Pipe Line Construction
Pipe Line Construction
PIPE LINE
CONSTRUCTION
Ju’aymah NGL Fractionation Department,
PRE-EXCAVATION CHECKLIST
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PROJECT OR PLANT WORK 10-BI-1868 EXCAVATION LOCATION PIPELINE CONSTRUCTION DATE 25-JUN-2021
ORDER NUMBER @ 0+000 TO 0 + 957 KM
utilities
Arrange cable/pipe detection to locate utilities not shown on
drawings and unmarked in the field
PROPONENT’S ENGINEERING / TECHNICAL
SERVICES REPRESENTATIVE
(Name, phone, signature & date)
Note:
Pre-Excavation checklist, as per the Saudi Aramco Safety Management Guide 06-002-2008 and SAES-A-114. All
excavations, including shoring and sheeting materials and systems, shall meet the minimum requirements established
by the Saudi Aramco Safety Management Guide 06-002-2008.
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UNIT: _ DATE: _
THIS IS NOT A WORK PERMIT
Unit Foreman/
Shift Superintendent: Phone No.
1. Work Location (Exact) : 12” JNGLF- 1 PIPE LINE @ FROM KM 0+ 000 TO 0+ 975
Duration: Start: Stop:
2. Purpose of Excavation: PIPELINE CONSTRUCTION OF 12" PIPE
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(Signature) (Signature)
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1.1.1
Issuer and receiver shall conduct Joint Site Inspection
1.Work Site preparation
(JSI) prior to start any activities.
such as Installation of 1.1Slip, Trips & Falls
Warning signs & Barricade Obtain Work Permit prior to commitment of activity as
1.1.2
per G.I. 2.100.
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2.2.7
While inside the CONFINED SPACE continuous
communication with the standby man.
2.2.8 Only PHYSICALLY FIT can work in Confined Space.
Before entering Confined Space, ensure at the space is
2.2.9
properly isolated, cleaned and adequately ventilated.
2.2.10
All employees who will work in a confined space must
be adequately trained.
Ensure the rescue plan for confined space is
2.2.11 implemented prior to the anyone entering the confined
space.
3.1.1 Prior to lifting jobs, a work permit shall be obtained.
3.1.2 Proper Lifting techniques must be use.
3.1 Improper manual Conduct Tool Box Talk about Lifting Techniques Use
3.Materials Handling and 3.1.3
handling of materials Proper PPE.
Preparation (Loading &
(causes back injury /
Unloading of Materials) 3.1.4 Do not take load you cannot lift
body harm)
3.1.5 Identify the pinch points and avoid them
3.1.6 All employees must be trained in hand safety training.
4.1.1 Prior to lifting jobs, a work permit shall be obtained.
Operator should have a valid SAG LICENSE and SA
Certification. Valid crane / equipment inspection
4.1.2
STICKER and periodic Inspection check list and color
coding.
All slings / rigging equipment to be used shall be
4.1.3 inspected regularly and LOG as per GI 7.025 & GI
4.1 Potential damage to 7.029 and shall
property and fire ensure that the capacity (SWL) manufacturer LOGO,
4.1.4
hazard. and Manufacturer serial number.
4.1.5
Qualified Rigger should be in the AREA. While crane
is under operational.
4. Rigging and Lifting of
pipes and Equipment:
4.1.6 Provide Critical Lift Plan as per G.I 7.028
Crane & Trailer Truck Use softeners to ensure web slings are not damaged
4.1.7
Rigging and Lifting Under by sharp edges.
OHPL Equipment: 4.1.8
Trucks and trailers must remain on established roads
Crane & Side boom only and must not go of the establish roads.
A TAG LINE should be used in any lifting. Employees
4.2.1 must not place the hands or try to handle the load with
their hands.
4.2.2
The lifting areas shall be barricaded to prevent
unwanted employees to enter the lifting area.
4.2 Crush accident /
Major Equipment TEST LIFT and CRANE lift checklist shall be performed
4.2.3
damage. prior to do the actual lifting.
4.2.4 Install a goal post as per G.I. 2.702
4.2.5
Any person not required for the work shall be kept
away while lifting is in progress.
4.2.6 DO NOT STAND UNDERNEATH the boom.
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1. Work Site preparation Issuer and receiver shall conduct Joint Site Inspection
such as Installation of 1.1.1
(JSI) prior to start any activities.
Warning signs & Barricade Obtain Work Permit prior to commitment of activity as
1.1.2
per G.I. 2.100.
Provide adequate visible warning signs and barricade
1.1 Slip, Trips & Falls prior to commence the activity & Put of lightings during
1.1.3
night time. Provide adequate portable fire extinguisher
and other firefighting equipment
Ensure there are clear access and egress to work site
1.1.4 areas to prevent employees from tripping over any
obstacles.
