SHELL – IRAQ

MAJNOON OIL FIELD – GENERAL

Method Statement for Pipeline Maintenance and Repair

EXDE 00 04-09-15 Issued for Comments MM DD

Validity Rev.
Status number Prepared Checked Approved Contractor Company
Date Description
by by by Approval Approval
Revision Index
Company logo and business name Project name Company Identification

000
MAJNOON OIL FIELD
DEVELOPMENT Job No. 000
SHELL - IRAQ
Contractor logo and business name Contractor Identification

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

Order No.
Facility Name Location Scale Sheet of Sheets
MAJNOON OIL FIELD - GENERAL OFF SHORE A4 1 of XX
Document Title Supersedes N.

Method Statement for Pipeline Maintenance and Repair Superseded by N.

Plant Area Plant Unit
N.A N.A
Software: Microsoft Word 97-2003

.
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REVISION HISTORY

Rev. Date Nr. of sheets Description

EXDE-00 24/09/2015 16 Issued for Comments

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INDEX

SCOPE.......................................................................................................................................... 4
1 RESPONSIBILITY......................................................................................................................... 4
2 HEALTH AND SAFETY

3 DRAWINGS / REFERENCE DOCUMENTS..................................................................................6

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

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

The purpose of this Method is to define the minimum requirements of method adopted by Al-
Kawther Engineering Contracting & Trading for the overall control of Pipeline Maintenance and
Repair, complete excavation , cold cut , hot tapping , pipe works and the in process NDT
examination for existing welds preferred both in plant Piping and infield Pipelines where fluid
service is either sour or non-sour for the existing Majnoon flowlines..

API – 570 [ INSPECTION, REPAIR, ALTERATION, AND RERATING OF IN-SERVICE PIPING

SYSTEMS ] defines a repair ' The work necessary to restore a piping system
to a condition suitable for safe operation at the design conditions. If any of the restorative
changes result in a change of design temperature or pressure, the requirements for rerating also
shall be satisfied. Any welding, cutting, or grinding operation on a pressure-containing piping
component not specifically considered an alteration is considered a repair.
The scope for ad hoc SERVICES includes but is not limited to
- Sectional repair and replacement of defective pipeline
- Sleeving of pipeline defects using approved propriety epoxy fillings
- Installation of pressure rated clamps
- Patch repair
- Wrap repair
- Draining, de-pressurizing, purging and cleaning of pipelines
- Pipeline isolation
- Flowline replacement and installation including commissioning and decommissioning
- Maintenance and repair of pipeline integrity systems including but not limited to
valves, flanges, cathodic protection systems and pig launchers and receivers.

Please refer to the general welding procedure 000 xxxxxxxxxxxxxx – & NDT Procedure N0.
000xxxxxxxxxxxxxxx and coating control procedure 000xxxxxxxxxxxxxx for general
information regarding activity to be carried out.

SELL – Iraq as the COMPANY undertaking the redevelopment of Majnoon Oil Field in
the south of the Republic of Iraq .

2 RESPONSIBILITY

2.1 Site Manager (SM)

Site Manager is responsible for the overall erection activities to be carried out during the project
execution of scope of work and for implementation of this procedure.

He shall be responsible for ensuring that all recommendations from any incident, Near misses
are investigated and recommendations are implemented.

General planning, giving instructions to area foremen to implement the safe and timely working
operations and adherence to the Project Quality Plan.

2.2 Construction Manager (CM)

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

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

2.4 Site Field Engineer

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

2.5 Supervisor

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

2.6 HSE Manager

Report to SM and is responsible for Ensuring compliance of Health, Safety and Environment
during erection and including safety plan and direct safety training.

He is responsible for ensuring that site management and supervisors correctly select and
maintain safety and protective equipment within the requirements of the project.

He is responsible for the investigation for all accidents and its causes and shall recommend
preventive measures.
Designated Supervisor for each activity will be assigned

2.7 HSE Supervisor

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

*Safety Policy
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2.7.1 Personal Protective Equipment(PPE) shall be issued to all workers such as

safety shoes, helmets, working gloves, earplug, safety goggles(if required) and safety harness
for workers who will be assigned in elevated places 1.8 meter and above

2.7.2 Personal Protective Equipment(PPE) shall be issued to all workers such as

safety shoes, helmets, working gloves, earplug, safety goggles(if required) and safety harness
for workers who will be assigned in elevated places 1.8 meter and above

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

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

2.7.5 High standards of housekeeping are understood to be indicative of a safe

workplace, during the course of all work activities workers shall continuously clear away any
waste materials from the task including general waste to a designated place

2.7.6 Understand that the environment is an important issue for the project, and shall
segregate the waste into the different waste streams generated by the work scope of this
procedure,

The working area shall be cleared to the satisfaction of company after work completed.

