RR1111-SPC-PL-00-002Pipeline Construction General Specification Rev0

NO.
R1111-SPC-PL-00-002
PIPELINE CONSTRCUTION GENERAL SPECIFCATION REV. 0
PAGE: 2 / 43
Revisions report:
Revision No Revision Description

0A Issued For Approval
0B Updated as SPPC comments 31/03/2012
0 Final Issue
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TABLE OF CONTENTS
1 INTRODUCTION .................................................................................................................... 6
1.1 GENERAL DESCRIPTION .................................................................................................................... 6
1.2 SCOPE ........................................................................................................................................................... 6
1.3 DEFINITIONS............................................................................................................................................ 6
1.4 ABBREVIATIONS ..................................................................................................................................... 6
1.5 ENVIRONMENTAL & SITE DATA ..................................................................................................... 7
2 CODES, STANDARDS AND REFERENCE DOCUMENTS ................................................ 7
2.1 PROJECT DOCUMENTS ........................................................................................................................ 7
2.2 CODES AND STANDARDS ................................................................................................................... 7
2.3 DOCUMENT CONFILCT AND PRECEDENCE ............................................................................. 8
3 GENERAL ................................................................................................................................. 8
4 RIGHT OF WAY (ROW)........................................................................................................... 9
4.1 GENERAL.................................................................................................................................................... 9
4.2 HIGH VOLTAGE INSTALLATIONS ................................................................................................10
5 PREPARATION OF RIGHT OF WAY .................................................................................. 11
5.1 CLEARING, GRADING AND BACKFILLING OF ROW ..........................................................11
5.2 SURVEY MARKS .....................................................................................................................................11
5.3 SETTING OUT THE ROW ...................................................................................................................12
5.4 TOPSOIL STRIP .......................................................................................................................................12
5.5 FENCES AND BARRIERS ....................................................................................................................12
5.6 REMOVAL OF DEBRIS .........................................................................................................................13
5.7 GRADING OF ROW...............................................................................................................................13
5.8 RESTRICTED ROW ................................................................................................................................13
5.9 ROW DAMAGES .....................................................................................................................................13
5.10 PROVISION OF DETOURS .................................................................................................................14
5.11 ACCESS .......................................................................................................................................................14
5.12 WORKING IN THE SAME ROW OF EXISTING PIPELINES .................................................14
6 HANDLING, HAULING, STRINGING AND STORAGE .................................................. 14
6.1 RECEIPT AND ISSUE OF MATERIALS ..........................................................................................14
6.2 HAULING AND STRINGING OF PIPE ..........................................................................................16
6.3 CARE OF MATERIALS ..........................................................................................................................17
7 TRENCHING ......................................................................................................................... 17
7.1 LOCATION................................................................................................................................................17
7.2 EXCAVATION .........................................................................................................................................17
7.3 NORMAL COVER AND TRENCH DIMENSIONS ......................................................................17
7.4 EXTRA DEPTH AND CLEARANCES ..............................................................................................18
7.5 PROTECTION OF UNDERGROUND UTILITIES AND SPECIAL METHODS ................18
7.6 GRADES, PADDING AND FINISH OF TRENCH .......................................................................19
7.7 TRENCH CROSSINGS ...........................................................................................................................19
7.8 PROTECTION OF TRENCH & AUGER PITS ...............................................................................20
7.9 PROVISIONS FOR POSITIVE BUOYANCY TO THE PIPE .....................................................20
7.10 EXPLOSIVES ............................................................................................................................................20
8 BENDING ............................................................................................................................... 21
8.1 PIPE BENDS .............................................................................................................................................21
8.2 ELASTIC BENDS .....................................................................................................................................21
8.3 COLD FIELD BENDS ............................................................................................................................21
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8.4 MITRE AND UNSATISFACTORY BENDS .....................................................................................22

9 LAYING UP AND WELDING ............................................................................................... 22
9.1 CARE OF PIPE .........................................................................................................................................22
9.2 PIPE DEFECTS AND REPAIRS..........................................................................................................22
9.3 SWABBING, PIPE BEVELLING AND CLEANING ENDS OF JOINTS ...............................23
9.4 PIPE HANDLING AND SKID SUPPORT .......................................................................................23
9.5 ALIGNMENT OF PIPE .........................................................................................................................24
9.6 NIGHT CAPS ............................................................................................................................................24
9.7 TEMPORARY CAPS ................................................................................................................................24
9.8 WELDING .................................................................................................................................................24
10 FIELD JOINT COATING AND LOWERING IN ................................................................ 24
10.1 FIELD JOINT COATING .....................................................................................................................24
10.2 METHOD AND TIME OF LOWERING PIPE ...............................................................................24
10.3 LOWERING SLACK LOOPS ...............................................................................................................25
10.4 CARE IN HANDLING COATED PIPE ............................................................................................25
10.5 REPAIR OF DAMAGED COATING .................................................................................................25
10.6 ERRORS ......................................................................................................................................................25
10.7 STRESSES ...................................................................................................................................................26
10.8 DRAINING ................................................................................................................................................26
10.9 PRECAUTIONS ........................................................................................................................................26
10.10 TIMING OF LOWERING IN OF PIPE.............................................................................................26
10.11 AS BUILT MEASUREMENTS ..............................................................................................................26
10.12 FIBER OPTIC CABLE (FOC) INSTALLATION)............................................................................26
11 CATHODIC PROTECTION REQUIREMENTS ................................................................ 26
12 BACKFILLING ....................................................................................................................... 27
12.1 APPROVAL BY THE CLIENT .............................................................................................................27
12.2 SELECT BACKFILL MATERIALS AND PADDING ....................................................................27
12.3 SPECIAL TREATMENT OF TRENCH BACKFILL ......................................................................27
12.4 FURROWS, TERRACES, WATER BREAKERS...............................................................................27
12.5 POSITION OF BACKFILL....................................................................................................................28
13 TYING IN................................................................................................................................ 28
13.1 JOINING UNCONNECTED SECTIONS.........................................................................................28
13.2 PUPS .............................................................................................................................................................28
13.3 TAPERING ................................................................................................................................................28
14 CLEAN UP AND RESTORATION OF ROW ....................................................................... 29
14.1 CLEAN UP OF ROW ..............................................................................................................................29
14.2 DISPOSAL OF ROCK/DEBRIS ..........................................................................................................29
14.3 SURPLUS MATERIALS ..........................................................................................................................29
14.4 PROGRESS OF INTERMEDIATE AND FINAL CLEAN-UP ....................................................29
15 CROSSINGS ............................................................................................................................ 29
15.1 GENERAL..................................................................................................................................................29
15.2 CONSTRUCTION METHODS ............................................................................................................30
15.3 INSTALLATION OF CASING .............................................................................................................31
15.4 INSTALLATION OF CASING BY BORING/JACKING .............................................................32
15.5 INSTALLATION OF CARRIED PIPE IN CASING PIPE............................................................32
15.6 INSULATION OF CARRIER PIPE FROM CASING .....................................................................33
15.7 CROSSING OF BURIED SERVICES .................................................................................................33
15.8 WATERCOURSE CROSSING ..............................................................................................................34
16 INSTALLATION OF APPURTENANCES ........................................................................... 34
16.1 GENERAL..................................................................................................................................................34
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16.2 DIMENSIONAL TOLERANCES ........................................................................................................35

16.3 FLANGED CONNECTIONS ...............................................................................................................35
16.4 THREADED CONNECTIONS............................................................................................................35
16.5 WELDED CONNECTIONS .................................................................................................................36
16.6 CIVIL WORK ............................................................................................................................................36
16.7 PAINTING .................................................................................................................................................36
16.8 COATING OF BURIED INSTALLATIONS, ETC .........................................................................36
16.8.1 Clean Up ........................................................................................................................ 36
16.9 INSTALLATION OF VALVES.............................................................................................................36
16.10 PIPELINE MARKERS ............................................................................................................................37
16.11 CATHODIC PROTECTION .................................................................................................................37
16.12 MISCELLANEOUS ITEMS ...................................................................................................................37
17 PAINTING .............................................................................................................................. 38
18 HYDROSTATIC PRESSURE TESTING .............................................................................. 38
19 ENCROACHMENTS AND WORKING NEAR OTHER UTILITIES ............................... 38
20 PRE-COMMISSIONING, COMMISSIONING AND HANDOVER ................................... 38
21 RECORDS AND REPORTS ................................................................................................... 39
21.1 DAILY .........................................................................................................................................................39
21.2 WEEKLY ....................................................................................................................................................39
21.3 MISCELLANEOUS ..................................................................................................................................40
21.4 HANDOVER DOSSIER .........................................................................................................................40
22 AS BUILT DRAWINGS & PIPE BOOK ............................................................................. 40
22.1 AS-BUILT DRAWINGS ..........................................................................................................................40
22.2 PIPE BOOK ...............................................................................................................................................41
22.3 IDENTIFICATION .................................................................................................................................42
23 HEALTH, SAFETY AND ENVIRONMENT ................................................................... 42
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1 INTRODUCTION
1.1 GENERAL DESCRIPTION
The Sudanese Petroleum Pipelines Company (SPPC) is the operator of the transport of hydrocarbon in
Sudan. SPPC intends to install a new 12 NPS multiproduct pipeline starts from Alrawyan Station at
Khartoum Refinery (KRC) in northern Khartoum and ends at Madani Terminal Station in Aljazeera State.
The pipeline is about 220 km in total length. There are 4 (four) block valve stations installed along the
pipeline with the terminal station including storage facility and transfer pumps.
1.2 SCOPE
This Specification defines the minimum requirements for activities to be carried out for the construction
of pipeline.
This specification covers the minimum requirements to perform the construction of the 12” Khartoum-
Madani 12" Multiproduct Pipeline project.
1.3 DEFINITIONS
For the purpose of this document the following definitions shall apply:
Client / Owner Sudanese Petroleum Pipelines Company (SPPC)
Engineering Company Engineering Procurement & Project Management (EPPM)
Contractor PCC Contractor
Project 12 NPS Multi Product Pipeline from Khartoum to Madani State
Vendor / Supplier The party(s) which manufactures and/or supplies equipment, materials,
technical Documents/drawings and services to perform the duties
specified
1.4 ABBREVIATIONS
ASME American Society for Mechanical Engineer

ANSI American National Standards Institute
API American Petroleum Institute
FAC Approved for Construction
FOC Fiber Optic Cable
ROW Right Of Way
SIS Swedish Standard
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1.5 ENVIRONMENTAL & SITE DATA
Refer to “DESIGN BASIS REPORT”, document number R1111-RPT-GE-00-001.
2 CODES, STANDARDS AND REFERENCE DOCUMENTS
2.1 PROJECT DOCUMENTS
R1111-SPC-CV-00-003 Specification For Soil Investigation

