are shown in Table 3.
9.3.4 NDE and final inspection shall be carried out after any PWHT which may be required
but not before the weld has cooled to ambient temperature. When PWHT is not
required, NDE and final inspection shall be carried out at least 48 hours after the
completion of welding.
9.3.5 Where less than 100% examination is specified, the prescribed examination shall be
carried out at those locations where the presence of defects is deemed to be most
harmful to the structure, and/or locations where experience has shown that defects are
most likely to occur. The percentage shall be based upon actual number of welds with

100% examination performed on each weld to be tested. The extent of examination

shall include welds made by each and every Welder/Operator.
Radiographic examination (to the specified extent) shall be performed after the
completion of the post weld heat treatment (if any). If during radiography inspection
20% or more defective found then inspection requirement will increase to 40% and if
20% or more again defective found then 100% radiography inspection have to
perform.
9.4 Methods of Non-Destructive Examination (NDE)
9.4.1 Visual examination shall be carried out before, during and after fabrication in
accordance with Article 9 of ASME Section V and the Code.
9.4.2 Magnetic particle examination, liquid penetrates examination and radiography shall
be carried out in accordance with ASME Section V and the Code.
9.4.3 Radiographic testing (RT) shall comply with the following:
− Where possible the single wall-single image technique shall be used.
− Wire type Image Quality Indicators (IQI) to a national standard shall be used.
− Only lead intensifying screens shall be used.
− Film density shall be 2 to 3. Fully processed films shall not be further treated to
alter film density.
− Unless otherwise specified, the sensitivity of the technique shall be a maximum of

2% of section thickness but shall not exceed 1% for thickness of 50 mm or
greater.
− The film shall be high contrast, fine grained (Agfa D5 or equivalent) or better.
9.4.4 When MPI is used, the following shall apply:
− Surface condition shall be sufficiently smooth to avoid false defect indications.

− MPI shall be performed using electromagnetic yolks. The "prod" method shall not
be used, except with Purchaser's specific approval.
9.4.5 Generally, MPI shall be used for ferritic steels and DPI shall be used for all other
materials.
9.4.6 Ultrasonic examination in accordance with Article 5 of ASME Section V may be

substituted for radiography of a completed weld subject to Company’s approval and
only providing following conditions are met:
− Inside surface of weld shall be 100% visually examined.
− When welding is performed from both sides of joint, inside surface of weld shall
be 100% inspected by magnetic particle technique.
− Outer surface of weld shall be 100% inspected by magnetic particle technique.
− Purchaser shall be given the opportunity to witness all NDE on weld in question.
− Transducers shall operate at a frequency between 1 MHz and 5 MHz.
9.4.7 NDE reference points shall be marked on the work piece by an Approved method and
clearly identified in NDE reports.
9.4.8 The general substitution of ultrasonic examination for radiography is not acceptable
for hydrocarbon services except for systems where the wall thickness exceeds 19 mm
or when approved.
9.5 Acceptance Levels For Defects
9.5.1 Limitations on defects shall be as stated in the Code, except as follows:
− Incomplete penetration is not allowed for any butt or branch welds of Inspection
Classes 1 or 2
9.5.2 Additional limitations for various materials are to be approved by the Company.

9.6 NACE Service Material
9.6.1 For CS, LTCS and Stainless Steel Type 316L or 304L, hardness measurements shall
be carried out on specimens from the parent metal, weld metal and the heat affected
zone (HAZ). Hardness shall be less than 22 HRC.
All process piping as indicated in isometrics shall fulfill the requirements of NACE
MR-0175/ ISO 15156. Accordingly heat treatment where required shall be performed
as per ASME section VIII to achieve the required hardness of welding joints.
9.7 Repair Welding
9.7.1 Repairs shall be carried out in accordance with the approved procedure and shall be
subjected to 100% NDE using the same methods as specified for the original weld.
9.7.2 Weld repair procedures shall be qualified by a test weld which simulates the repair
technique, unless the repair is effected using an identical weld procedure to that of the
original weld.
9.7.3 All repairs to pipe work shall be specifically recorded.
9.8 Production Mechanical Tests
9.8.1 For inspection, when required in case of high pressure lines, when the number of
welds made using a particular weld procedure exceeds fifty, one production joint shall
be cut out for mechanical testing for every one hundred (or part thereof) welds made.
Joints to be cut shall be selected by the Company. The Contractor shall restore the
affected line by welding a new piece of material of the required quality and size.
9.8.2 Each production test weld shall be subjected to the same mechanical testing as the
corresponding procedure qualification test and shall meet the same requirements. In
the event of failure to meet specified requirements, the Company may require
additional tests to be made or may require more stringent NDE acceptance criteria.
9.9 Production Hardness Testing
9.9.1 For carbon steel subject to PWHT and/or post bending heat treatment hardness checks
shall be performed on welds and/or bends as follows:

− Where complete spools are furnace heat treated, 10% of welds and 10% of bends
in each furnace charge.
− For any other method, 100% of welds and bends.
The extent of testing may be reduced at the Company’s discretion if satisfactory

results are consistently being achieved.
9.9.2 The test shall be performed by the portable Brinell method according to ASTM E110
using a "Poldi", "Tele Brineller" or other tester (such as "Equotip) subject to written
agreement with Company. For welds each check shall consist of two indents with one
in the weld bead and one in the base material as close as practicable to the edge of the
weld. The macro-hardness values shall not exceed 200 BHN for carbon steel welds or
225 BHN for ferritic alloy welds.
9.10 Hydrostatic Testing
9.10.1 Contractor shall submit a detailed procedure for hydrostatic testing for Company’s
approval. Testing shall be performed in accordance with the approved procedure.
9.10.2 Pressure testing shall be carried out after completion of cleaning and flushing
operations and before painting or insulation of the pipe work. Pressure testing may be
integrated with flushing following pickling operations; however, if rusting of the pipe
work is likely to occur after pressure testing, pickling shall be carried out after
pressure testing and before drying.
9.10.3 Pipework which is to be pressure tested shall be prepared as follows:
− Positive displacement meters and their strainers, turbine meters, orifice plates,
rupture discs, control valves, relief valves and all in-line instruments shall not be
installed or, if already installed, shall be removed and replaced by a dummy spool,
spacer or blind flange, as appropriate;
− All in-line valves shall be in the fully-open position; check valves may be left in-
situ provided that the source of pressurization is upstream and that, after testing,
a the system can be relieved/drained downstream;

− Block valves shall be in the fully-open position, with a blind flange fitted;
− All equipment, such as vessels, pumps etc., shall be blanked off;
− The pipe work to be tested shall be fitted with a vent at each high point and a drain
at each low point;
− Spring pipe supports and other variable type supports shall be blocked to prevent
movement.
9.10.4 At least two pressure gauges shall be fitted and these shall be positioned at the highest
and lowest points in the pipe work. The pressure gauges (dial size 4”) shall be
selected to show the required test pressure at between 50% and 90% of full-scale
deflection and shall be calibrated prior to use. To permit temperatures effect to be
correctly accounted for, pipe work temperature shall be monitored in representative
locations by thermocouples; where possible, combined pressure/temperature/time
recorders shall be used to provide a permanent record of each test.
9.10.5 Unless otherwise specified, the test fluid shall be clean, fresh water. For pipe work
which includes stainless steels, the water shall contain 15 ppm maximum chloride.
The pipe work shall be filled slowly with the test fluid, with all vents and other
connections which may serve as vents, open to allow air to be expelled.
9.10.6 Pressure testing shall be carried out, generally in accordance with the Code. The test
pressure shall be as shown on the relevant piping class data sheet (see project Piping
Material Specification). The test pressure shall be held for sufficient time to permit all
joints to be inspected, with a minimum duration of 1 hour.
9.10.7 After completion of the test, the pressure shall be released slowly. The vents shall be
opened and then the test fluid shall be drained out. All drains shall be opened to
ensure that the test fluid is removed.
9.11 Flushing
9.11.1 After successful completion of hydrostatic testing, the lines shall be cleaned by
flushing, blowing or swabbing.

9.11.2 The PC Contractor shall provide the equipment required and shall carry out all
operations involved in cleaning.
9.11.3 All foreign material e.g. scale, rust, dirt, welding rods, etc., shall be removed form the
inside of the piping system.
9.11.4 Compressors, pumps, control valves, relief valves, filters, steam trap and instruments
shall be removed before cleaning operations. The PC Contractor shall provide
temporary connections to bypass these items. After these items in the piping system
using new gaskets.
9.11.5 Steam and gas piping shall be blown with compressed air until it is completely clean.
9.11.6 Other lines shall be flushed with water till they are completely clean.
9.11.7 Cleaning operations shall be performed until OGDCL/ Engineering Consultant is

satisfied that the piping systems are thoroughly cleaned.
9.12 Test Records

Records shall be made of each piping system or pipe section thereof, during the
testing procedure. All related documentation shall be sent to the OGDCL/Engineering
Consultant for information. These records shall include:
1) Date of test
2) Isometric view of tested pipe section with test duration and identification.
3) Test fluid full specification including possible inhibitor etc.
4) Test pressure in gauge bar
5) Certification by the field OGDCL/Engineering Consultant
6) Photocopy of the chart showing both pressure and time of test
The following requirements are additional with regard to the article 345.2.7 of chapter
VI of ASME B31.3 code.
9.13 Post Test Works

The PC Contractor shall be the only person fully responsible for removal of the water
used for cleaning and testing operations, under the OGDCL's previous approval.

The PC Contractor shall supply all necessary devices and works, such as temporary
connections, draining lines and/or ditches as may be necessary, connected to the
general plants drainage system with the previous approval of the OGDCL/Engineer-
ing Consultant.
Upon completion and acceptance of tests, provisory devices as previously described,

shall be removed, and jobsite left in its final contractual like condition according to
the relevant drawings issued and/or approved by the OGDCL. The gaskets shall be
renewed on dismantled flanged joints.
9.14 Repairing
In case leaks have been detected, the following procedure shall apply:
• Repairing works shall be performed according to ASME B31.3.

• The repaired section shall be brought up to full test pressure.
• The pipe section shall be allowed to stabilize with respect to temperature, and
the test started and run for the full time period required. See here above Para
about testing.
• In all cases, leaks with develop during the test and cause the pressure to fall shall
be cause for the test to be restarted.
• The documentation to be supplied shall be according to MW-1031 and the
present specification.
9.15 Cleanup and Acceptance
9.15.1 Cleanup
Further to welding, testing back filling and OGDCL’s acceptance of said works, the
PC Contractor shall be in charge of clearing up the job site.
Structures shall be placed in condition as good as or better than at the beginning of

constructions. These repairs shall be satisfactory to the OGDCL and his tenant.
PC Contractor shall restore to original condition all public Rights-of-Way, which have
been interested by the works.
PC Contractor shall remove from site all materials, including the pipes, left along the
right-of-way after the construction work, whether owned by himself or by OGDCL
and shall deliver OGDCL's materials, at points as designated by OGDCL.

PC Contractor shall remove from the premises all equipment, tools and appliances,
which were used by him in the performance of the work.
PC Contractor shall be responsible for all claims, which may result from damage done
by him off the right-of-way of the pipeline and plants area. PC Contractor shall make
all and any repairs and restorations and shall satisfy all proper claims.
9.15.2 Acceptance
Upon completion of the works, and conformity with the here stated rules being
checked, the OGDCL's acceptance will take place according to the terms and
procedures as defined in API Standard 700 latest edition and completed and/or
amended by the contract terms.
10.0 CORROSION PROTECTION
10.1 Cleaning
10.1.1 On completion of fabrication, the Contractor shall clean inside and outside of all
fabricated assemblies to ensure removal of all loose scale, dirt, sand, weld spatter,
cutting chips, etc.
10.1.2 When pipe work is to be pickled, pickling of pipe work shall be carried out in
accordance with the appropriate specification.
10.2 Galvanized Pipework
10.2.1 Unless otherwise specified, pipe work of 1½” NB and smaller, designated as
galvanized shall be fabricated from pre-galvanized pipe and fittings and shall be of
screwed construction.
10.2.2 Pipework 2 inch NB and above designated as galvanized, shall normally be of welded
construction and shall be hot dipped galvanized after fabrication. Spool sizes shall be
chosen to suit available galvanizing facilities.
10.2.3 Cleaning, galvanizing and subsequent painting of fabricated pipe work shall be in
accordance with the Painting Specification.

10.2.4 Any damage to galvanized coatings, such as cutting back for field welding, shallow
wrench markings or exposed pipe threads shall be repaired in accordance with the
Painting Specification.
10.3 Coating
10.3.1 Surface preparation and painting or coating shall be carried out in accordance with the
Painting Specification.
10.3.2 Shop fabricated pipe spools in carbon steel shall be prepared and primed as soon as
possible after completion of fabrication, inspection and testing.
10.4 Preservation
10.4.1 After internal cleaning and inspection, all ends; shall be closed off and sealed to
prevent mechanical damage and ingress of dirt or water. Flange gasket surfaces shall
be protected with a corrosion preventative compound, in accordance with the Project
Specification for Preservation and Packing, and covered with either 3 mm thick cover
of the same metal as the flange or high density polyethylene sheet with 10 mm thick
plywood cover. Covers shall be secured by at least 4 bolts.
10.4.2 Threaded connections shall be sealed using caps or plugs distinctively colored to
identify threaded connections.
10.4.3 When open ends of pipes are to be left overnight or between shifts, cover plates or
caps shall be fixed to avoid ingress of dirt or water.

11.0 MARKING
11.1 General Requirements
11.1.1 Pipe spool identification shall be clearly written on the pipe using non-corrosive white
paint. Die stamping; scratching or bead welding of pipe identification is not
permitted.
11.1.2 If temporary identification markings will be obscured by cleaning, painting, heat

treatment or other operations, marking shall be die stamped on a compatible metal
disc securely wired to the fabrication.
11.1.3 Loose piping items and fabrications too small for individual paint marking, which will
be supplied in hessian or canvas sacks shall be identified using die stamped metal
discs securely wired to individual items or to the sack in which case the identification
disc shall also denote the contents of the sack.
11.2 Material Certification
11.2.1 Each batch of free issue piping material will be marked and identified by the Mill
with the Heat Number corresponding to Heat Number on the Material Certificate.
11.3 Line Identification Code
11.3.1 Each line will be designated with an identification code which will be referenced and
used on Company’s approved drawings and schedules.
11.3.2 Line identification code will be a composite code containing reference numbers and
abbreviations for the following:
− Area
− Service
− Line Number
− Nominal Line Size
− Piping Pressure Class
− Piping Material Class

11.4 Spool Identification Numbers
11.4.1 Each individual spool supplied as a separate item for installation shall be allocated a
spool identification number with which it shall be identified.
11.4.2 Spool sequence numbers shall be of two digits, commencing with 01 and shall follow
numerical sequence in the direction of flow indicated on the piping isometric. Unless
pre-specified on the approved drawings, spool numbers shall be agreed between the
Contractor and the Company.
11.4.3 Composite spool identification numbers shall comprise the line identification code
without insulation code, plus a spool sequence number plus an additional area or
module reference if advised by the Company.

12.0 INSTALLATION OF PIPEWORK
12.1 General Requirements
12.1.1 Pipe work shall be installed in accordance with the codes and standards specified in
Section 2.0 and the OGDCL/Engineering Consultant approved piping general ar-
rangements, supporting drawings, specifications and schedules.
12.1.2 Installation of pipe work shall be carried out under conditions satisfactory to OGDCL/
Engineering Consultant.
12.1.3 All work performed and complete must meet the approval of OGDCL/Engineering
Consultant.
12.1.4 The scheduling of work to carry out the installation of pipe work shall be coordinated
with the work schedule of other trades and discipline involved in the overall
construction. The schedules shall be prepared to the satisfaction of and agreed with
OGDCL/ Engineering Consultant.
12.2 Pipe Work Erection
12.2.1 All pipes shall be inspected before erection to ensure that they are perfectly clean
internally.
12.2.2 Where possible, pipe work shall be erected on permanent supports designated for the
line.
12.2.3 During erection of pipe work, suitable supports are to be provided to ensure that no
undue stresses are imposed on the pipe.
12.2.4 Control or block valves shall not primarily be used to support pipe work.
12.2.5 Temporary supports and assemblies used to facilitate the erection of pipe work shall
meet the approval of OGDCL/Engineering Consultant regarding safety and suitability.
12.2.6 Care shall be taken to avoid undue strain being placed on a vessel or item of equip-
ment etc., by unsupported lengths of piping.

12.2.7 Drainage falls shall be maintained throughout as specified on the drawings.
12.2.8 It should be noted that vessel flanges generally are not set sufficiently true to permit
prefabrication of the mating pipe flanges without prior checks being made.
12.2.9 Where drawings show flanges loose on a closure length of piping, a careful physical
check shall be made of closing distance and alignment of flange before cutting and
pipe and welding on the flanges.
12.2.10 The PC Contractor shall ensure that piping connected to equipment is supported so
that minor equipment, valves etc., can be readily removed without further
supporting of the pipe and with the minimum of dismantling.
12.2.11 The erection of a spool incorporating cut to fit requirements shall be carried out
taking full advantage of the inbuilt adjustment to avoid undue stresses in the
completed pipe line, the only exception to this shall be when ‘cold pull’ is specified
on the piping drawings, in which case the specified pre-mating gap shall be
carefully maintained and the pull made against permanent and secure support
anchors.
12.2.12 Pipe work shall be fitted into place without springing or forcing.
12.3 Flanged Joints
12.3.1 All flanged joints shall be brought up flush and square so that the entire mating
surfaces bear uniformly on the gasket, and then made up with uniform bolt tension.
12.3.2 It is recommended that the maximum differential stress between two bolts in a flange
joint shall not exceed 20% of the lower stress.
12.3.3 When bolting flange joints with spiral wound gaskets, the gasket shall be compressed
evenly to the thickness of the guide ring. This would be equal to 25% to 35%
compression of the original gasket thickness (gasket compression shall be spot
checked during bolt tensioning),
12.3.4 Steel to cast iron flanged joints (if any) shall be made with extreme care, taking up
bolts uniformly after careful lateral and parallel alignment.

12.4 Equipment Flange Connections
12.4.1 Flange covers shall be retained on all flange connections to pumps, compressors,
turbines and similar mechanical equipment until ready to connect the mating piping.
12.4.2 Unless called for hydrostatic test blanks are fitted at the connections to equipment
covered in 9.4.1 above. A thin metal plate shall be inserted to protect the equipment
against ingress of internal pipe debris resulting from the continuing erection of the
piping.
12.4.3 Flanges connecting to strain sensitive mechanical equipment e.g., pumps,

compressors, turbines, inline instruments etc. shall be fitted up in close parallel and
lateral alignment prior to tightening the bolting. To achieve this true alignment, full
advantage shall be taken of the 'cut to fit’ allowances and loose flanges provided.
12.4.4 Flange connections to strain sensitive equipment shall be the last connection made on
completion a line or interconnecting system of lines complete with permanent
supports.
12.4.5 All openings in vessels, columns and other similar equipment items shall be clean and
free from obstruction prior to being connected to the pipe work.
12.5 Clamp Type Connector Joints (if specified)
12.5.1 Clamp type connectors shall be installed in accordance with the manufacturer's
installation instructions.
12.5.2 Hub protectors shall remain on the hubs until they are welded into place or when the
connection is toeing assembled.
12.5.3 All lubricants and foreign matter shall be cleaned form the hub seating surface and
seat ring prior to installation of the connector. The sealing ring should be lubricated
only when no coating or plating is present on the seating surface.
12.5.4 Correct alignment of the stubs, seal ring & clamps shall be checked before assembly.

12.5.5 Torque wrenches are recommended for large stud sizes (1⅝" and larger) to ensure that
the minimum preload values are met.
12.6 Gaskets and Jointing
12.6.1 The PC Contractor shall ensure that the correct gasket material and thickness as
specified in the OGDCL/Engineering Consultant approved Piping and Valve
Materials Specification is used.
12.6.2 The PC Contractor shall ensure that correct gasket lubricant as specified and required
by the OGDCL/Engineering Consultant approved Piping and Valve Materials
Specification is used.
12.6.3 Care shall be taken to ensure that the gasket and mating flanges are clean true and free
from defects.
12.6.4 Joint rings will be supplied as pre-cut joints and shall be set inside the bolt circle.
12.6.5 The PC Contractor shall ensure that joint rings do not under any circumstances
protrude into the bore.
12.6.6 The PC Contractor shall install insulated joint rings, sleeves and washers where
indicated on the isometric piping drawings.
12.6.7 Electrical testing on insulated joints shall be carried out by the PC Contractor. Each
stud bolt shall be 'meggared' in turn to each flange and between adjoining flanges.
12.6.8 The annular space between insulated flanges shall be completed filled after testing
with either hot or cold electrical compound or the whole outer periphery of the flanges
shall then be wrapped with 0.3 - 0.5mm thick PVC tape.
12.7 Bolting
12.7.1 The PC Contractor shall ensure that all bolting materials and types used are in
accordance with the service requirements as specified on individual material
specifications in the OGDCL/Engineering Consultant approved Piping and Valve
Materials Specification.