3 DRAWINGS / REFERENCE DOCUMENTS

3.1 DOCUMENTS , CODES and STANDARDS

- SIPD-1496: Pipeline Maintenance and Repairs Sec IV Scope of

Work
- 03516-PLI-MEC-SPC : Construction and installation of pipelines. Mechanical
Works
- ASME B31.3 Latest Edition Process Piping
- ASME B31.4 : Transportation System for Liquid Hydrocarbons
- ASME Section V : Non-destructive Testing, Latest Edition.
- API 5L Latest Edition : Specification for Line Pipe
- API 1104 Latest Edition : Welding of Pipelines
- 0000000XXXXXXXXXX : NDT Procedure
- API 570 Latest Edition Inspection, Repair, Alteration, and Rerating
of In-service Piping Systems
- ASME Sec. Ⅷ : Rules for construction of pressure vessel
- 00XXXXXXXXXXXXXX : Welding Consumable Control Procedure
- 00XXXXXXXXXXXXXX General Welding Procedure
- 000 XXXXXXXXXXXXXX PROJECT QUALITY PLAN
- 000 XXXXXXXXXXXXXX Health –Safety and Environment (HSE) Plan
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3.2 TERMS AND DEFINITIONS

2.2.1 Abbreviations

- SHELL – Iraq (COMPANY)

- Contract Administration: (Engineering Contractor)
- CONTRACTOR: Al-Kawther Engineering [ AKE ]
- Project Manager : ( PM )
- Project Quality Manager (PQM)
- Right of Way (ROW)
- Scope of Work (SOW)
- Personal protective equipment (PPE)
- Quality Control Plan (QCP)
- Job Safety Analysis (JSA)
- Construction Manager : (CM)
Const - Site Manager : (SM)
- Inspection Test Plan : ( ITP)
- Explosives Reminisces of War ; (ERW)
- Unexploded ordnance
(UXO)
-Tool Box Talk (TBT)

- Personal Protective Equipment (PPE)

- Majnoon Field Development (MFD)
- Right Of Way (ROW)
- Majnoon Operations Team (MOT)

2.2.2 Definitions

- Site Mean the location where the project is to be constructed and the vicinity
thereof
- Company : Shell - Iraq
- Contractor : Alkawther Eng.

4 HEALTH AND SAFETY

4.1 RISK ASSESSMENT

Refer to Project specific 00250600DFRC7402S – Risk Assessment the specific Risk

Assessments apply:

It is responsibility of the Site Manager, Project Engineer, Supervisor and HSE Project Manager
to consider any concurrent risk or simultaneous operations when planning welding activities, in
order to identify the need for further Risk Assessment of the Welding activities.

It is responsibility of the Supervisor to assess, with the help of the HSE Officer in charge, to
check the fully applicability of the above mentioned Risk Assessments.

In case any of the activities to be carried out are not fully covered, because of concurrent
operations and / or adjacent risk a specific Risk Assessment (Job Safety Analysis) shall be
drafted and submitted to the HSE Project Manager.

The JSA can refer to the above listed Risk Assessments and add only the identified additional
risks.
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The JSA shall be discussed with all involved crew before activities commencing during the
toolbox Talks.

It is furthermore responsibility of the Supervisor to identify any change in the activities or

incoming risk from adjacent environment and to take them into consideration in a specific JSA as
described above.

4.2 SAFETY PRECAUTIONS

All the new members of the contractor shall undergo a safety induction course in order to be
aware of the work.

Safety officer shall be available as and when required.

HSE compliance shall be ensured as per contractor Management Plan –

Workmen shall have all relevant PPE as required for the job.

Only experienced technicians / skilled workmen shall be allowed to undertake the job.

Necessary fire extinguishers & Personal H2S monitor shall be provided in the vicinity.

A toolbox meeting shall be conducted to brief all concerned about Dos & Don’ts. Special
coverage of salient points related to the job undertaken and risk involved, including course of
action in case of emergency, shall be ensured during the session.

After completion of the activities, the area shall be cleared of all equipment, Tools & tackles,
surplus materials and debris generated from the works.