R1111-SPC-CV-00-004 Specification For Topographic Survey
R1111-RPT-GE-00-001 Design Basis Report
R1111-SPC-PL-00-001 Line Pipe General Specification
R1111-SPC-PL-00-003 Line Pipe Coating General Specification
R1111-SPC-PL-00-004 Specification for Main Line Valves
R1111-SPC-PL-00-005 On Site Pipeline Coating and Coating Reparation Specification
R1111-SPC-PL-00-006 Anchor Flange General Specification
R1111-SPC-PL-00-007 Hot Tapping General Specification
R1111-SPC-PL-00-008 Pipeline Welding Specification
R1111-SPC-PL-00-009 Pipeline Hydraulic Testing Specification
R1111-SPC-PL-00-010 Specification for Barred Tee
R1111-SPC-PL-00-011 Specification for Induction Bends
R1111-SPC-PL-00-012 PL/PP NDT General Specification
R1111-DWG-PL-00-001 Typical Crossing Detail Drawing
R1111-SPC-PP-00-001 Storage and Preservation General Specification
R1111-SPC-PP-00-005 Painting Specification
2.2 CODES AND STANDARDS
Contractor/Manufacturer shall meet or exceed the requirements of the latest edition of the following
codes, regulations and standards, except as superseded herein.
American Society of Mechanical Engineers (ASME)
ASME IX Welding and Brazing Qualification
ASME B 31.4 Liquid Transportation system for Hydrocarbons, LPG, Anhydrous