12.7.2 All flanges bolting shall be checked for correct grade and damage prior to fittings.
12.7.3 All flange bolting shall be free to move through mating flanges holes to a plane at
right angles to the flange (ace and parallel to the pipe run (misalignment of flange
holes resulting in knurling of the nut on the flange will be rejected).
12.7.4 All flange stud bolts shall extend fully through their nuts.
12.7.5 Stud bolts cut from long lengths of studding shall have the material grade stamped on
the end at each cut.
12.7.6 All nut bearing faces, bolt threads shall be lubricated with suitable lubricant during
fittings.
12.7.7 Bolt tension shall be applied in three stages using the diametrical sequence. 1st stage
25%. 2nd stage 50%. 3rd stage 100%.
12.7.8 The PC Contractor shall re-check all bolting for tightness and correct tension on
completion of pressure testing.
12.7.9 Bolting for ANSI Class 600# and above on size 1½" and over will be one diameter
longer and installed using a hydraulic tensioning device.
12.8 Valves
12.8.1 Valves shall be orientated in the line so as to be readily operable, and removable,
either fully or in part.
12.8.2 Gate, Butterfly and Globe valves in horizontal lines shall be installed with their stems
orientated as follows in order of preference:
Manual
a) Vertically upwards
b) Horizontal (Preferable for Butterfly Valves)
c) Upwards of 45 deg.

Actuated
a) Gate/Globe, (including 3 way and Y type) shall only be mounted with the stem
vertically upwards.
b) Rotary valves (butterfly, throttling ball. etc.) shall only be mounted with the
stem horizontal.
12.8.3 The PC Contractor shall provide for the checking of gland packing in all valves and
for leakage during hydrostatic testing.
12.8.4 All but welds and socket welded valves shall be tack welded in the position show on
the piping drawings and approval of position obtained from OGDCL/Engineering
Consultant before carrying out final welding.
12.9 Pipe Supports
12.9.1 Pipe supports shall not be welded to the pipe unless specified in the design and piping
isometric drawings.
12.9.2 Pipe support elements which are welded directly to the pipeline shall be attached by
non-penetrating welds during the fabrication of the pipe or pipe spool. Welding shall
be to approve welding procedures in accordance with Welding and Inspection of
Piping Specification.
12.9.3 The PC Contractor shad ensure that only supports of the type specified in the design
and piping drawings are used.
12.9.4 During installation pipe lines shall not be forced so as to suit the installed support and
thereby introduce undue stresses into the line.
12.9.5 Permanent pipe supports shall be installed before the erection of pipe work associated
with them.
12.9.6 The PC Contractor shall, ensure that adequate support of (heavy valves and fittings
before the pipe work is subjected to pressure test or put into service.
12.9.7 Attachment by drilling or welding to structural steel on site shall be carried out only
with the approval of OGDCL/Engineering Consultant.

12.9.8 The burning of holes in structural steelwork or component parts is strictly forbidden.
12.9.9 Supporting steelwork shall be set at the correct elevation, being true and level in all
respects.
12.9.10 Metallic surfaces of supports which will be inaccessible after erection shall receive
a protective coating of paint before assembly of the component, in accordance with
the General Painting Specification.
12.9.11 All welding of supports shall be carried out using continuous fillet welds.
12.9.12 Hanger rods shall be adjusted to hang correctly after tightening of all component
parts/surplus threading may be removed.
12.9.13 Pipe hangers shall not be used as temporary lifting attachments.
12.9.14 The use of adjacent structures or equipment as temporary supporting of listing at-
tachments shall not be permitted unless authority has been obtained from OGDCL/
Engineering Consultant.
12.9.15 Spring support units shall be installed in accordance with the manufacturer's instruc-
tions and shall not have 'stops' removed until completion of testing. 'Stops' shall be
color tagged by manufacturer for identification.
12.9.16 The PC Contractor shall ensure that all temporary supports and lashings are
removed after the pipe work has been flushed and pressure tested.
12.10 Branch Connections

The branch connections shall be in full compliance with the material specifications
according to the piping system.
They shall also comply with the ASME B 31.3 article 304-3, branch connections in
metallic piping.
In case of conflictual statement the piping classes overrule the ASME B31.3 require-
ments.
All branch connections shall be jointed to the header with full penetration welds.

All instrument air connections, if any, shall be from the top of the header.
12.11 Instrumentation
12.11.1 In-line instruments e.g. Orifice plates, control valves, meter etc. shall be installed by
the PC Contractor under the direction and control of the OGDCL’s/Engineering
Consultant's Instrument Engineer.
12.11.2 All instruments installed shall be capable of complete or part removal for mainte-
nance purposes
12.11.3 Unless otherwise instructed by Instrument Engineering, in-line instruments shall not
be installed prior to pressure testing of the pipe work.
12.11.4 As specified by the Flushing & Pressure Testing Specification the PC Contractor
shall fit "dummy" spools in place of in-line instruments during erection to facilitate
pressure testing.
12.12 Field Run Pipe work
12.12.1 Field run lines shall normally be restricted to pipe work of 1.5" nominal bore and
below. Galvanized pipe will be field run at sizes 2" NB and below.
12.12.2 Field run lines shall be run in accordance with the routing indication on the piping
drawings and to the satisfaction of OGDCL/Engineering Consultant.
12.12.3 All field run lines shall be installed in an orderly manner, consistent with good
operation, neatness of appearance, safety of personnel, economy and usage of the
minimum number of fittings consistent with provision for expansion and flexibility.
12.12.4 All piping shall be arranged to facilitate supporting and shall be planned for ease of
removal of equipment for inspection and servicing.

FIGURE 1: BRANCH REINFORCEMENT DESIGN
Note – 5
Full Pen" Butt
Full Penetration

6mm Vent Hole to be tapped NPT
Dimensions for Root Face and Gap

THICKNESS SMAW GTAW/GMAW
(mm) g(mm) f (mm) g(mm) f (mm)
≤ 22 l.6-4.0 0.8-2.4 0.8-l.6 l.2-2.5
>22 2.5-4.0 0.8-2.4 l.6-3.0 1.2-2.5
Notes
(1) Reinforcement pads may be split circumferentially or along the axial centre-line
and rewarded to the header by full thickness/full penetration weld.
(2) In all cases the reinforcing pad shall be attached after the branch to header weld
has been made and examined.
(3) Fig l(a) applies to angled branches in which the branch to header angle is less the
75°. Angles less than 60° are not permitted unless otherwise specified.
(4) If the crotch weld of angled branches cannot be made from the outside with
reliable penetration, the weld at "E" shall be made from the inside for 1/3 times
diameter of the branch, i.e. 1/6 x D on each side of the axial centre-line.
(5) Dimension R = 6 times thickness of the header as a minimum.
(6) If branch reinforcement pads/plates are used the branch connection weld shall be
inspected before the reinforcement pad/plate is fitted. The reinforcement weld
shall also be examined.
(7) When socket welds are permitted, they shall be subject to 100% MPI/DPI only.

FIGURE 2: DIMENSIONAL TOLERANCES FOR FINISHED PIPEWORK
±3 mm from indicated dimensions for

face to face, centre to face location of
Branch and Attachments.
8% max. (for internal pressure) 3%

max. (for external pressure) flattening
measured as difference between the
max. and min. OD at any cross
section.
±3 mm misalignment between branch
centre line and pipe run centre line.
±1.5 mm max. rotation of flanges

from the indicated position.
0.75 max. out of alignment of flanges

from indicated position measured
across any diameter.

FIGURE 3: PROXIMITY OF WELDS
Separation S = Sp or Sa as applicable.
Where Sp = Separation between any two pressure containing welds

= 100 mm (above 4" NB)
=1 diameter (4" NB or less) - can be reduced to 'the greater of 3 times the
wall thickness or 40 mm minimum.
and Sa = Separation between an attachment weld and any other weld

= 40 mm minimum.


TABLE 1: TYPE AND NUMBER OF MECHANICAL TEST SPECIMENS

AND NDE REQUIREMENTS FOR WELDING PROCEDURE
QUALIFICATIONS TESTS
Joint Pipe Non –Destruct.Cross Bend Charpy Hardness

Configuration Wall Examination Weld Tests V- Macro
Thick. t (100%) Tensile Notch Tests
(mm) Tests Tests
Butt-weld t < 19 RT+MPI+Visual 2 2 root + 4 2
19 ≤ t < RT+MPI+Visual 2 2 face 4 2
30 RT+MPI+Visual 2 4 side 5 2
t ≥ 30 4 side
Branch-weld t < 19 UT+MPI+Visual 2

t ≥ 19 UT+MPI+Visual 2
Fillet/Part All MPI+Visual 2

Pen. Weld
TABLE 2: PRE-HEAT REQUIREMENTS FOR CARBON STEEL
Combined Minimum pre-heat, °F

Thickness, Low Hydrogen (max 10 ml/100 g)
Heat Input:
<1 (kj/mm) >1 (kj/mm) >2 (kj/mm)
<30 - -
<35 122 - -
<40 167 - -
<45 212 - -
<50 212 - -
<55 257 68 -
<60 257 122 -

TABLE 3: WELDING INSPECTION REQUIREMENTS APPLICABLE

FOR DESIGN, SUPPLY & COMMISSIONING
Piping Visual Service Radiography Rating

Class Inspection
A,B 100% Non-hydrocarbon 5% 150#, 300#
Hydrocarbon 10%
D 100% Non-hydrocarbon 10% 600#
Hydrocarbon 20%
E 100% Non-hydrocarbon 20% 900#
Hydrocarbon 100%
Above 100% ALL 100% 1500#
Any line with wall thickness over ½" (12.7mm) shall be 100% radio graphed.
All Tie-in but welded joints shall be 100% radio graphed.
All Stainless steel piping shall be 100% radiographed.

APPENDIX A - ADDITIONAL REQUIREMENTS FOR LOW TEMPERATURE

SERVICE
1.0 GENERAL
1.1 This Appendix applies to all pressure-containing materials and direct attachments
which may be subjected to low temperatures during their operational life. It includes
low temperatures arising from non-normal service such as auto-refrigeration during
blowdown.
1.2 All Carbon steel piping systems shall comply with the requirements of the Codes.
1.3 All charpy impact tests shall be V-notch type, performed in accordance with ISO
R148.
1.4 When weld metal impact tests are specified sufficient sets of samples shall be taken
and so notched as to represent each process and consumable brand used in the
welding of the joint. Branch and attachment weld procedures shall be qualified by a
butt-weld joint which has been subjected to Charpy impact testing.
2.0 IMPACT TESTING REQUIREMENTS
2.1 Carbon Steel

2.1.1 All pressure-containing items, and attachments directly welded to such items, shall
comply with ANSI B31.3, except as modified by the Piping and Valve Specification.
2.1.2 All weld procedures for pressure-containing welds shall be qualified by appropriate
procedure qualification tests which shall include charpy impact testing of weld metal
and heat-affected zone, in accordance with ANSI B31.3,.
2.1.3 Heat affected zone impact testing is required on all production test coupons
representing low temperature piping.
Heat affected zone impact tests shall comply with the requirements for the parent
material, as stated in the Piping and Valve Specification.

2.2 Stainless Steels and Dissimilar Metal Joints

2.2.1 Weld procedures for welds in austenitic stainless steels and for welds between these
materials and ferritic steels, shall be subject to charpy V-notch impact testing of the
weld metal only. Test requirements shall be the same as specified by ANSI B31.3.
2.2.2 When dissimilar joints, which include ferritic steel, are tested, additional impact tests
shall be taken from the ferritic heat affected zone. Test requirements shall comply
with ANSI B31.3.
2.2.3 Weld procedures for welds in duplex austenitic - ferritic steel shall be subject to the
same requirements as for carbon steel. When the impact energy requirements of the
above cannot be met, impact tests may be accepted if they comply with a minimum
average lateral expansion of 0.38 mm, minimum individual lateral expansion of 0.25
mm.

APPENDIX B - ADDITIONAL REQUIREMENTS FOR 300 SERIES

STAINLESS STEEL PIPING
1.0 SCOPE
1.1 This appendix covers the special requirements for the fabrication of stainless steels
(300 series).
1.2 This appendix applies to the following materials:

"18-8" type austenitic stainless steels, including: 304, 304L, 316L, 321 types and
other stainless steels as specified by the Company.
2.0 GENERAL
2.1 Fabrication of stainless steel shall be carried out in an area separate from that used for
carbon/low alloy steels and copper alloys.
2.2 Saws, grinders and other tools used on stainless steel shall not be used on other
materials.
2.3 Cold bends shall be made at or below 797°F, followed by solution annealing.
2.4 Hot bends when permitted shall be made at 1697°F - 2102°F followed by solution
annealing. Prior to hot bending, stainless steel shall be free from grease, soap and any
compound containing sulphur, halogens or low melting point metals.
3.0 WELDING
3.1 Preparation
Cutting shall be by cold sawing or plasma-arc process. Fused edges and heat-affected
zone from plasma-arc cutting shall be removed by grinding or machining.
3.2 Process
3.2.1 Gas Tungsten Arc Welding (GTAW) shall be used for root runs of single-sided welds.
The argon gas back purge shall be maintained during the first filler pass.

3.2.2 Submerged arc welding (SAW) shall not be used, except for welding of heavy
sections with Company’s prior approval, when heat input shall be restricted to 4
kJ/mm maximum.
3.3 Consumables
3.3.1 Welding consumables for conventional austenitic stainless steel shall be as follows:
Material Consumable Type (AWS designation)
Type 316 or 316L E316L or ER316L

Type 321 E347 or ER347
Type 304 or 304L E308L or ER308L
3.3.2 For the welding of conventional austenitic stainless steels to carbon steel,
E309/ER309 (or E309Mo/ER309MO for joining Type 316/316L to carbon steel) shall
generally be used, provided post-weld heat treatment is not required. When post-weld
heat treatment is required, E Ni Cr Fe-3 consumables shall be used.
3.3.3 Consumables for stainless steels shall produce deposits with 3 to 10% ferrite.
3.4 Heat Control

3.4.1 Maximum interpass temperature shall be 302°F.
3.4.2 Pre-heating and post-weld heat treatment are not required unless required for ferritic
steel in a dissimilar-metal joint.
3.5 Procedure Qualification

3.5.1 Weld procedure qualification tests for stainless steel shall be carried out on the same
type and grade of material as used in production.
4.0 CLEANLINESS REQUIREMENTS
4.1 Protection of Bore

4.1.1 The bore of pipes and other components shall be protected from oxidation during
welding by inert gas purge.

4.1.2 The extent of purging and/or the use of dams to confine the gas purge shall be
specified in the weld procedure specification.
4.2 Limits of Oxidation

4.2.1 Light oxidation of the weld/HAZ is acceptable. This is generally evidenced by
discoloration varying from straw to dark brown.
4.2.2 Heavier oxidation, as evidenced by dark blue weld metal and/or the formation of a
coke-like surface, has a deleterious effect on the corrosion resistance in service and
hence is unacceptable.
4.3 Remedial Action

4.3.1 Heavily oxidized surfaces, spatter, welding slag and other residues shall be removed
by grinding. The final surface condition shall be attained by light grinding with rotary
abrasive papers/cloths and by pickling.
5.0 INSPECTION AND TESTING
5.1 Visual Examination

5.1.1 All welds shall be 100% visually examined after completion.
5.1.2 Weld procedure qualification test assemblies for all stainless steels shall be subject to
internal bore examination for correct weld profile and discoloration.
5.2 Non-Destructive Examination

5.2.1 The extent of examination shall be as indicated in ANSI B31.3.
5.3 Acceptance Criteria

5.3.1 Criteria for cleanliness are given in 4.2 and 4.3.
5.3.2 The following features are unacceptable:

− Any cracks
− Any lack of fusion or lack of penetration at the bore surface
Surface-breaking porosity.

Job No. 14-4985
Spec. No. 4985-PA-2022
Page 1 of 49 Rev. 0
SPECIFICATION FOR
PIPELINE CONSTRUCTION
Client: Oil & Gas Development Co. Ltd.
Prepared by: WRK

Checked by: MK
Approved by: FS
Revised by: -
0 ISSUED FOR BID 1-Mar-12

Pipeline Construction
TABLE OF CONTENTS
1.0 GENERAL ............................................................................................................ 4
2.0 CODES, STANDARDS & SPECIFICATIONS ................................................ 6
3.0 PIPELINE ROUTE . ........................................................................................... 6
4.0 UNLOADING, STOCKPILING, HAULING & STRINGING OF
MATERIALS ................................................................................................................... 7
5.0 RIGHT-OF-WAY ................................................................................................ 9
6.0 TRENCHING ..................................................................................................... 12
7.0 BENDING ........................................................................................................... 18
8.0 CLEANING & INSPECTION OF PIPES & BEVELS .................................. 20
9.0 WELDING .......................................................................................................... 21
10.0 LOWERING IN ................................................................................................. 33
11.0 TIE-INS............................................................................................................... 34
12.0 BACK-FILLING OF THE TRENCH.............................................................. 34
13.0 SPECIAL MECHANICAL PROTECTION ................................................... 36
14.0 CROSSINGS ...................................................................................................... 38
15.0 SPECIAL ITEMS .............................................................................................. 39
16.0 APPURTENANCES .......................................................................................... 39
17.0 FINAL TESTING .............................................................................................. 39
18.0 PAINTING.......................................................................................................... 43
19.0 CONCRETE ....................................................................................................... 43
20.0 WET AREAS, SWAMPS DITCHES AND AREAS SUBJECT TO
FLOODING .................................................................................................................... 43
Doc. No. 4985-PA-2022 Page 2 of 49

21.0 LINE MARKERS AND CATHODIC TEST ASSEMBLIES ........................ 44
22.0 FINAL CLEAN-UP OF THE CONSTRUCTION RIGHT-OF-WAY AND
PERMANENT JEEPABLE TRACK. .......................................................................... 44
23.0 COMMISSIONING AND START-UP ............................................................ 45
Doc. No. 4985-PA-2022 Page 3 of 49

1.0 GENERAL
1.1 Scope
OGDCL intends to develop the Gas field by installing Plant comprising surface
facilities, flow lines, commingling system and gas purification plant. The gas
purification plant unit will be capable of to processing on an average 300 MMSCFD
raw gas stream. For implementation of the project, Flowlines/Pipelines to be installed
from wellheads to UCH-II Development.
This construction specification outlines the minimum basic pipeline construction

requirements for Flowlines/Pipelines to be installed from wellheads to UCH-II
Development.
This specification establishes the methods of construction, testing and repair,

acceptable construction tolerances, construction record requirements and such details
as ditch dimensions, amount of cover required, allowable change of slope and tie-in
temperature limits etc. Installation of Mobile Scraper Traps, Insulating Joints, Anchor
Flange and Barred tee etc are also included in the scope.
1.2 Definitions
“Company” means “Oil and Gas Development Company Limited (OGDCL)”.
“Engineering Consultant” shall mean “ENAR Petrotech Services (Pvt.) Limited”.
“Supplier” means Entity with whom the Company will execute a Contract for supply
of equipment/material as per this document.
“Project” means “UCH-II Development Project”.
1.3 Error or Omission
All deviations to this specification, other referred document or attachments shall be

brought to the knowledge of the Company/Engineering Consultant in the bid. All
deviations made during the installation, testing and inspection shall be with written
approval by the Company/Engineering Consultant prior to execution of work. Such
deviations shall be shown in the documentation prepared by the Contractor.
Doc. No. 4985-PA-2022 Page 4 of 49

1.4 Conflicting Requirements
In the event of any conflict, inconsistency or ambiguity between these documents,

referred documents, codes & standards referenced in the documents the Contractor
shall refer to the Company/Engineering Consultant whose decision shall prevail.
Doc. No. 4985-PA-2022 Page 5 of 49

2.0 CODES, STANDARDS & SPECIFICATIONS
- API specification 5L Specification for line pipe, (Latest Edition)
- ANSI B 31.8 Gas Transmission & Distribution Piping System
- API specification 6D Specification for pipeline valves (Gate, Plug, Ball &
Check Valves)
- API 1110 Pressure testing of liquid petroleum pipelines
- API Standard 1104 Standard for welding pipelines and related facilities
- API RP 1102 Recommended practice for liquid petroleum

pipelines crossing railroads & highways
- API RP 5LW Recommended practice for transportation of line

pipe on barges and marine vessels
- ASME SE-709 Standard Guide for Magnetic Particle Examination
- ASME SE-165 Standard Test Method for Liquid Penetrant

Examination
Project Specifications
Relevant Specifications
Relevant Typical Drawings
Certain codes and regulations may have been adopted by the jurisdictional agencies
over the locations where the work is to be performed. It shall be the Contractor’s
responsibility to determine whether local codes and regulations exist. In the event
local codes and regulations exist the Contractor shall determine their scope and abide
by all their provisions on its own cost.
3.0 PIPELINE ROUTE

Company/Engineering Consultant has surveyed and prepared drawings for the
pipeline route and set survey markers in order to establish the edge of pipeline route.
However, it shall be the Contractor's responsibility to establish working grades, and
levels in accordance with design and drawing provided by the Company/Engineering
Doc. No. 4985-PA-2022 Page 6 of 49

Consultant and maintain/establish survey markers/monuments at every 500m along

the route on ground at its own expense.
Demarcation
The pipeline route drawings (plan/profile) show generally the alignment that is to be
followed by the Contractor and pipeline corridor shall be marked accordingly on
ground.
Contractor shall at its own expense carryout all necessary survey to locate under-
ground/buried services such as electric cables, telephone lines, gas lines, foreign
pipelines etc. and other permanent structures in order to protect and prevent any
accident or damage to other's work.
4.0 UNLOADING, STOCKPILING, HAULING & STRINGING OF