Assigned Standby& Flagman wearing reflective vest to
1.2.1
assists the Vehicle/Equipment working on the area
Provide barricade & road block to control the
1.2.2
authorized Personnel & Equipment allowed
Provide parking area for vehicle/equipment to be used
1.2.3
in the activity.
1.2 Struck-by/Against Provide sufficient lightings during night time and install
(vehicle accident) 1.2.4
reflectorized directional signage.
1.2.5 All drivers to be trained in defensive driver training.
Human machine interphase must be planned, and
1.2.6 employees separated from areas where there is traffic.
Clear walk ways for employees to be used.
1.2.7
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Truck, STT Truck, Grinder, Only qualified/SA Certified welders shall be used in site
Cutting Torch Set, & Hand within their position a welding cards/clearance. They
5.1.3
Tools shall follow the approved welding procedure in all
welding works.
Welding gloves, apron, welding helmet with hood and
proper glass shade based on the welding material
5.1.4
MSDS and respiratory mask(P100) shall be worn at all
the time
5.1.5
In case of emergency stop all activity and proceed to
the pre- defined assembly area
Grease and oil shall be removed and kept away from
5.2.1 oxygen. Acetylene cylinders should be stored, capped,
handled and transported with cage in vertical position.
Inspection of hoses and fitting shall be done regularly,
5.2.2
and color-coding shall be recognized.
All cylinders shall be protected from extreme
5.2.3
temperatures.
Flash back arrestors shall be fitted to all oxy-acetylene
5.2.4
cylinders.
Jubilee clip should not be used to secure the hose
5.2.5
connection
Oxidizers shall be stored away from all combustible
5.2.6
materials.
5.2.7 Appropriate warning signs shall be provided.
All welding equipment shall be examined immediately
5.2.8
before use and regularly maintained.
5.2. Property damage
from fire and explosion All welding and cutting equipment shall be of Saudi
5.2.9 Aramco approved type and operated with latest Saudi
Aramco and industry safety procedures.
Fire extinguisher (UL/FM Rated) shall be provided in
5.2.10 the immediate welding area. Extinguisher shall be
properly sealed and tagged.
Standby man, fire watch shall be assigned during
5.2.11
welding operations.
PPE shall be used, i.e. welding helmet, face shield,
5.2.12
welding clothes and others.
Any sewer within 75 feet away from the welding area
shall be covered and other existing facilities /equipment
5.2.13
like valves, flange etc. shall be boxed-up with fire
protected blanket.
5.2.14 Ensure all equipment are properly Grounded.
In case of emergency stop all activity and proceed to
5.2.15
the pre- defined assembly area
5.3.1.
All personnel shall wear a proper PPE (welding gloves,
welding jacket, welding mask.
5.3. Health impairment 5.3.2. Only physically fit are allowed to work on this activity.
5.3.3. Periodic health check-up should be carried out
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5.5.1
For poor visibility stop any activity and park the light
and heavy equipment away from the main road.
5.5.2
A shelter with plenty of water shall be install on jobsite
in a hot weather condition.
If necessary conditions are severe give at least a 10
5.5.3
minutes break for every 30 minutes’ activity.
5.5. Weather Condition
5.5.4 Stop all activity if the weather conditions are severe
MOC hazards should be identified during the execution
of task, work should be stopped if required. Employees
5.5.5 should be empowered to stop the job if they noticed
any unsafe act/condition. Stop work policy should be
strictly implemented
No Unauthorized personnel allowed during Welding
5.6.1
Activities
Proper Coordination & Communication must establish
5.6.2
prior to start any SIMOPS (Simultaneous Operations).
Full PPE (Safety Shoes, Face Shield, High Visibility
Vest, Safety Glass, Gloves, Fire Resistant Clothing,
5.6.3
Ear Plug & Safety Helmet) must be used during
Simultaneous Activities)
5.6 SIMOPS No Personnel allowed to work without Proximity
5.6.4
Warning Alarm System Tag
Barricade and Signage’s must be in place during the
5.6.5
simultaneous activities
No Flammable Material and Chemical allowed to use
5.6.6
near Welding Activities
5.6.7 Full Supervision for the Activities
5.6.8
Visitors should be accompanied by a supervisor or site
in charge
Remove any potential tripping hazards from the area
6.1.1
6.1 Tripping hazards such as rocks, litter or clutter,
6.1.2 Maintain good housekeeping on the work area
6.2.1
Heavy Equipment movement must be assisted by a
spotter
6. Demobilization of tools Certified rigger and operator shall be used on lifting of
& equipment. 6.2.2
materials and tools.