Ammonia and Alcohols
American National Standards Institute (ANSI)
ANSI B16.5 Steel Pipe Flange Fitting
ANSI B16.9 Factory Made Wrought Steel Butt – welding Fittings
ANSI B16.25 Butt Welding Ends
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American Petroleum Institute (API)
API 5L Specification for Line Pipe
API RP 1102 Steel Pipelines Crossing Railroads and Highways
API RP 5L1 Recommended Practice for Railroad Transportation of Steel Line Pipe.
API RP 5LW Recommended Practice for Transportation of Line Pipe on Barges and
Marine Vessels.
API Spec.1104 Welding of Pipelines and Related Facilities
Swedish standard institute (SIS)
SIS 055900 Surface Preparation Standards
Regulations, Codes and Statutes of Authority having jurisdiction in location of pipeline installation.
2.3 DOCUMENT CONFILCT AND PRECEDENCE
(a) In cases where more than one code, regulation or standard apply to the same condition, the most
stringent shall be followed. In the event of a conflict between this specification and other
specifications or correspondence, the Client/Owner shall be consulted and a ruling, in writing,
shall be obtained before any work is started.
(b) Some requirements in this specification may be modified by specific requirements in the purchase
specification. In case of conflict, the specific requirements supersede this specification.
(c) Any deviation from this specification must be approved, in writing, by Client/Owner. Such
written approval must be obtained prior to the commencement of any work which would
constitute such a deviation.
3 GENERAL
The Contractor shall, with due care and diligence, execute the work in compliance with the highest
standards of international practice and all local laws, by-laws, ordinances, regulations, etc.; provide all
plant, services and labor, inclusive of supervision thereof; provide all materials, equipment, appliances or
other articles of whatsoever nature for the execution of the work, whether of a temporary or permanent
nature.
The Contractor shall take full responsibility for the stability and safety of all operations carried out and all
methods of work adopted.
The Contractor shall be deemed to have inspected the work sites and their surroundings and to have
satisfied himself as to the form and nature thereof, including sub-surface conditions, hydrological and
climatic conditions, the extent and nature of the work, the materials necessary for the completion of the
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work and the means of access to all the work sites. No claims, either by way of cost or time, shall be
admissible on account of non-familiarity with site conditions due to the Contractor's failure to fully assess
and fully allow for possible conditions at the work sites or in gaining access to them.
The Contractor shall be deemed to have obtained all necessary information as to the risks, contingencies
and all other circumstances which may influence the work.
The Contractor shall, in connection with the work, provide and maintain at his own costs all lights, safety
barriers, fencing, watchmen (and associated facilities) etc., as required by the owner or by the authorities
having jurisdiction thereof for the protection of the work and properties and for the safety and the
convenience of the public and others.
All work shall be carried out in compliance with the present specification, owner procedures, international
codes and standards, local regulations and requirements as specified in paragraph 2.
4 RIGHT OF WAY (ROW)
4.1 GENERAL
The wide Right of Way shall be prepared by the Contractor. The Contractor is required to perform his
construction activities within the width of the Right of Way through tracks crossing it and under public
roads etc. The Contractor shall provide and pay for any access necessary to the ROW and shall negotiate
this access with the appropriate Authorities/landowners.
Before starting any clearing operations, the Contractor shall familiarize himself with all the requirements
of the Authorities having jurisdiction over the ROW for work along the pipeline route or in connection
with the use of other lands or roads needed for construction purposes.
The orientation of the ROW (left or right of pipeline alignment) or the ROW width to be made available
to the Contractor may differ from those specified. In case of change in orientation of the ROW with
respect to pipeline alignment, the Contractor shall provide suitable cross-overs for safe crossing of the
pipeline by equipment/vehicles etc. All such work shall be carried out by the Contractor with no cost or
time implication to the Client.
Any damage or debris outside the ROW caused by the Contractor's activities shall be remedied by the
Contractor to the landowners and to the Client's satisfaction. A certified statement from the landowners
shall be required.
All work carried out in the vicinity of existing pipelines, facilities and other installations shall comply with
strict safety precautions to be prepared by the Contractor for the Client's approval. Where the Right of
Way comes within the area of influence of high voltage electrical installations, Section 4.2 shall be
followed.
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4.2 HIGH VOLTAGE INSTALLATIONS
This section consists of mandatory guidelines which shall be followed when performing pipeline
installation work in the close proximity to High Voltage Installations. The Contractor shall be responsible
for ensuring the overall safety of the work.
 Pipelines which are constructed inside the area of high voltage lines may be electrically influenced by
these lines. The voltage caused by the influence may at times be so high as to pose a danger to
personnel working on the pipeline. It is imperative, therefore, that the instructions given below should
be accurately observed.
It is a prerequisite that all personnel working on the pipeline which is being laid in the area influenced
by the high voltage system be given clear instructions on the safety measures to be taken:
- Vehicles and equipment must be earth-connected. This may be achieved by attaching an un-insulated
cable or chain (which touches the ground) or adequate length to the underside of the vehicle.
- For plant and/or materials operational within 50 m of a high voltage system, special measures must be
taken to prevent any approach within this distance, unless they are earth-connected.
- During thunderstorms or when electrical discharges are observed on insulators, all personnel have to
leave the area of the high voltage line.
- To prevent electrical voltages in a non-buried section of the pipeline from rising to dangerous values,
the length of the pipeline section which has been welded together before burial must not exceed the
length at which the maximum allowable voltage may be induced.
- Before a pipeline section is lowered into the trench, earth electrodes as indicated on the Contractor
prepared drawings must have been installed and connected both to the pipeline section already buried
and to the section which is about to be buried. The electrical connections which serve the purpose of
preventing dangerous voltages must have a minimum area of 35 mm².
These connections must not be interrupted until after the permanent safety earth connections have
been installed and connected to the entire uninterrupted pipeline. The earthing arrangement shall be
subject to the Client's approval.
- Personnel doing work inside the area influenced by the high voltage system must wear electrically
insulating foot-wear (e.g. rubber soled boots) and wear unworn insulating rubber or plastic gloves.
 Additional measures for work at less than 50 m from the high voltage system: If work is done at less
than 50 m from the high voltage system, the regulations below must be complied with in addition to
the rules specified in the first point.
- The work must not be started until Agreement has been reached with the authorities who control the
high voltage system, about the implementation of the safety measures necessary.
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- Measures must be taken to prevent any equipment from approaching high voltage lines to within the
appropriate distance.
This distance depends on the voltage carried. For individual connections the minimum recommended
distance is:
 0 - 50 KV :3m
 50 - 200 KV :5m
 200 - 380 KV :8m
The measures taken may be as follows:
1) Special selection of equipment, or limiting or blocking certain directions of movement, or limiting the
operational area, thereby making it definitely impossible for any work to be done at a distance from
the high voltage line of less than the specified minimum.
2) In case the measures recommended in 1) above are not feasible, installation of clearly visible markers
stating 'no passage beyond this point' and painted bright red and white must be placed to prevent any
work being done inside the danger area. Furthermore, a well trained inspector on this specific task
shall be present at all times.
 In the event that a vehicle, crane, etc. should accidentally come into contact with a live cable of a high
voltage system or if a flash-over of electrical charge occurs, the driver must not leave his vehicle until
he has managed to leave the danger area, or alternatively until the Electricity Authorities have given
notice that the cable(s) have been put out of circuit. In case a serious fire starts in the vehicle, he is
permitted to jump from the vehicle, clearing it as far as possible, and landing on dry ground.
The vehicle or crane must break the contact without any help from outside.
5 PREPARATION OF RIGHT OF WAY
5.1 CLEARING, GRADING AND BACKFILLING OF ROW
The Contractor shall clear and prepare the ROW for the convenient passage of all vehicles and
construction equipment by removing all obstacles liable to impede such passage. Methods of working
shall be as the owner procedure for pipeline right of way and the present specification and shall be subject
to the Client approval.
Prior to the start of clearing and grading activities, the Contractor shall advise the Client of the sections
where the ROW width will be restricted and shall obtain the Client's approval.
5.2 SURVEY MARKS
The Contractor shall maintain and preserve all survey monuments such as Bench Marks and
Intersection/Turning Points until the construction is completed. In case of any missing bench marks, the
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Contractor shall re-establish them, in order to carry out leveling work during laying and for the as-built
survey of the pipeline.
The Contractor shall carry out all surveys and leveling of line and grades necessary to complete the work
and shall be responsible for the accuracy for of such surveys and grades.
All the surveying activities shall be made as per the present specification and related surveying documents
(R1111-SPC-CV-00-004 : Specification For Topographic Survey)
The requirements for the geotechnical and thermal conductivity surveying of the pipeline and its ancillaries
that fall within the Contractor's scope are contained within Document No.(R1111-SPC-CV-00-004),
specification for soil investigation.
5.3 SETTING OUT THE ROW
The ROW for the pipeline shall be staked by the Contractor to define the ROW boundaries for purpose
of clearing, grading and backfilling. The stakes shall be of such regularity that the continuity of the line
may be maintained throughout construction.
The Contractor shall install distinct markers locating and indicating all special points, such as Contract
limits, warning notices, obstacle crossings, changes of wall thickness, including corresponding chainage.
The Contractor shall be responsible for the maintenance and replacement of the reference line markers
until the permanent pipeline markers have been placed and the as-built drawings have been submitted and
approved.
5.4 TOPSOIL STRIP
In cultivated areas topsoil shall be stripped only over the trench width and suitably stored. Upon
completion of the backfill, the topsoil shall be replaced and reinstated to the original condition.
5.5 FENCES AND BARRIERS
On completion of construction the Contractor shall restore any fencing to its original condition. The
Contractor shall be liable for any damage, claims or actions arising from breaches made in existing fences.
The Contractor shall install suitable warning tapes on either side of the ROW where it is considered
essential to ensure safety and non-interference, especially in industrial or in inhabited areas, or in the
proximity of roads or other installations.
The Contractor shall provide and install heavy grade barriers at any position where traffic might
accidentally encroach on the pipeline working areas.
Fencing and barriers shall be continuously maintained.
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5.6 REMOVAL OF DEBRIS
The Contractor shall remove all debris such as timber or rock/stones from the ROW and dispose of the
debris in a manner and method satisfactory to the Client and Government Authorities having jurisdiction
over the areas concerned. The Contractor shall be responsible for all surplus material disposals, if any,
arising out of clearing and grading operations.
5.7 GRADING OF ROW
The clearing of the ROW shall be carried out in conjunction with the construction of any access roads in
the ROW. After clearing the ROW and when grading has been performed so as to allow passage of loaded
trucks and equipment without undue wear and tear thereon the Contractor may commence his phased
work.
No filling of the ROW is to be done on the trench line. The Contractor shall grade and construct the
ROW so that the trench is excavated in undisturbed ground. The Contractor shall excavate through rock
where necessary.
The Contractor shall make all arrangements, such as ramps and temporary bridges, necessary for crossings
with men, vehicles and machinery. This shall be accomplished in such a way as to permit their continued
use and to preserve the banks and structure of the crossings. No existing crossings shall be filled or
otherwise obstructed without approval of the Person or Authority having effective control over such
crossings.
5.8 RESTRICTED ROW
Where the ROW passes through plantations, public roads, electric cables or other confined areas, only
such width as is available in the ROW for the actual digging of the trench and for constructing the
pipeline shall be used. The Contractor shall perform the work in such a way so as to minimize the
possibility of damage to property, roads, cables and other such items. The Contractor shall ensure that no
damage occurs to any tree or plantation, designated for protection on or adjacent to the ROW.
The Contractor shall not be entitled to extra compensation for the hardship and or increased costs caused
by the construction areas being adjacent to or in areas of difficult terrain or across roads, berms, flooded
areas, communication structures, wires, cables, other pipelines, power poles, plantations, farms or other
obstacles which may physically restrict or limit the use of the ROW provided.
5.9 ROW DAMAGES
The Contractor shall be liable for any and all remedial work called for by the Client for damages to
existing pipelines, tracks, roads, highways, and all other utilities, etc., caused by him. The Contractor shall
perform such remedial work as and when required by the Client.
The Contractor shall further ensure that all roads are kept clean, including ensuring that soil and mud are