MATERIALS
Contractor shall receive, load-out, transport and stockpile coated pipes at the
designated delivery points, and shall reload and string with equipment of a suitable
capacity using Company/Engineering Consultant approved slings, spreader bars and
protected hooks. Coated pipes shall not be handled in any manner, which distorts,
scratches, scars, or dents the pipe. Unloading of pipes from trucks shall be done
carefully. Pipe shall never be dropped. It shall be handled and transported to prevent
any damage. The pipe coating, insulation and, concrete coating, if any, shall be
protected from damage. Pipe shall be stockpiled as directed by Company/Engineering
Consultant.
Pipes shall be loaded on truck in a pyramid form and tiers shall be according to ANSI
B31.8.
Materials other than pipes and which are susceptible to dispersing, deteriorating or
suffering from damages, especially due to humidity, exposure to high thermal
excursions or other adverse weather conditions shall be suitably stored and protected.
Doc. No. 4985-PA-2022 Page 7 of 49

In particular, material for protective coatings, heat shrinkable sleeves, rock shields fall
within this class.
Pipe stringed along the construction right-of-way shall be protected by setting the pipe
on padded supports. No pipe shall be strung along the right-of-way before all clearing
and grading is completed. In order to maintain the spread within reasonable length,
the pipe stringing shall precede welding by a sufficiently short distance.
Pipe shall not be strung on the construction right-of-way in advance of trenching

where blasting will be necessary in rocky areas.
Pipe shall be strung in such a manner as to result in the least amount of interference to
the normal use of the land and/or other properties crossed, and gaps shall be left at
frequent intervals to permit the use of the land and the passage of farm animals,
equipment or other normal traffic across the construction right-of-way.
All materials shall be unloaded, stored if such is required, hauled to the site of the
work and assembled on the site in such a manner as to prevent damage, theft, etc.
Flammable materials such as paints, primers, volatile substances etc. shall be kept in
separate storage having proper ventilation until the final use and both inside and
outside of the storage all kind of preventive measures shall be taken against danger of
a possible fire.
The Contractor shall be fully responsible for all storage areas.
The Contractor shall prevent ingress of dirt or debris into the pipe during stringing.
The stock piling of coated pipes will be carried out on surfaces previously leveled and
coated with a layer of sieved earth or sand having sufficient thickness to prevent
coatings from being damaged or on wood wedges or sand bags.
Doc. No. 4985-PA-2022 Page 8 of 49

The Contractor shall carefully lower the pipe, within the right-of-way, on to sandbags.
Line pipe shall not be rolled off or dropped from the vehicles.
Lifting and handling of Factory Made large Radius Hot Bends and other materials
shall be accomplished without damage of any sort. Contractor shall adhere to all
lifting and handling instructions laid down by the Company/Engineering Consultant
in this specification.
The Contractor shall be fully liable for repair or replacement materials or equipment
damaged by Contractor.
For handling of coated pipes, equipment shall be selected carefully to avoid any
damage to the coating. Pads are recommended on forklifts and a spreader bar shall be
used when handling pipe with an overhead crane. These pipes shall be handled with
wide belt strips and not with chain or wire.
If the pipe is to be stored for long periods of time, the ends should be protected from
the elements to ensure cleanliness and to prevent deterioration of the coating. The
most common method of protection is to use a polyethylene bag securely taped over
the ends of each pipe, carefully stacked in a secured area to prevent damage from
other operations incidental to the job.
Pipes stacks shall be suitably secured against collapse and will consist of pipes having
the same diameter and thickness. Continuous pipes having different sizes, wall
thickness or coating thickness shall be clearly separated.
5.0 RIGHT-OF-WAY
General
The construction right-of-way shall be cleared and graded to a smooth surface for the
full width and prior to the stringing of pipe. In addition, fills or cuts may be indicated
on the plan and profile drawings in order to eliminate or lighten over bends or sags in
the pipeline.
Doc. No. 4985-PA-2022 Page 9 of 49

For the purpose of construction, 40 meter wide construction RoW to the right of
permanent Row (facing the direction of flow) shall be acquired by the Company. Any
requirement of land in addition to this, for construction, storage, access or residential
camps shall be arranged by the Contractor at its own cost.
The Contractor shall pay for all damages resulting from operations outside the
construction right-of-way.
The Contractor, at its own expense, shall verify by suitable means in advance of
actual construction, the precise location and actual depth of all existing pipelines,
utilities and subsurface structures that either cross or are in close proximity to the
proposed pipeline. Contractor shall avoid damages to and shall be liable for all
damages to all such structures.
Contractor shall restore all damaged property including but not limited to buildings,
fences, hedges, roads, bridges, culverts, drainage ditches, terraces, drainage, tile,
creeks, levees and rivers occupied or crossed in said construction. Any property
damaged in the prosecution of the work shall be put into as good condition as before
damage occurred and upto the satisfaction of concerned local authorities and as
agreed to by the Company/Engineering Consultant.
In rough or steep terrain the Contractor may be required to grade access roads into the
construction right-of-way for use in the moving in of materials, men and equipment.
Where such roads are required the Contractor shall obtain the necessary permission
from land owners and tenants involved and shall furnish the Company/Engineering
Consultant with a written copy of such permission. The Contractor shall be
responsible for all the damage caused by the construction and use of such roads.
Where the construction working area is shared or located on an existing pipeline

RoW, extreme caution shall be used at all times to avoid damage to existing facilities.
Doc. No. 4985-PA-2022 Page 10 of 49

Before any work can begin on shared RoW, the existing pipeline (if any) shall be
marked by the Contractor with red flags, for clear indication and Company will
inform the Contractor about pipe size, operating pressure, depth of pipeline and
product in the pipeline. Contractor shall take extreme care not to ply the equipment
over the existing pipeline.
Contractor shall cross its equipment only at the designated points over the existing
pipeline if deemed necessary. Earthen ramps shall be constructed/maintained at such
crossing points till completion of the pipeline construction.
Site Marking
The road and railway crossings shall be marked and the Contractor shall warn for
special operations.
If the right-of-way width is reduced, entrance to and exit from the narrow area shall
be clearly marked and stakes shall be placed if necessary.
A marker post shall be placed every 500 m along the right of way on the trench side
and it should be visible from the working track.
The Contractor shall maintain and possibly correct the marking during the
construction operations.
Preparation of the RoW
The Contractor, within the area made available to him by the Company shall at its
own cost perform the following:
Make all required arrangements (cleaning, leveling etc) permitting the delivery and
transfer of pipe, moving of vehicles, all operations required for the good performance
of work, traffic of vehicles belonging to any agent responsible for the supervision of
work, and if necessary installation of culverts, back-filling of ditches or reinforcing of
certain portions of natural ground which could be in poor condition.
Doc. No. 4985-PA-2022 Page 11 of 49

Remove or have removed all power line or telephone line poles. The Contractor shall
take all necessary steps to secure, in due time, the corresponding agreement from the
concerned governmental agencies.
Cutting down of Trees
Within the RoW made available by the Company, the Contractor shall proceed with
cutting down of trees, clearing of tree stumps and large roots.
Cutting down of trees shall be performed so as to avoid damages to other trees, plants,
crops and any construction.
Clearing and Grading operation shall not be more than 20 Km ahead of completed
trench unless approved by the Company.
All cut-down trees shall remain the sole property of the Company. Trimmed trunks
shall either be stacked along the R.O.W. or removed to a place specified by the
Company/Engineering Consultant.
The same shall be applied for bushes and branches resulting from the clearing
activity.
6.0 TRENCHING
Particular care shall be taken to locate all buried installation, crossing the pipe line
route in advance of grading and ditching.
The Contractor shall take centre-line of the pipeline as per relevant drawings to dig
and maintain the pipeline trench.
General
In locations where the trench is cut across roads, paths, walkways, etc., the Contractor
shall provide temporary bridges of adequate strength and properly constructed to
Doc. No. 4985-PA-2022 Page 12 of 49

allow the passage of normal traffic with a minimum of inconvenience and interrup-
tion.
Proper warning signs shall be placed and maintained while such crossings are open. If
the crossings are open at night, the Contractor shall provide and use Warning Lights
or Lanterns, all as required by the agency having jurisdiction and/or the
The Contractor shall provide, at its cost, necessary pumps, de-watering equipment,
sheet piling, shorting well points, etc. as required to prepare trench in marshy and
high water table areas. Contractor shall ensure satisfactory disposal of water pumped
through the ground.
Where gravel, rock, and/or other hard materials are in the bottom of the trench in non
traffic areas and where in Company/Engineering Consultant opinion, such conditions
will result in damage to the pipe coating, the Contractor shall pad the bottom of the
trench with sand to a depth such as to give the pipe, in place, at least 150mm of
clearance from the hard materials.
Depth
Minimum depth of cover shall be measured from the top of the pipe coating, to the
top of the undisturbed surface of the soil. Fill material in the construction right-of-way
shall not be considered to add to the depth of cover.
The Contractor shall carry out deeper trenching at all parts of the RoW, where a
deeper cover is required by the Company/Engineering Consultant, or indicated on
drawings near roads, water course/Nala crossings, other pipeline crossings, and in
short sections of cultivated areas where special installations or surface arrangements
exist or are foreseen, or where this is required to avoid unnecessary bending of the
pipe.
Doc. No. 4985-PA-2022 Page 13 of 49

If, during performance of work, the minimum depth of cover cannot be achieved, the
Contractor shall submit for the Company/Engineering Consultant’s approval all
necessary provisions to ensure equivalent protection.
Width
The trench shall be wide enough to allow for lowering-in without damage to the pipe,
pipe coating. The trench shall be excavated so as to provide a minimum clearance of
200 mm on either side of pipeline. Each side of the pipe shall be measured from the
outside of any coating at the horizontal centerline of the pipe when it is placed in the
trench.
The Contractor may be required to excavate deeper than shown on the Drawings, or to
excavate a trench wider than required by the Specifications and Drawings, in order to
properly construct the pipeline at road, path, walkway, dike and stream crossings, and
other locations of a similar type. It is understood that the Contractor recognizes such
possibilities and that he has included such possible costs in the Contract Price.
Ditches
Ditching operations, increase in width and depth, supply of back-filling material of

the ditch bottom shall be at the Contractor’s expense.
When required in locations where ditch walls shall be protected by shielding, the
Contractor shall perform the corresponding work at its own cost.
Ditch walls and bottom shall be free of damaging elements (stones, roots, etc.). Ditch
walls shall be as vertical as possible.
At points where trench is known to cross other pipelines or underground systems.

Excavation shall be performed manually.
Doc. No. 4985-PA-2022 Page 14 of 49

The bottom of the finished trench shall be adjusted in such a manner that the bottom
of pipe, bent according to the design, will fit on its whole length so that the pipe will
not be ovalized or overstressed in any way.
In rocky areas, the Contractor shall protect the ditch bottom with a padding of sieved
sand of 200 mm thick. Pipeline being backfilled in the rocky areas shall be provided
with the mechanical protection of a minimum of 10-mm thickness.
Top Soil
Top soil shall be conserved by removing one layer of top soil to a depth of between
100 mm and 150 mm. Removed top soil shall be stockpiled in a location that will
minimize any loss due to erosion or mixing with other materials.
Top soil conservation shall be carried out in all areas where excavation or leveling is
necessary including the trench line, graded pipeline route, temporary stock piles and
camp sites.
The excavated materials shall be stored within the RoW.
When required by concerned governmental agencies, the Contractor shall remove all
excavated materials and move them to locations chosen in agreement with the
Company/Engineering Consultant. The Contractor shall also supply and perform the
necessary back-filling.
Crossing of Unstable Areas
If the zones crossed by the line present any risk of settling and sliding, the Contractor
shall, immediately, inform the Company/Engineering Consultant of such risk.
In steep areas of hillside before starting the work, the Contractor shall provide for
suitable arrangements as per relevant drawings or other similar protections approved
by Company/Engineering Consultant in order to prevent the material removed from
Doc. No. 4985-PA-2022 Page 15 of 49

falling down the hill. The foregoing is particularly applicable where lines of
communication, houses, water courses and cultivations exist.
Temporary Crossings
Wherever it is permissible to open cut a road with an improved surface to make a road
crossing, the Contractor shall remove the surface in accordance with the restrictions
and requirements of the national, provincial, municipal or other agency having
jurisdiction thereof.
Where possible the Contractor shall arrange to complete the trenching, laying and
back-filling of such crossings and to remove the temporary bridging before the end of
the regular work day in order to minimize the hazard to night traffic.
Water Drainage
The Contractor shall be responsible for the protection of the Site against water of any
kind and origin.
The Contractor shall be responsible for maintaining surface or deep water drainage
under all circumstances.
The Contractor shall also be responsible for all consequences resulting from problems
caused by surface or deep water drainage and for any damage or accident likely to
occur.
The Contractor shall be responsible for drainage of water of any origin from the site
up to the adequate outlets. Such obligations cover the construction and maintenance
of water supply connections (drain-pits, drains, etc.), the supply of power and
equipment necessary for drainage, operational and supervisory personnel, the
restoration of the site etc. so that ditching operations and lowering-in of pipe into the
ditch be carried out under good conditions.
Doc. No. 4985-PA-2022 Page 16 of 49

When the back-filled trench making a drain effect is liable to cause damages to the
pipeline or to the nearby lands, the Contractor shall submit to the
Company/Engineering Consultant adequate measures to prevent damages from
occurring.
Underground Drainage
Within drained areas or areas to be drained, the pipe shall be laid in order that the
distance between the top of pipe and the bottom of each drain is at least 300 mm.
The Contractor shall take similar measures for separate drain lines which may have
not been reported earlier and which is likely to be encountered during the
performance of Work. The Contractor shall immediately inform the
Company/Engineering Consultant of the existence of such drain lines.
As soon as the pipe has been laid down, the Contractor shall restore all drain lines in
such a way so as to obtain a draining system similar to the initial one.
Drain lines which are damaged by vehicles shall be replaced and restored to the
original conditions.
Special measures shall also be taken in order to prevent the ditch, after back filling,
from being used as drain line.
Within grounds drained by underground systems, the Contractor shall restore any cut
network, at its own cost, using a method satisfactory to the land owner and approved
by the Company/Engineering Consultant.
Bell Holes
When pipe tie in is to be performed in the ditch, the Contractor shall provide, at its
own expense, bell holes having at least the following dimensions:
Depth: 60 Sixty cm below the lower part of pipe.
Doc. No. 4985-PA-2022 Page 17 of 49

Length: 70 (seventy) cm in excess of the outside diameter of the Pipe.

Width: 90 (ninety) cm between the outside of the pipe and the bell hole wall
on either side of the pipe.
7.0 BENDING
Preformed Bends
Preformed bends shall be installed in the pipelines where the changes in direction are
larger than permissible with the elastic bends. Bends may require more cover than the
minimum cover at straight run of pipelines.
Preformed bends can be broadly classified into:
• Factory made preformed bends (for angles 16º and above)

• Site bends using bending machine (for angles between 3º and 16º)
• Site bends using bites (for angles less than 3º)
Factory Made Preformed Bends
The factory made preformed bends shall be installed where the changes in direction
are equal to or greater than 16º. Factory made preformed bends will be procured in
three sizes i.e. 22.5 º, 45º and 90º. Any other angle shall be achieved by fabricating
the 45º and 90º bend at site.
Site Bends Using Bending Machine
Preformed bends less than 16º but greater than 3º shall be made by welding into the
correct location of the string a length of pipe which has been bent with a smooth
stretch bending machine. The bending radius shall be minimum forty (40) times the
diameter of the pipe.
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Bends shall not be made closer than 2 ft. from a circumferential weld unless the weld
is back welded. The weld shall be X-rayed after the bend is made.
Site Bends Using Bites
Horizontal changes of direction which are larger than permissible with elastic bends
are to be made using preformed bends in 3º (maximum).
More specifically, when horizontal bends are to be made by using pipe bending
machine, the maximum permissible bend or `bite' at one place on the pipe shall be
zero degree thirty minutes (0º 30’) and the minimum spacing of such bites shall be 3
feet. The limitation of horizontal bend shall be 3º per 37 feet pipe length. Normally,
this means 6 each 1/2º bites spaced 3 feet with 11 feet straight tangent at the ends of
each pipe length.
Linear and Angular Tolerances
Bends shall be provided with a total angularity tolerance of ± .5 degrees as

determined by the intersection of the tangent centerlines measured by appropriate
equipment.
Contractor's Responsibility
Small sag and over-bends can be handled by careful trenching of the pipeline trench
and/or field bending the pipe.
Contractor shall submit for Company/Engineering Consultant’s approval the

procedure for field bending of line pipe and repair of coating of the pipeline in the
field.
Miter bends are not allowed.
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8.0 CLEANING & INSPECTION OF PIPES & BEVELS
• All pipes shall be internally cleaned prior to assembling.
• The means of cleaning shall be proposed by the Contractor for approval of the
Company/Engineering Consultant’s Representative.
• All operations performed later on shall be conducted so as to prevent any foreign

body, especially water and earth, from penetrating into the pipes.
• Any assembled section or part shall be carefully sealed closed at each interruption
of work by night caps agreed upon by the Company/Engineering Consultant, so as
to prevent water, dirt, animals and any foreign substance from entering the pipe.
• All Site personnel shall be fully aware to comply with the provisions and be
informed that equipment, tools or suits shall not be left in the pipe, for any reason.
• If, upon removal of night caps, it appears that some foreign bodies have
penetrated into the pipe, the contaminated portion shall be properly cleaned before
proceeding with further assembling operation.
• Immediately, prior to proceeding with alignment, each pipe end shall be carefully
cleaned, using metallic brushes.
• In the event such surfaces show rust, mill scales, grooves, burrs, etc. a grinding
machine of flexible disk type shall be used.
• Cleaning shall be performed on the inside and outside of the pipe and at least up to
ten (10) cm from the edge.
• When cleaning is performed by grinding, the bevel root face shall be

reconditioned using a file.
• Prior to welding, pipe diameter and thickness will be verified at each pipe end.
Bevel design shall comply with type of welding.
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9.0 WELDING
General
Welding and welding related requirements of the following codes and standards shall
be considered part of but subject to the more stringent provision of these
specifications:
• API 1104 latest edition (Standard for welding pipelines and related facilities).
• American National Standard Institute ANSI B31.8 (Latest edition).
• ASME Code - Section IX welding / brazing qualification.
No circumferential weld shall be located within 150 mm of the center of a support.
All welds shall be marked with waterproof crayon or paint stick by the welders
according to numbers assigned to them by Company/Engineering Consultant at the
time they qualify. Should any welder leave, his number will become void and it shall
not be duplicated on the project. No punch or steel stenciling will be permitted.
Except as otherwise required herein, all welding shall equal or exceed the
requirements of API 1104, Standard for welding pipelines and related facilities, latest
edition.
All welding machines, line-up clamps, machines, cutting torches, and other
equipment, tools, and supplies used in connection with the welding work shall be kept
in good mechanical condition so as to produce sound welds.
All welding electrodes furnished and used by Contractor shall be of an approved type
and quality suitable for pipeline welding acceptable to Company/Engineering
Consultant. All welding electrodes found to be deteriorated, defective, or otherwise
damaged shall be rejected and prohibited from use on the pipeline.
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No cutting or welding on the line pipe, other than that required for making the normal
circumferential joints will be allowed without written permission from
No welding electrode or grounding shall be permitted to arc the pipe except in the
actual bevel being welded.
Procedure & Qualification

Prior to starting of production welding, a welding procedure shall be established in
accordance with API 1104, Standard for welding of pipelines and related facilities,
latest edition, and shall be approved by the Company/Engineering Consultant.
Approved pipe welding procedure shall be recorded in detail as outlined in API

Standard 1104 and be adhered to during subsequent construction. The Contractor shall
obtain a certificate of qualification of welders, from the Company/Engineering
Consultant, before any welding is carried out on site.
Welding procedures which have been established approved and qualified shall not be
changed. Re-qualification shall be required for any change in welding procedure
already established approved and qualified. The entire welding procedure, qualifica-
tion tests shall be conducted in presence of the Company/Engineering Consultant.
Contractor shall organize the test at a fixed place on site to be intimated to the
Company/Engineering Consultant at least one week before the date fixed for these
tests.
Contractor shall, for the execution of welds, designate one or two welders to undergo
the procedure qualification tests to meet the code requirement and the welders
involved shall qualify for production welding on the qualification of procedure test.
The pipes welded at the time of the test shall be two job size nipples free from dirt,
paint, etc. and ends beveled with machine.
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For each procedure test, four specimens shall be removed from the completed joint as
per API Standard 1104 for carrying out necessary mechanical tests (destructive). Each
procedure test shall be macro-hardness tested using Vickers equipment with a 10kg
load. Hardness shall not exceed 300 HV10. All hardness surveys shall be witnessed
by the Company/Engineering Consultant. The procedure qualification shall be carried
out at Contractor's expense.
Welder Qualification
The qualification test of welders shall be conducted strictly in accordance with API
Standard 1104 (latest edition). Test shall be conducted in the presence of the
Company/Engineering Consultant.The welder(s) who have performed successful
procedure qualification test shall be automatically qualified in that procedure.
This qualification shall, in particular, enable to distinguish between welders capable

of executing any pass, root bead, hot pass, filler bead, capping in mainline,
fabrication, tie-ins and repairs.
All the qualified welders shall be given the identification tag consisting of following
information:
• Photographs
• Welder identification symbol
• Welder’s name
• Contractor’s name
Reports
The Contractor shall draw up a report of each qualification procedure which shall
contain the results of all inspections and tests performed on the corresponding welds.
This report shall be signed by the Contractor and the Company/Engineering
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Consultant representative and the Inspection Agency. These documents shall be

available on Site when the welding is performed.
A form of the API 1104 type or equivalent shall be used for recording test
performance conditions and results of the welding procedure qualification test.
Validity
The validity of qualification of a welder shall be maintained subject to the following
conditions:
The welder has worked on identical parts/procedure for total duration of at least 60
days and the partial or total inspection of welds which he has performed, proved the
work to be of high standard.
In case welder leaves the site his identification shall be cancelled.
A qualified welder whose production work is found to be repeatedly defective can be

replaced by other welder. The Company/Engineering Consultant reserves the right to
disqualify such elder.
Any welder who fails the qualification tests or who has lost his qualification during
the course of his work, may after a further training of a minimum of 15 days, take
another qualification test.
Electrode Specification
Welding electrodes shall be sealed in tin packing and only that number of tins opened
on each day that are likely to be consumed during the day. The electrodes/rods must
be free from any trace of oxidation.
Welding electrodes at the job site during construction and open electrodes overnight
shall be stored in ovens to keep the electrodes dry and in good condition.
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The electrodes for API 5L X-52 pipe shall conform to AWS-E-70XX specifications
except that the stringer bead may be made with E-6010 electrode. Different electrodes
may be used if approved in the welding procedure.
The size of electrodes shall be established in the welding procedure.
Welding electrodes should be of acceptable makes such as LINCOLN, ESAB,

PIPEWELD & PHILLIPS. Contractor would be required to obtain
Company/Engineering Consultant’s approval of the selected make.
Production Welding
General
Weld qualification procedure shall be provided to the Company/Engineering
Consultant for approval.
Production welding shall not begin until all the following qualifications have been
performed and found acceptable in accordance with this specification:
• Qualification of welding procedures.
• Qualification of weld repair procedures.
• Qualification of welders and welding operators.
• Qualification of radiographic procedures.
• Qualification of mechanical testing procedure.
The welding conditions that apply to production welding shall be those used for the
welding procedure qualification tests.
Preheating & Interpass Temperature
If preheating is found necessary, the required temperature shall be reached at the joint
and over a distance of a least 76 mm (3”) in all directions from the joint. This
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temperature shall be checked regularly (e.g. using temperature indicating crayons).