6.2 Struck by Heavy
Ensure lifting equipment have a valid sticker by Saudi
Equipment 6.2.3
Aramco
TB PWAS should be installed in all earth moving
6.2.4 equipment and the tags must be issued all nearby
working personnel
7. Housekeeping & 7.1 All personal injuries All un-necessary materials shall be removed at the job
7.1.1
Restoration including equipment site.
(CLEANLINESS ON and machinery Housekeeping shall be kept as a part of daily working
7.1.2
WORKING AREA) damaged. talk
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7.1.4
Garbage shall be disposed daily adequate trash can /
7.2 Trip / Slip and Fall drums with cover shall be installed.
hazard Waste rubbish shall be kept away from the aisles and
7.1.5
walk ways.
Radiography Test Activity
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Controls/Recommended Action
Critical Steps Hazard(s)
Issuer and receiver shall conduct Joint Site Inspection
1.1.1 (JSI) prior to start any activities.
Obtain Work Permit prior to commitment of activity as
1.1.2
per G.I. 2.100.
Provide adequate visible warning signs and barricade
1.1 Slip, Trips & Falls 1.1.3 prior to commence the activity & Put of lightings during
night time.
Provide adequate portable fire extinguisher and other
1.1.4 firefighting equipment
1.Work Site preparation
such as Installation of Ensure there are clear access and egress to work site
Warning signs & Barricade 1.1.5 areas to prevent employees from tripping over any
obstacles.
1.2.1
Assigned Standby& Flagman wearing reflective vest to
assists the
1.2.2 Vehicle/Equipment working on the area
1.2 Struck-by/Against
(vehicle accident) 1.2.3
Provide barricade & road block to control the
authorized Personnel & Equipment allowed
Provide parking area for vehicle/equipment to be used
1.2.4
in the activity.
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1.2.5
Provide sufficient lightings during night time and install
reflectorized directional signage.
1.2.6 All drivers to be trained in defensive driver training.
Human machine interphase must be planned, and
1.2.7
employees separated from areas where there is traffic.
1.2.8 Clear walk ways for employees to be used.
2.1.1 Permit to work and drawings needed to the area.
Documents shall be secured before any work
2.1.2
2.1 Incompliance to commence.
specification / required 2.1.3 TOOLBOX MEETING requires to all.
procedure Safe work plan / permit shall be discussed by the
2.1.4 supervisor with his crew on a daily basis before the
actual work start.
2.Work Permit 2.2.1 Arrange materials in order of usage
Unwanted materials shall be removed regularly to
2.2 Untidy work area avoid accumulation. Keep access / egress free from
could result to slipping 2.2.2
obstruction all the time. Carry out housekeeping /
/ tripping hazard & Gas cleaning before & after work.
monitoring Organized materials staging area will be maintained
2.2.3 equipped with barricade appropriate signboard and
with designated ENTRY and EXIT POINT.
3.1.1 Prior to lifting jobs, a work permit shall be obtained.
Operator should have a valid SAG LICENSE and SA
Certification. Valid crane / equipment inspection
3.1.2
STICKER and periodic Inspection check list and colour
coding.
3.1 Potential damage to
All slings / rigging equipment to be used shall be
property and fire
inspected regularly and LOG as per GI 7.025 & GI
hazard. 3.1.3
7.029 and shall ensure that the capacity (SWL)
manufacturer LOGO, and Manufacturer serial number.
Qualified Rigger should be on the AREA. While crane
3.Rigging and Lifting of 3.1.4
is under operational.
Pipes, Equipment &
Materials Equipment: 3.1.5 Provide Critical Lift Plan as per G.I 7.028
Crane, Side boom & Trailer 3.2.1 A TAG LINE should be used in any lifting.
Truck TEST LIFT and CRANE lift checklist shall be performed
3.2.2 prior to do the actual lifting. Install a goal post as per
3.2 Crush accident / G.I. 2.702
Major Equipment Any person not required for the work shall be kept
damage 3.2.3
away while lifting is in progress.
3.2.4 DO NOT STAND UNDERNEATH the boom.
3.2.5 WIND SPEED should be 32Kph below.
3.3 Shock due to Place Goal Post at a safe distance from o/h power line
contact overhead 3.2.6 and conduct pre job meeting with heavy equipment
Power lines drivers to highlight this hazard.
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4.5.1
Unauthorized personnel should not be allowed during
Painting and Coating Activities
Proper Coordination & Communication must be
4.5.2 established prior to start any SIMOPS (Simultaneous
Operations).