CONTRACTOR shall have a developed HSSE Management System covering all

activities under the CONTRACT that is compatible with COMPANY’s HSSE management
system as described in Section VI – HSSE.
As part of CONTRACTOR’s HSSE management system, CONTRACTOR shall develop a
Contract HSSE Plan describing the specific actions, programs and procedures that will be
implemented by CONTRACTOR to manage hazards associated with the execution of the
Services. The HSSE Plan shall be developed in accordance with the COMPANY
requirements. The Contract HSSE Plan shall cover all Contract phases from mobilisation
through execution and demobilisation.
CONTRACTOR shall ensure that any person, admitted to the Worksite by
CONTRACTOR shall comply with COMPANY requirements. All persons engaged in the
Services shall be conversant with and, at all times, strictly comply with the HSSE standards.
CONTRACTOR shall be required to continuously maintain a system of hazard
management so that HSSE lapses are quickly identified and corrected before they result in
an accident.
All equipment, including but not limited to vehicles, lifting equipment, accessories etc
used in the execution of the Services are required to fully comply with COMPANY HSSE
standards and any Iraqi law, regulation and/or approval process.
Equipment must be correctly maintained, with a valid record of such maintenance
available for audit and validation at COMPANY request. COMPANY reserves the right to
restrict or reject the use of certain equipment, if in their opinion, any breach of
standards has or likely to have occurred.
CONTRACTOR shall ensure that all personnel involved in the execution of this
CONTRACT will be issued with the appropriate Personal Protective Equipment (PPE)
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and shall ensure all

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

4.3 Emergency Response and Evacuation Plan

CONTRACTOR shall make available the Core Team, Equipment and Temporary &
Other Facilities above for an Emergency on a 24hr/7day call-out basis to deal with
a pipeline emergency.
Core Team shall be on site as per normal working hours in 2.1.1 above, and all team
members must be available for call-out at any time to provide first line support in an
emergency such as a pipeline leak.

3.4 Worksite Handover ERW CLEARANCE and Permit to Work

The PROJECT SITE is characterized by local population and high level of
unexploded ordnance (UXO) and Explosives Reminisces of War (ERW) from recent
conflicts. COMPANY shall provide UXO and ERW clearance of the WORK SITE. Before
commencement of the WORK, independent confirmation of ERW clearance must be
received by CONTRACTOR from COMPANY complete with third party ERW QA/QC
Documentation.
CONTRACTOR shall comply with the ERW CERTIFICATES & ERW QA/QC limits and
excavation WORK requirements. Where excavations are required deeper than the ERW
permit clearance limits, then CONTRACTOR shall clearly define such locations and
request additional ERW Clearance from COMPANY.
CONTRACTOR shall obtain all permits issued under COMPANY’s Permit-to-Work
System, required to perform the WORK, such as, but not limited to, access and excavation
permits. CONTRACTOR shall keep and maintain record of all permits to Work and
release of area by ERW clearance complete as per Section - VI (Health, Safety,
Security and Environment) and where otherwise specified.

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

Environmental Risk Description ACTION/ MITIGATION

Spill Control Re-fueling of the plant will not be A designated re-fueling area will be established
undertaken within 30m of an existing and spill kits will be provided on the trucks at all
surface water course times to ensure they have the necessary
equipment to deal with any hydrocarbon spill.
cleared vegetation shall be disposed of in an according to the approved environmental
environmentally friendly manner waste management procedures
Waste & contaminations generated by the work scope of this Shall be segregate the waste into the
procedure, different waste streams waste

6 WORKING HOURS

Working hours to be dictated as per programme of works and statutory norms requirements.

AKE Eng. will erect localised task lighting if extended working hours are required. COMPANY will
be informed if extended hours are required.
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7 RESOURCES

7.1 PERSONNEL

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

7.2 EQUIPMENT’S

1 x 400 Amp Welding Set (Excluding Consumables)

1 x Welding Rectifier LTG 400 or equivalent

1 x Welding Generator KHG 500 P ESAB or equivalent

1 x Electrode Baking Oven

1 x Grinding Machine

1 x Air Operated Cold Cutting Machine

1 x Beveling Machine (4 Inch to 32 Inch)

1 x Hydraulic Torque Wrench (6 Inch to 32 Inch 600# Flange Wrench and above)

1 x Gas Tester (H2S, CO, MH4 etc) & Breathing Apparatus equipment

1 x Holiday Detector

1 x Mobile Generator Set 20 KVA - mobile

Car(s) and 4WD truck(s)

60 tons Side-boom(s)

100-200 HP Excavator(s)

External Clamp(s)
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Oxy-acetylene cutting machine(s)

Technical gas (e.g. propane, etc.)

Lifting devices (e.g. slings, etc.)

Hessian bags

7. Facilities
1 x Mobile Toilet Facility, including wash basin, soap dispenser, hand drying equipment

1 x Storage Container (Air Conditioned) - 20 foot - including shelving

1 x Storage Container - 20 foot (Non Air Conditioned) - including shelving

1 x Pick-Up Truck 4 x 4 (4 Seater/double cabin) (No.1)

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

Fabrication Workshop (minimum 10M x 10M) for Fabrication of Steel Structures, Testing and Calibration

Site office, minimum 8m x 3m Cabin or similar, with air conditioner, well stocked first aid box and
suitably equipped for four personnel

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

lighting for the Temporary Base Location

8 . REQUIREMENT

8.1 DRAWINGS , ENGINEERING AND REPORTING

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

8.1.2 COMPANY shall review and approve the CV’s of all KEY Personnel

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

8.1.5 CONTRACTOR shall be responsible to submit and carry out Welding Procedure
Qualifications and Welder Qualifications, as applicable for the CONTRACT, which shall be
subject to approval by COMPANY.