not transferred from ROW to public roads.
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5.10 PROVISION OF DETOURS
At locations where any part of the work is routed along, over, under or across tracks, roads or highways,
the Contractor shall, with no extra compensation, provide and maintain such detours, temporary bridges
and road controls including warning lights as may be required by the Authorities.
Public travel shall not be unnecessarily inconvenienced nor shall it be wholly obstructed at any point.
The Contractor shall supply watchmen at any locations where safety and work operations justify their use,
or where called for by the Client. The Contractor shall maintain detours, and shall supply and maintain
lanterns, barricades and signs, wherever necessary, to fully protect the public and facilitate the smooth
running of the work.
5.11 ACCESS
Throughout the construction period, the Contractor shall ensure that access to all public and private
properties is maintained.
Where the Contractor identifies the need for additional accesses and working areas outside the working
width, he shall, at his own cost, make all necessary arrangement with the relevant affected owners of
properties and authorities.
5.12 WORKING IN THE SAME ROW OF EXISTING PIPELINES
The Contractor is not authorized to work on the same ROW of existing pipeline except upon the
approval of the Client and the Owner/Authority of the existing utilities without any extra cost to the
Client. The Client shall have the right to use the ROW of existing pipelines for survey and all other
maintenance works during exploitation.
Details of the ROW to existing pipeline (distance to the left and to right of the existing line) at the Urban
areas & Remote areas are specified in the documents Typical Crossing Detail Drawing
(R1111-DWG-PL-00-001 ), Special Crossing Detail Drawing (R1111-DWG-PL-00-002) and Right Of
Way Detail ( R1111-DWG-PL-00-003).
6 HANDLING, HAULING, STRINGING AND STORAGE
This section provided the minimum requirements for handling, hauling, stringing and storage of
constructions materials. In addition, the contractor has to refer to owner procedure for material control
and handling and accordance with the “Storage and Preservation General Specification”
R1111-SPC-PP-00-001.
6.1 RECEIPT AND ISSUE OF MATERIALS
The Contractor shall provide line pipe and all other materials at suitable locations arranged and prepared
by the Client.
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Pipes and coatings which have been found damaged at the time of delivery to the stock piles, particularly
those which are dented, buckled or otherwise permanently deformed, shall be stacked separately and shall
only be transported to the site after the defects have been repaired or eliminated. The Contractor shall be
fully responsible for selecting, arranging permits and paying for all storage and stockpile areas and pipe
dumps. The method of storage shall be subject to the Client approval.
Pipe and factory bends shall be stocked, chocked and padded, and secured in position during
transportation and during storage at pipe dumps or during stringing in a manner approved by the Client.
Pipes shall not be allowed to drop or strike objects which will damage the pipes but shall be lifted or
lowered from one level to another by suitable equipment. Lifting hooks, when used, shall be equipped
with a plate bent to fit the curvature of the pipe and shall be fitted with a soft insert to prevent damage to
the bevel. During hoisting, cables and wire ropes shall not come into contact with external coatings.
Rolling, skidding or dragging of pipes shall be strictly forbidden.
Coated pipes may be handled by means of suitable slings and belts made of non-metallic and non-abrasive
materials. In this case, pipes to be stacked shall be separated row by row to avoid damage when removing
the slings.
Coated pipes shall at all times be stacked completely clear from the ground so that the bottom row of
pipes remains free from any surface water. The pipes shall be stacked at a slope so that driving rain does
not collect inside the pipe.
The coated pipes may be stacked by placing them on ridges of sand free from stones and covered with a
plastic film or on wooden supports provided with suitable cover. The supports shall be spaced in such a
manner as to avoid over stressing the pipes. The pipes shall be stacked so that the uncoated beveled ends
are in line at one end, thus making differences in lengths clearly noticeable.
The coated pipes shall be stacked in a manner and to a height in such a manner as to prevent any damage
in the coating. Each pipe section shall be separated by means of spacers suitably placed for this purpose.
Stacks shall consist of pipe sections having the same diameter, and wall thickness. The welded bead of
pipes shall be positioned in such a manner so as not to touch the adjacent pipes.
Coated pipes stacked in open storage or dump yards shall be suitably covered to prevent direct exposure
to sunlight.
The ends of the pipes during handling and stacking shall always be protected with bevel protectors. The
Client will require the Contractor to replace any bevel protectors found to be missing.
The Lorries transporting the line pipe shall be equipped with adequate pipe supports placed on the
bottom of the lorry bed. Supports shall be provided for at least 10% of the pipe length. These supports
shall be lined with a rubber protection and shall be spaced in a manner as to support equal load from the
pipes. The rubber protection shall be free from all nails and stables where pipes are in contact. The second
layer and all subsequent layers shall be separated from each other with adequate numbers of separating
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layers of a suitable protective material such as straw in biodegradable covers or mineral wool strips or
equivalent, to avoid direct contact between the coated pipes.
All stanchions of lorries/rail wagons used for transportation shall be covered by non-abrasive material
such as rubber. Care shall be exercised to properly cover the stanchions and all relevant parts of the
truck/rail wagon body to prevent damage to the pipe coatings.
The Contractor shall submit a complete procedure indicating the manner and arrangement to be used for
the handling and stacking of coated pipes for the Client approval prior to the commencement of handling
operations.
6.2 HAULING AND STRINGING OF PIPE
Pipe is to be unloaded from the stringing trucks and is to be lowered onto the ground by means of side
booms, or other suitable equipment.
In rocky areas the trench is to be completely excavated and the area cleared of all debris and the requisite
base padding placed before stringing. However the Contractor is to note and allow for sand drift into the
trench in sandy areas, especially where any sand dunes exist.
All coated pipe strung on the ROW shall be supported in such a manner that the pipe is free from contact
with the ground at all times (a distance of 2 ft to 3 ft above ground shall be ensured). Sweet sand bags are
permissible for use as pipe supports except in wet areas where skids with wooden pads shall be employed.
Skids shall be at least 10 meter long. The skid surface in contact with the pipe shall have a width of at least
150 mm.
The pipes shall be strung parallel to the ditch at a suitable and constant distance from the centre line of
the ditch. The stringing on the ROW shall be done in such a manner as to cause the least interference with
the normal use of access tracks and roads crossed. Gaps shall be left at intervals or wherever requested by
other users to permit the passage for traffic or equipment across the ROW or along public roads or
highways. Pipe stringing shall be done in such a manner as not to cause a hazard to or to be subjected to
possible damage by traffic.
It shall be the responsibility of the Contractor to see that the pipes are strung in accordance with the
Contractor's schedules and drawings. Any additional handling of pipes resulting from failure to comply
with these requirements shall be at the Contractor's expense.
The Contractor shall record the pipe numbers, steel heat numbers, pipe lengths, wall thickness and
location of each piece of pipe as strung.
These records shall be amended "as laid" to include the weld numbers and the welder or welding
operator's identification numbers and shall be submitted to the Client as part of the final data book.
Pipes shall not be strung on the ROW more than 1 (one) kilometer in advance of the mainline welding,
unless specifically permitted in writing by the Client.
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Pipe ends shall be protected with suitable end covers to prevent dirt, dust and water from entering the
pipe while the pipes are strung along the ROW.
6.3 CARE OF MATERIALS
All materials shall be suitably stored and protected so that they do not deteriorate as a result of exposure
to high thermal conditions or adverse weather conditions. Deteriorated materials shall not be used and
shall be replaced at no extra cost to the Client.
The materials shall always be stored and handled so as to prevent any deterioration.
Any contact of the materials with water, mud, earth, dust, crushed stone and any other foreign material
shall be carefully avoided. The Contractor shall strictly conform to manufacturers' instructions regarding
storage of volatile materials which are susceptible to changes in properties.
For materials susceptible to corrosion, the Contractor shall exercise proper care, including the application
of grease or manufacturers' recommended treatment to susceptible areas/surfaces.
Flammable materials shall be stored in special safe locations.
7 TRENCHING
7.1 LOCATION
The Contractor shall excavate the pipeline trench on the surveyed route as staked or flagged, and may only
deviate in exceptional circumstances with the prior written approval of the Client.
7.2 EXCAVATION
The Contractor shall recognize that the personnel working in the trenches or excavation are at risk from
ground collapse and/or collision with excavated materials and construction equipment and shall make all
efforts to prevent any personnel injuries caused by working in trenches and excavations.
The Contractor shall excavate the pipeline trench on the cleared and graded ROW using methods
approved by the Client as per the present procedure. Care shall be exercised to see that fresh material
recovered from the trenching operation, and which is intended to be used for backfilling over the pipe in
the trench, is not mixed with loose debris or foreign material.
7.3 NORMAL COVER AND TRENCH DIMENSIONS
The trench shall be carried out in accordance with the related project drawings and in accordance to
geotechnical survey report.
The trench shall be excavated to a minimum width so as to provide, on both sides of the installed
pipeline, a clearance and to depth sufficient to provide the minimum cover .The cover shall be measured
from the top of the pipe, after is has been laid in the trench, to the graded ROW level.
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Details of soil nature along the pipeline route and the minimum trench depth at each type are specified in
the documents Soil Investigation Report R1111-RPT-CV-00-002, Typical Crossing Detail Drawing
(R1111-DWG-PL-00-001) and Special Crossing Detail Drawing (R1111-DWG-PL-00-002).
7.4 EXTRA DEPTH AND CLEARANCES
At points where the contour of the earth may require extra depth to fit the radius of a bend or to eliminate
unnecessary bending of the pipe according to customary good pipeline practice, or where a deep trench is
required at the approaches to crossings of roadways, tracks, wades, and the like, the Contractor shall
excavate such additional depth as may be necessary at no extra cost to the Client.
The Contractor shall excavate to additional depth where the pipeline approaches and crosses other
pipelines, sewers, drain pipes, water mains, telephone conduits, and other underground structures, so that
the pipeline may be laid with the minimum free clearance from the obstacle as may be required by
Authorities having jurisdiction.
Where the pipeline crosses areas whose easements specifically require greater than normal depths of
cover, the trench shall be excavated to extra depth in accordance with the ROW Agreements or as
required.
The Contractor shall excavate all such additional depths as may be necessary at no extra cost to the Client.
7.5 PROTECTION OF UNDERGROUND UTILITIES AND SPECIAL METHODS
The Contractor shall obtain plans and full details of all existing and planned underground facilities, such as
utilities, pipelines, cables and services. The Contractor shall be responsible for locating and protecting all
such facilities for locating and marking of existing pipelines. The crossing of existing pipe or cable shall be
carried out in accordance with relevant project drawings.
In locations where the use of trenching machines or back hoes would result in damage to property and
subsurface facilities and structures, the Contractor shall excavate the trench manually at no extra to the
Client.
Where the pipeline crosses existing underground facilities and structures, the Contractor shall first
manually excavate to uncover these, and clearly mark their presence i.e. type, diameter, horizontal and
vertical location and angle relative to the new pipeline.
Temporary underpinning or any other means necessary to protect the facilities or structures from damage
shall be provided by the Contractor at no extra cost to the Client.
If, despite all precautions, any damage should occur to any structures or facilities, the Owner/Authority
concerned shall be contacted by the Contractor and repair shall forthwith be carried out by the Contractor
at his expense and to the satisfaction of the Client and the Owner/Authority. If the Contractor fails to
repair in a reasonable time, the Client reserves the right to have the repairs executed at the cost of the
Contractor.
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7.6 GRADES, PADDING AND FINISH OF TRENCH
The trench shall be cut or made to a grade that shall provide a firm, uniform and continuous support for
the pipe. Bends shall be made in the pipe at significant changes in the grade of the trench. The Client
desires to reduce to a minimum the number of cold field bends required to lay the pipe to conform to the
general contour of the ground and maintain the necessary cover. This can be accomplished by cutting the
trench slightly deeper at the crest of ridges and by gradually deepening the trench in approaches to road
crossings and small water courses.
The Client intends that there will be a minimum of hand grading of the trench bottom. To achieve this,
the Contractor shall dig the trench bottom as square as possible with his equipment. The Contractor shall
do such hand work in the trench as is necessary to remove from the bottom of the trench all loose rock
and hard lumps of material.
In all cases where rock or gravel or hard material is encountered in the bottom of the trench, the trench
shall be at least 150 mm deeper than otherwise required, and it shall be evenly and sufficiently padded to
keep the pipe, when in place, at least 150 mm above the rocky bottom of the excavated trench.
Acceptable padding shall be placed under the pipeline before lowering in, and around the pipeline after