These requirements also apply to tack welds.
The interpass temperature is normally not to exceed the maximum temperature

recorded during the Welding Procedure Qualification Test, and restricted to 250 ° C
max.
Tack Welds
Tack welds shall be performed in accordance with a Company/Engineering
Consultant’s approved procedure and by qualified welders. They shall be 75 to 100
mm(3 to 4”) long for O.D. > 12 ¾” and minimum of 50 mm (2”) or 4 times the W.T.
(whichever is less) for OD. < 12 ¾”, to prevent any crack formation at the root of the
finished weld.
Welding Sequence
The second pass (hot pass) shall be made within five minutes (or less) after deposit of
the root pass.
No pass shall be commenced until the preceding pass is completed.
Alignment Clamp
Use of an alignment system inside the pipeline (internal clamp) is preferred.
Internal line up clamp shall not be released until the root bead is 100% complete and
pipe has been properly supported.
External line up clamp can only be removed when root bead is 50% completed in
equal segments uniformly spaced around the circumference of the pipe.
Cleaning
Before welding, the surfaces to be connected shall be cleaned of any trace of mill
scale, slag, rust, grease, paint etc.
Upon completion of each welding pass the weld run shall be cleaned of any trace of
slag and various deposits.
After completion of the welded joint, the surfaces next to the weld shall be cleaned of
any trace of slag, spatters and various deposits.
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Arc Strikes
No arc strikes shall be permitted outside the bevel area. Any accidental arc strikes
shall be ground out then submitted to magnetic particle or liquid penetrant inspections
in accordance with ASME SE-709 or ASME SE-165 respectively.
Post-weld Treatment
No heat treatment is required on completed production welds provided hardness
requirements are respected.
Protection against Rough Weather

The Contractor shall take all necessary measures for protecting the welds and welders
from bad weather conditions (rain, wind, etc.) for the duration of the work. Adequate
protective means and equipment shall be made available on the Site.
Welding Conditions Control

The following parameters shall be checked during welding:
• Preheating temperature (when required).
• Minimum and maximum interpass temperatures.
• Welding current amperage and voltage.
• Travel speed.
The Contractor shall provide all measuring instruments necessary for making these
checks to the satisfaction of the Inspector.
As far as possible, the instruments shall be the same or of the same type as those used
for the procedure qualification performance.
Identification of Welds
After execution and before the inspection, the welded joints are numbered by the
Contractor and furthermore, in the case of piping of pipeline installations, marked on
the drawing.
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In line, each welded number shall be written again over the coating material.
Welders are requested to stamp their identification number on the first in - line welds
they perform and also when a modification is brought in the composition of their
welding crew.
Marking on pipe shall never be made by punching.
Weld Inspection
General
The Contractor shall provide visual inspection of the set-up prior to welding and
whilst the welding is in progress. The Contractor shall provide non-destructive
testing (NDT) to test the finished welds.
The Contractor’s inspection personnel and equipment shall be submitted for prior
approval by the Inspector.
Non-Destructive Inspections
NDT inspector shall have certificate of NDT conforming to ASNT level II or level III
from a recognized institute and have adequate experience in the NDT inspection of
pipeline laying work.
a) Visual Examination
Weld preparations and completed welds shall be visually inspected by the Contractor
and the Inspector.
Once the welding is completed, all welds shall have a uniform outside appearance and
shall blend progressively and without undercut into the base metal. The adjacent
surface shall be cleaned of any spatters or other deposits.
b) Radiographic Inspection
Radiographic inspection using X-ray or gamma-ray methods shall be performed in
accordance with the requirements of API 1104 (radiographic procedure specification,
qualification test, etc.) taking into account the following specific requirements:
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• The Image Quality Indicator (IQI) shall be of the wire type as per DIN 54109
Standard or ISO Standard.
• The geometrical unsharpness shall not exceed 0.2 mm,
• The detection sensitivity shall not exceed 2% of the weld thickness.
• The image density shall be between 2.0 and 3.5.
Each film shall include a weld number as well as figures or letters corresponding to
the weld actual external marking.
All radiographs shall be submitted for examination and acceptance by the
The Contractor shall submit the radiographic inspection report to the
Company/Engineering Consultant that it may be approved as soon as possible.
c) Inspection Requirements
All welds shall be visually examined.
Visual examination of butt welds shall essentially be carried out whilst the weld is
still above the minimum interpass temperature recorded in the qualified welding
procedure, so that any remedial work necessary to the capping pass can be carried out
before non-destructive testing.
Radiograph of welds using X-ray or gamma-ray methods shall be carried out by the
Contractor in accordance with the following schedule:-
Non-Specific Welds
All double-joint butt welds and running field butt welds shall be 100% radiographed
whenever any one of the following conditions applies:-
1. The start or recommencement of each and every different welding procedure by a
welder or group of welding operators working together as a team.
2. Whenever a new root run welder is assigned to or within a team of welding

operators.
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3. When production welding by any operator or team of operators recommences

after a cessation of more than 72 hours for whatever reason.
This 100% radiography shall be maintained for 100 joints or two days work
performed at the normal rate, whichever is the greater.
If it is agreed by the Company/Engineering Consultant and the Contractor and the

Inspection Agency that sound welds are being consistently produced and any defects
are within the limits of acceptability, then the level of radiography may be reduced to
10%. The reduction shall be effected in the number of welds and the full length of
each weld chosen for examination shall be radiographed. The Company/Engineering
Consultant will select welds to be radiographed following visual inspection.
During operation of 10% radiography, if the radiograph of any weld joint shows a
defect requiring either a repair or a cut-out, then the whole of the adjacent weld joint
on each side of the defective weld joint shall be radiographed by the Contractor. If in
so doing, any additional defects necessitating either a repair or a cut-out are shown to
be subjected to full radiographic examination and 100% radiography shall be re-
imposed on further welds produced by the welding team concerned.
The period of 100% radiography shall continue until the Company/Engineering

Consultant. and Contractor again agree that sound welds are being consistently
produced by the welding team concerned.
Specific Welds
The following specific butt welds shall be subjected to 100% radiographic tests.
1. Within populated areas such as residential sub-divisions, shopping centres and

designated commercial and industrial areas.
2. River, lake and stream crossing within the area subject to frequent inundation; and
river, lake and stream crossing on bridges.
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3. Railway or public highway rights of way, including tunnels, auger bores, bridges
and overhead railway and road crossing.
4. Welded joints to valves, flanges or other fittings and specials, insulating flanges
and anchor flanges.
5. Connecting joints on pipes of different wall thickness.
6. Tie-in joints.
7. Welds which have been wholly or partially repaired.
8. Any weld performed to qualify a welding procedure or a welder.
The Company/Engineering Consultant reserves the right to carry out magnetic crack
detection or ultrasonic examination of any weld if this is considered necessary to
assist radiographic interpretation or to determine the soundness of the weld.
Ultrasonic testing shall be performed using written procedures, equipment and

operators approved by the Company/Engineering Consultant.
The Contractor shall perform a magnetic particle or liquid penetrant inspection at any
time upon the request of the Inspector. These inspections shall be performed
according to ASME SE-709 and ASME SE-165 respectively.
Extent of Radiographic Inspection
Upon completion of the works, all radiographs shall be handed over to and become
the property of the Company/Engineering Consultant..
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Weld Acceptance Criteria

The weld acceptance standards of API 1104 (Latest Edition) shall apply to the visual
and non-destructive inspections (radiographic, etc.) for welding procedure
qualification tests, welder qualification tests and production welds.
The Inspector on Site shall be sole judge of weld acceptability and his decision is
final.
Repair & Removal of Defects
Welds which do not meet the acceptable standards of this specification, shall be cut
out at the Contractor's expense by removing a cylinder of pipe containing the weld, or
with the prior approval of the Company/Engineering Consultant..
Cutouts and repairs shall be made by the Contractor as soon as possible.
Repairs may normally be allowed, at Company/Engineering Consultant’s discretion,

under the following conditions:
• Where there are no cracks in the weld.

• Where the segment of weld to be repaired was not previously repaired.
• Where the weld is inspected after repairs by the method used to originally
inspect the weld.
Defect removal: Weld defects shall be removed by grinding. The repair cavity shall
be of sufficient size to allow adequate access for welding.
Cleaning: The requirements for cleaning of weld beads shall also apply for repairs.
Arc burns shall be removed by grinding. Grinding shall have a smooth contour. After
grinding, the remaining wall thickness in the area will be verified by the
Company/Engineering Consultant. and shall not be less than 90% of the nominal wall
thickness
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If the thickness is less than that acceptable, the Contractor shall cutout a cylinder of
pipe containing the arc burn and replaces it.
10.0 LOWERING IN
• Pipe shall not be lowered into the trench when, in Company/Engineering

Consultant’s opinion, the temperature is such that damage to coating may result.
• All skid marks and other possible places of damage to the coating shall be
checked with a holiday detector and damaged area properly repaired before the
pipe is finally lowered into the trench.
• The distance between two side booms shall not exceed then the
Company/Engineering Consultant procedures while lowering. The coated pipes
shall be lifted with non-abrasive nylon belts to prevent the coating damage.
• Coated pipe shall not be placed in the trench until bare field joints have been
coated as per by coating supplier recommended Practice and cave-ins, plugs, hard
clods, stones, skids, welding rods, etc., have been removed and padding has been
placed. Coated pipe shall not be dragged along the ground. If coating is damaged
due to mishandling it shall be repaired as per procedure recommended by coating
supplier recommended Practice.
• If water or mud is found in the ditch, whenever possible, proceed with pumping
out of water and cleaning of the ditch before lowering-in takes place.
• In case it is not possible to drain the water from the ditch, the Contractor shall
submit for the Company/Engineering Consultant’s approval, all necessary
measures in order to have the pipe normally rest on the bottom of the ditch.
Pigging and Air Testing

• All weld segments shall be air pigged and soap tested at 90 psig before lowering
into the trench. All weld repairs shall be completed and sections shall be cleared
radio graphically before pigging and air testing.
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11.0 TIE-INS
The pipe shall be cut so as to permit a good line-up and weld. Unless pipe has been
placed in the ditch and shaded, tie-ins shall not be made at the temperature less than
10ºC. Bell hole welding shall be done in bell holes which provide adequate clearance
to enable the welder to exercise normal welding skill and ability. The overlap of pipe
strings at tie-in shall be at least 2 meters.
• The weld seams of the adjoining pipes shall offset by 30% or 76 mm (which ever
is greater). If not possible, a spool piece of not less than 1.2 meters in length shall
be inserted.
The minimum length of pup that shall be used is 1 meter. All pups of 1 meter or over
shall be moved ahead and welded into the pipeline daily. Pups under 1 meter shall be
gathered up and delivered to the Company/Engineering Consultant's nearest storage
area.
12.0 BACK-FILLING OF THE TRENCH

The Contractor shall backfill the trench after the pipe is in place as set forth in the
following:
The trench shall not be back-filled until Company/Engineering Consultant has

approved the fit and cover of the pipe in place in the trench and has approved starting
the back-filling operation.
The trench shall be back-filled to 0.2 meter initially. The backfilling shall be such
that initial back-filling shall be performed as soon as possible after the trench is
approved for back-filling.
After the initial backfill has been placed in the trench to the level of the surrounding
ground the Contractor shall compact the backfill by making as many passes as
necessary with a rubber tired compacting device or as per Company/Engineering
Consultant’s approved procedure.
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After the initial backfill, the remaining material excavated shall be neatly crowned
over the trench and lightly compacted. The crown remaining shall be large enough in
Company/Engineering Consultant’s opinion to prevent the formation of a depression
in the soil when the backfill has settled into its permanent position.
The backfill shall be crowned to a height of not less than 0.3 m, after the settlement.
Spoil that cannot be used in the backfill shall be considered as surplus and shall be
removed from the ROW by the Contractor. Contractor shall dispose off the spoil in a
manner and at locations satisfactory to Company/Engineering Consultant.
Where the trench has been dug through driveways, walkways, roads, dikes, etc. the
backfill shall be thoroughly compacted by mechanically tamping the fill material into
place in properly wetted layers not thicker than 150mm. The surface of such areas
shall be restored to their original condition in a manner satisfactory to
Company/Engineering Consultant and the responsible authorities.
Trenches crossing ditches shall be back-filled with the material excavated from the
trench at that location except that in locations where the excavated material in
Company/Engineering Consultant's opinion is not suitable for back-filling, the
Contractor shall provide and use suitable material from another source. Ditches with
lined or otherwise improved surfaces shall be resurfaced in a manner satisfactory to
and approved by the Company/Engineering Consultant and the responsible
authorities.
Where the excavated material is rock, gravel or other hard materials which in
Company/Engineering Consultant ‘s opinion, would damage the pipe or pipe
insulation the Contractor shall furnish and place sufficient sand or soft earth to give
the pipe protective cover before the trench is back-filled with the hard materials. Also
Rock shield is to be provided for the protection of the pipe and coating.
Rock boulders not larger than 1 cubic foot volume may be placed in ditch after the
padding is in place; however, in cultivated areas, no rocks shall be placed on top of
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the backfill which would interfere with ploughing or cultivating. All surplus rock
shall be disposed off to the satisfaction of the Company/Engineering Consultant, land
owner and/or tenant at no additional compensation.
When back-filling across irrigated fields, Contractor shall provide furrows across
pipeline right-of-way as required by the Company/Engineering Consultant, land
owner or tenant to direct the flow of water into normal irrigation furrows. Extra cover
is required at vertical, horizontal and composite preformed bends in some cases.
In areas where pipeline in land on sloping ground, the backfill/trench shall be

stabilized as per details shown in Alignment sheets.
The Contractor shall provide diversion ditches and/or culverts for floodwater in order
to keep the pipeline from acting as a dam and channel bank.
Spot back-filling is required to tie down, and restrain the pipe in the ditch after it has
been lowered in. Spot back-fills shall provide full-specified cover and shall cover all
preformed bends a distance of 6 meter to each side of the centres of the bends. The
maximum clear distance between spot back-fills shall be 20 meter. Spot back-fills
shall cover the pipe for at least 5 meters along the pipe. Completion of back-filling
shall follow spot back-filling as closely as practicable.
Backfilling shall be carried out immediately after lowering-in, within 48 hours, in

order to give the pipe a natural anchorage, avoiding long exposures of the coating to
significant variations of temperatures, harmful spells of adverse weather conditions
and caving-in of the trench walls.
13.0 SPECIAL MECHANICAL PROTECTION
The Contractor shall apply an additional mechanical protection around pipeline in

case where there is a danger of damage to pipeline or pipeline coating.
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These cases may originate due to pipeline laying in rocky areas and other concrete
works regarding pipelines.
Mechanical protection is also used to protect the pipeline coating from accidental
abrasion and from subsequent abrasion during lifetime of the pipeline.
Characteristics
• Mechanical protection shall be a flexible padding designed specially for the

protection of the corrosion coating on pipeline.
• Mechanical protection shall be flexible to shape and cut easily. It shall remain
flexible at lower temperatures and its application shall not be affected by colder
temperature.
• It shall be unaffected by wet or extreme weather conditions.
• Mechanical protection shall provide the padding required for pipe coatings
without the concern of blocking out cathodic protection or it must have zero
dielectric properties.
• It shall absorb impact of uneven backfill material and protect pipe from protruding
rock in trench. Also, it shall minimize abrasion of coating from pipe movement in
ground.
• The protection shall be lightweight and shall be available in appropriate sizes for
optimal match to pipe diameter.
• The protection shall be longer and wider than the set-on weight and any other
concrete works.
• In any case, its thickness shall be at least 10 mm.
• The Contractor shall specify the following properties of the protection along with
the sample, prior to the Company/Engineering Consultant’s approval:
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• Weight
• Tensile strength
• Toughness
• Impact resistance
• Roll width and length
• Elongation
14.0 CROSSINGS
• This section refers to all the details regarding Pipeline crossing roads, highways,
canals, distributaries etc. The details primarily reflect the minimum requirements
to ensure safe crossings of pipeline through the above-mentioned crossings.
Contractor shall use such equipment and procedures that shall not cause damage
to any structure or facility intercepted by or adjacent to the crossing.
• The trench on either side of the tunnel/bore shall be de-watered and the inside of
the tunnel shall be cleaned before the casing pipe (for Cased Crossing) and carrier
pipe are pulled or pushed into place.
• The pipe shall be pulled or pushed into the tunnel/bore in such a manner that the
pipe is centered in the tunnel/bore, the carrier pipe coating is not damaged, and the
rate of travel into the tunnel/bore is uniform.
• Crossing of all underground pipes, cables, etc. shall be Contractor’s responsibility.