Full PPE (Safety Shoes, Face Shield, Safety Glass,
4.5.3 Working Gloves, Fire Resistant Clothing, Ear Plug &
4.5 SIMOPS Safety Helmet) must be
(Simultaneous 4.5.4 used during Simultaneous Activities)
Operations)
Spray painting shall not be performed within 23 m (75
ft.) of ignition sources (e.g., welding, flame cutting,
4.5.5
smoking areas, electrical generators). Conditions at the
work site may justify greater clearances. Barricade and
Signage’s must be in place during the simultaneous
activities
4.5.6 Full Supervision for the Activities
5.1.1 Maintain good housekeeping on the work area
5.1Tripping hazards Remove any potential tripping hazards from the area
5.1.2
such as rocks, litter or clutter
Heavy Equipment movement must be assisted by a
5.Demobilization of tools & 5.2.1 spotter Certified rigger and operator shall be used on
equipment. lifting of materials and tools.
5.2 Struck by Heavy Ensure lifting equipment have a valid sticker by Saudi
5.2.3
Equipment Aramco
TB PWAS should be installed in all earth moving
5.2.4 equipment and tag must be distributed to all nearby
working personnel
All un-necessary materials shall be removed at the job
6.1 All personal injuries 6.1.4
6.1.5
site. Removal of all combustible and flammable
including equipment
materials shall be strictly implemented.
and machinery
6.Housekeeping & Housekeeping shall be kept as a part of daily working
damaged. 6.1.6
Restoration talk
(CLEANLINESS ON Garbage shall be disposed daily adequate trash can /
WORKING AREA) 6.2.3 drums with cover shall be installed. All waste shall be
6.2 Trip / Slip and Fall
segregated at source.
hazard
6.2.4
Waste rubbish shall be kept away from the aisles and
walk ways.
HOLIDAY TEST
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3.5 Injury (Falling into Ensure that daily pre-excavation checklist is compiled
3.5.2
Excavation) prior to work inside the excavation.
3.5.3 Install ladders for evacuation in case of emergency.
Distance between access/exit points in an excavation
3.5.4 shall not exceed 7.5 meters (25 feet) or ladders shall
be spaced at least every 15 m [50 ft.] along a trench.
Provided the trained flagman if the excavation nearby
3.5.5
the floating population or vehicle movement area
Ensure that soil is strong enough to hold and stable
3.6.1
prior to place Heavy equipment in the area.
3.6 Injury to personnel Motor vehicles, cranes and heavy equipment shall be
(Collapse of soil) kept away from the edge of the excavation a distance
3.6.2 of 2 m (6.5 ft) or the depth of t excavation, whichever is
greatest, unless the excavation is in stable rock or is
protected against collapse by shoring that has been
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INSTRUCTIONS
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1. CONSTRUCTION METHODOLOGY
All the survey instruments shall be calibrated and copy of the calibration
certificate shall be maintained with each instrument and submitted for
approval.
Surveying work shall be carried out by employing the services of a
competent Land Surveyor, subject to prior approval.
The temporary benchmarks & control points shall be established on any
nearby permanent Structures.
Existing original ground level will be recorded in a grid manner.
The surveyor will set out the ROW corridor limits by marking the centerline
of the ROW for grading and embankment fill, the top of ROW levels will be
marked on pegs. To easily transfer any stakes such as centreline or limits of
the ROW, NBC will establish the reference points outside the construction
area so that it will not to be removed during clearing operation. Temporary
progressive kilometre markers will be provided along the pipeline corridor at
intervals of 500 meters or at bends.
Embankment fill height on the Sabkha area will be based from the existing
ground elevation level. This guarantees that the highest ground water level
will be 150mm (Min) below the bottom of the pipes. NBC will therefore
comply with Saudi Aramco Standard which requires that the pipe’s bottom
must be above 150 mm (Min) from the highest recorder groundwater table.
NBC will utilize the approved Borrow pits with Aramco standards and project
requirement.
NBC will transport the materials from the Borrow pits to specific location by
using approved machines and trucks
KENTZ will construct temporary access marl roads in Sabkha areas to allow the
access and facilitate safe movement of equipment to the site location.
METHOD STATEMENT
for
RIGHT OF WAY CONSTRUCTION-SABKHA
Access road shall also be suitable for the hauling and delivery of the double joints (if
adopted) pipes for stringing out along the ROW.
Fill material to use are from dune Sand or Marl in line with SAES-A-114.
Fill materials shall be transported from borrow pit by dump trucks.
Fill material shall be placed in lifts not exceeding 300 mm in loose depth.
Other lift thicknesses may be approved by Saudi Aramco Inspection
Representative based on field test section using the intended compaction.
However, 900 mm instead of 300mm may be approved by the appropriate
Saudi Aramco Inspection Representative based on a field test section using
the intended compaction equipment and verification that compaction was
achieved for full depth.