lowering in to establish at both sides and on top of the pipe a permanent layer of padding. The thickness
of the compacted padding on top of the pipe shall be at least 150 mm. Padding materials to be used shall
be free from rocks, stones and hard lumps of material.
Where the route of pipeline indicates either a horizontal and/or vertical change of direction, the
Contractor shall trim the trench to such a profile that the pipe is supported throughout its length and
proper clearance is maintained between the pipeline and trench wall.
When a pipeline is not installed to the required depth or is not evenly bedded, it shall be lifted from the
trench before any additional excavation or backfilling is carried out.
7.7 TRENCH CROSSINGS
Excavation, minimum cover and general arrangement at crossings of ditches, roads, foreign services and
tracks shall be in accordance with the AFC (Approved For Construction) drawings. Such the minimum
cover shall be confirmed by generic stress analysis calculations and, where necessary, by specific
calculation for selected crossing.
Where the trench has been cut across access roads or tracks etc., the Contractor shall install substantial
temporary bridge work to the full width of the tracks, of adequate strength and properly constructed to
ensure safety of the public and to allow passage of normal traffic with minimum inconvenience and
interruption. The Contractor may also propose a suitable diversion for approval.
Wherever deemed necessary by the Client, the Contractor shall arrange to complete the trenching, laying
and backfilling of such crossings and to remove the temporary bridging before the end of the regular
working day in order to minimize the hazard to night traffic.
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The Contractor shall obtain the permission of the appropriate Authorities, in writing, before commencing
work and shall ensure that all regulations and requirements of the Authority having jurisdiction are
complied. Proper warning signs shall be placed and maintained while such crossings are open. If such
crossings are open at night, the Contractor shall provide and use warning lights of a type approved by the
Client and by the responsible Authorities.
7.8 PROTECTION OF TRENCH & AUGER PITS
The Contractor shall keep the trench pits in good condition until the pipe is laid and until backfill takes
place and no claim is to be made to the Client by reason of its caving in either before or after the pipe is
laid. All materials necessary to shore the trenches and pits in order to prevent caving are to be furnished
by and subsequently removed by the Contractor.
The Contractor shall provide adequate de-watering equipment, shoring and any other equipment and
materials required to excavate the trenches and pits, to install the pipe and to backfill the trenches and
pits. The trenches and pits in high water table areas shall be kept dry during all phases of work until
completion of backfilling.
7.9 PROVISIONS FOR POSITIVE BUOYANCY TO THE PIPE
The Contractor shall check if positive buoyancy is likely and shall then take appropriate measures to
prevent it such as by applying material dams. Such measures shall be subject to the Client's approval.
In the case of water on the ditch bottom when the pipe line is being laid, the ditch shall be drained to the
extent and for the time required to make a visual inspection of the ditch bottom. After this inspection, the
presence of water may be allowed provided its level is such that positive buoyancy of the pipe will not
occur and that it will not cause sliding of the ditch sides before backfilling.
The water pumped out of the ditch shall be discharged into a natural water course.
Wherever positive buoyancy of the pipeline after backfilling is likely, anti-buoyancy measures shall be
provided by the Contractor using one or a combination of the following methods:
- Weighting by applying a continuous concrete coating around the pipe if pipe is laid in flooded trench.
- Weighting by pouring lean concrete on the pipe laid in dry trench.
- Deeper burial of the pipeline.
- Provision of selected backfill material.
7.10 EXPLOSIVES
The contractor shall not use explosive without the express written permission of the client. The contractor
shall acquire, store and use the explosive in accordance with the requirements of the relevant authorities
within the Government of Sudan.
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8 BENDING
8.1 PIPE BENDS
The Contractor should preferably provide for changes of vertical and horizontal alignment by making
elastic bends. The Contractor may also provide cold field bends, for changes of direction and changes of
slope. Hot bends (R= 7D) shall be used only where approved by the Client. The entire pipe bend shall be
recorded in bending inspection report.
The pipe-bending shoe shall correspond to the pipe diameter.
The maximum angle of filed bend shall be 18°.
8.2 ELASTIC BENDS
The elastic bend shall be continuously supported over its full length. A radius smaller than permitted in
elastic bending shall require a cold bend.
8.3 COLD FIELD BENDS
 Bends shall be made by a cold smooth stretch method approved by the Client, in such a manner as to
preserve the cross-sectional shape of the pipe. In no case shall heat be used for the purpose of bending
the pipe.
 The radius of cold bends shall not be more than 40 times the pipe nominal diameter.
 The Contractor shall use a bending machine and mandrel and shall employ recognized and accepted
methods for the bending of coated pipe in accordance with good pipeline construction practice.
Bending machine shall be of a type approved by the Client and shall make bends without wrinkles or
buckles and without damage to the coating. Any coating damage shall be repaired by the Contractor.
 The bending procedure shall conform to the recommendations of the manufacturer of the bending
machine. The procedure shall include amongst other steps - lengths, maximum degree per pull and
method and accuracy of measurement during the pulling of the bend. This procedure and the
equipment used shall be subject to the Client's approval.
 The pads, dies and rolls of the bending equipment shall have relatively soft surfaces to avoid damage to
the pipe coating. Where applicable, fully retaining bending shoes shall be used. Roller type bending
machines are preferred.
 The ends of each bent length shall be straight and not involved in any way in the bending. The length
of the straight section shall permit easy joining. In no event shall the end of the bend be closer than 2
m from the end of a pipe.
 The ovalisation of a bent pipe shall not exceed 1.0% of the normal diameter at any point. A check shall
be performed on all bends in the presence of the Client by passing a gauge consisting of two steel or
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aluminum discs each with a diameter equal to 97% of the nominal internal diameter of the pipe
connected rigidly together at a distance equal to five pipe diameters.
 The pipe diameter shall not be reduced at any point by more than 2.5% of the nominal diameter.
8.4 MITRE AND UNSATISFACTORY BENDS
All bends showing buckling, wrinkles, cracks or other visible defects or which are in any way in non-
compliance, in whole or in part, with this specification shall be rejected.
No miter bends shall be permitted in the construction of the pipe line. The Contractor shall cut out and
remove any bend or bends which do not meet the specifications and shall replace the same with
satisfactory bends at no additional cost to the Client.
Cutting of factory made bends and cold field bends for any purpose is not permitted.
9 LAYING UP AND WELDING
9.1 CARE OF PIPE
The Contractor shall lay out and measure the pipe so that the number of cut off pieces of less than 1.5
meters long is held to a minimum.
The Contractor shall, as far as possible, make cuts and tie-ins so that any 'off-cuts' are more than two
meters long. These 'off-cuts' shall be used for welded connections between positioned line pipes instead
of cutting length from long pipe spools for this purpose.
Notwithstanding the above, the minimum distance between any two circumferential welds shall be at least
three (3) diameters and there shall be no more than three (3) circumferential welds in any eight (8) meters.
9.2 PIPE DEFECTS AND REPAIRS
The Contractor shall be responsible for the repair and removal of all internal and/or external pipe defects
to the extent that they are acceptable to the Client.
 Acceptability of defects in the pipe detected during inspection at the work site shall be determined in
accordance with the Client's approved material specification in accordance with which the pipe was
purchased or Code ASME B31.4 whichever is more stringent for the type of defect under
consideration.
 The maximum permissible depth of dents in pipes shall be 0.5 mm. All dents shall be examined by
means of NDT for the presence of cracks.
 Dents which contain a stress concentrator such as a crack, scratch, gouge, arc burn or groove, and
dents located at the longitudinal weld or pipe end shall be removed by cutting out the damaged portion
of pipe as a cylinder.
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 Repair on line pipe shall be executed as specified in the Client's approved material specification or
Code ASME B31.4, whichever is more stringent. A record of all repairs is to be maintained by the
Contractor. This record, provided with the pipe identification number, is to be submitted to the Client
in the Pipeline Data Book.
 If the pipe identification number is removed due to cutting or repairs, it shall be reprinted immediately
by the Contractor. No pipe without identification number shall be welded into the pipeline.
9.3 SWABBING, PIPE BEVELLING AND CLEANING ENDS OF JOINTS
 Prior to aligning pipes for welding, each length of pipe shall be thoroughly examined internally and
externally to make sure that it is free from visual defects and damage, general corrosion and corrosion
pitting, dirt, dust and any other foreign objects. Each length of the pipe shall be adequately swabbed,
either by use of a leather or canvas belt disc of proper diameter (97% nominal pipe id) or by other
methods approved by the Client. Damaged or corroded pipes shall be kept separate and shall not be
used. Each length of pipe shall be pulled through with a gauging plate of a size acceptable to the Client
(97% nominal pipe id) just before being welded to ensure there are no unacceptable pipe deformations.
 Immediately prior to aligning pipe for welding, the beveled ends of each joint of pipe and the area
immediately adjacent thereto (at least 25 mm from the edge on the inside and outside of the pipe) shall
be thoroughly cleaned of paint, rust, mill scale, dirt or other foreign matter by use of power-driven
wire buffing brushes, or by other methods approved by the Client.
 All damaged ends of pipe that are bent, cut, or otherwise mutilated, such that, in the opinion of the
Client, faulty alignment or unacceptable welding would result, shall be repaired or cut off and
rebeveled to the correct angle with a beveling machine of a type approved by the Client.
 Dents in bevels with a depth of less than 1 mm shall be removed by the Contractor during the cleaning
and grinding, ahead of the welding in the field. The Contractor shall rebevel dented bevel ends with a
depth of dent between 1 and 3 mm. Dents over 3 mm shall be repaired by cutting.
 Repair of damaged pipe ends by hammering and/or heating is not allowed.
9.4 PIPE HANDLING AND SKID SUPPORT
 When lifting pipe, care must be taken not to kink or overstress it. Proper pipe slings of a type and at
lift points approved by the client shall be applied. The Contractor shall submit his proposed type of
skidding and skid spacing for the Client's approval. A strip of soft material shall be placed in between
the skid and the pipe to protect the factory applied coating. The material shall be of a type approved by
the Client.
 Pipe supports shall be stable, so that pipe movement will not cause the supports to move. Skids shall
not be removed from under a string before lowering in. The welded pipe shall be maintained on skids
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at the minimum distance of 500 mm above ground. Crotches shall be installed at frequent intervals (at
least every 10th support) with a greater number required at bends and undulating grounds.
9.5 ALIGNMENT OF PIPE
 All pipe joints shall be aligned with clamps approved by the Client. Strong backs are not permitted.
 All joints shall be aligned and welded with a uniform spacing. No backing rings will be permitted. The
high low misfit shall be scattered about the periphery or swaged to fit. The use of hammers, if used,
shall be kept to a minimum and shall have bronze coated or other suitable head and shall be used in a
manner as to avoid damage to the pipe.
9.6 NIGHT CAPS
At the end of each day's work or every time when joining and welding operations are interrupted, the
open ends on the welded strings of pipes shall be capped with a securely closed metal cap or plug as
approved by the Client, so as to prevent the entry of dirt, water, or any foreign matter into the pipeline.
These covers shall not be removed until the work is to be resumed. The caps/plugs used shall be of a
mechanical type and shall not be attached to the pipe by welding or by any other means which may dent,
scratch or scar the pipe.
9.7 TEMPORARY CAPS
Whenever welded strings of pipes are left open to be tied in later such as under roads, streams and other
crossings, temporary caps approved by the Client shall be welded to the ends of the pipe.
9.8 WELDING
Pipeline welding shall be carried out in accordance with specification No. R1111-SPC-PL-00-008.
The pipe shall be fully supported against any movement whilst position welding is taking place to ensure
no weld cracking results. Earthing clamps shall be connected to the bevel face and shall not rest on parent
metal surface adjacent to the weld preparation area. Clamps shall by subject to the Client's approval.
10 FIELD JOINT COATING AND LOWERING IN
10.1 FIELD JOINT COATING
Field joints shall be corrosion coated in accordance with "On Site Pipeline Coating and Coating
Reparation Specification" document No. R1111-SPC-PL-00-005.
10.2 METHOD AND TIME OF LOWERING PIPE
 Lowering can start after removal from the trench bottom of all cut offs, pipe supports, stones, debris,
stakes, rock projections and any other rigid materials which could lead to perforation or scratching of
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the pipe coating. Sand padding shall be provided in accordance with applicable clauses of this
specification and with the typical drawings, prior to the lowering operation.
 Lowering shall follow as soon as possible, after the completion of the field joint coating of the
pipeline.
 Before lowering in, short completed sections of the pipeline shall be cleaned with compressed air in
order to remove all dirt, etc. from the inside of pipe sections.
10.3 LOWERING SLACK LOOPS
After such backfilling has been done as may be necessary to hold bends in the proper position, slack loops
shall be lowered.
10.4 CARE IN HANDLING COATED PIPE
Coated pipe shall not be handled or moved by means of cable or chains, or by prying with skids or bars,