The Contractor is responsible for obtaining necessary permission, if required, and
coordination with relevant authorities during construction.
• Carrier pipe, under metal roads, tracks and any water stream shall be installed
with minimum cover of 1.2 m for Track and 2m for the Nala Crossing, as
measured from the top of the pipe to the top of the surface.
• All crossings shall be as per relevant Drawings.
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Contractor’s scope shall include supply and installation of the Plastic Grating. Also,
Contractor shall provide detail engineering design for the Crossing Design which
includes detail design calculation, Design Analysis Reports and Drawings for
Construction and Installation.
15.0 SPECIAL ITEMS
Installation of the following equipment shall be included as a special item in pipeline

construction:
• Scraper Traps
• Fitting
• Insulating Flanges
• CP stations
They shall be installed in accordance with the applicable Drawings.
16.0 APPURTENANCES
Appurtenances include test lead assemblies for cathodic protection of pipeline,
abutment, markers, etc.
The Contractor shall supply the material and install the appurtenances in accordance
with the drawings.
In addition the Contractor shall be required to carryout pipeline protective works in

terrain liable to erosion which include but are not limited to, stone pitching,
abutments, bunds etc.
17.0 FINAL TESTING
The Contractor shall hydrostatically test each completed section of the pipeline as per
the requirements set forth in ANSI B.31.8, latest edition, except the test pressure
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which will be specified by the Company/Engineering Consultant. The Contractor

shall submit the test procedure to the Company/Engineering Consultant for approval
before starting hydrostatic test.
The Contractor shall hydrostatically test each segment according to the wall thickness
and pressure as per API 5LX-52, API/1110 and ANSI B31.8.
Test pressure for heavier wall thickness at crossing shall be the same as that for the
adjoining pipe and should be pre-tested.
All appurtenances, test headers and crossings shall be pre-tested prior to installation.
A minimum of two underground temperature measurement points shall be established

accurate to 0.1oC, two days prior to a test commencing, and read at 12 hour intervals.
In general, the length of each test section shall be specified by the

Company/Engineering Consultant’s Representative. Contractor may recommend
length of sections for company/engineering consultant’s approval.
Valves shall not be subjected to differential pressures greater than the maximum
operating pressure while in closed position. All permanently installed mainline and
bypass valves shall be in the open position during the test.
The test pressures for each section shall be specified by Company/Engineering

Consultant, but will not exceed 98%, nor be less than 90% of the specified minimum
yield strength of the pipe.
Before filling the line with water for hydrostatic test, the line shall be cleaned by
passing cleaning pig.
The line shall be cleaned by running of cleaning pigs, at least one pig with gauge
plate. The cleaning shall be done with water. The gauging pig shall be equipped with
Doc. No. 4985-PA-2022 Page 40 of 49

a metal “gauging flange”. The diameter of the gauging plate shall be 96% of the pipe
ID. The material of gauging flange shall be steel.
Each section shall be brought up to test pressure and stabilized. A calibrated and
certified (within the previous six months) recording pressure gauge, dead weight
tester and thermometers shall be furnished by the Contractor to verify the test. The
unit of pressure measurements shall be Bar or PSI and all pressure measuring
instruments calibrated in the same unit. The Contractor shall record all data required
by any or all Governmental Agencies, Acceptance Authorities and
Company/Engineering Consultant and shall prepare and submit records and reports in
as many copies as may be required to these organizations.
The Contractor shall furnish clean fresh water and all equipment, labor, materials,
services, supervision and supplies required for the hydrostatic test, except any
chemicals required treating the test water. All chemicals shall be provided by the
Contractor and not by the Company/Engineering Consultant. When so required, the
Contractor shall inject treating chemicals at the fill point in such amounts and at such
rates as specified by the Company/Engineering Consultant. All water shall be filtered
through a mechanical filter to remove all solids exceeding 250 microns in diameter.
The test pressure shall be attained and maintained for 24 hours and recorded every
hour by installing a deadweight tester and pressure recording instrument in the section
at both ends isolated for the test. Unexplainable pressure drops or increases during the
test period shall not be acceptable to the Company/Engineering Consultant. A test
shall be extended if necessary until such time that the section is proved leak-tight or
the evidence for a leak is established by comparison of pressure changes with those
anticipated due to underground temperature fluctuations. The Contractor shall be
responsible for providing pig launching and receiving traps and all necessary fittings
and equipment for testing purposes. Test segment shall be filled continuously until
clear water is obtained at the discharge end.
Doc. No. 4985-PA-2022 Page 41 of 49

Leaks, or breaks in the pipeline during the test which are a result of defective
materials furnished by the Company/Engineering Consultant shall be located and
repaired by the Contractor, but cost thereof shall be paid by the Company/Engineering
Consultant as extra cost.
After each section has been tested, it shall be tied into the previously tested section or
sections and the areas of damage cleaned up. Water removal from the completed
system will be done by the Contractor using compressed air as the propelling fluid for
running scrapers or spheres, until such time when no water comes out ahead of the
pigs and pipeline is reasonably clear of all water.
Leaks, or breaks in the pipeline during the test which are a result of defective
materials or workmanship furnished by the Contractor shall be located and repaired
by Contractor at its own cost.
The Contractor shall have the sole responsibility for disposing off the test water at tie-
ins leaks or breaks, and at the dewatering points. Tie-ins shall be done in such a
manner that the convenience and safety of the general public is protected and in a
manner satisfactory to the responsible authorities. Any damage resulting from careless
or improper disposal of water shall be rectified and paid for by the Contractor.
Continuous two way communication, preferably by voice, radio, shall be maintained

between filling pumps, test pumps, scraper traps, recording pressure gauges and all
other significant points along the portion of the line being filled or tested.
Communication equipment shall be made available for use by the Contractor.
The charts from the pressure-recording and temperature reading instruments during
the pressuring and test operations shall be preserved for Company/Engineering
Consultant as official record of tests. The charts shall be properly identified and
signed by the Contractor's Superintendent as being true records of the test involved.
Doc. No. 4985-PA-2022 Page 42 of 49

The chart or charts shall cover the interval of the test from the time that the pressure
exceeds 1 Bar until a successful test has been completed and the pressure has been
reduced below 1 Bar.
All failures shall be numerically and chronologically dated and reported with
pertinent description and data.
The Contractor shall properly clean the pipeline after final tie-in by air pigging. All
the testing and cleaning procedure shall be done to the entire satisfaction of the
After the hydraulic testing is complete, Contractor will run magnetic bi-directional
disc pigs and or any other suitable cleaning pigs through the pipeline until such time
that all construction debris, mud, sand, stones and foreign material is completely
removed from the pipeline.
18.0 PAINTING
All exposed above ground metal surfaces on piping, structure, equipment, or attached
appurtenances shall be painted by the Contractor with equipment and labor supplied
by the Contractor as per the painting specification.
19.0 CONCRETE
All concrete works required for pipeline construction shall be carried out by the
contractor including supply of all material, labor, equipment and machinery. The
work shall be carried out in accordance with the project specification for concrete
works.
20.0 WET AREAS, SWAMPS DITCHES AND AREAS SUBJECT TO FLOODING

The Contractor shall perform all the work necessary to install the pipelines across wet
areas, swamps, ditches and areas subject to flooding.
Doc. No. 4985-PA-2022 Page 43 of 49

21.0 LINE MARKERS AND CATHODIC TEST ASSEMBLIES

Line markers shall be supplied and installed at every 500m, upstream of every road,
track, highway, nala, distributaries, and river crossings in accordance with the
requirements of drawings.
Cathodic Protection Test Assemblies shall be installed as per the relevant alignment
sheets along the buried pipeline sections in accordance with the relevant detail
drawings.
22.0 FINAL CLEAN-UP OF THE CONSTRUCTION RIGHT-OF-WAY AND

PERMANENT JEEPABLE TRACK.
The Contractor shall restore the construction right-of-way as near as practically
possible to its original condition.
All surplus and defective materials supplied by the Company/Engineering Consultant

shall be collected by the Contractor and delivered to the Company/Engineering
Consultant 's specified location.
All surplus and defective material supplied by the Contractor and all trash, refuse, and
spoiled materials shall be collected and disposed off by the Contractor.
All loose rock exposed by the construction operations, which is scattered over the
right-of-way and adjacent property shall be removed and hauled by the Contractor.
The permanent Jeepable track both in shared and non-shared section of RoW shall be
maintained and restored to Jeepable condition. All water courses, depression, etc.
shall be provided with proper crossings using appropriate size RCC flume pipes and
land filling/cutting so as to make the entire RoW Jeepable in one continuous stretch.
Doc. No. 4985-PA-2022 Page 44 of 49

23.0 COMMISSIONING AND START-UP
This part of the specification defines the various responsibilities of the Contractor for
the commissioning of the complete pipeline system and lists the preparatory work to
be performed and the requirements to be met before the pipeline system can be
commissioned.
The operations personnel of the Company/Engineering Consultant shall be involved in

pipeline commissioning within the framework of the specified training program
Contractor’s Responsibilities:
The Contractor shall prepare a commissioning plan for each part of the pipeline
system in consultation with the Company/Engineering Consultant. The Contractor
shall determine the work, services, equipment and personnel required for
commissioning and shall be responsible both for the co-ordination of commissioning
and for liaison with the Company/Engineering Consultant. The Contractor shall
instruct the personnel to be deployed for commissioning about the commissioning
procedures to be used and shall cause such personnel to give an undertaking to
comply with all safety regulations applicable to commissioning.
The Contractor shall provide all personnel and equipment required for the
performance of all work required for commissioning in accordance with the
commissioning plan. The services to be performed by the Contractor for
commissioning shall include without limitation:
• Take an active part in preparing the commissioning plan in accordance with sub-
section 26.2.1 above,
• Supply and provide any equipment, facilities, etc. which may be required for
commissioning, manage and co-ordinate commissioning work and monitor
compliance with safety regulations,
Doc. No. 4985-PA-2022 Page 45 of 49

• Install, test, inspect, calibrate and commission instruments, control system, panels,
supplies in strict accordance with specifications prior to commissioning of the
pipeline system,
• Install any additional lines and facilities which may be required for
commissioning including such lines and facilities which may be required for the
disposal of water or for the treatment of waste products,
• Procure and supply (if not provided by the Company/Engineering Consultant fill
and dispose off methanol and nitrogen, (if required) or any other drying agent
including the provision of any facilities which may be required for the handling
of methanol and nitrogen or any other drying agent and cause suitable safety
precautions to be taken in handling such products,
• Supply transport equipment and mobile lifting equipment with all accessories
required,
• Supply and install pressure indicators and pressure recorders required for the
works hereunder if required,
• Operate mechanical and electrical implements in accordance with the

commissioning plan,
• Provide personnel required for the works hereunder including personnel for the
observation and maintenance of the pipelines and for the recording, evaluation
and documentation of meter reading taken during the works hereunder,
• Provide a standby crew with suitable specialists and equipment to perform any
repairs or additional work which may become necessary during commissioning,
• Prior to the commencement of commissioning works, the Contractor shall:
- Install and level all mechanical equipment cold-aligned, subjected to no-load tests
and load tests (if practical), and make ready for operation. Fresh charges of
Doc. No. 4985-PA-2022 Page 46 of 49

lubricants, coolants and fuels shall have been installed according to

manufacturer's instructions,
- Ensure that all certificates required for commissioning are available,
- Check which environmental and other regulations must be complied with during
commissioning and obtain any necessary approvals from authorities,
- Select and name persons to contact for work on the pipelines and work on the
stations,
- Ensure ease of access to all plans, equipment, etc.,
- Ensure that adequate means of communication (telephone, radio) are available for
the commissioning work,
- Calculate, obtain and remove the methanol or nitrogen required as a safety batch
in front of product medium, separated by scrapers in pipelines,
- Train personnel for the commissioning operation, patrol the route and check the
effectiveness of radio communications,
- Provide all fire fighting and other safety equipment required for the
commissioning operation,
- Provide all explosion-proof equipment required for the commissioning operation.
- Supply all protective clothing which may be required for the works hereunder,
- Make a final clean-up after work is completed and accepted by the

Company/Engineering Consultant. All remaining scrap, debris, waste, surplus
materials, tools and equipment shall be removed from the job site, except for the
equipment required for maintenance in the guarantee period, in accordance with
the Contract. All surplus materials shall be returned to the Company/Engineering
Consultant 's warehouse,
Doc. No. 4985-PA-2022 Page 47 of 49

- Bear all costs of the works hereunder including the costs of the supply,
transportation, connection and erection of all equipment required therefore,
- Keep complete records of the works hereunder.
Before any pipeline section is commissioned, the following conditions shall be met
and the Contractor shall carry out a review to ensure that said conditions have been
met .A test of functions shall be made to ensure that all flow paths which may be set
on the pipeline including station inlet and outlet lines during commissioning can
effectively be set,
• Any installation, commissioning and operation instructions issued by the supplier

or manufacturer of any equipment or facilities installed in or in the pipeline
section shall be available on site and shall be complied with,
• Check shall be made to ensure that all equipment which must be installed in a
specific direction with reference to the direction of flow has been installed in the
correct direction,
• The electrical control installation and instrumentation shall have been tested and
accepted in accordance with specifications. Proper rotation of motors, polarity,
and circuit continuity and insulation resistance checks shall have been completed.
Functional checks of electrical and control circuits shall have been completed,
• Explosion-hazard areas shall be determined and marked with appropriate signs.

The Contractor shall ensure that all personnel comply with safety precautions laid
down for explosion-hazard areas including areas which are designated as
explosion-hazard areas temporarily (e.g. during methanol or any other drying
agent filling and disposal),
• An emergency plan shall be prepared detailing all immediate actions to be taken

in the case of a fire or an environmental pollution incident,
Doc. No. 4985-PA-2022 Page 48 of 49

• Functional checks of alarm and shut-down systems shall be completed and

accepted by Company/Engineering Consultant prior to commissioning.
General Start-up Conditions:
• Contractor shall provide a complete operating team, including necessary vendor

representatives capable of starting up and operating the plant under the
supervision of Company/Engineering Consultant's operating personnel. It is
required that Company/Engineering Consultant operations personnel grant prior
approval to Contractor before any operating decisions are implemented. It will be
Contractor's responsibility to not only prove the operation of the new facility, but
also to train Company/Engineering Consultant operating and maintenance
personnel in the proper procedures for safe, reliable facilities operation.
• Instrumentation shall have operated correctly in the manner intended by the

project specifications. It shall have maintained the plant operating at the required
set points, allowed safe start-up, running and shut-down. It shall have monitored
the plant in such a manner that it provided the plant operators with a clear
understanding of the plants condition at all times. Emergency shut- down systems
shall be tested for proper operation.
Doc. No. 4985-PA-2022 Page 49 of 49

Job No. 14 – 4985
Spec. No. 4985-PA-2023
Sheet 1 of 3 Rev. 0
SCOPE & SPECIFICATION VALVE INSTALLATION
Prepared by: IN
Checked by: MMM
Approved by: TH
Revised by: -

TABLE OF CONTENTS
1.0 VALVE INSTALLATION ...................................................................................... 3

Specification for Valve Installation
1.0 VALVE INSTALLATION
1) The valves shall be kept closed at all times before installation for protection purpose
of the valve seats.
2) During welding operations of butt-welded end valves, the valves shall be opened and
their seats properly protected.
3) Valves flanges or screwed connections shall be protected by proper means before

erection.
4) During installation undue stresses shall be avoided by proper alignment of piping

section, so that the free moving of gate or ball between the seats will be preserved.
Spec. No. 4985-PA-2023 Page 3 of 3

Job No. 14 – 4985
Spec. No. 4985-PA-2024
Sheet 1 of 8 Rev. 0
SPECIFICATION FOR APPLICATION OF

UNDERGROUND PIPE & FITTINGS
ANTI-CORROSION FIELD WRAPPING
Client: OIL & GAS DEVELOPMENT COMPANY
Prepared by: NJ
Checked by: MK
Approved by: FS
Revised by: -

Specification for Application of Underground Pipe and
Fittings Anti Corrosive Field Wrapping
TABLE OF CONTENTS
SECTION DESCRIPTION SHEET

NO. NO.
1.0 SCOPE ............................................................................................3
2.0 REFERENCE CODES AND STANDARDS ...............................4
3.0 APPLICATION REQUIREMENTS............................................5
4.0 INSPECTION .................................................................................8
Spec. No. 4985-PA-2024

Rev. 0 Sheet 2 of 8
1.0 SCOPE
This Specification contains the general requirements applicable to the application and
testing of exterior anti-corrosion wrapping, in field, to the fittings, bends, joints,
flanges and any un-coated pipe lengths of underground piping for the UCH-II
Development Project.
Spec. No. 4985-PA-2024

Rev. 0 Sheet 3 of 8
2.0 REFERENCE CODES AND STANDARDS
This specification should be read in conjunction with the following specifications:
4985-PA-2000 Specification for Piping Fabrication and Installation
ISO 8501 Pictorial Cleanliness Standard
In case of deviations from this Specification or any referenced specification the

contractor shall bring the matter to the Company's attention for resolution and
approval in writing.
Spec. No. 4985-PA-2024

Rev. 0 Sheet 4 of 8
3.0 APPLICATION REQUIREMENTS
3.1 General Application Requirements

The responsibility for dry storage and handling of coating and wrapping materials for
protective coating shall lie with the contractor. Material which becomes wet and
unusable shall be replaced by the contractor at no expense to the Company.
The completed coating shall be solid, free of wrinkles, buckles, pockets and tears and
thoroughly bonded to the pipe throughout.
3.2 Specific Application Requirements
The Densolen S-40 and Denso Mastic system in conjunction with the Densolen HT
primer, or an equivalent system approved by the Company may be used.
3.2.1 Surface Preparation
The Densolen coatings specified require the removal of all loose deleterious surface
materials and surface grease in accordance with Class St 1, I.S.O. 8501. This can
normally be achieved by mechanical wire brushing followed by a solvent wash.
3.2.2 Primer Application
The Densolen Primer HT shall be used in conjunction with both the Densolen S-40
Tape as well as the Denso Butyl Mastic Strip. Application shall be made by brush, or
roller to a dry film thickness of 60 microns to 10 microns. Primer shall be allowed to
tack dry prior to application of the S-40 tape or Butyl Mastic.
3.2.3 Welded Joint-Tape Application
The weld and surface of the pipe shall be cleaned as specified in Section 3.2.1, to
150mm each side of the weld, where the edge of the shop coating will be encountered.
The surface of the shop coating shall then be cleaned back a further 100mm from the
edge of the coating, making a total of 500mm along the pipe to which the field
wrapping shall be applied. The edges of the existing shop coating shall be feather
trimmed so as to make a smooth transition from the shop coating to the pipe.
Spec. No. 4985-PA-2024

Rev. 0 Sheet 5 of 8
A single coat of the Densolen HT Primer shall be applied as specified in Section

3.2.2.
The Densolen S-40 Tape shall be applied in a spiral fashion incorporating a minimum
of 55% overlap to ensure a double tape thickness at all times. End laps occurring at
the end of individual rolls shall be a minimum of 1/3 of a turn.
The Densolen S-40 Tape system should be applied by use of a Densomat 1 wrapping
machine which shall ensure that the coating is applied free of creases and air bubbles
and has sufficient tension to enable full amalgamation between the butyl layers.
3.2.4 Fittings and Appurtenances - Mastic Application
The surface of the pipe shall be cleaned, as described in Section 3.2.1, to 150mm from
the weld or appurtenance. The existing coating shall be feather trimmed end cleaned
a further 100mm back from the edge of the shop coating, as described in
3.2.3. Primer shall be applied as specified in Section 3.2.2.
The Denso Butyl Mastic Strip is a mouldable material, supplied :s: 95mm wide x
3mm thick x 1 Om long rolls.
The mastic shall be wrapped or placed in strip form allowing a 25mm overlap onto
itself to ensure no missed areas, as well as a minimum 100mm overlap onto the
neighboring coating system. The mastic shall be applied in a method to provide
100% contact with the substrate requiring protection ensuring that all overlap areas
are pressed firmly into place.
3.2.5 Field Repairs
Any holes, defects, discontinuities, pinholes, torn, abraded or mutilated spots found at
site in the original coating shall be repaired. Refer to Section 4 for the Inspection
Procedure.
If the damaged area is large, the original coating shall be removed back 50 to 100mm.
The pipe shall then be cleaned to the coating limits in accordance with 3.2.1. The
remaining coating shall then be feather trimmed and cleaned a further 100mm back
Spec. No. 4985-PA-2024

Rev. 0 Sheet 6 of 8
from the related circumference. The Densolen S-40 Tape and Primer HT shall be
applied as described in Section 3.2.3.
Spec. No. 4985-PA-2024

Rev. 0 Sheet 7 of 8
4.0 INSPECTION
Taping and mastic coating over the entire length of each field joint, field repair,
underground appurtenances and fittings shall be inspected by means of a Holiday
Detector (electrical inspection device), which shall be approved by the C All holes or
defective coating discovered shall be repaired and tested again.
The calibration of the Holiday Detector shall be carried out regularly to the
satisfaction of the Contractor. The Detector shall be a Contractor approved 8 to 10
kilovolt DC Holiday Detector. The Holiday Detector Probe shall be a brass bristle
brush.
All phases of the work covered by this Specification shall be subject to the approval
of an Inspector to be appointed by the Company.
The Company's Inspector shall be free to visit the site when and where ever any work
to which this Specification applies is in progress.
Any faults found in the application of the wrapping shall be rectified by the contractor
at his expense.
Spec. No. 4985-PA-2024

Rev. 0 Sheet 8 of 8
Job No. 14 – 4985
Spec. No. 4985-PA-2026
Page 1 of 4 Rev. 0
SPECIFICATION FOR FIELD CALLIBRATION AND

PRESSURE SAFETY VALVE
Prepared by: FAS

Checked by: AJ
Approved by: FS
Revised by: -

Specification for field calibration and pressure safety valve
TABLE OF CONTENTS
1.0 SCOPE .......................................................................................................................... 3

1.0 SCOPE
This document covers the procedure for the field-testing and calibration of pressure
safety valves and thermal relief valves. These valves shall be tested in the field or in
the contractor workshop prior to installation on their permanent places.
All tests on Safety Relief Valves shall be recorded on the test sheet and the signature
of witness shall be obtained.
The Relief Valves shall be tested in two stages:
1) Popping & Reseating

2) Seat Leakage Test
1.1 Popping & Reseating
a) Before popping the Relief Valve the outlet flange cover shall be removed.
b) The Inlet Nozzle shall be wiped clean prior to testing.
c) The Relief Valve “Cold Set Pressure” shall be ascertained and entered on the
Test Record Sheet. This pressure should be found on the valve data plate or on
the Valve Data Sheet.
d) The Test Pressure shall be increased slowly until the Relief Valve is observed to
pop and the pressure (as indicated on the test gauge) shall be noted on the test
record sheet. If the difference between the measured popping pressure and the
cold set pressure is outside acceptable tolerances, the valve setting shall be
adjusted in accordance with the manufactures instructions.
e) The test pressure shall then be lowered and the reseating pressure noted and
checked that it agrees with the manufactures instructions.

1.2 Seat Leakage Test

This test procedure is summarized as follows:
a) Immediately after the popping test the test pressure shall be lowered and held at
10% below the set pressure (or 0.35 bar g minimum).
b) The body cavity shall then thoroughly dried with instrument air.
c) The valve outlet shall be observed for 10 minutes for leakage.
d) Failure of leakage test shall be corrected by dismantling the valve and lapping
the disc and seat in accordance with the manufacturers instructions. Then
retesting as per Section – 1.
e) After testing the valve shall be identified by a suitable colored sticker.