The dumped material shall be spreaded by Grader and Dosser so that the
layer thickness shall be of 900mm in loose depth.
The water shall be sprayed on the material spreaded and the compaction
shall be done by the roller compacter (10ton) with average of 20 to 25
passes to meet the compaction strength as mentioned in IFC drawing
In-Place density shall be determined using one of the following (SAES-A-
114):
- Sand Cone Method
- Rubber Balloon Method
- Nuclear Method
- Drive-Cylinder
Nuclear density gauges, when used, shall have a valid calibration certificate
per requirement of SAES-A-114 Sec. 3.2
The depth of test holes shall no greater than 300mm (12 inches) deep
(SAES-A-114- Sec. 3.2) Each backfill layer shall be compacted and tested.
As a minimum, at least one in-place density test must be performed on Every lift of fill
and further placement shall not be allowed until the required Density has been
achieved.
Compacted surfaces of fill and backfill shall be finish graded to the cross Sections,
lines, grades, and elevations as indicated on the drawings.
All records relevant to the above procedure shall be retained by the Quality Control
department in the site office, for the duration of the project, before being handed over
to the KENTZ in accordance with the requirements of the contract documents.
Copies of all records shall be made and transferred to the KENTZ Office where they
shall be retained for the guarantee period of the contract.
METHOD STATEMENT FOR
PIPELINE STRINGING
Trailers transporting pipe to site shall be equipped with transport under desert
conditions. Timing of trips and movement of trailers shall comply with the
approved HSE Manual and HSE Plan with regard to limitations on heavy
vehicles driving hours, driving over bridges diversions, U-turns, night driving,
rest hours, entry and road access pass from local and Saudi Government
authorities, etc. as appropriate.
Vehicle/trailer loads shall not exceed the weight limitation indicated on the
vehicle registration documents by the government authorities.
The material man/coordinator assigned in vendors Coating Yard is
responsible for acceptance of Line Pipe at the pipe-coating yard (or material
yard). Any damage to the pipe shall be reported to the concerned personnel
at the loading location and the damaged pipes shall be segregated and not
loaded and shifted to site.
METHOD STATEMENT FOR
PIPELINE STRINGING
If damage to the external coating of line pipe exceeds limitations of SAES-H-
200, pipe shall be rejected and such rejection shall be documented and
communicated to Company representative, Contractor and Coating
Vendor/Factory.
The assigned Logistic Coordinator or Inspector at the Coating yard shall
ensure that all pipes to be delivered to site have been inspected, and
accepted including the correctness of pipe specification and ensured that,
FBE coated pipes are free from damage and shall document and report all
damages, shortages and defected and/or unsatisfactory pipes as appropriate.
The pipes will be hauled from the coating terminal to the work sites by means
of trailer type truck. These trailer type trucks are customized to transport
coated pipes with proper supports/saddles and padding for coating protection.
The trailer type to be used will be either a flatbed type trailer or dolly type
trailer depending on length of pipe. Dolly trailers will be used for double (+/-
24meters) joints and flatbed trailer for single (+/- 12 meters) pipe joints.
Depending on the stringing plan and/or actual site condition, the Site Material
Coordinator shall coordinate with Transportation Coordinator located at
Coating Terminal on the quantity and specification of the pipes to be strung
each day. The pipe hauling and stringing progress shall be constantly
assessed to meet daily stringing progress and to ensure staying ahead of the
bending and welding activities.
Coated pipes shall be loaded onto trailers provided with saddles. The pipes
shall be secured by non-metallic straps. All saddles on the trailers shall be
covered with a non- abrasive material like rubber to avoid damage to coating.
While pipes loading on trucks, each length of pipe shall be lowered to position
without dropping and each succeeding length shall rest on truck and shall be
separated from the adjacent pipe by rubber pad.
Upon adequate safety arrangements and visual inspection, pipe unloading
may proceed. Pipes will be normally unloaded using side boom CAT 594H or
583H.
All pipe stringing operation shall be carried out under the guidance of Saudi
Aramco certified Rigger Ill and Saudi Aramco certified Side Boom Operator.
If the load condition doesn’t allow inserting a lifting belt between the pipes to
lift directly by the side boom, then the pipe shall be lifted by fixing padded
lifting clamps at both ends. The belts shall be connected by shackles to lifting
belts which can be connected directly to the side boom hook or to a spreader
bar, depending on length of the belts to be used.
During the stringing operation along the right-of-way, the pipe shall be
supported on padded skids, sandbags, tires or similar material to protect the
coating from being damaged. Particular care shall be taken to store the pipe
at least 6 inches off the ground and supports spaced at regular intervals.