or by dragging along the ground. The pipeline shall be lifted and laid using, for all movements necessary,
suitable equipment of non abrasive material having adequate width for the fragility of the coating and
approved by the Client. Care shall be exercised while removing the slings from around the coated pipe
after it has been lowered into the trench. Lowering in utilizing standard pipe cradles shall be permitted if
the Contractor demonstrates that the pipe coating will not be damaged. No slings or other lifting or
lowering aids shall be put around field joint coatings.
10.5 REPAIR OF DAMAGED COATING
Immediately before lowering in, a complete check by a full circle holiday detector shall be carried out on
the pipe coating and the field joint coatings, to ensure a 100% holiday free pipeline coating system. All
damages shall be repaired in accordance with "On Site Pipeline Coating and Coating Reparation
Specification" No. R1111-SPC-PL-00-005. All points on the pipeline where the coating had been in
contact with either the skids or with the lifting equipment during laying shall be carefully inspected for
damage, denting or other defects which shall be properly repaired. If, after checking, it becomes necessary
to place the pipeline again on supports at the bottom of the trench, these must be padded in such a way as
to prevent damage to the coating, thus avoiding the necessity for further repairs when the pipe is finally
raised and laid. Before the last operation, a check shall be made of the coating at points of contact with
the supports.
10.6 ERRORS
Wherever the pipeline is laid under tension, as a result of an assembly error (for example, incorrect
positioning of bends), the trench shall be rectified or in exceptional cases a new assembly shall be carried
out, to be approved by the Client so that it fits the excavation and laying bed.
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10.7 STRESSES
Laying shall be carried out under safe conditions so as to avoid unacceptable stresses and temporary
deformations which may cause damage to the pipeline itself and to the coating. At localized points where
the ROW is restricted to less than the minimum necessary for the transit of mechanical equipment, the
laying shall be carried out using other suitable means. The pipe shall be placed on the bottom of the
excavation, without jerking, falling, impact or other similar stresses. In particular, care must be taken that
the bending caused during the raising of the pipe work from the supports, does not exceed the values for
the minimum allowable radius of elastic curvature, so as to keep the stresses on the steel and on the
coating within safe limits. The portion of the pipeline between trench and skids shall be supported by as
many side booms as required for holding the line in a gentle S curve maintaining the minimum allowable
elastic bend radius.
10.8 DRAINING
Where water is present, no laying shall be permitted until the ditch has been drained to the extent and for
the time necessary to make visual inspection possible of the bed on which the pipe is to be laid.
10.9 PRECAUTIONS
The Contractor shall take precautions immediately after lowering in to prevent the movement of the pipe
in the trench.
10.10 TIMING OF LOWERING IN OF PIPE
The time of the lowering in operation and the amount of pipe to be lowered in shall take into account the
required backfilling operation in the event of unstable ditch walls or inclement weather. The lowering in
operation shall be stopped if the required backfilling operation cannot keep up.
10.11 AS BUILT MEASUREMENTS
All measurements required for the preparation of "as built" drawings, to the extent required, shall be made
prior to backfilling.
10.12 FIBER OPTIC CABLE (FOC) INSTALLATION)
Refer to optical fiber specification (R1111-SPC-IN-00-009).
11 CATHODIC PROTECTION REQUIREMENTS
As backfilling proceeds the Contractor shall install the cathodic protection system as per the requirements
of cathodic protection specification approved by the client, and shall be activated in the shortest possible
time. If for some reasons this is delayed, the Contractor shall supply and install temporary impressed
current cathodic protection system.
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12 BACKFILLING
12.1 APPROVAL BY THE CLIENT
No backfilling shall be undertaken until the pipe and appurtenances have the proper position and depth to
provide the required cover. Before any backfilling is commenced it shall be the Contractor's responsibility
to first secure the approval of the Client. If any backfilling is done without the Client's approval, the Client
shall have the right to require removal of the backfill for examination. Subject to compliance with the
specifications, the backfilling operation shall follow as closely behind the lowering in as practicable so as
to securely position the pipe in the ground as soon as practicable.
All the backfilling activities shall be made as per the present specification and related backfilling
documents.
Backfilling shall not be completed until all drains and services crossed by the pipeline have been repaired
and approved by all relevant parties.
12.2 SELECT BACKFILL MATERIALS AND PADDING
Backfill and padding materials shall not contain gravel or rock over 6 mm in largest dimension.
Hard materials like gravel, rock, etc. shall not be backfilled directly on the pipe.
Loose rock, wherever encountered, may be returned to the trench after the required selected backfill
material has been placed subject to the approval of the Client.
Topsoil shall not be used for intimate backfill.
12.3 SPECIAL TREATMENT OF TRENCH BACKFILL
Where the trench has been dug through tracks, etc., all backfill shall be thoroughly compacted to 95%
Proctor Density. In certain cases, special compaction methods may be required. This will have to be
followed up by stabilization of the surface of the backfill with crushed rock or some other suitable
material. In all such cases, the Contractor shall comply with the requirements of the Authorities
concerned.
Underground drainage interrupted by the trenching operation shall be carefully restored and protected and
damaged portions replaced. For all of these works, no backfilling shall take place with mechanical
equipment where damage could result to any service or structure in the vicinity.
12.4 FURROWS, TERRACES, WATER BREAKERS
When backfilling trenches on sloping terrain (slope generally 10% or more) and on the banks of water
courses where backfill may be washed out of the trench, terraces or effective water breakers across the
trench shall be provided by the Contractor, to divert the flow of water away from the trench into normal
drainage. In no case shall surface drainage be diverted into channels other than those followed before the
line was laid.
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12.5 POSITION OF BACKFILL
In track crossings, where restoration is necessary to assure the safety of the pipeline and the passage of
traffic, the Contractor shall regrade the ground to its original contour. For compaction of backfill along
the pipeline, mounding over the pipeline without any mechanical compaction is acceptable. The
Contractor shall calculate the height of the mound to allow for a typical bulking factor for the backfill
material used and for the compactive effort employed.
The final compaction of the backfill at various locations shall be accomplished by tamping or by running
on top of the fill a rubber tyred compacting device approved by the Client.
13 TYING IN
13.1 JOINING UNCONNECTED SECTIONS
Where sections of the line are to be tied in after the sections have been lowered in and backfilled, the
length of pipeline left unbackfilled specifically for the purposes of tying in shall be kept to a minimum.
The Contractor shall carry out tie in welding, and other operations for the tie-ins in accordance with
procedures approved by the Client.
Tie in welds in restrained sections of the line shall be made when the pipe temperature is as stated in the
procedures. If necessary to avoid strain in the pipe, sufficient restrained pipe shall be uncovered to allow
slack loops to be held during the line up and welding of the tie in. Under no circumstances shall the line
be left in tension after the tie-in. Bell holes made to facilitate welding shall provide adequate clearance to
enable the welder to exercise normal welding ability and skill. The overlap of the strings at tie-ins shall be
at least 2.5 meters. All tie in welds shall be 100% radiographically examined. Field jointing and backfilling
at tie in locations shall then be performed.
13.2 PUPS
If a pup piece is to be added for tie in, the minimum length that may be used shall be at least three (3)
diameters. Two or more such pups shall not be welded together. Tie in with two or more pups may be
used provided that they each have a minimum length of 1.5 meters and are separated by an entire length
of pipe. In no case shall more than three (3) welds be permitted on any eight (8) meter length of pipeline.
13.3 TAPERING
In the use of special items, fittings and equipment to weld together pipe of different wall thicknesses, the
Contractor shall follow the procedures indicated in ASME B 31.4 Fig. 434.8.6(a) (2). The required tapering
shall be done by the Contractor at no extra cost to the Client. The minimum allowable wall thickness after
tapering (pressure design thickness plus corrosion allowance) shall be maintained at all locations.
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14 CLEAN UP AND RESTORATION OF ROW
14.1 CLEAN UP OF ROW
Immediately following a completed backfill the Contractor shall clean up the ROW and dispose of all
surplus and defective construction materials, except as provided for in Section 15.3. The Contractor shall
dispose of all refuse such as broken skids and debris to the complete satisfaction of the Client and
government authority having jurisdiction thereof.
On completion of clean up, the ground and access ways etc. shall be restored to such stable condition as is
reasonably consistent with the condition of the ground prior to laying the pipeline. Any plantation area
shall be repaired, reseeded and restored to the original condition. Drains along the ROW shall be
reinstated. Any fences damaged by construction activities shall be replaced and reinstated by the
Contractor.
14.2 DISPOSAL OF ROCK/DEBRIS
All residual rock and debris left on and beyond the ROW by construction operations shall be picked up by
the Contractor and disposed of to the satisfaction of the Client.
14.3 SURPLUS MATERIALS
Any surplus and defective materials shall be collected by the Contractor and delivered to designated
stockpile areas. No material shall be disposed of as scrap without the approval of the Client.
14.4 PROGRESS OF INTERMEDIATE AND FINAL CLEAN-UP
Final clean up must not be left incomplete except with the approval of the Client, who will also have the
right to shut down, without any compensation except for backfilling and clean up. Special attention shall
be given to the removal of left over electrodes in the ROW and the trenches. Electrodes shall be removed
on a daily basis.
15 CROSSINGS
15.1 GENERAL
 Crossings of roads, railways, rivers, water crossings, buried services, etc. with equipment and/or
personnel shall only take place after the Contractor has obtained written approval from the authorities
having jurisdiction.
 It shall be the Contractor's responsibility to acquaint him with all relevant requirements and regulations
of authorities and governmental bodies having jurisdiction and to obtain their approval in writing and
all necessary permits before commencing work. Notwithstanding the provision of drawings and
specifications by the Client, it shall also be the Contractor's responsibility to ensure that the work is
performed to the requirements and specifications of the relevant authorities.
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 Highways, Main Roads and their verges are not allowed to be used for loading, unloading or stacking
of materials and/or equipment. For secondary roads, such loading/unloading is permitted only after
prior approval from the concerned authorities The Contractor is not allowed to close or divert roads
without prior approval from the Client and the concerned authorities. The Contractor shall never
unnecessarily hamper other users of the roads.
 In the event that no specification is made available from relevant authority, the requirements of API
RP 1102 shall apply to the highway and railway crossing.
15.2 CONSTRUCTION METHODS
 Crossing of designated major roads and railways as indicated in the alignment sheets shall be cased and
installed as per the detailed crossing drawing by auger bore or thrust bore methods subject to the
Client's approval.
In all cases the Contractor shall submit to the Client his proposals for the installation of the crossing,
particular crossing drawings, program, detail of the methods to be used, the type of equipment and the
results of any investigation and surveys. Word on the crossing shall not commence until the
Contractor's drawings, methods and procedures have been approved by the Client in writing.
 Construction of crossings shall be carried out in accordance with the relevant drawings.
 Construction of crossings shall include all necessary clearing and grading, excavating, shoring,
dewatering, trenching to the required depths and widths, welding of casing and carrier pipes, coating
and wrapping, lowering, backfilling, clean up, restoration to the original condition and any further
strengthening and protective works required. Testing, installation of vent assemblies, insulators, seals,
casing pipes, etc. shall also form part of the work.
 Before the installation work of crossings is started, the Contractor shall provide suitable barricades.
Adequate traffic warning signals and/or traffic lights and suitable diversions shall be provided as
directed by the Client/Authority having jurisdiction over these areas .Such diversions shall not cross
the pipeline where it has already been installed, unless proper safeguards are provided.
 Actual installation of crossings shall comply with the detailed crossing drawings approved by the Client
for construction. The Contractor shall have fully investigated; all details of the crossings provided and
have carried out his own investigations at conditions that might be encountered at the time of
construction.
 All track crossings shall be uncased and shall be constructed by open cut method followed by backfill
and reinstatement.
 To avoid settlement in uncased crossings, the pipe shall have firm bearing on the bottom of the trench
for a distance of not less than five meters beyond each side of the crossing. This shall be accomplished
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either by compacting the bottom of the trench or by placing sand filled bags under the pipe at one
meter intervals.
 The sub surface and surface layers shall be reinstated to the satisfaction of the relevant highway
authority and in accordance with this specification and construction drawing approved by the Client.
 Pipe to be installed at waterway crossings with permanent water shall be hydrostatically tested to a
hoop stress of 90% SMYS, based on nominal wall thickness, prior to installation.
The drawings documents of crossing indicated above are:
- Typical Crossing Detail Drawing R1111-DWG-PL-00-001