8.1.6 All relevant documentation shall be available in the work pack before it is issued to the Performer.

8.1.7 The Performer shall identify, select and offer for the QC review, the most suitable welder(s)
to perform the welding. The welder selection shall be based on technical competency, historical
performance records from recently performed welds, historical repair rate and current certification.
Selected welder/s shall be approved by the company.

8.1.8 CONTRACTOR shall prepare and submit reports on the Work done as required by
COMPANY and in a format acceptable to COMPANY. All such reports shall require approval
of COMPANY prior to being issued formally. COMPANY reserves the right to reject any
report, in part or in whole, which does not comply with the requirements stated.
However, CONTRACTOR can agree with COMPANY, deviations on format and contents.
CONTRACTOR shall prepare and submit the following reports on the Work done. The
preparation and submission of these reports shall be considered a fundamental condition
for satisfactory completion of the Work.
8.1.9 Daily Report
CONTRACTOR shall submit a daily report detailing the availability of equipment and personnel
working as Core Team during the previous 24 hours.
During the SERVICE ORDER period, CONTRACTOR is required to submit a daily activity
report every morning to the COMPANY representative which shall include details of
the work performed, the activities undertaken, number of man-hours worked, all incidents
and accidents (if any and as per Shell HSSE policy), time constraints and areas of concern
for the previous 24 hours.
The daily report shall be submitted to the COMPANY Site Representative no later than
17.00 hours on the day following the date of the report. CONTRACTOR shall prepare
report format for COMPANY approval.
8.1.9 Weekly Progress Report
During the SERVICE ORDER period, COMPANY may request CONTRACTOR to submit a
weekly progress report (a week shall be from Saturday to Friday) to the COMPANY
Representative in the form of a Gantt chart, the progress of each plan including actual
progress versus planned progress. The weekly report shall be submitted to the COMPANY
Site Representative no later than 09:00 hours on the Saturday of the following week.
CONTRACTOR shall prepare report format for COMPANY approval.

8110 Monthly Report

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

CONTRACTOR shall be responsible for the management of the resources to be provided.

CONTRACTOR shall provide the personnel, systems, equipment, tools and facilities necessary to
effectively perform the WORK. This shall include, but not limited, to:

8.5.1 WORKSITE management services as per the CONTRACT requirement. Provision of

other general and administrative support, as may be required for the efficient performance of
the WORK.

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

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

of
Scope of WORK.

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

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

8.5.7 CONTRACTOR shall develop and implement a Materials Management System and
procedures to ensure the safe and secure handling of all materials.
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8.5.8 CONTRACTOR shall hand over all the surplus COMPANY Free Issued materials to
COMPANY in good condition suitable for future use and complete with all associated
certification, permits and licenses. All surplus COMPANY Free Issue Material
shall be fully documented in accordance with a Materials Management procedure to be
developed and implemented by CONTRACOR.

8.9 CO-ORDINATIONS WITH OTHERS

CONTRACTOR shall, at all times coordinate with the COMPANY REPRESENTATIVE to

ensure that interfaces with COMPANY and other contractors are managed correctly.
CONTRACTOR shall coordinate with COMPANY Operations authority for all related
construction activity requisites by:

8,9.1 Attending coordination meetings with COMPANY

8.9.2 Planning and shifting resources to meet specific Project/operational needs

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

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

8.10 EARTH-WORK MATERIALS

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

8.1.1 All material to be supplied by CONTRACTOR is subject to inspection

and approval by COMPANY. Wherever possible CONTRACTOR shall comply with
COMPANY approved Vendor Lists. CONTRACTOR shall submit the required
documentation and certificates of compliance before start of WORK, which shall confirm
that all materials provided by CONTRACTOR, meet COMPANY requirements.

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

9.1 Site preparation.

9.1.1 Conduct site survey with the Company’s representative and confirm plant
specifications

9.1.2.The site specifications should be recorded and cross-checked with the

Company.

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

9.1.2 Conduct pre-work risk assessment.

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

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

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

9.1.6 Raise appropriate work permits.

9.2 FREEZE PLUG & PIG ISOLATIONS

Site field Engineer and Pipe supervisor should coordinate with Construction manager to ask
company/MOT that isolation valve on existing pipeline line should be closed and verified.
Also they should check whether pressure release on existing pipe or not after valve closed.

Verification of process and mechanical isolations by CONTRACTOR/COMPANY/MOT

Confirm identified isolations and spades are cross referenced onto PTW and isolation
certificates

CONTRACTOR shall, when required, mobilize a specialist Contractor for the Freeze
Plug Isolation of pipeline sections. CONTRACTOR shall provide full assistance to
COMPANY to complete and maintain the freeze plug isolation for the period required for
flushing, cold- cutting and welding of the new line section, in order to complete the required
pipeline repair.