The unloaded/stringed pipes shall be safely positioned away from the trench
(if trench ready) and in a manner that will facilitates inspection,
excavation/trenching and subsequent mechanical activities, like bending, pipe
end bevelling, pre-blast, coating cut back and so on.
Identification and staking of location class limits at site by the Site Surveyor
with Stringing Foreman to ensure that, the pipes are strung at the right
METHOD STATEMENT FOR
PIPELINE STRINGING
location to control and avoid unnecessary movement or shifting during
stringing operation.
Each pipe shall be visual inspected carefully, for any pipe fiscal damages that
could occur during transportation.
The pipes shall be unloaded from trailers and lowered to their supporting skid
by suitable side boom. Tagline must be used to control the unloaded pipe
and to avoid rotation.
Pipe shall not be rolled into form in any manner, which distorts the round form
of the ends, or scratches, gouges or dents the pipe. Pipe shall not be
dragged along the ground. Unloading shall be done by Side Boom CAT 594H
or 583H and spreader bar with slings and, lifting hooks.
Pipe shall be strung in such a manner to permit the use of the land and
passage of equipment, or other normal traffic across the construction right-of-
way.
Gaps in the strung line pipe are to be left for passage of personnel,
equipment, livestock. Line pipe shall be strung along side of road to allow for
safe working on both sides of strung pipes.
Experienced stringing Foreman shall be responsible and supervise slinging or
lifting task.
The Stringing Foreman (certified rigger III) or a rigger III is the only person
authorized to give instruction to all personnel involved in the stringing
operation.
The work method will be different depending on the size and length of the
pipes to be strung, the number of pipes loaded on the trailer as well as if the
stringing operation precede or follows after the opening of the trench.
Stringing of the pipe for existing roads crossings, pipeline crossings shall be
done outside crossing area to maintain continuity of the access road. Pipes
shall be strung in the final position when the trench of the crossings will be
ready. At that time, detour or by pass road would be available to maintain the
accessibility.
During pipe stringing, the Quality control to be in accordance with applicable
SATIPs.
the pipes will be positioned as per the approved alignment sheets and placed
according to their wall thickness. The stringing Foreman will insure that the
offloaded pipe material and heat numbers are registered. All the pipe details
are verified by the Quality Inspector and records are kept in the pipe tally
table
Secure the pipe to prevent rolling to the ROW.
The quality inspector visually inspects the pipe after offloading and marks
visible coating defects, dents, damages to pipe ends. the damages will be
reported to the concerned supervisor for further instigation and repairs
Keep enough exits and space for security and pipeline riders.
METHOD STATEMENT FOR
PIPELINE STRINGING
FOR INDIVIDUAL PIPE STRINGING
Line pipes and bends with required angle will be strung along the pipeline
route as per approved Project Alignment Sheets Along the pipe string, line
pipes will be located over temporary pipe supports made up of sand berms
and/or sand bags from the ground level. Sand berms or sand bags shall be at
least 6 inches (150 mm) or more thick to keep pipes high enough from the
ground to avoid the damages to the pipes. Temporary pipe supports will be
set up before the commencement of pipe transportation by a dedicated crew.
Externally coated pipe strung along the right-of-way is supported on rock free
sand, sand bags, rubber tires, or similar compressible material to prevent
damage.
Line pipe will be strung along the ROW and placed on the temporary supports
in the sequence of welding.
Stringing crew shall check that the pipe number has been clearly marked on
the outside of the pipe and write the pipe number on the outside of the pipe
with permanent marker if the pipe number has not been marked or has
become illegible. Strung pipes will be recorded for further traceability. The
position of the line pipe seam weld will be on the top between 10 & 2 o’clock
position in alternate manner. While offloading pipes, followings will be
ensured:
o The hooks of the side boom will be fastened to both ends of the pipes.
Rubber, plastic or soft metals, such as aluminum plate or copper plate,
shall be added between the hook and the contacting part of the pipes to
prevent the pipe bevels from being damaged
o In case of bevel-damaged, pipes will be piled separately marked, issue
NCR, inform Company as per Schedule Q and will be used after they
have been repaired/re-beveled and accepted & closing of NCR.
o Coated pipe is not rolled or dragged on the ground.
o Equipment in contact with coated surface of pipe is padded.
o Slings for lifting pipe shall be nylon or similar material to prevent damage
to the pipe surface.
Open ends of pipeline strings shall be capped to prevent entry of debris or animals and birds. Each
string of the pipeline shall be cleaned to remove all debris.
METHOD STATEMENT FOR MAINLINE
WELDING AND REPAIR
Welding procedures for Mainline Mechanized Welding shall comply with the
requirements of SAES-W-012, ASME B31.8 & API-1104.