- Special Crossing Detail Drawing R1111-DWG-PL-00-002
- Right Of Way Detail R1111-DWG-PL-00-003
15.3 INSTALLATION OF CASING
 The Contractor shall install the casing pipe in accordance with typical and detailed drawings approved
by the Client and permits and instructions issued by the Authority.
Boring machines used for the installation of casing pipe shall be of a type approved by the Client.
 Casing shall be installed with an even bearing throughout its length. The casing pipe shall be sand
blasted and primed prior to installation. The welding of casing pipe shall be done in accordance with
the Welding Specifications.
While no internal high or low is allowed on the finished weld for the casing and vent/drain pipes,
welding of casing and vent/drain pipes need not be radiographed. Visual checks, however, shall be
carried out. Before welding, each pipe shall be inspected in order to check that there is no out of
roundness and/or dents. When such defects are present, they must be completely removed before
joining the pipes. If these defects cannot be repaired, the defective section shall be cut out and
replaced.
 The assembly and installation of vent and drain pipe units as per the drawings approved by the Client
shall be carried out before introducing the carrier pipe. The operation of assembling and extending the
vent pipe shall be carried out in such a way that there is no contact with the carrier pipe. The painting
and coating of the vent and drain pipes shall be applied before backfilling.

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15.4 INSTALLATION OF CASING BY BORING/JACKING
 The diameter of the hole for a bored section shall have a whole diameter as close as practicable to the
outside diameter of the casing pipe. If an excessive void or too large a hole results, or if it is necessary,
to abandon the bored hole, prompt measures such as filling the hole with suitable material shall be
taken to the entire satisfaction of the Client and Authorities having jurisdiction thereof.
 An installation consisting of hydraulic jacks shall be provided with easily readable pressure gauges and
sealable pressure limits. Their proper operation shall be demonstrated before the work is started. The
Client retains the right to restrict the maximum pressing force.
 During jacking the progress of the pipe to be jacked and the cutting capacity of the auger shall be
mutually adjusted, by regulating the speed of the auger, to prevent the surface from bulging (rpm too
low) or cave ins (rpm too high). In any case no more material shall be removed than the volume of the
pipe. The auger drive shall be provided with a clutch.
 The progress in the work, the readings of the gauges the jacking pressures observed, etc., shall be
recorded in a log book, to be shown to the Client upon request. All information shall be supplied to
the Client on completion of the work.
 If the jacking fails, the casing shall not be withdrawn .It shall be filled with sand and plugged at either
end.
 The procedure for checking the alignment shall be provided by the Contractor for the Client's
approval. The alignment shall be checked in accordance with the approved procedures.
 The casing by boring and jacking shall be used for railways and asphalt roads and in case when road
crossing by trenching is not permitted by the Sudanese authorities.
15.5 INSTALLATION OF CARRIED PIPE IN CASING PIPE
 Prior to the installation of the carrier pipe in the casing pipe, the casing shall be cleaned of all dirt,
water and debris.
The casing pipe shall be considered ready for installation of the carrier pipe after careful inspection and
internal cleaning and after the removal of all materials including stones and other foreign bodies.
 The section of carrier pipe that is to be placed in any casing shall have been hydrostatically pre tested
prior to field joint coating. The section of the pipeline for each crossing shall be tested as a single
string. The test pressure shall be the one resulting in a hoop stress corresponding to 90% of SMYS of
pipe material based on nominal wall thickness. Test pressure shall be held for a minimum period of 4
hours. The test section shall be visually examined for leaks and defects.
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 The corrosion and field joint coatings of the carrier pipe shall also be thoroughly tested with a holiday
detector before installation in the casing. Any coating damage shall be remedied to the Client's
satisfaction prior to installing the carrier pipe.
 Care must be taken in pushing or pulling carrier pipe into the casing that the pipe is aligned correctly in
the casing and that the pushing or pulling force is evenly and constantly applied to avoid damage to the
insulators. A nose piece having a diameter equal to that of the pipe shall be welded on the front and
back end of the carrier pipe to facilitate installation of the carrier pipe properly in the casing and to
keep it dry and clean.
 The Contractor shall provide additional trenches for inserting the carrier pipe if so required due to the
pipeline alignment.
15.6 INSULATION OF CARRIER PIPE FROM CASING
After installation of carrier pipe, casing and appurtenances, but prior to making tie in welds and
backfilling, electrical tests shall be conducted by the Contractor, in the presence of the Client, to
determine the resistance between the casing and the carrier pipeline. These tests shall show infinite
resistance. After backfilling and compaction, additional tests shall be conducted. If the installation is found
to be defective, the Contractor shall make the necessary corrections and repairs, until a test result to the
satisfaction of the Client is obtained.
The extent of casing pipe and depth of cover to be provided at each cased road and rail crossing is
indicated in the construction drawings approved by the Client. Before commencement of construction,
the Contractor shall obtain approval from Authorities having jurisdiction as to the extent of casing pipe
and requirement for cover to top of pipe for each crossing. In case Authorities having jurisdiction require
a larger extent of casing pipe or deeper cover, the Contractor shall install such additional lengths of casing
pipe and/or shall install the pipe at greater depth to fully comply with the requirements of Authorities.
15.7 CROSSING OF BURIED SERVICES
The pipeline under construction is to pass below the existing buried facilities such as pipelines, cables, etc.
except in exceptional cases where it may pass above, subject to the Client's approval. The type of crossing
shall be such that a minimum depth of cover as required in the drawings and specifications are guaranteed.
The minimum clearance required between the pipeline and the existing facility shall be 500 mm or such
greater depth as may be demanded by the controlling authorities or owners.
Whatever buried services in the ROW are to be crossed by the Contractor, the Contractor shall safeguard
the buried facilities and the required precautions shall be executed as approved by Owners of the buried
services and by the Client.
For buried services to be crossed by boring or jacking, the relevant provisions of this Section shall apply.
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15.8 WATERCOURSE CROSSING
Water course crossings shall be in compliance with ASME B31.4 para 434 as followings:
For Crossings of rivers, streams, lakes, and inland bodies of water, the designer shall investigate
composition of bottom, variation in banks, velocity of water, scouring, and special seasonal problems. The
designer shall determine whether the crossing is to be underwater, overhead on a suspension bridge, or
supported on an adjacent bridge. Continuity of operation and the safety of the general public shall be the
controlling factors both in design and in construction. Where required, detailed plans shall be prepared
taking into account these and any special considerations or limitations imposed by the regulatory body
involved.
For underwater Construction, plans shall describe the position of the line, showing relationship of the
pipeline to the natural bottom and the depth below mean low water level when applicable. To meet the
conditions set out in ASME B31.4 para 434.13.1, heavier wall pipe may be specified. Approach and
position of the line in the banks is important, as is the position of the line across the bottom. Special
consideration shall be given to depth of cover and other means of protecting the pipeline in the surf zone.
Special consideration shall be given to protective coating and the use of concrete jacketing or the
application of river weights. Complete inspection shall be provided. Precautions shall be taken during
construction to limit stress below the level that would produce buckling or collapse due to out-of
roundness of the completed pipeline.
16 INSTALLATION OF APPURTENANCES
16.1 GENERAL
In addition to constructing the pipeline, the Contractor shall also install certain other auxiliary facilities
which are complete in all respects and ready for operations.
Without limiting the generality thereof, the work required to complete the installations shall include all site
surveys, site preparation, filling, grading, fencing foundations, installations of block valves, side valves,
pipe work, pipe supports, pressure gauges, mechanical facilities, civil and structural work, painting,
installation of all electrical equipment, control systems, motors, cables, conduits, wiring and fixtures,
drains, vents, utilities, cathodic protection systems, and hooking up of same; installation of all instruments,
piping, valves and fittings; mounting all instruments and make up of all piping and electrical connections,
etc.
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On completion, all elements of each entire installation shall be checked out and tested for full and correct
operation in the presence of, and to the satisfaction of the Client. All work shall be carried out strictly in
accordance with the appropriate codes and the approved drawings, specifications and procedures.
The Contractor shall ensure that the piping assemblies are not under strain prior to final bolting or
welding. The Contractor shall also ensure that all equipment and piping are thoroughly swabbed clean of
all dust, refuse, welding spatter, scale, and any potentially detachable matter prior to tie in or final bolting.
16.2 DIMENSIONAL TOLERANCES
These tolerances apply to in line items and connections for other lines. These tolerances can be exceeded
on items such as vents, drains, dummy supports, field supports, and temperature and pressure
connections where the deviation will not affect another spool.
 General dimension such as face to face, face or end to end, face or end to centre, and centre to centre:
3mm.
 Inclination of flange face from true in any direction: 4mm per meter.
 Displacement of branch connection from indicated location: 1.6mm.
 Rotation of flange bolt holes shall not exceed 1.6mm.
16.3 FLANGED CONNECTIONS
The Contractor shall ensure that all flange faces are parallel and centered, prior to final bolting. The
Contractor shall not use bolting forces as a means for attaining alignment. A gasket of proper size and
quality shall be installed between the flanges at each joint.
Bolts shall be tightened in diagonal sequence and shall be centered with equal amounts of thread visible
on both sides. Bolts shall be uniformly tightened to produce a leak proof joint. Bolts that yield during
tightening shall be removed and discarded. It is mandatory that a torque wrench is used for bolt
tightening, and that bolt torques and residual stresses are submitted to the Client in advance for approval.
16.4 THREADED CONNECTIONS
Damaged threads shall be cut from the end of a run and the pipe shall be rethreaded.
The Contractor shall properly align all threaded joints. Pipe entering unions shall be true to the centerline
so that the union will not be forced during make up. The threaded pipe shall not project through fittings
to cause interference with valves or other operating mechanisms.
Except for the threaded connections of instruments which will require periodic testing and maintenance,
all threaded joints shall be seal welded. The latter joints shall be made up without pipe joint compound
and with a minimum of oil from the thread cutter. Seal welds should taper into the pipe with as little
discontinuity as possible, and should cover all threads.
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16.5 WELDED CONNECTIONS
All welding shall be performed in accordance with the project pipeline welding specification document
number R1111-SPC-PL-00-008.
Tie ins between fixed points shall be made at minimum ambient temperature.
16.6 CIVIL WORK
Civil work shall be performed in accordance with approved Specifications and procedures prepared for
the purpose.
16.7 PAINTING
All above ground surfaces like piping, valves, structures, and miscellaneous appurtenances shall be painted
in accordance with the Painting Specification document number R1111-SPC-PP-00-005.
16.8 COATING OF BURIED INSTALLATIONS, ETC
All buried pipes used for piping at sectionalizing valve stations, (other than main line pipe) shall be coated
in accordance with the requirements of Specification document number R1111-SPC-PL-00-005. The
Contractor shall submit to the Client a procedure for the application of the coating along with all the test
certificates for the materials to be used. After obtaining written approval from the Client, the Contractor
shall commence the work of coating. Coating integrity shall be checked by "Holiday Detector" over the
full length of coated pipe. Field weld joints shall be coated in accordance with the requirements of the
Coating Specification document number R1111-SPC-PL-00-005.
All buried tees, valves, bends other in line fittings and appliances shall be coated to specification
document number R1111-SPC-PL-00-005.
16.8.1 Clean Up
After all required tests have been concluded satisfactorily the Contractor shall clean up the site to the
Client's satisfaction.
16.9 INSTALLATION OF VALVES
 Valves with flow arrows shall be installed according to the normal flow in the pipeline. During
installation, the valves shall be in the fully open position. In addition all manufacturers’ instructions
shall be followed.
Great care shall be taken to avoid entry of sand particles, etc., to valve body, seals, etc., during
transportation, storage, assembly and installation. The Contractor shall specify his methods to avoid
'contamination' of the equipment and materials.
 Sectionalizing valves shall be installed at the locations shown on the alignment sheets, on sections of
the pipeline in the horizontal position only or with an inclination not greater than that allowed by the
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valve manufacturer. Installation shall be done in such a way that there is no strain in the flanged joint
and that the pipeline upstream and downstream is straight.
 All valves shall always be handled carefully to avoid impact, shaking and other stresses. In particular,
the lifting and handling shall never be done through attachments to the handwheel, valve stem, flange
joints or other parts which may suffer damage.
 All valve assemblies shall be installed at the agreed locations only after all other sections of pipeline
have been adequately cleaned internally. This is in order to protect the valve internals from damage due
to mill scale, dirt, dust and weld icicles etc. during filling, flushing, hydro testing and dewatering. All
works shall be executed in accordance with the relevant specifications.
 The valve stations shall be equipped with all relevant sign boards and warning sign boards.
16.10 PIPELINE MARKERS
The Contractor shall supply, fabricate and install pipeline marker signs along the pipeline route. Markers
shall be installed at changes of direction, and at every one kilometer interval throughout the pipeline route.
They shall also be installed at each side of the highway crossings, track, road and water crossings,
crossings of foreign pipelines and other utilities crossings, and at all electrical test lead locations. The
markers shall identify the existence of a buried pipeline and display the name of the Client, with an
emergency telephone number and the cumulative distance in kilometers.
They shall also be installed at pipe grade or wall thickness changing point and at coating material changing
point.
These markings shall be in both the Arabic and English languages. Grit blasting and painting shall be in
accordance with Painting Specification document number R1111-SPC-PP-00-005.
16.11 CATHODIC PROTECTION
All permanent cathodic protection items that require installation on the pipeline shall be fully installed
before hydrotest.
16.12 MISCELLANEOUS ITEMS
Miscellaneous items shall be installed in accordance with the drawings included in the Agreement and in
accordance with specifications, designs, procedures and drawings prepared by the Contractor and
approved by the Client. Vents, drains and instruments shall be protected from pipe movement.
All welding of attachments to pressure pipe shall be performed by qualified welders and qualified
procedures reviewed and approved by the Client.
In fabrication of the structural steelwork, the component members shall be kept clamped and/or secured
in position during welding to provide restraint against distortion and to keep angles square.
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All welding shall be made with the proper filler material required for the material being joined. Proper
penetration welds shall effected on strength joints with no undercutting, burn through or splattering.
Finished welds shall be chipped or ground cleaned for inspection.
17 PAINTING
The sections of the pipeline classed as ASME B31.4, exposed and above ground including pipe, pig traps,
fittings, supports, and other appurtenances, shall be cleaned, primed and painted as per the Painting
Specification document number R1111-SPC-PP-00-005.
18 HYDROSTATIC PRESSURE TESTING
The hydrostatic test shall be carried out on the entire length of the pipeline.
The test shall be performed in accordance with hydrostatic test specification document number:
R1111-SPC-PL-00-009.
19 ENCROACHMENTS AND WORKING NEAR OTHER UTILITIES
In locations where the pipeline has to be laid in the body of a road, or other location under jurisdiction of
Government/Public Bodies, the Contractor shall perform such work to the requirement of the concerned
Authorities even when it becomes necessary for the Contractor to resort to hand digging, well pointing or
water removal by other means, or to the erection of sheet piling or any other special construction method
in these areas. The Contractor should contact the Authorities concerned in order to become familiar with
their requirements.
In locations where the pipeline has to be laid more or less parallel to an existing pipeline, cable and/or
other utilities in the ROW, the Contractor shall perform the work to the satisfaction of the
Owner/Authority of the existing pipeline/cable/utility. In such locations, the Contractor shall not
perform the work in such way that even under the worst weather and flooding conditions, the existing
pipeline/utilities shall remain stable and shall become undermined, nor have the tendency to slide towards
the trench. All work carried out in the vicinity of existing pipelines and associated installations shall be
performed under strict safety procedures.
The Contractor shall be liable for any damage to other pipelines and underground structures/utilities
caused by the Contractor's activities.
20 PRE-COMMISSIONING, COMMISSIONING AND HANDOVER
After the hydrostatic pressure test carried out in accordance with the Specification
No R1111-SPC-PL-00-009, the pipeline shall remain full of inhibited water until pre-commissioning and
commissioning operations are ready to commence.
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As part of the pre-commissioning the Contractor shall ensure that all the permanent works are complete
and ready for commissioning. This shall include ensuring that all work has been completed and that all
pipeline hook-up and tie-in work has been undertaken, and that all the necessary performance checks have
been made.
The Contractor shall commission the permanent works and hand it over to SPPC in accordance with the
commissioning procedure approved by the client.
Commissioning the line includes discharging the inhibited test water using crude oil with the oil/water
interface maintained by a pig train. A positive gauge pressure should be maintained within the pipeline at
all times.
All materials (including pigs), labor, supervision etc. needed for pre-commissioning, commissioning, start-
up and handover of the permanent works shall be provided by the Contractor.
The Contractor shall pay particular attention to the disposal of the inhibited test water in respect of
environmental requirements. The Contractor shall be responsible for selecting the method and place of
disposal which shall be subject to approval by the Owner/Client, and the relevant Authorities.
21 RECORDS AND REPORTS
The Contractor shall submit daily and weekly records and reports. These shall as a minimum include, but
not be limited to the following:
21.1 DAILY
- Separate progress reports for each crew