CONTRACTOR shall, when required, mobilize a specialist Contractor for pipeline isolation
using friction or smart pigs. CONTRACTOR shall provide full assistance to COMPANY to
complete and maintain the line isolation for the period required for flushing, cold-cutting
and welding of the new line section in order to complete the required pipeline repair.

9.3 EXCAVATION

Excavation is a temporary civil work on which persons work and which provides support for the
materials used in construction, maintenance, repair or demolition work. It can also be used to
obtain access to certain areas of equipment and pipelines to proceed the required inspection .
CONTRACTOR shall use pipe detectors for identifying the pipeline location and route. All
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excavation and back filling/padding shall be carried out as per specification to be specified in
the SERVICE ORDER. CONTRACTOR shall submit a detailed method statement for
each excavation. All pipe exposing activities shall be carried out manually unless specified
otherwise in the Permit to Work.

9.4 . COFFERDAM CONSTRUCTION

CONTRACTOR when required shall construct cofferdams to provide an all

season work environment for emergency pipeline repairs in areas with high water table and
water canals. CONTRACTOR shall provide all materials and equipment required for the
construction of the cofferdam. All cofferdam construction materials (H-beams, sheet piles
etc.) shall be retrieved and WORKSITE re-instated to the original condition after the pipeline
repairs. CONTRACTOR shall submit a detailed method statement for each coffer-dam
application.Coating Removal
Paint, Coating or Wrapping material shall be carefully removed from the existing pipeline area
to be subjected to inspection . Before coating removal, where applicable, disconnect cathodes
protection from the buried sections of pipes.

9.5 WATER & OIL DRAIN

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

9.6 SURFACE CLEANING , WALL THICK. & VISUAL INSPECTION

CONTRACTOR shall survey and re-establish COMPANY ROW boundaries prior to

clearing the ROW for pipeline repair. All clearing shall be restricted within COMPANY ROW
and as per the SERVICE ORDER scope. All cleared vegetation shall be disposed of in
an environmentally friendly manner according to the approved environmental waste
management procedures. The CONTRACTOR shall obtain COMPANY approval for additional
temporary ROW required for the execution of Scope of WORK. The additional soil fill materials,
where required, shall be from COMPANY approved borrow pits.

CONTRACTOR when required and by instruction of COMPANY, shall expose and prepare
for inspection, sections of flowlines and pipelines in accordance with the applicable
documents within the CONTRACT. The identified pipeline flowlines sections shall be
exposed, de-coated and UT inspected by COMPANY approved inspection CONTRACTOR.
Based upon the inspection results, CONTRACTOR shall execute the COMPANY preferred
pipeline repair method. The section of existing run pipe to which the repair and maintenance to
be carried out shall be thoroughly cleaned properly with grit blasting , power brush for a
distance extending 150O mm either side of the location of the specified area. After cleaning, the
pipe shall be visually examined externally for laps, cracks, pitting and other signs of mechanical
damage or general corrosion . defect and leak locations to be identified .
The minimum actual wall thickness to be checked and comparison with the design data
respected with corrosion allowance to be verified / Company approval to be taken on thickness
readings reports and visual in
spection reports with recommendations.
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9.7 ABANDONMENT OF PIPELINE

CONTRACTOR when required shall assist in the execution of abandonment of

pipeline. The main activities consist of the excavation of the applicable pipeline section and
this section needs to be cut and removed by the CONTRACTOR. All recovered sections shall be
cut into 3m pieces and returned to COMPANY yard.

In case a section of the line is not fully accessible for recovery, CONTRACTOR shall
drain the section from oil and apply a cleaning programme under COMPANY direction.

CONTRACTOR shall ensure that no spills occur during cut-out and removal of pipeline
section / pieces. All recovered crude shall be discharged at COMPANY nominated flow station.

9.1 HOT TAP & STOPPLING

CONTRACTOR when required shall mobilize a specialized Hot Tapping Contractor to

provide hot tapping and stoppling activities. CONTRACTOR shall provide full assistance to
COMPANY for completion of this activity.

9.8 REPAIR METHOD

CONTRACTOR shall suggest the recommended repair method for each pipeline section
according to site survey , visual inspection and thickness measurement readings .