Manual Welding procedures for Mainline, Piping, Pipeline related facilities and
its structural attachments shall comply with the requirements of SAES-W-012/
W-011, ASME B31.4 / ASME B31.3 /ASME B31.8, ASME SEC-IX, API-
1104,01-SAMSS-010, 01-SAMSS-044 & SAES-W-016.
Welding procedures for the miscellaneous structures can be Pre-Qualified as
per AWS D1.1.
The PWE, in consultation with the PQM, shall select the suitable WPS from
the list of Aramco pre-approved Welding procedures of earlier projects. If
suitable is not available a new WPSs shall be prepared and qualified in
accordance with the applicable standards.
Prior to start of any welding operation, all New Welding Procedures (If
required) shall be qualified by the Contractor which shall be Witnessed,
Tested and Certified by an Aramco approved third party inspection & Testing
agency. Once the procedure is certified, the WPS shall be finalized and
submitted to Saudi Aramco for approval prior to use. All submittals of Welding
Procedure Specifications shall include a WPS Summary with Line service
description.
Raise the pipe up to the required location. Position and tighten the pipe
support to secure the pipe.
The pipe will be checked for correct level, alignment and position and if
necessary, adjusted on the pipe support or relevel the pipe.
The welder will use a normal welding transformer to join pipe by tack welding
them.
The skilled welders then will start a root weld, and wire brush the root joint so
that the flux on the joint is completely removed. If necessary grinding will be
perform to remove the flux.
After allowing the joints to solidify for a few minutes, the final weld shall be
performed and the flux shall be removed.
Ensure proper penetration and no undercut during welding of the pipe.
After completion of welding remove the burrs, dirt and welding slugs and
install temporary caps at open end.
Clean the work location.
METHOD STATEMENT FOR MAINLINE
WELDING AND REPAIR
2. JOINT PREPARATION
Line Pipe Groove End preparation for Mechanized Welding process shall be
machined as per the groove details in the WPS.
Line Pipe / Piping Groove End preparation for Manual Welding process can
be prepared by machining or Flame cut and ground to finish as per the
groove details in the applicable WPS or as per the ASME B31.4/ ASME B31.8
/ ASME B31.3 Standard.
The groove size and angle shall be measured with a groove angle gauge,
Depth Gauge and Ruler.
Acceptable combinations of Pipe Groove ends for Manual welding process
can be as per the WPS or as per the ASME B31.4 /ASME B31.8 /ASME
B31.3
For groove welds without backing ring, the tolerance for maximum weld gap
(root opening) shall be established in the WPS; in no circumstance the gap
should exceed 5 mm (3/16"). Maximum internal misalignment for the Pipe
welding under SAES-W-011 shall be l.5 mm or as established in the WPS.
Maximum misalignment (Hi-low) at the inside surface of the pipe for
circumferential joints shall be less than 1/4 t or 3 mm whichever smaller,
where (t) is the wall thickness of the thinner section of the joint. Misalignment
can be checked by the use of hi-low gauge.
3. WELD REPAIR
1.3.1 KENTZ ATTENTION IS DRAWN TO THE POTENTIAL EXISTENCE OF UNDERGROUND SERVICES,
DRAINS, CABLES AND PIPES. HE SHALL BE RESPONSIBLE FOR ASCERTAINING THE PRESENCE OF
SUCH OBSTRUCTIONS. WHERE SUCH OBSTRUCTION IS KNOWN TO EXIST OR IS CONSIDERED IN
THE VICINITY, CONTRACTOR SHALL TAKE ALL NECESSARY STEPS TO PREVENT DAMAGE TO
THESE SERVICES BY APPROVED METHODS OF WORKING INCLUDING HAND EXCAVATION,
PROTECTION AND DIVERSION OF SERVICES.
This section covers the Excavation of pipeline trench inside pipeline ROW in
Sandy area or rocky area in accordance to SAES-L-450:
The Center line for pipeline shall be marked.
Trench shall be excavated up to a depth to maintain the cover of the pipe and
the pipe is 150mm above the water table in accordance to SAES-L-450.
The excavated material shall be kept adjacent to trench but opposite side of
the stringing line and If the material is found unsuitable for backfilling, the
material shall be removed from site to a designated disposal area.
Water shall be sprayed on the trench to avoid any collapse until the lowering
is done.
METHOD STATEMENT for
GENERAL AND PIPELINE TRENCH EXCAVATION
The trench shall be backfilled with the same excavated material if suitable
within 24hrs of lowering and inspection.