Job No. 14 – 4985
Spec. No. 4985-PA-2027

Page 1 of 8 Rev. 0
SPECIFICATION FOR CHEMICAL CLEANING
Prepared by: FAS

Checked by: AJ
Approved by: FS
Revised by: -

R Description of Revision Date Revised Page
Nos.
Specification for Chemical Cleaning
TABLE OF CONTENTS
1.0 SCOPE .....................................................................................................3
2.0 PURPOSE ................................................................................................4
3.0 RESPONSIBILITY OF THE PC CONTRACTOR .................................5
4.0 GENERAL CONDITIONS FOR CHEMICAL CLEANING .................6

1.0 SCOPE
This specification covers the requirements for chemical cleaning of equipment &
piping for UCH II Development Project.
This specification is general and gets forth the basic guidelines and conditions for
chemical cleaning; however, the PC Contractor has the responsibility of developing a
detailed procedure and of supervising and monitoring its use.

2.0 PURPOSE
• Certain pieces of equipment & pipes must be chemically cleaned to remove mill
scale, dirt, greases used as rust preventatives.
• Chemical cleaning will generally be done after completion of unit construction.

If cleaning is done prior to completion of construction, the cleaned equipment
must be protected from atmospheric exposure and entry of any outside debris or
dirt.
• The PC Contractor shall be responsible for the selection of the chemicals, which
selecting the chemicals, the Contractor shall consider material of the piping and
the equipment to the cleaned. Such chemicals shall not be used which has
negative effects on the piping and equipment material to be cleaned. The PC
Contractor shall be responsible to demonstrate the suitability of chemical to be
used by appropriate tests.
• If hydrocarbon feed is not to be charged to the unit within a few hours after the
equipment & pipes is cleaned, the cleaned equipment & piping should be filled
with nitrogen and blinded off. If startup is to be delayed longer than two weeks,
the nitrogen purge may be continued, provided the system is monitored daily to
maintain a positive nitrogen pressure. As an alternate, the system may be filled
with water containing a passivating material, which shall be drained before
startup. CAUTION: The effects of the passivating solution on the equipment
and specific requirements of the process must be carefully considered and the
selection of such chemicals shall be done after getting approval from the

3.0 RESPONSIBILITY OF THE PC CONTRACTOR
3.1 The PC Contractor shall accept the responsibility of proposing and carrying out an
acceptable and proven procedure for the entire cleaning operation. This shall cover
all applicable steps in detail, such as flushing, degreasing, chemical cleaning,
neutralizing, passivating, dean water flushing, draining, and safety. A copy of the
procedure shall be submitted to OGDCL/Engineering Consultant.
3.2 The PC Contractor shall use inhibitor, detergent, emulsifier, or other addition agents
in accordance with accepted practice and experience, and to suit the equipment layout
and metallurgy, of the unit.
3.3 The PC Contractor shall be responsible for the arrangement of equipment considering
pumps, chemical storage tanks, temporary piping connection blinds etc necessary for
the job completion. The PC Contractor shall inform the OGDCL/Engineering
Consultant about chemical or trade names and required quantities of all chemical
cleaning, degreasing, neutralizing, inhibiting, and passivating agents (also the
nitrogen to be used for agitation and blanketing) in time for these materials to be
made: available at the job site before the cleaning operation is to start.
3.4 After the completion of chemical cleaning the PC Contractor shall be responsible for
the safe disposal of chemical (acids, degreaser and neutralizer etc) and drying of
equipment and piping to the entire satisfaction of OGDCL/Engineering Consultant
given at site.

4.0 GENERAL CONDITIONS FOR CHEMICAL CLEANING
• Control valves shall be replaced by a spool assembly during chemical

cleaning.
• All instruments shall be protected from the chemical cleaning solution.
1. Orifice plates shall not be in place in the lines.

2. Spool assemblies shall be substituted for all inline turbine meters.
3. The valve in the pressure taps adjacent to the line or vessel of all
instruments shall be closed and the drain valve on the instrument opened.
4. Externally mounted liquid level instruments, such as displacement type
level transmitters and gage glasses, shall have block valves adjacent to
the vessel closed and drain valves opened. Internal displacement type
level instruments shall not be in place and the nozzle through which they
are inserted shall be blinded off.
5. Thermo wells shall not be in place and their connections shall be blinded
off.
6. Piping strainer screens shall not be in place.
• All relief valves shall be removed and nozzles blanked off.
• Temporary valves, 3/4" minimum size, shall be installed at the high points of
the systems to be circulated.
• Re-boilers or exchangers that are part of the process unit shall not be used as
a means of heating any of the chemical solutions. All heating is to be
external to the systems being cleaned, and by equipment furnished by the
chemical cleaning PC Contractor. Steam should never be introduced into any
part of the system. Overheating must be avoided.
• Process pumps shall not be used to circulate the chemical cleaning solution.
All process reciprocating and rotating equipment and their ancillary systems
shall be disconnected and blinded off, and jumper lines or spools furnished
as required to complete piping circuits. All transfer and circulating pumps for

handling chemical cleaning, degreasing, neutralizing, and passivating

solutions are to be furnished by the PC Contractor and should operate from a
dependable power source. In order to reduce the time required for filling and
circulation, the pumping rates shall be the maximum consistent with good
practice and proper protection of the base metals.
• The chemical cleaning solution must not be allowed to stand undisturbed in

any part of the equipment at any time. The filling, circulating, draining,
flushing, and neutralizing operations are to be continuous for each of the
systems to be treated.

Job No. 14-4985
Doc. No. 4985-PA-2028
Page 1 of 9 Rev. 0
SPECIFICATION FOR CORROSION PROBES &

COUPONS
Prepared by: FAS

Checked by: MK
Approved by: FS
Revised by: -

Specification for Corrosion Probes & Coupons
UCH II Development Project
TABLE OF CONTENTS
1.0 SCOPE .......................................................................................................................... 3
2.0 HAZARDOUS AREA REQUIREMENTS ................................................................ 4
3.0 TROPICALIZATION ................................................................................................. 5
4.0 PAINTING AND PREPARATION FOR SHIPMENT ............................................ 6
5.0 SPARE PARTS ............................................................................................................ 7
6.0 DEVIATIONS/EXCEPTION ..................................................................................... 8
7.0 TESTING ...................................................................................................................... 9
Spec. No 4985-PA-2028 Page 2 of 9

1.0 SCOPE
This specification covers the minimum requirements but not necessary limited to the
design, testing, site testing and commissioning of the Corrosion Probes and Coupons
to be installed at UCH II Development Project.
The system will be complete of corrosion coupons and probes as specified in the
attached data sheets and all auxiliary equipments for the correct working of the
system.
The system will be designed by the PC Contractor to operate at the specified line
conditions and fluids composition indicated in the attached data sheets.
The PC Contractor shall calculate the length of corrometers in accordance with

specified data.
The PC Contractor shall select and specify the system only from renowned and
reputed manufacturers in the corrosion protection industry.
All material, labor, etc. shall be provided by the PC Contractor at his own cost and
responsibility, which shall be considered included in the rates quoted by the PC
Contractor.
The PC Contactor shall be responsible for testing and commissioning of the items in
accordance with the requirements of this specification.

2.0 HAZARDOUS AREA REQUIREMENTS
• Electrical Classification Exia II CTS/T4
• Area Classification Zone -2 II BT3

3.0 TROPICALIZATION
All electrical components shall be tropicalized by means of hermetically sealed units,

protective coating on circuit boards, gold plated edge connectors etc.

4.0 PAINTING AND PREPARATION FOR SHIPMENT
After test and inspection, all corrosion probe non-mechanical exterior surface shall be
prepared and painted in accordance with the Project Painting Spec. 4985-GS-9523.
Any approval of an alternative paint finish does not reduce the responsibility of the
PC Contractor to satisfy the quality requirements of the Project Painting specification.

5.0 SPARE PARTS
Spare parts required for commissioning/startup and two years operation shall be
included.

6.0 DEVIATIONS/EXCEPTION
Equipment provided in accordance with this specification shall have to be protected,

manufactured, inspected, tested and warranted in full accordance with requirements
defined in this specification and attached documents.
Any deviation from what above required shall have to be submitted from PC
Contractor to OGDCL for approval.

7.0 TESTING
The PC Contractor shall propose necessary test procedures for review and approval by
OGDCL/Engineering Consultant, prior to conducting any test. The procedure shall
fully detail all the testing that will be carried out by the PC Contractor to demonstrate
to the satisfaction of OGDCL that the equipment supplied functions in accordance
with the requirements specifications. The PC Contractor shall provide all equipment,
test material, including any required to meet the codes and standards specified.
OGDCL/Engineering Consultant shall witness all testing.
The results of tests of each instrument shall be recorded in the form of an inspection
dossier, signed copies of which shall be submitted to OGDCL.

Job No. 14 – 4985
Doc. No. 4985‐A‐1000
Page 1 of 7 Rev. 0

SITE, ENVIRONMENT & UTILITY DESIGN DATA

Project: UCH‐II Development Project


Prepared by: MAM
Checked by: FHR
Approved by: FS
Revised by: ‐

0 ISSUED FOR BIDDING October 5, 2011
UCH II DEVELOPMENT PROJECT
Site, Environment & Utility Design Data

TABLE OF CONTENTS

1 Introduction ................................................................................................................................................ 3
2 Environmental Conditions............................................................................................................................ 4
2.1 AMBIENT PRESSURE DATA ............................................................................................................................... 4
2.2 AMBIENT TEMPERATURE DATA.........................................................................................................................4
2.3 RAINFALL DATA ............................................................................................................................................4
2.4 WIND DATA .................................................................................................................................................4
2.5 HUMIDITY ....................................................................................................................................................4
2.6 ICE/FROST DATA ...........................................................................................................................................4
2.7 ELEVATION...................................................................................................................................................4
2.8 EARTHQUAKE DESIGN DATA ............................................................................................................................4
3 Utility information....................................................................................................................................... 5
3.1 HOT OIL ......................................................................................................................................................5
3.2 FUEL GAS ....................................................................................................................................................5
3.3 INSTRUMENT AIR...........................................................................................................................................5
3.4 PLANT AIR ...................................................................................................................................................5
3.5 NITROGEN ...................................................................................................................................................6
3.6 ELECTRICAL POWER .......................................................................................................................................6
3.7 WATER ANALYSIS ..........................................................................................................................................6
4 National Environmental Quality Standards (NEQS):...................................................................................... 7

Doc. No. 4985‐A‐1000 Sheet 2 of 7
Rev. 0
1 Introduction

The UCH gas field owned by Oil & Gas Development Company Limited (OGDCL)
is located in Tribal Dera Bugti Agency District of Baluchistan Province. OGDCL
has been operating the UCH gas field and supplying gas to UCH Power Plant,
located at 50 Kms distance from UCH gas field. The UCH Power Plant has
586MW per day power production capacity.
OGDCL intends to develop the UCH field by installing UCH‐II Plant comprising
surface facilities, flow lines, commingling system and gas purification plant. The
gas purification plant unit will be capable of to processing on an average 300
MMSCFD raw gas stream.

OGDCL has engaged ENAR Petrotech Services (Pvt.) Limited (ENAR) for the
Basic & detailed Engineering of the UCH‐II Gas Processing Plant.

This document covers the Site, Environment & Utility Design Data for the UCH‐
II Development Project.

Doc. No. 4985‐A‐1000 Sheet 3 of 7
Rev. 0
2 Environmental Conditions

2.1 Ambient Pressure Data

Maximum Monthly Normal Pressure 14.689 psia
Minimum Monthly Normal Pressure 14.337 psia

2.2 Ambient Temperature Data

Description January June
Mean Daily Maximum (°F) 73 113
Mean Monthly Maximum (°F) 79 121
Record Maximum (°F) 83 131
Mean Daily Minimum (°F) 44 85
Mean Monthly Minimum (°F) 38 79
Record Minimum (°F) 30 72
Maximum Wet bulb Temperature (°F) 83

2.3 Rainfall Data

Maximum Daily Rainfall (24 hours) 124.5mm
Highest Average Monthly Rainfall 59mm

2.4 Wind Data

Maximum Velocity 100mph
Design Velocity 120mph

2.5 Humidity

Relative Humidity (Monthly Normal) 18% to 76%

2.6 Ice/Frost Data

Not applicable.

2.7 Elevation

The UCH Field has a mean elevation of 250 feet MSL.

2.8 Earthquake Design Data

The region in which the UCH Field is located does not experience earthquakes.
However, the recommended earthquake factor for structural design is g/10.
Doc. No. 4985‐A‐1000 Sheet 4 of 7
Rev. 0
3 Utility information

3.1 Hot Oil

Properties of Hot Oil Inlet Outlet

Temperature (ºF) 250 300
Heat capacity “Cp” (BTU/lb °F) 0.4313 0.457
Viscosity “μ” (Lbs./ft. hr) 4.991 1.477
Thermal Conductivity “K” (BTU/hr. °F) 0.095 .0918
Specific Gravity 0.9347 0.915
* Hot oil of similar properties shall be utilized; to be finalized during detailed
engineering phase.

3.2 Fuel Gas
Fuel gas conditions and composition are presented in Table 1 below.

Table 1: Fuel Gas Composition
HP fuel Gas LP Fuel Gas
Components Raw Gas **Raw Gas
Sales Gas
Winter Summer Winter Summer
Conditions
Pressure (Psig) 400 (max) 100 (max)
Temperature (°F) 75‐110 60‐100
Composition (Mole%)
H2S (ppmv) 214 ‐ 750 214 ‐ 750 214 ‐ 750 214 ‐ 750 5
CO2 22.80 22.73 22.80 22.73 34.17
N2 8.44 8.41 8.44 8.41 22.39
C1 65.56 65.32 65.57 65.32 41.50
C2 1.98 1.97 1.98 1.97 1.066
C3 0.66 0.66 0.66 0.66 0.400
iC4 0.17 0.17 0.17 0.17 0.102
nC4 0.17 0.17 0.16 0.17 0.118
iC5 0.09 0.10 0.09 0.10 0.063
nC5 0.05 0.06 0.05 0.06 0.040
C6+ 0.02 0.13 0.04 0.13 0.14
H2O 0.01 0.26 0.01 0.26 0.009
* Fuel gas composition based on available composition of single well of Eastern Lobe (i.e. UCH‐
28); to be updated during detailed engineering phase.
** Only available during plant startup operation.

3.3 Instrument Air
Instrument Air Normal Operating Pressure: 120 psig
Dew point: ‐20 ºF

3.4 Plant Air
Plant Air Normal Operating Pressure 120 psig
Doc. No. 4985‐A‐1000 Sheet 5 of 7
Rev. 0
3.5 Nitrogen
Normal Header Operating Pressure 88 psig

3.6 Electrical Power
Power Generation / Main Distribution 6.6KV, 3 Phase, 50Hz
Power for Motor Control 400 V, 3 Phase, 50Hz
6.6KV, 3 Phase, 50Hz
Lighting 230 V
Instrumentation 24 V DC

3.7 Water Analysis
Table 2: Water Analysis
Demin
Specifications Raw Water Potable Water*
Water
Taste ‐ Unobjectionable ‐
Appearance ‐ Clear & Odorless ‐
pH @ 25 °C 8.73 6.5‐8.5 6.5‐7.5
Conductivity µs/cm 265 < 10 < 10
Total Hardness ppm 54 < 500 Nil
Calcium Hardness ppm 33 ‐ Nil
Magnesium Hardness ppm 21 ‐ ‐
Turbidity NTU 02 < 5 ‐
Total Suspended Solids ppm 02 < 5 ‐
Total Dissolved Solids (TDS) ppm 127 < 500 5.0
Chlorides (Cl) ppm 24 < 250 Nil
Sulphate (SO4) ppm 38 < 250 ‐
Iron (Fe) ppm 0.006 < 0.3 Nil
Total Silica ppm 0.5 ‐ ‐
Alkalinity ppm 80 < 500 Nil
* As per WHO standards

Doc. No. 4985‐A‐1000 Sheet 6 of 7
Rev. 0
4 National Environmental Quality Standards (NEQS):

National environmental quality standards (NEQS) are attached as Annexure‐I

Doc. No. 4985‐A‐1000 Sheet 7 of 7
Rev. 0
NATIONAL ENVIRONMENTAL
QUALITY STANDARDS
ENAR Petrotech Services (Pvt.) Limited

REGISTERED No. M-302
L. 7646
The Gazette of Pakistan
EXTRAORDINARY
PUBLISHED BY AUTHORITY
ISLAMABD, THURSDAY, AUGUST 10, 2000
PART-II
Statutory Notification (S.R.O)
GOVERNMENT OF PAKISTAN
MINISTRY OF ENVIRONMENT, LOCAL GOVERNMENT AND

RURAL DEVELOPMENT
NOTIFICATION
Islamabad, the 8th August 2000
S.R.O. 549 (I)/2000.___ In exercise of the powers conferred under clause (c) of
sub-section (1) of section of 6 of the Pakistan environmental Protection Act. 1997 (XXXIV of
1997), the Pakistan Environmental Protection Agency, with the prior approval of the Pakistan
Environmental Protection Council, is pleased to direct that the following further amendments
shall be made in its Notification No. S.R.O. 742(I)/93, dated the 24th August, 1993, namely: ___
In the aforesaid Notification, in paragraph 2._____
(1289)
[4138(2000)/Ex.GAZ]
Price : Rs. 5.00

1290 THE GAZETTE OF PAKISTAN, EXTRA, AUGUST 10, 2000 [PART-II]
(1) for Annex, I the following shall be substituted, namely:_____
Annex-I
“NATIONAL ENVIRONMENTAL QUALITY STANDARDS FOR MUNICIPAL AND

LIQUID INDUSTRIAL EFFLUENTS (mg/I,
UNLESS OTHERWISE DEFINED)
S. No. Parameter Revised

Standards
Existing Into Into Into
Standards Inland Sewage Sea ( )
Waters Treatment (5)
1 2 3 4 5 6
1. Temperature or 400C δ3oC δ3oC δ3oC

Temperature Increase *
2. pH value (H+) . 6-10 6-9 6-9 6-9
3. Biochemical Oxygen
Demand (BOD)5 at 200C (1) 80 80 250 80**
4. Chemical Oxygen Demand
(COD) (1) .. . 150 150 400 400
5. Total Suspended Solids
(TSS) .. . 150 200 400 200
6. Total Dissolved Solids 3500 3500 3500 3500
(TDS)
7. Oil and Grease 10 10 10 10
8. Phenolic compounds (as
phenol) 0.1 0.1 0.3 0.3
9. Chloride (as C1- ) 1000 1000 1000 SC***
10. Fluoride (as F- ) 20 10 10 10

11. Cyanide (as CN-) total .. 2 1.0 1.0 1.0
12. An-ionic detergents (as 20 20 20 20
MBAS) (2)
13. Sulphate (SO42-) 600 600 1000 SC***
14. Sulphide (S2-) 1.0 1.0 1.0 1.0
15. Ammonia (NH3) 40 40 40 40
16. Pesticides (3) 0.15 0.15 0.15 0.15
PART-II] THE GAZETTE OF PAKISTAN, EXTRA, AUGUST 10, 2000 1291
1 2 3 4 5 6
17. Cadmium (4) .. . 0.1 0.1 0.1 0.1

18. Chromium (trivalent 1.0 1.0 1.0 1.0
and hexavalent (4).. .
19. Cooper (4) .. . 1.0 1.0 1.0 1.0
20. Lead (4) .. . 0.5 0.5 0.5 0.5
21. Mercury (4) .. . 0.01 0.01 0.01 0.01
22. Selenium (4) 0.5 0.5 0.5 0.5
23. Nickel (4) .. . 1.0 1.0 1.0 1.0
24. Silver (4) 1.0 1.0 1.0 1.0
25. Total toxic metals .. . 2.0 2.0 2.0 2.0
26. Zinc .. . 5.0 5.0 5.0 5.0
27. Arsenic (4) .. . 1.0 1.0 1.0 1.0
28. Barium (4) .. . 1.5 1.5 1.5 1.5
29. Iron .. . 2.0 8.0 8.0 8.0
30. Manganese .. . 1.5 1.5 1.5 1.5
31. Boron (4) .. . 6.0 6.0 6.0 6.0
32. Chlorine .. . 1.0 1.0 1.0 1.0
Explanations:
1. Assuming minimum dilution 1:10 on discharge, lower ratio would attract

progressively stringent standards to be determined by the Federal Environmental
Protection Agency. By 1:10 dilution means, for example that for each one cubic
meter of treated effluent, the recipient water body should have 10 cubic meter of
water for dilution of this effluent.
2. Methylene Blue Active Substances; assuming surfactant as biodegradable.
3. Pesticides include herbicides, fungicides, and insecticides.
4. Subject to total toxic metals discharge should not exceed level given at S. N. 25.
5. Applicable only when and where sewage treatment is operational and BOD5=80mg/I
is achieved by the sewage treatment system.
6. Provided discharge is not at shore and not within 10 miles of mangrove or other
important estuaries.
* The effluent should not result in temperature increase of more than 30C at the
edge of the zone where initial mixing and dilution take place in the receiving
body. In case zone is not defined, use 100 meters from the point of discharge.
** The value for industry is 200 mg/I
Discharge concentration at or below sea concentration (SC).
Note:______ 1. Dilution of liquid effluents to bring them to the NEQS limiting values is
not permissible through fresh water mixing with the effluent before
discharging into the environment.
2. The concentration of pollutants in water being used will be substracted

from the effluent for calculating the NEQS limits” and
(2) for Annex-II the following shall be substituted, namely:____
Annex-II
“NATIONAL ENVIRONMENTAL QUALITY STANDARDS FOR