The proposed repair and maintenance method to be submitted to COMPANY should do

Assessment and identification of repair method for approval prior to implementation. These
methods should be one of the following :

9.1 Sleeving of Pipeline Defects

CONTRACTOR shall, when required, execute the sleeving of defective pipeline sections in
accordance with the responsibility matrix and other documents within the CONTRACT.
This work shall include the excavation to expose the defective pipeline section. In
addition the work includes de-coating and full NDT inspections to confirm the areas to be
sleeved. Where metal sleeves are specified, DPT, MPT or X-ray tests shall be carried out
by CONTRACTOR to determine the quality of welds.
CONTRACTOR shall, when required, provide sleeving repair with epoxy filling which may
require using a specialist service provider. The service provider and repair procedure shall
be pre-approved by COMPANY.
metal sleeves are specified, DPT, MPT or X-ray tests shall be carried out by CONTRACTOR
to determine the quality of welds.
CONTRACTOR shall, when required, provide sleeving repair with epoxy filling which may
require using a specialist service provider. The service provider and repair procedure shall
be pre-approved by COMPANY.

The longitudinal seam welds of full encirclement sleeves should be tested in accordance with
5.6. The backing material, if used, should be removed and the specimens may be flattened at
room temperature before testing.
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Appropriate gasket material

Figure C-1—Encirclement Repair Sleeve

Fluid in
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Note: T = tensile; RB = root bend; FB = face bend; NB =

Nick-break; SB = side bend; MT = macro test.

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

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

approximately 9 in. (230 mm) long and approximately 1 in.

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

SLEEVE WELD

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

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

1/ " (13 mm)

2

Attachment wall thickness

Pipe wall thickness

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

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

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Wall thickness

Weld ground flush

(see Note 2)

Wall thickness

BRANCH WELD

SLEEVE WELD Test specimen

(see Note 3)

See Note 1

Approximately 1" (25 mm)

Approximately 9" (230 mm)

SLEEVE/ BRANCH REMOVED

1/ " (3 mm) max. R

8
all corners

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

Figure B-5—Face-bend Test Specimen

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

9.2 Pipeline Clamping

CONTRACTOR, when required, shall carry out pipe clamping using pressure rated clamps
and in accordance with COMPANY Specifications.
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Temporary repairs of locally thinned sections or circumferential linear defects may be made on-stream by installing a
properly designed and fabricated bolted leak clamp. The design shall include control of axial thrust loads if the
piping
component being clamped is (or may become) insufficient to control pressure thrust. The effect of clamping
(crushing)
forces on the component also shall be considered. During turnarounds or other appropriate opportunities,
temporary leak sealing and leak dissipating devices, including valves, shall be removed and appropriate actions taken
to
restore the original integrity of the piping system. The inspector and/or piping engineer shall be involved in
determining
repair methods and procedures. Procedures that include leak sealing fluids (“pumping”) for
process piping should be reviewed for acceptance by the inspector or piping engineer. The review should take into
con-
sideration the compatibility of the sealant with the leaking material; the pumping pressure on the clamp (especially
when
repumping); the risk of sealant affecting downstream flow meters, relief valves, or machinery; the risk of subsequent
leakage at bolt threads causing corrosion or stress corrosion cracking of bolts; and the number of times the seal area
is repumped

9.3 Patch repair

Fillet-welded patches require special design considerations, especially relating to weld-joint efficiency and crevice
corrosion. Fillet-welded patches shall be designed by the piping engineer. A patch may be applied to the external
surfaces
of piping, provided it is in accordance with 8.1.3 and meets either of the following requirements:
a. The proposed patch provides design strength equivalent to a reinforced opening designed according to the
applicable code.
b. The proposed patch is designed to absorb the membrane
strain of the part in a manner that is in accordance with the
principles of the applicable code, if the following criteria are
met:
1. The allowable membrane stress is not exceeded in the
piping part or the patch.
2. The strain in the patch does not result in fillet weld
stresses exceeding allowable stresses for such welds.
3. An overlay patch shall have rounded corners (see
Appendix C).
Size of the patch should not exceed 1/2 the pipe diameter.
A full encirclement sleeve should be used if the corroded
area exceeds 1/2 the diameter
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9.1 . Flowlines Construction (New and Replacement)

10
9.3.1 During the life of CONTRACT it may be necessary to replace existing or install brand
new flowlines. CONTRACTOR shall, when required by COMPANY, replace part of, or
install a completely new flowline, which will typically be no more than 7 km long. Scope
of flowlines, repair or installation will be described in a SERVICE ORDER and include but
not be limited to:
10

9.3.2 Receiving handling, storage, transportation of line pipe material to yard or Work
Site

9.3.3 Stringing, bending, lining up, swabbing, bevelling, alignment, preheating

as required, c- Field testing & installation of valves and any other ancillary

9.3.4 WPQR, WQT and welding of field joints

9.3.5 Installation of fittings/induction bends/inline items etc, NDT, heat treatment (if
applicable), lowering, tie-in welds, repair of weld joints,

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

9.3.7 Clearing trench, installation of temporary & permanent pipeline markers, cleaning
etc
10
9.3.8 CONTRACTOR shall submit method statements and resources to complete the work safely.
CONTRACTOR shall prepare and qualify proposed welding procedure specifications
according to the requirements of COMPANY Standard Specification DEP 31.40.60.12, API
RP 2200 and latest edition of API 1104.
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9.9 Grinding and welding for repaired pipelines .