1. WORK EXECUTION
Lowering of the pipeline shall commence following removal from the trench bottom of all pipe-
off cuts, skid supports, stones, debris, stakes, rock projections and any other rigid Welding,
welding inspection and materials which, if underneath the pipe, could lead to perforation or
tearing of the pipeline coating/insulation.
The lowering operation shall be followed as soon as possible, after completion of the Field
Joint Coating of the pipeline and clearing of the trench bottom and bedding with sand or soft
material approved by the COMPANY.
Before lowering, short, completed section of the pipeline shall be cleaned with compressed air
in order to remove all debris from inside of the pipe sections and for longer sections as per
SAES-L-450 requirements.
Lowering the welded pipe into the trench demands close coordination and skilled operators.
Using a series of side-booms, which are tracked construction equipment with a boom on the
side, operators simultaneously lift the pipe and carefully lower the welded sections into the
trench. Non-metallic slings protect the pipe and coating as it the lifted are equipped with
moved into position.
The side booms will be positioned 1 m away parallel from the edge of the open trench or to
insure the trench walls do not collapse during the lowering operation.
The minimum number of side booms shall be decided based on the length of the string and
diameter of pipe in order not to exceed the elastic bending radius of the pipe. The side booms
are equipped with roller cradle and flat belts used for lowering. Smaller sections of crossings
or shorter main line sections etc. can be lowered with adequate capacity flat belts.
Operator of each side boom should adjust the height and forward distance of the lifting boom
accordingly. The side booms should move slowly with the same speed in the same direction,
and pipeline should be laid on the centre of the trench until the whole section is lowered in.
Depending on site conditions, the space between the side booms shall be kept around 20
meters maintaining gentle S - curve in vertical as well as inclined horizontal plane.
The lowering operation shall be led by the lowering foreman. Lowering shall be carried out
under safe conditions so as to avoid stress and deformation/damages of the pipe/coating. The
section of the pipe string should form a gentle & smooth S curve without exceeding allowable
elastic bend radius in contract drawing and documents.
Rigging supervisor will be responsible for safe lifting operation. He shall be the only
person directing for lifting and lowering the pipeline.
Rigging supervisor shall position the side booms as per lifting plan, clearing off the
area.
The pipe strings shall be visually inspected and pre-holiday tested, while they are on
the skids/pad, to minimize the number defects found during lowering.
Locations where lowering-in of the pipe is routed along, over and under or across
tracks, roads or highways and in such cases, provide and maintain adequate
diversions, temporary bridges/access, and traffic control including warning signs and
lights as maybe required by the respective authorities.
Provide and maintain detours, suitable lightings, barricades, warning signs/boards,
etc. as appropriate to protect personnel, public properties and to facilitate the smooth
running of the project.
METHOD STATEMENT FOR
PIPELINE LOWERING
Prior to lowering, the pipe will be cleaned from debris. as per SAE-L- 450.
Prior to lower-in, the trench shall be cleaned of debris, stones and rocks. Install and
test cathodic protection leads, where applicable, prior to backfill.
Complete placement of any padding material. Verify that at no point pipe spans a
distance exceeding the maximum allowable, pipe span for ditch condition.
The lowering-in operation shall follow as soon as possible after completion of the field
joint coating of the pipeline and clearing of the trench bottom as above.
Before lowering is started no personnel are allowed inside the trench.
When the pipe is lowered into the ditch, the pipe shall conform to the ditch bottom
and must be substantially supported at all points.
Lowering shall be done using sufficient side booms, with roller cradles. The side
boom in the front shall lift the pipe string from the supports. The second side boom
shall hold the pipe string on top of the ditch without slack. The third side boom shall
guide the pipe string in to the ditch to ensure a gentle ‘s’ shape with minimum
allowable radius of elastic curvature to prevent undue stress.
The number of side booms used to lower a pipe string shall insure that the lifting
profile induces controlled or reduced stresses on the pipes.
For both 12” pipeline lowering, subcontractor will use side boom with 70 Ton
Capacity. And the maximum length of lowering section will be 1 KM for 12”.
The pipe shall be carefully lowered to prevent abrasions, scuffing, cracking or other
damage to the coating.
The roller cradles shall be made from steel strings and Teflon rollers. The distance
between rollers in a string shall be in such a way that, there is enough clearance
between the string and pipe.
Holiday testing crew shall be ahead of the first side boom. Holiday detection shall be
witnessed by QC inspector. He shall periodically check the calibration of the
instrument and record the number of holidays per joint.
Spot backfilling shall be followed to restrain the pipe and 450 in the ditch after it has
been lowered in, padded with sweet sand.
The string shall then be backfilled as per SAES-A-114, SAES-A-450. Backfilling
material shall be free of stones, sharp objects, roots, stumps, limbs, boulders, skids
and construction debris.