INDUSTRIAL GASEOUS EMISSION (mg/Nm3, UNLESS
OTHERWISE DEFINED).”
S. No. Parameter Source of Emission Existing Revised

Standards Standards
1 2 3 4 5
1. Smoke Smoke opacity not to 40% or 2 40% or 2
exceed Ringlemann Scale Ringlemann Scale
or equivalent
smoke number
2. Particulate malter (a) Boilers and
Furnaces
(1) (i) Oil fired 300 300

(ii) Coal fired 500 500
(iii) Cement Kilns 200 300
(b) Grinding, crushing,

Clinker coolers and
Related processes,
Metallurgical 500 500
Processes,
converter, blast
furnaces and
cupolas.
3. Hydrogen Any 400 400

Chloride
1 2 3 4 5
4. Chlorine Any 150 150

5. Hydrogen Fluoride Any 150 150
6. Hydrogen Sulphide Any 10 10
7. Sulphur Oxides (2) (3) Sulfuric
acid/Sulphonic
acid plants
Other Plants
except power 400 1700
Plants operating
on oil and coal
8. Carbon Monoxide Any 800 800
9. Lead Any 50 50
10. Mercury Any 10 10
11. Cadmium Any 20 20
12. Arsenic Any 20 20
13. Copper Any 50 50
14. Antimony Any 20 20
15. Zinc Any 200 200
16. Oxides of Nitrogen Nitric acid
manufacturing 400 3000
unit.
(3) Other plants

except power
plants operating
on oil or coal:
Gas fired 400 400

Oil fired - 600
Coal fired - 1200
Explanations:-
1. Based on the assumption that the size of the particulate is 10 micron

or more.
2. Based on 1 percent Sulphur content in fuel oil. Higher content of

Sulphur will case standards to be pro-rated.
3. In respect of emissions of Sulphur dioxide and Nitrogen oxides, the

power plants operating on oil and coal as fuel shall in addition to
National Environmental Quality Standards (NEQS) specified above,
comply with the following standards:-
1294 THE GAZETTE OF PAKISTAN, EXTRA, AUGUST 10, 2000 PART-II]
A. Sulphur Dioxide
Sulphur Dioxide Background levels Micro-gram per cubic meter (ug/m3) Standards.
Background Air Annual Max. Criterion I Criterion II

Quality (SO2 Average 24-hours Max. SO2 Max. Allowable
Basis) Interval Emission ground level
(Tons per Day increment to
Per Plant) ambient (ug/m3)
(One year Average)
Unpolluted <50 <200 500 50

Moderately
Polluted*
Low 50 200 500 50
High 100 400 100 10
Very Polluted** >100 >400 100 10
* For intermediate values between 50 and 100 ug/m3 linear interpolations should be used. **
No projects with Sulphur dioxide emissions will be recommended.
B. Nitrogen Oxide
Ambient air concentrations of Nitrogen oxides, expressed as NOx should not be exceed the
following:-
Annual Arithmetic Mean 100ug/m3

(0.05 ppm)
Emission level for stationary source discharge before missing with the atmosphere,
should be maintained as follows:-
For fuel fired steam generators as Nanogram (100-gram) per joule of heat input:
Liquid fossil fuel 130

Solid fossil fuel .. 300
Lignite fossil fuel 260
Note:- Dilution of gaseous emissions to bring them to the NEQS limiting value is not
permissible through excess air mixing blowing before emitting into the
environment.
[File No. 14(3)/98-TO-PEPC.]
HAFIZ ABDULAH AWAN

DEPUTY SECRETARY (ADMN)
PRINTED BY THE MANAGER, PRINTING CORPORATION OF PAKISTAN, PRESS

ISLAMABAD. PUBLISHED BY THE MANAGER OF PUBLICATIONS,
KARACHI.
COMPANY
OIL & GAS DEVELOPMENT COMPANY LTD ENGINEERING
CONSULTANT
UCH-II DEVELOPMENT PROJECT
SPECIFICATION FOR FABRICATION, ERRECTION

Document Title:
AND TESTING OF ATMOSPHERIC STORAGE TANKS
Date: 02-OCT-2012 Document No: 4985-SA-7507 Rev :0 Sheet 1 of 28
SPECIFICATION FOR FABRICATION, ERECTION

AND TESTING OF ATMOSPHERIC STORAGE TANK
0 Issued For Approval 01-Oct-2012 WRK MYA FS
Rev Description Date Prepared Checked Approved

COMPANY
CONSULTANT

Document Title:
TABLE OF CONTENT
1 GENERAL ............................................................................................................... 4
1.1 Scope ................................................................................................................ 4
1.2 Abbreviations and Definitions ............................................................................ 5
2 CODES AND STANDARDS .................................................................................... 6
3 REFERENCED DOCUMENTS ................................................................................ 6
4 AMBIENT CONDITIONS ......................................................................................... 6
5 DOCUMENTATION ................................................................................................. 6
6 scope of supply ..................................................................................................... 7
7 FABRICATION ........................................................................................................ 8
7.1 General ............................................................................................................. 8
7.2 Plate Preparation .............................................................................................. 9
8 ERECTION ............................................................................................................ 10
8.1 General ........................................................................................................... 10
8.2 Reception and Storage of Materials ................................................................ 11
8.3 Preparation of Materials .................................................................................. 11
8.4 Workmanship .................................................................................................. 11
8.5 Wind Bracing ................................................................................................... 12
8.6 Erection Holes and Attachments ..................................................................... 12
8.7 Setting Out Bottom Course of Shell Plates ..................................................... 12
8.8 Checking of Alignment .................................................................................... 12
8.9 Roof Framing .................................................................................................. 13
8.10 Shell Tolerances .......................................................................................... 13
8.11 Welding ........................................................................................................ 14
9 FOUNDATIONS .................................................................................................... 20
9.1 Checking of Foundations ................................................................................ 20
10 INSPECTION ..................................................................................................... 20
10.1 General ........................................................................................................ 20
10.2 Initial Weld Inspection .................................................................................. 21
10.3 Finished Weld Inspection ............................................................................. 21
10.4 Visual Inspection .......................................................................................... 22
10.5 Weld Defects ............................................................................................... 23
10.6 Retention and Recording of Radiographs .................................................... 23
11 TESTING ............................................................................................................ 23
11.1 General ........................................................................................................ 23
11.2 Testing Tank Bottom .................................................................................... 24
11.3 Testing Reinforcing Pads ............................................................................. 24
11.4 Tank Shells .................................................................................................. 24
11.5 Initial Filling .................................................................................................. 25
11.6 Fixed Roofs .................................................................................................. 25
11.7 Repair of Leaks ............................................................................................ 26
11.8 Retesting ...................................................................................................... 26
COMPANY
CONSULTANT

Document Title:
12 SAFETY PRECAUTIONS .................................................................................. 27

13 PAINTING .......................................................................................................... 27
14 PREPARATION FOR SHIPMENT ..................................................................... 28
COMPANY
CONSULTANT

Document Title:
1 GENERAL
OGDCL intends to develop UCH field by installing UCH-II Plant comprising surface
facilities, flow lines, commingling system and gas purification plant. The gas purification
plant unit will be capable of processing 300 MMSCFD (Avg.) raw gas stream. For
implementation of the project four (04) no’s storage tanks are required including one
(01) fire water tank, one (01) raw water tank, one (01) diesel storage tank and one (01)
demin water tank.
In this connection, ENAR prepared tender document for the procurement, fabrication,
erection, inspection and testing of atmospheric storage tank.
1.1 Scope
This Specification covers the requirements for the fabrication, erection,

inspection and testing of field erected Welded Steel Atmospheric Storage Tanks
and their appurtenances to be used for UCH-II Development Project.
This specification details the requirements of the code under which the tanks are
to be fabricated.
Storage Tanks made to this specification shall be fabricated according to the

requirements of this specification, of the CONSULTANT’s detailed drawings and
the Codes, standards and specifications as listed in Chapter 2.
This specification is applicable to tanks with the following characteristics:
 Vertical, cylindrical shell tanks of all welded steel construction.
 Fixed coned type roof either self-supported or structurally supported.
Should details or requirements in referenced codes or specifications be

contradictory or deviate from the listed codes and standards, the CONSULTANT
shall be notified, preferably at the bidding stage but, in any case, before any
costs may arise due to an alternative decision. No deviations from
CONSULTANT documents shall be allowed if not approved previously by the
CONSULTANT.
COMPANY
CONSULTANT

Document Title:
Should any conflict occur as a result of applying Specifications, the order of

precedence shall be as follows;
 This specification and applicable detailed drawing
 Referenced codes and standards
Compliance by the PC CONTRACTOR (here in referred to as contractor in the

rest of the document) with the provisions of this Specification does not relieve
him of his responsibility to furnish equipment and accessories of a proper
mechanical design suited to meet the specified service conditions and/or local
codes governing health and safety.
The CONTRACTOR shall indicate in his offer all deviations of his standard
design from the inquiry documents. The CONTRACTOR carries the sole
responsibility for the correctness of his equipment.
1.2 Abbreviations and Definitions
COMPANY Oil & Gas Development Company Limited

(OGDCL)
ENGINEERING CONSULTANT ENAR PETROTECH SERVICES (PVT) LTD.
PC CONTRACTOR A party which manufactures and/or supplies

equipment, and services to perform the duties
specified by the COMPANY / CONSULTANT
PROJECT UCH-II Development Project

API American Petroleum Institute
COMPANY
CONSULTANT

Document Title:
2 CODES AND STANDARDS
API 650 Welded Steel Tanks for Oil Storage
API 12D Specification for Field Welded Tank for Storage of

Production
ASME Section-IX Welding and Brazing qualifications (Only where refer-

enced in API 650)
ANSI B16.5 Steel Pipe Flanges. Flanged Valves and Fittings
ANSI B16.21 Non-metallic Flat Gaskets for Pipe Flanges
ASME Boiler and Pressure Vessel Code Section V, Non-destructive Examination

(only where referenced in API 650)
3 REFERENCED DOCUMENTS
4985-A-1000 Site, Environment & Utility Design Data
4985-STA-4002 Specification for Steel Structure
4985-GS-9523 Specification for Painting
4985-GS-9524 Specification for Packing and Protection of Material

& Equipment
4 AMBIENT CONDITIONS
Ambient Conditions are outlined in document # 4985-A-1000 .
5 DOCUMENTATION
All contractual documents shall be in the English language unless specified

otherwise in the project specification and dimensions shall be in Metric System
except lengths in millimeters.
COMPANY
CONSULTANT

Document Title:
CONTRACTOR shall provide to the CONSULTANT following Documents for

Approval.
 Detailed Construction Plan (including Construction Method Statement)
 Construction and Fabrication sequence plans
 CONTRACTOR schedule / progress (updated weekly)
 Welding Procedures Specification and Qualification Records
 Heat Treatment Procedures, Charts and Certificates
 CONTRACTOR Test Procedures
 Inspection and Test Procedures (including, but not limited to, NDE, Painting/
Coating)
 Hydraulic Testing Procedures
 Hydraulic Test Certificates
 Test Reports (including NDE, Painting/Coating)
 Mill certificates
 Material Certificates
6 SCOPE OF SUPPLY
CONTRATORS's scope includes supply of all materials and accessories,

manufacture, and assembly - at shop or field, inspection, non-destructive
examination; testing, painting and delivery of shop fabricated tank accessories
(as applicable) at site.
CONTRACTOR shall ensure compliance with the codes, listed in section 2, and
all authority regulations and shall obtain local authority approval (if applicable).
This includes delivery of all documents required to satisfy the codes.
COMPANY
CONSULTANT

Document Title:
Any deviations from the specifications or standards after purchase order award
must be submitted to COMPANY / ENGINEERING CONSULTANT in writing for
approval prior to implementing the changes.
CONSULTANT's approval of CONTRACTOR’s documents does not relieve

CONTRACTOR of their responsibilities.
The tanks shall be supplied complete including, but not limited to, the following:-
 All accessories as specified on the tank detailed drawings.
 All welded on internal and external attachments
 Stairway, ladder and platform support clips.
 Stairways, ladders and platforms.
 Pipe support and guide clips
 Pipe supports and guides.
 Earthing lugs.
 Nameplate.
 Internal/external coating or painting as required.
 Mechanical Guarantees.
7 FABRICATION
7.1 General
Field erected tanks shall be fabricated in accordance with API Standard 650.
Workmanship and finish shall be first class throughout and all work shall be
subject to the closest inspection by CONTRACTOR's inspection department
whether or not any inspection by the COMPANY / CONSULTANT is executed.
COMPANY
CONSULTANT

Document Title:
No fabrication shall begin until the CONTRACTOR has received approval of

proper material certification, weld procedures specification (WPS) and procedure
qualification record (PQR) from the COMPANY/ CONSULTANT.
To minimize the amount of field work, for field fabricated tank, tank components
and appurtenances shall be prepared and prefabricated in the CONTRACTOR's
shop to the greatest practicable extent. In addition, shop trial assembly checks
shall be utilized as appropriate to ensure accurate fit-up for subsequent field
erection.
All welds and weld preparations shall be detailed and annotated to the relevant
weld procedure specification.
Rolled fabricated plate necks shall be butt welded and fully radio graphed to
100% joint efficiency for all tanks.
Plates, structural members and other material shall not be made up to the
required length by splicing together shorter lengths.
7.2 Plate Preparation
7.2.1 General
Plate preparation shall be carried out in accordance with API 650.
The preparation of plate edges and in particular the edges of shell plates, shall
be carried out carefully in a well equipped workshop.
After preparation all edges shall be examined and all plates showing laminations,
slag inclusions, edge cracks or other faults shall be rejected.
Curved edges of roof or bottom sketch plates or annular plates (if required) shall
be cut to shape in the workshop by mechanized gas cutting or machining.
Handling of plates and sections shall be done using suitable plate clamps or
other methods approved by the COMPANY / CONSULTANT to avoid damage of
any plate materials.
COMPANY
CONSULTANT

Document Title:
7.2.2 Tolerances
The profile of all shell plates shall be accurate within a tolerance of ± 2mm in
length and ± 1 mm in width. In addition, to ensure that plates are truly
rectangular, the length of the diagonals measured across the rectangle formed
by scribing lines 50mm from each edge shall not differ by more than 3mm.
For roof and bottom plates with lapped seams, normal mill tolerances are
acceptable.
7.2.3 Rolling and Pressing
All shell plates shall be rolled to the correct tank curvature in a well equipped
workshop. Shell plates shall have their ends pre-set to the proper curvature.
Attention shall be given to prevent bending over the width of the shell plates
during the rolling process.
8 ERECTION
8.1 General
Erection of field erected tanks covered by this Specification shall be in

accordance with API Standard 650.
CONTRACTOR shall submit full details of sequence of erection including site

welding for COMPANY / CONSULTANT’S review and approval.
CONTRACTOR shall inform the COMPANY / CONSULTANT least six (6) weeks
prior to commencement of erection, of the site facilities and equipment required
for erection.
The CONTRACTOR shall furnish all labor, tools, welding equipment and cables,
scaffolding, and other equipment necessary for erecting tanks that are complete
and ready for use.
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8.2 Reception and Storage of Materials
The CONTRACTOR shall inspect and keep stock of all materials delivered at
site and be fully responsible for their safekeeping.
All fittings, plates, etc. shall be properly laid out on wooden supports clear of the
soil. Special care shall be taken that damage does not occur to faces of flanges
or to beveled ends of fittings.
8.3 Preparation of Materials
All materials shall be examined and repaired as necessary at the site before
being erected, to ensure that any damage incurred in transit is made good to the
satisfaction of the COMPANY / CONSULTANT. Particular attention shall be paid
to the removal of the buckles and distortions in the shell and bottom plates.
8.4 Workmanship
All workmanship shall be of a quality to ensure that the requirements of API

Standard 650 and this Specification are met. Only appropriate and standard
erection practices shall be used throughout the tank erection program and they
shall be applied only by skilled personnel. All work shall be subjected to close
quality control by the COMPANY / CONSULTANT, whether or not the
COMPANY / CONSULTANT waives any part of his own inspection. Bolt holes in
plates, structural members and other items shall be drilled, not punched. The
burning of such holes will not be permitted.
Manual gas cutting may be used for trimming the corners of bottom or roof plates
where two lapped joints intersect and for cutting openings for fittings positioned
on site.
Manual gas cutting shall not be used for any other purpose without the approval
of COMPANY / CONSULTANT's representative.
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8.5 Wind Bracing
During erection, tanks shall be safeguarded adequately against distortion or

damage due to wind pressure, by the provision of suitable steel wire guys or
braces.
A minimum of one guy every 8m of circumference is recommended. These shall

remain in place until welding of the shell plates and erection of the roof framing
has been completed, or with open top tanks (as applicable), until the wind girder
has been completed. Particular attention shall be given to the reliability of the
anchor blocks for the guys especially in weak, muddy soils.
8.6 Erection Holes and Attachments
Holes in plate work, to assist in erection, shall not be permitted.
Lugs, nuts, clamps and other devices to assist in erection may be attached to the
tank plates by welding, but all such attachments required only for the purposes
of erection shall ultimately be removed and any noticeable projections of weld
metal remaining shall be carefully ground or chipped away. Plates shall not be
gouged or torn in the process of removing attachments and any indentations
caused thereby shall be filled with weld metal and ground flush with the plate
surface.
8.7 Setting Out Bottom Course of Shell Plates
In setting out the bottom course of shell plates, allowance shall be made for the
contraction of the vertical joints during welding. While the plates are being
plumbed and checked for circularity and before they are tack-welded to the
bottom, they shall be held in position by metal clamps or other devices attached
to the bottom plates.
8.8 Checking of Alignment
Before final welding of the bottom course of shell plates begins, a check shall be
made to ensure that the alignment of the plates and the width of the gaps
between them are correct and that any inaccuracies after welding will be within
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the tolerances mentioned below. If the tolerances are expected to be exceeded,

the plates shall be re-aligned before final welding begins.
After the first course has been erected and welded, the internal radius,
measured horizontally from the centre of the tank to any point on the inside of
the tank shell, shall not vary from the nominal internal radius by more 13mm for
tank diameter less than 12.5m and 19mm for tanks with a diameter greater than
12.5m and less than 45m.
8.9 Roof Framing
Before erection of the roof framing begins, the tank shell shall be carefully
checked for uneven settlement and any misalignment of the top of the shell shall
be corrected before the roof members are positioned.
The strength of erection poles used for temporary support of the roof structure
shall be CONTRACTOR’s responsibility.
Roof plates shall not be welded to supporting structural elements unless

otherwise shown on the drawings.
8.10 Shell Tolerances
8.10.1 Verticality of the Tank Shell
After completion, the maximum out of plumbness of top of the shell relative to
the bottom of the shell shall not exceed 1/200 of the total height.
These tolerances are mandatory for the tank shell as a whole and should also be
used as guidance for each individual course.
8.10.2 Local Departures from the Design Form
Local departures from the design form for the shell horizontally and vertically
should not exceed 16 mm for a plate thickness less than 12.5mm when
measured over a gauge length of 2.5m remote from weld seams.
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Such departure from the design form shall be gradual over the gauge length,
sharp changes in form are not permitted.
8.10.3 Tolerances at Horizontal and Vertical Shell Seams
At horizontal and vertical shell seams, the shell profile should not deviate from its
design form by more than 12 mm for plate thickness less than 12.5mm,
measured over a gauge length of 1m.
8.10.4 Tolerances for Misalignment of Plates at Butt Welded Joints
Plates to be joined by butt welding shall be matched accurately and retained in

position during the welding operation. Misalignment of the centre line of the
plates shall not exceed the following:
 In completed vertical joints, 10% of the plate thickness, or 1.5mm for plates
16mm thick and under.
 In completed horizontal joints, 20% of the upper plate thickness, or 1.5mm for –
plates 8 mm thick and under and 3mm for plates over 8mm thick; whichever is
the smaller.
8.10.5 Top of Tank Shell
The tank shell shall be carefully checked for circularity, dimensions and level
before the roof members.
8.11 Welding
8.11.1 General
This part of specification covers the minimum requirements and procedures for
welding and does not relieve the CONTRACTOR from his responsibilities and
guarantees with respect to welding results.
The layout of all welded seams shall permit both internal and external inspection
of all main tank seams where possible.
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All butt welds shall be full penetration and full fusion welds as shown in the
applicable code or specified in this Specification. No lap joints are permitted on
shells.
Bottom plates of all tanks shall be lap welded throughout.
All welds of lugs, brackets, structural steel, etc., shall be located so as to miss all
tank welds by a minimum distance between the edges of the welds of 100mm, or
3 times the thickness of the thicker part being welded, whichever is greater.
Where tanks are to be internally lined, weld joints shall be smooth and free from
sharp edges and corners.
No welding shall be performed when the metal temperature is 5ºC and below
without the application of preheat.
All fillet welds shall be continuous.
8.11.2 Welding Processes
The scope of application of welding processes shall require the approval of the
COMPANY / CONSULTANT. High heat input processes such as electro slag
welding is prohibited. In all cases the heat input of the welding process shall be
limited to a maximum of 5KJ/mm.
8.11.3 Welder Qualification
All welders and welding machine operators shall be qualified in accordance with
ASME IX. Those welders and operators shall only be allowed to weld using the
approved process and in the position for which they are qualified. Welders shall
wear a personnel identification badge showing name and welder qualification.
8.11.4 Welding Procedure Qualification
The CONTRACTOR shall submit weld procedures, qualifications and weld