The production welding shall be performed in accordance with the approved Welding
Procedure Specification

The welder and welding operator shall be qualified in accordance with welder and
welding operator performance qualification procedure

Welding consumable control shall be as per approved Welding Consumable Control

Procedure

9.10 WELD INSPECTION

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

9.11.1 Visual Inspection of Welds

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

9.11.2. Radiography

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

Radiography works shall be carried out in accordance with approved procedure

. 10 Hydro Testing, Pre-Commissioning & Commissioning

CONTRACTOR scope during hydro-testing, pre-commissioning and commissioning includes
but is not limited to:

10.1 Submit a general pressure testing procedure for COMPANY’s review and
approval

10.2 - Prepare detailed test procedures for COMPANY’s review and approval, before actual tests are
carried out

10.3 Provide certification for all test equipment for use in hazardous areas d-
Obtain approval from COMPANY for all test instruments

10.4 Carry out witnessed calibration tests at COMPANY’s sole discretion

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10.5 Carry out pressure testing in the presence of COMPANY’s Site Team and CONTRACTOR’S
QA/QC personnel of the affected section in accordance with COMPANY Specifications

10.6 Record, compile and retain copies of the test clearance sheets, pressure test records and
charts. Originals of these documents to be submitted to COMPANY as part of the as-built
package immediately after the pressure test operation.

10.7 Request from COMPANY a certificate of “Complete and ready for commissioning” which shall
be issued by COMPANY if the work for the said part is performed to satisfaction
Testing and Pre-commissioning of all pipelines includes but is not limited to; supply & filling suitable
quality water with chemical inhibitors (if required), supply & install all temporary connections, hydro
testing, pressurization for required duration, dewatering, disposal of hydro test water
including temporary connections as required, flushing, drying, all pigging (except intelligent
pigging), nitrogen purging, etc. in accordance with the CONTRACT.
CONTRACTOR shall de-water all pipelines after repairs, testing but prior to commissioning.
All equipment and fittings required for de-watering shall be supplied by CONTRACTOR. All
pipeline contents shall be retrieved into CONTRACTOR supplied tanks or excavated lined containment
pits.
CONTRACTOR shall submit method statement for hydro testing and pipe cleaning
clarifying water source used for hydro test and disposal of hydro test water, complete with
equipment list and arrangement, in accordance with COMPANY HSSE requirements .

10 GRIT BLAST COATING AND WRAP WORKS

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

11 Back filling

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

12 Removal of isolations in sequence

On satisfactory completion, in accordance with the MOT PTW procedure,

CONTRACTOR shall inform Company in order for process and mechanical isolations
to be removed.

Removal of isolations by MOT shall be in sequence and verified by CONTRACTOR and

Company.

13 Re Coating

Coating and wrapping shall be carried out in accordance with procedure No:
(00XXXXXXXXXXXXX_EXDE00_00 Coating Control Procedure).

14.1 HOLIDAY DETECTION

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The whole surface will be inspected with a holiday pulse-type detector.

The detector voltage for wrap will be: MAX . 25 KV – (to be confirmed by the Manufacturer
Spc.)
The detector voltage for coating will be 8.0 KV /1000 µ ( max 20 KV ) The electrode used for
locating holidays shall be designed to ensure direct contact with the coating (with no visible
gaps) and must provide complete coverage of the whole coated surface. Holiday detection shall
not be conducted if the surface temperature of the pipe is above 90°C.
The travel rate of the detector's electrode shall not exceed 0.3 m/s and shall not be allowed to
remain stationary while the power is on.
The holiday detector output voltage shall be calibrated twice per ten (10) hour shift.

11 . Cathodic Protection and Corrosion Monitoring

15.1 CONTRACTOR shall, when required by COMPANY, use an approved specialist service
provider to carry out cathodic protection survey, design and troubleshooting services.
SERVICES include but not limited to:
15.2 Installation and maintenance of transformer rectifier
units b- Installation and replacement of ground bed material

15.3 Installation, replacement and commissioning of sacrificial

anodes

15.4 Installation and maintenance of junction boxes, reference electrodes and test
posts e- Installation of spark gap arrestors and isolation kits

15.5 Cable laying and splicing g-Cad welding

Pre-commissioning and commissioning of impressed current and sacrificial anode systems
15.6 Support COMPANY Corrosion Engineer in execution of routine Cathodic Protection and

15.7 Corrosion Monitoring activities.

16 IN-PROCESS EXAMINATION

In-process examinations shall be performed by Performer JV QC and witnessed by the company

in accordance to the requirements of ASME B31.3 Section 344.7. All phases of the process shall
be documented on approved by company forms.