- Daily welding results and weld repairs reports (& NDT results as per contract welding spec.)
- Accidents
- Damages
- Activities required from the Client at short notice
- Material Receipts
- Urgently required materials
- Planned activities for the next day
21.2 WEEKLY
- Up-to-date list of confirmed Site Instructions issued by the Client

- Material defects and repairs
- Outstanding activities of the Client
- List of installed markers, chainage
- Required approvals from the Client
- Progress planned versus actual, to include plans to rectify slippage
- Report of manning of all crews, equipment and plant
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- Report of equipment and plant

- Report of accidents
- Report of damages
- Report of Acquired Releases and Permits
- Required materials for next week
- Planned activities for the next week
21.3 MISCELLANEOUS
The Contractor shall supply to the Client (for approval if required) documents such as but not limited to:
- Acquired permits and/or approvals from Authorities, endowments, if any

- Minutes of Meeting with the Client
- Full material traceability including pipe tracking and weld consumables including manufacturers’
consumable certificates identifying heat, lot and batch numbers
- Material tests (coating, welding, painting, etc.)
- Calculations, temporary works, buoyancy, blasting, etc.
- Pipe and welding book including reports
- All 'as built' drawings
- Water samples
- Cleaning, pigging and gauging report before hydrostatic test
- Hydrostatic test report
- Equipment certificates (dead weight tester, instruments, vessels, equipment, etc.)
- Manuals
21.4 HANDOVER DOSSIER
As a pre condition of the Client issuing the completion certificate, the Contractor shall submit for the
Client's approval a Handover Dossier containing key information the Client may need during the life of
the permanent works. The contents of this Dossier shall be comprehensive and shall be agreed prior to
the commencement of construction and are outlined in paragraphs hereafter.
22 AS BUILT DRAWINGS & PIPE BOOK
22.1 AS-BUILT DRAWINGS
The Contractor shall prepare 'as built' drawings of all work such as but not limited to:
For pipeline section:
- Route maps of appropriate scale to show all necessary details

- Pipeline alignment drawings
- Changes of wall thickness, materials
- Location and details of valves, insulating joints, fencing, etc
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- Location and details of existing buried services, utilities and pipelines, cables, drains etc.
- Location and details of road, water crossings, etc
- Location and details of casing pipes, vents, etc
- Location and type of coating
- Location and type of weighting, anchoring
- Location and type of markers
- Location of all appurtenances (pig signaler, etc.)
- Location of ROW and of pipeline with respect to ROW
- Type of soil
- Type of rock
- Sand padding
- Type of roads and paths crossed
- Details of bank or plantation protection, number of insulators, seals, etc.
- Vendor drawings
22.2 PIPE BOOK
The Contractor shall prepare a pipe book as part of the as built and material traceability documentation.
Every page of the pipe book shall contain the following information:
- Data relevant to the project and section thereof

- Sequential number of each pipe
- Length brought forward (for pipes and other materials)
- Length to bring forward (for pipes and other materials)
- Alignment sheet number and the location thereon of at least two welds
The following information shall also be provided for each pipe.
- Diameter of pipe
- Length of pipe
- Wall thickness
- Pipe number
- Identification number, certificate number
- Cut and renumbered pipe ends
- Type of coating
- Date of stringing
- Date of welding
- Direction of working
- Welding procedure used for each weld
- Weld number
- Welder number
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- NDT test reports

- Details of weld repairs (size, type of defect, location of defect in weld, full pen/part pen, repair
procedure used etc)
- Type of welding, electrode, diameter including welding consumable certificate numbers
- Weld heat treatment
- Equipment used for radiography
- Limits of valve stations, water crossings, etc
- Test pressure, date and duration of tests (hydrostatic)
- Length of section per page in line separated in the pipes including field bends and factory bends
and/or other inline fittings
- Length to bring forward (pipes and other materials)
- Length brought forward (pipes and other materials)
In order to achieve this, the Contractor shall identify all pipe elements. Sample format of pipe book shall
be submitted for the Client's approval.
22.3 IDENTIFICATION
The Contractor shall provide all pipes, bends, etc., with serial numbers as soon as possible and measure
their length and state it on the pipes, etc. Pipes to be bent shall be measured prior to bending.
Identification (i.e. letter, number and length) shall be indelible.
All serial numbers shall be recorded in a list, which shall also cross reference the pipe numbers.
The stamped in pipe numbers, length of pipe and painted on serial numbers, the stamped in numbers of
T-pieces, bends, valves, etc. and the batch numbers of bends, T pieces, valves, etc. and the maker of
valves, shall be recorded in this list.
Before a pipe length, pipe end, etc., is cut, the painted serial number and stamped in pipe number shall be
transferred by the Contractor in the presence of the Client to either side of the joint which is to be made
by cutting, and the changes shall be recorded in the above mentioned list stating the (new) length.
The result shall be such that all pipes, pups, etc. bear clear painted identification marks.
The Contractor shall explicitly instruct his personnel that parts which are unmarked and cannot be
identified must not be incorporated into the permanent works unless the Client specifically authorize
otherwise in writing.
As a general rule parts must be marked as described above before being moved.
23 HEALTH, SAFETY AND ENVIRONMENT
The contractor's scope regarding safety requirement shall only be limited to providing minimum basic
health requirement.
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NO. R1111-SPC-PL-00-002
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The safety plan shall consider the product as flammable and explosive substance. Other items within the
scope will include:
1. Noise of Equipment
2. Work condition/habits of construction team
3. Overall arrangement of site
4. Quality of Equipment
The environmental plan will adopt processes to keep the local air, water, soil and vegetation in the original
state prior to construction of the project.
The Contractor shall adopt particular consideration to control noise, sewage and waste resides.
002/AR 11/11 04/10

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Revision No Revision Description

002/AR 11/11 04/10

002/AR 11/11 04/10

8.4 MITRE AND UNSATISFACTORY BENDS .....................................................................................22

16.2 DIMENSIONAL TOLERANCES ........................................................................................................35

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1.1 GENERAL DESCRIPTION

Client / Owner Sudanese Petroleum Pipelines Company (SPPC)

Engineering Company Engineering Procurement & Project Management (EPPM)

Contractor PCC Contractor

Project 12 NPS Multi Product Pipeline from Khartoum to Madani State

ASME American Society for Mechanical Engineer

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1.5 ENVIRONMENTAL & SITE DATA

Refer to “DESIGN BASIS REPORT”, document number R1111-RPT-GE-00-001.

2 CODES, STANDARDS AND REFERENCE DOCUMENTS

2.1 PROJECT DOCUMENTS

R1111-SPC-CV-00-003 Specification For Soil Investigation

2.2 CODES AND STANDARDS

American Society of Mechanical Engineers (ASME)

ASME IX Welding and Brazing Qualification

ASME B 31.4 Liquid Transportation system for Hydrocarbons, LPG, Anhydrous

American National Standards Institute (ANSI)

ANSI B16.5 Steel Pipe Flange Fitting

ANSI B16.9 Factory Made Wrought Steel Butt – welding Fittings

ANSI B16.25 Butt Welding Ends

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American Petroleum Institute (API)

API 5L Specification for Line Pipe

API RP 1102 Steel Pipelines Crossing Railroads and Highways

API Spec.1104 Welding of Pipelines and Related Facilities

Swedish standard institute (SIS)

SIS 055900 Surface Preparation Standards

2.3 DOCUMENT CONFILCT AND PRECEDENCE

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4 RIGHT OF WAY (ROW)

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4.2 HIGH VOLTAGE INSTALLATIONS

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The measures taken may be as follows:

5 PREPARATION OF RIGHT OF WAY

5.1 CLEARING, GRADING AND BACKFILLING OF ROW

5.2 SURVEY MARKS

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5.3 SETTING OUT THE ROW

5.4 TOPSOIL STRIP

5.5 FENCES AND BARRIERS

Fencing and barriers shall be continuously maintained.

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5.6 REMOVAL OF DEBRIS

5.7 GRADING OF ROW

5.8 RESTRICTED ROW

5.9 ROW DAMAGES

5.10 PROVISION OF DETOURS

5.12 WORKING IN THE SAME ROW OF EXISTING PIPELINES

6 HANDLING, HAULING, STRINGING AND STORAGE

6.1 RECEIPT AND ISSUE OF MATERIALS

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