details in accordance with API Standard 650 for all weld types utilized for
COMPANY / CONSULTANT’s review and approval prior to commencing any
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production welding. Welds not made in accordance with the approved qualified
procedure shall be subject to rejection
Each procedure shall be qualified in accordance with procedures previously

approved by the COMPANY / CONSULTANT.
The CONTRACTOR shall weld test plates using his procedures to demonstrate
to the CONSULTANT that these procedures are suitable for making welds which
conform to the specified requirements. Each welding procedure shall be qualified
in accordance with the latest practice as given in the applicable rules of Section
IX of the ASME Boiler and Pressure Vessel Code.
The CONSULTANT shall be notified of any proposed changes to the applicable

welding procedure. Repair welding shall be performed using qualified
procedures and welders/operators.
8.11.5 Sequence of Welding
The sequence employed both for the tack welding and final welding of the
bottom shell and roof plates shall be arranged to minimize the distortion due to
weld shrinkage. The sequences shall be approved by the COMPANY /
CONSULTANT before erection starts.
8.11.6 Weather Conditions
Welding shall not be carried out when the surfaces to be welded are wet; nor
when rain or hail is falling or high winds are blowing, unless the welder or
welding operator and the work are properly shielded.
When the air temperature is below 0°C, the base metal at either side of the joint
shall be preheated before welding is started. For carbon steel the metal shall be
a temperature warm to the hand for a distance of not less than four times the
plate thickness, or 75mm whichever is the greater, in any direction from the joint
to be welded.
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8.11.7 Electrodes and Welding Wires
Welding materials shall be in accordance with the current list of approved

welding consumables published by Lloyds Register of Shipping or other
internationally acknowledged bodies.
Electrodes shall be stored in their original packets or cartons in a dry place

adequately protected from weather effects.
Low hydrogen electrodes shall be dried or baked at the temperature level and
times specified by the manufacturer and shall be used within 8 hours when
stored in quivers. Electrodes stored in quivers, but not used within the specified
times, shall be restored in ovens.
All consumables shall be stored and handled in accordance with manufacturer's

recommendations. Any unidentifiable consumable or those showing signs of
damage or deterioration shall be discarded.
Similar precautions shall be taken in the storage of flux and wire for submerged
arc welding.
If the electrodes become damp but are not otherwise damaged they may be
used only after being dried out in a manner approved by the electrode
manufacturers. Any electrodes which have areas of the coating broken away or
damaged shall be discarded.
No electrodes shall be left lying about the site or in workshops. Electrodes so left
shall be discarded.
Welders and welding operators shall be experienced in the manipulation of the

electrodes and wires used before proceeding with the tank welding. Basic or low-
hydrogen electrodes are recommended for sealing runs and root layers. For low-
hydrogen electrodes, an oven shall be available at the welding site to ensure the
use of dry electrodes in accordance with the recommendations of the electrode
manufacturer.
For manual welding of shell plates of medium high-tensile steel, low-hydrogen

electrodes only shall be used.
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8.11.8 Tack Welds
Tack welds used in the vertical joints between shell plates and in the horizontal
Joint between the bottom course of shell plates and the bottom plates, during the
assembly of the tank, shall be removed prior to welding and shall not remain in
the finished joints.
Tack welds in the horizontal joints between shell plates and in the joints between
roof plates and bottom plates, need not be removed provided that they are
sound and free from cracks, that the covering beads are thoroughly fused into
them and that the quality of the welding is to the satisfaction of the
CONSULTANT’s representative.
8.11.9 Plate Edge Joints
If the CONTRACTOR requests for different plate edge preparations details shall
be submitted as soon as possible together with the proposed weld procedures
for the review and approval by the CONSULTANT.
8.11.10 Welding Procedure
The welding procedures shall be as follows:
 In multi-layer welding each layer of weld metal shall be thoroughly cleaned of

slag and other deposits before the next layer is applied. All completed welds
shall be freed from slag, brushed and thoroughly cleaned before final
inspection and subsequent painting.
 There shall not be any undercutting of the base metal.
 The weld metal on both sides of all butt joints, except offset faces of
horizontal joints of unequal plate thickness, shall be built up in the form of an
overlay so that all the finished face in the area of fusion shall extend above
the surface of the adjoining plates to a height of preferably not more than
1.5mm.
 The edges of the welds shall merge with the surface of the adjoining plates
without a sharp angle.
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 Welds shall be left as welded and not be modified with a gas torch or by any
mechanical means which may change their appearance.
 Where applicable, post weld heat treatment shall be carried out as required
by and in accordance with API Standard 650.
8.11.11 Bottom Plate Joints
All bottom plate joints shall be welded in accordance with the detail drawings.
It shall be checked that all locations where supports for accessories (e.g. roof
supports, roof drains, vacuum breakers, etc.) are welded to the bottom or will be
touching the bottom are provided with a suitable pad plate to prevent leakage.
The pad plates to be round or at least have rounded corners.
8.11.12 Bottom to Shell Plate Joint
The shell plates shall be continuously welded on both sides to the bottom sketch
plates or annular plates in accordance with the detail in drawings.
8.11.13 Shell Butt Joints
Shell butt joints shall be made as follows:
 All seams shall be single-vee butt-welded.
 All vertical butt joints shall have complete weld penetration and fusion
through the full thickness of the parent plate.
 All horizontal single-bevel butt joints shall have complete penetration and
fusion through the full thickness of the parent plate.
 In single-vee or single-bevel butt joints the vee or bevel shall be made on the
outside of the tank.
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9 FOUNDATIONS
9.1 Checking of Foundations
For a tank to have a shell which is truly circular and free from buckles and flat
spots, the foundation must remain flat and level as the tank shell is erected. For
this reason the foundation shall be checked, not only at the commencement of
operations, but several times during the various stages of tank erection. The
measurements shall be stated in a report. This final report shall be handed to the
CONSULTANT for maintenance purposes.
An indication that the tank is settling unevenly is the appearance of gaps in the
circumferential seams, and departure of the shell from the perpendicular. If these
signs appear, no attempt should be made to close the gap by pulling with the key
plates and wedges or cutting of plates.
The tank level shall be checked and corrected by leveling, if necessary. If the
gap is due to inaccurate fabrication, plate edges shall be built up with weld
metal, and the joint welded.
10 INSPECTION
10.1 General
CONSULTANT's inspector may engage in the inspection of the tank. The

inspectors shall have free access to CONTRACTOR's work at both shop and
erection site at all reasonable times and during all tests.
The CONTRACTOR shall supply all reasonable facilities for ensuring that the
work is being carried out in accordance with the requirements of this
Specification.
The CONTRACTOR shall provide inspection in accordance with API

Specification 12F together with API Standard 650 as a minimum.
The CONTRACTOR shall submit for the approval by the CONSULTANT his
Inspection and Test plan prior to commencement of any field activities. The
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CONTRACTOR shall inform the CONSULTANT at the time of placing the order
of any tests which cannot be adequately performed.
All heat numbers shall be marked by paint or other legible means in such a way
that these can easily be noted and read after erection. For bottom plates these
shall be on the inside, for all other parts, on the outside.
10.2 Initial Weld Inspection
All shop and/or site welding shall be subjected to close visual inspection by an
approved welding inspector of the CONSULTANT as the welding progresses,
and any faults or bad practices shall be corrected as soon as possible.
Particular attention shall be paid to the vertical and horizontal joints in the shell
plates, lap joints in bottom annular plates and other joints that pass under the
shell plates.
All these joints shall be thoroughly de-slagged by chipped and brushing, and
examined between each run of weld metal for faults such as lack of fusion,
surface cracks, slag inclusions and undercutting.
10.3 Finished Weld Inspection
All welds shall be inspected visually in accordance with (10.4). The use of
destructive methods of testing welds shall not be permitted.
In addition to visual inspection, butt welds in the tank shell shall be

radiographically inspected in accordance with API Standard 650.
The acceptance criteria for all non-destructive examinations of the tank parts
shall be in accordance with the requirements of API Standard 650. All
radiography shall be performed using X-ray radiation except where it is
impractical, in which case the CONSULTANT shall nominate a suitable
alternative method of the examination for the approval of CONSULTANT.
At CONSULTANT's discretion, ultrasonic examination may be substituted for

radiographic, magnetic particle and/or liquid penetrant examinations. However, if
the shell plate vertical joints have been welded by an automatic welding process,
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the completed welds shall be fully ultrasonically examined, unless they are to be
fully radiographed.
All compliance examination procedures as described herein shall be at the

expense of the CONTRACTOR. The cost of additional non-destructive
examinations which may be requested by the CONSULTANT will be borne by
CONTRACTOR except where defects are revealed. The cost of such
examinations revealing defects and the cost of further examinations proving the
acceptability of the associated repairs shall be borne by the CONTRACTOR.
All inspection shall be conducted and interpreted by qualified persons utilizing

proven techniques and equipment. The inspection results shall be substantiated
by charts, photographs and reports, which shall be submitted to the
CONSULTANT. The CONSULTANT shall be notified in advance of all these
tests to enable him or his appointed Agency to witness the tests.
10.4 Visual Inspection
All welds shall be visually inspected.
Visual inspection shall show that the following requirements are met:
 The weld is made in accordance with the design requirements.
 The profile of fillet welds is such that leg lengths are equal within 1.5mm and
the surface of the weld is slightly convex and free from overlap at the toes of
the weld.
 The profile of butt welds is uniform, slightly convex and free from overlap the
toes of the weld
 The height and spacing of ripples are uniform
 The weld is free from undercutting
 There are no pronounced lumps or cavities caused by starting or finishing a

weld bead
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 The surface of the weld is free from cavities and trapped slag, and does not
display any porosity.
10.5 Weld Defects
Welds that are shown by radiography to have any of the defects or imperfections
as defined in API Standard 650 shall be judged to be unacceptable, and the
CONSULTANT’s welding inspector or representative shall decide to what extent
the welds shall be repaired in accordance with API Standard 650.
Imperfection revealed by other non destructive tests where applicable shall be

repaired at the discretion of the CONSULTANT and in accordance with API 650.
10.6 Retention and Recording of Radiographs
The CONTRACTOR shall record all films with their identification marks, on a
diagrammatically developed elevation of the shell plates and floor plates. The
defects shown on the radiographs shall be indicated on this diagram.
Finished radiographs shall be retained by the CONTRACTOR for a minimum

period of 3 years from the completion of site erection.
All radiographs shall be stored in such a manner as to prevent deterioration over

time as a result of light, pressure, excessive heat, excessive humidity, fumes or
ionizing radiation as appropriate. Reference should be made to the radiographic
film manufacturer's recommendations on storage.
The CONTRACTOR shall allow free access to radiographs at all times during the
3 years storage period by the CONSULTANT.
11 TESTING
11.1 General
As a minimum requirement, field fabricated tank shall be tested in accordance

with API Standard. As a minimum requirement, the testing of field erected tanks
shall be in accordance with API Standard 650.
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11.2 Testing Tank Bottom
The bottom of the tank shall be tested after installation by applying a vacuum to
the plate welded joints and checking for leaks, using a suitable soap film
solution. There shall be no air leakage.
This can be done using a vacuum box, which enables any leaks in the seams to
be positively located by visual examination.
The test shall preferably be made as soon as possible after welding of the
bottom, removal of slag, and wire brushing, but before any surface coating is
applied. The bottom plates shall in any case be tested before water is let into the
tank for hydrostatic testing.
11.3 Testing Reinforcing Pads
Reinforcing pads for manholes, nozzles and similar openings shall be tested
after installation by applying air pressure via each telltale hole and checking for
leaks, using a suitable soap film solution. There shall be no air leakage. Suitable
precautions shall be taken to ensure that excessive pneumatic pressure is not
applied during the test. Test pressure shall not exceed (15psi).
11.4 Tank Shells
The shells of fixed roof tanks shall be tested after completion of the roof.
For fixed roof tanks, testing shall be done by filling the tanks with, fresh water to
the level of the top leg of the top curb angle, and noting any leaks over a period
of at least 24 hours.
For field tests, the filling rate, holding time and drainage shall be as per API 650.
CONTRACTOR shall, for all field-fabricated tanks, submit a test procedure for
approval by CONTSULTANT.
CONTRACTOR shall notify CONSULTANT at least five days before the actual
test begins, and unless agree otherwise it shall not take place in the absence of
CONSULTANT or without CONSULTANT’s prior approval.
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The tank shall not have been previously hydrostatically tested. Prior to testing, it
shall be thoroughly cleaned internally of all dirt, oil, grease and other foreign
materials.
The CONTRACTOR shall be responsible for furnishing all apparatus and items
normally required for such testing, including fill and drain lines, blanking plates,
gaskets and associated bolting. However, service bolts and gaskets to be
furnished by the CONTRACTOR as spare parts shall not be used during the test.
Test gaskets shall be used on nozzles and gasketted joints which are to be
broken after the test (e.g. for draining, venting and drying the tank).
11.5 Initial Filling
The initial filling of a tank with water, shall be done slowly and a continuous
inspection shall be maintained for the whole of the filling period. The filling
procedure shall be established taking soil conditions into account. The filling
procedure shall be described in detail in a specification agreed by the
CONSULTANT strictly.
Uneven settlement of the tank on its foundation shall be reported immediately to

CONSULTANT, and filling shall be stopped at any signs of excessive settlement
pending a decision by CONSULTANT on the action to be taken.
On completion of the test, the tank shall be completely drained and all residual
water, silt and dirt shall be removed so that it is left in a ‘broom-clean’ condition
inside.
11.6 Fixed Roofs
When the tank shell is tested with water, the roof shall be tested by pumping air
under the roof plates while the tank is still full of water. The influence of sudden
barometric changes and possible condensation during the night shall be
considered.
Fixed roof tightness testing shall be done in strict accordance with the
requirements of the API 650.
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The pressure shall be strictly controlled using a very accurate pressure gauge
during the entire period of the test.
Non-pressure tank roofs shall be tested to a pressure at pressure specified in

detailed drawings.
For the detection of leaks, soap suds or some alternative substance shall be
applied to all joints.
Alternatively, the roof weld seams may be tested by the vacuum box method.
11.7 Repair of Leaks
All leaks detected during testing shall be repaired to the satisfaction of

CONSULTANT, and on completion the entire tank shall be tight and free from
leaks.
In the joints between shell plates or bottom plates, or both, the defective part
shall first be cut out and repaired by welding. Isolated pinhole leaks in joints
between roof plates or indication of porosity in the joints, or of cracking, repair
welds shall be made for the affected parts of the joint. Mechanical caulking is not
permitted for any repair.
When the tank is filled with water for testing, defects in the shell joints shall be
repaired with the water level at least 0.3m below the work.
11.8 Retesting
After all defects have been repaired the repaired weld shall be retested by the
methods previously described.
If it is impractical to use these methods a second time, extra care shall be taken
in the inspection of welded repairs, and all defects which have been repaired
shall be tested with dye penetrants.
If further leaks are discovered when the tank is first filled with product, repairs
shall not be made until the tank has been rendered safe in accordance with
section 10.
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12 SAFETY PRECAUTIONS
The following safety precautions shall be taken:
 Product connections shall not be made to any tank for any purpose until the
tank is accepted to be filled with product by CONSULTANT.
 Once product connections have been made to a tank, welding or other hot-
work shall not be carried out until all lines connected to the tank have been
disconnected, the open ends of the pipelines blanked off, and the tank and its
vicinity tested and rendered safe to the satisfaction of the CONSULTANT.
 Once a tank has contained product, welding or other hot-work is prohibited

before, in addition to the requirements above, the tank has been completely
emptied and rendered safe in accordance with the local safety regulations,
and written authority for the work has been issued by CONSULTANT.
 Roof manholes shall be open while filling or emptying a fixed roof tank for
purposes, so that the tank is not damaged by excessive vacuum or pressure
loading.
 CONTRACTOR shall provide adequate lighting/venting for work carried out

inside tanks.
 CONTRACTOR shall submit for approval air pressure test procedure for fixed
roof tanks.
13 PAINTING
For external Painting and protective coating and the procedures for preparation
for painting shall be in accordance with the requirements having document no’s
4985-GS-9523, 4985-GA-9524, and 4985-STA-4002. Internal coating of the tank
shall be specified in the applicable detailed drawings of the tank.
All the tanks shall be cleaned inside and outside of weld spatter, weld slag, flux
deposits, burrs and splinters, loose mill scale and all other foreign matter.
Steel plates stored, pending for erection, shall be suitably protected against
oxidation.
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For field-erected tanks, all plates shall be primed prior to delivery to erection site.
Heat numbers shall in this case be left unpainted.
Before erection, the outside surface of bottom plates shall be brushed,

degreased, and then coated with hot applied bitumen paint.
14 PREPARATION FOR SHIPMENT
The CONTRACTOR shall be responsible for the adequacy of packing and

protection employed to ensure that the parts are delivered in an as new and
undamaged condition.
All pre-fabricated parts for field erected tanks shall be thoroughly cleaned, match
marked and beveled for welding at site prior to shipment.
Carbon-steel flange facings (except on nozzles shipped with gaskets in place),

shall be coated with an easily removable rust preventative. All flange facings
must be protected with temporary shipping covers.
CONTRACTOR must ensure that equipment and / or all parts thereof is properly
loaded and secured to the carrier to avoid damage by the use of suitable support
/ transport cradles, hold-down devices or otherwise.
CONTRACTOR shall also ensure that road transport clearance requirements are
met.

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GAS PLANT FACILITY PROJECT

ISSUED FOR BIDDING

0 10-Apr-11 Issued For Bidding WRK MTZ MK FS

DATA SHEET OF INSULATING GASKET FOR RTJ FLANGES

31 Dimensional Standard: ASME B16.20

Client: Oil & Gas Development Company Limited

Tag No. 100-CC-001 101-CC-001 102-CC-001 103-CC-001

Type Corrosion Coupon Corrosion Coupon Corrosion Coupon Corrosion Coupon

Dimension from top of pipe to

n-Butane 0.17 0.17 0.17 0.17

Client: Oil & Gas Development Company Limited

Tag No. 104-CC-001 105-CC-001 106-CC-001 107-CC-001

Type Corrosion Coupon Corrosion Coupon Corrosion Coupon Corrosion Coupon

Methane 29.13 28.82 27.91 27.48

n-Butane 0.03 0.07 0.07 0.07

Client: Oil & Gas Development Company Limited

Tag No. 108-CC-001 109-CC-001 110-CC-001 111-CC-001

Type Corrosion Coupon Corrosion Coupon Corrosion Coupon Corrosion Coupon

Methane 27.80 28.04 41.17 30.04

n-Butane 0.07 0.07 0.11 0.08

Client: Oil & Gas Development Company Limited

Tag No. 112-CC-001 113-CC-001 114-CC-001 100-CC-002

Type Corrosion Coupon Corrosion Coupon Corrosion Coupon Corrosion Coupon

Dimension from top of pipe to

0.08 0.08 0.07 0.17

Client: Oil & Gas Development Company Limited

Tag No. 101-CC-002 102-CC-002 103-CC-002 104-CC-002

Type Corrosion Coupon Corrosion Coupon Corrosion Coupon Corrosion Coupon

Dimension from top of pipe to

Methane 65.37 65.37 65.37 29.13

n-Butane 0.17 0.17 0.17 0.03

Client: Oil & Gas Development Company Limited

Tag No. 105-CC-002 106-CC-002 107-CC-002 108-CC-002

Type Corrosion Coupon Corrosion Coupon Corrosion Coupon Corrosion Coupon

Dimension from top of pipe to

Methane 28.82 27.91 27.48 27.80

n-Butane 0.07 0.07 0.07 0.07

Client: Oil & Gas Development Company Limited

Tag No. 109-CC-002 110-CC-002 111-CC-002 112-CC-002

Type Corrosion Coupon Corrosion Coupon Corrosion Coupon Corrosion Coupon

Dimension from top of pipe to

28.04 41.17 30.04 31.76

n-Butane 0.07 0.11 0.08 0.08

Client: Oil & Gas Development Company Limited

Tag No. 113-CC-002 114-CC-002 200-CC-001 200-CC-002

Type Corrosion Coupon Corrosion Coupon Corrosion Coupon Corrosion Coupon

Dimension from top of pipe to

0.08 0.07 0.17 0.17

Client: Oil & Gas Development Company Limited

Tag No. 200-CC-003 200-CC-004 200-CC-005 200-CC-006

Type Corrosion Coupon Corrosion Coupon Corrosion Coupon Corrosion Coupon

Dimension from top of pipe to

0.17 0.17 0.11 0.08

Client: Oil & Gas Development Company Limited

Tag No. 200-CC-007 200-CC-008 200-CC-009 200-CC-010

Type Corrosion Coupon Corrosion Coupon Corrosion Coupon Corrosion Coupon

Dimension from top of pipe to

0.08 0.08 0.07 0.03

Client: Oil & Gas Development Company Limited

Tag No. 200-CC-011 200-CC-012 200-CC-013 200-CC-014

Type Corrosion Coupon Corrosion Coupon Corrosion Coupon Corrosion Coupon

Dimension from top of pipe to

Propane 0.26 0.27 0.26 0.25