The following items and parameters shall be witnessed, verified and recorded:
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16.1 Material certification and traceability verification. This shall be performed prior to the
commencement of the job.
13.1 WPS applicability. This shall be performed prior to the commencement of the job.

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

13.3 Welders’ certification. Welders selected shall be the most qualified contract welder(s).

13.4 The welder selection shall be based on technical competency, number of previous repairs and current
certification. This shall be performed prior to the commencement of the job.

13.5 Verify NDE personnel by company that have demonstrated the test. This shall be demonstrated prior
to the commencement of the job.

13.6 Verify NDE equipment meets the requirements of the applicable NDE procedure. This shall be
performed prior to the commencement of the job.
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13.7 Verify if a temporary shelter needs to be erected to provide weather protection as the weld is being
made.

13.8 Hydrogen bake-out. Witness band setup and verify temperature if applicable.

13.9 Witness bevel, parent metal preparation and NDE of the beveled face.

13.10 Witness joint fit-up. Verify root gap and ensure that any inside miss match are within required
specifications.

13.11 Verify pre-heat temperature.

13.12 Verify welding parameters are within those specified in the WPS. These include Amperage, Voltage,
inter pass temperature and travel speed. If the parameters do not meet the requirements of the
WPS, the weld shall be cut out.

13.13 Witness the MPI or DP inspection of the root and hot pass.

13.14 Perform visual inspections on all filler passes and cap.

13.15 Witness setup for PWHT if applicable. Verify number of thermocouples. Sign PWHT chart at the
beginning and at the end of the heat cycle.

13.16 Verify that the appropriate hardness tests have been performed.

13.17 Witness required NDE, i.e. UT, RT and MPI (DP). Ensure the approved procedures are followed and
the required forms are completed.

17 NDT REQUIREMENTS

17.1 Hardness testing shall be required on all “closure welds in sour service”. (This does not apply to
austenitic materials). JV Hardness Testing Procedure as per 00250600DBQR7215 – NDT
Procedure shall be used. All hardness values shall be below 237 HB/250 HV10.
17.2 Visual inspection of all welding passes shall be performed. This includes root tacks. No evident
visual imperfections shall be allowed.
13.18 MPI (DP for austenitic welds) shall be performed on the root and hot pass of carbon steel welds
while the pre-heat temperature is being maintained. The use of permanent magnetic yokes is
prohibited. No linear indications are allowed. Note: Additional care and safety precautions shall be
taken while working around hot surfaces.
13.19 MPI/UT shall be performed on all completed carbon steel welds after PWHT (DP for austenitic
materials). No linear indications are allowed.
13.20 Each closure welds shall be examined with a combination of NDE methods & techniques as to ensure
that the entire weld volume is scanned in different directions in order to ensure any detection of
linear defects located within different weld planes. This will be primarily achieved by examining the
welds with volumetric NDE (i.e. RT or UT) methods. This shall be in addition to MPI/UT performed
during in-process examination and after PWHT (points 3 and 4 as above). Whenever the weld joint
thickness or other technical difficulties will affect the feasibility of performing RT or UT, a specific
method/technique shall be developed by Performer. These specific cases will be submitted to the
company for approval.
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13.21 Welded joints with thickness < 35 mm shall be inspected by radiography utilizing D4 film. Any existing
provisions for radiography on partially completed thick wall welds shall apply. The acceptance
criteria for Severe Cyclic Service shall apply except no evidence of under cutting or concave root is
allowed. Note: An ultrasonic critical root scan (as defined in the referenced JV UT procedure - as
per – NDT Procedure) is required for all “closure welds” in sour service and 10,000 psi systems.
13.22 An ultrasonic inspection shall be performed on all welds > 35 mm (except for austenitic materials if
any-dedicated NDE procedure to be qualified). The acceptance criteria listed in ASME Section VIII
Appendix 12 shall apply. Imperfections which produce a response greater than 20% of reference
level shall be investigated. Indications characterized as cracks, lack of fusion or incomplete
penetration are unacceptable regardless of length. Other imperfections are unacceptable if the
indications response exceeds the primary reference level and have lengths which exceed:

Length of imperfections Thickness of the weld

6 mm (1/4 in.) Thk up to 19 mm (3/4 in.)
1/3t Thk from 19 mm to 57 mm
(3/4 to 2 ¼ in.)
19 mm (3/4 in.) Thk over 57 mm (2 ¼ in.)

Note: A sensitive ultrasonic root scan is required for all “Welds” in sour
service and 10,000 psi systems.

13.23 1At the welding contractor’s option, NDE may be performed on a weld before PWHT for informational
purposes only. One of the two required volumetric methods can be performed before PWHT but
only the one performed after PWHT shall be selected as method as per section 7 points 6 and 7.
Weld acceptance shall be performed after PWHT and shall meet the requirements of sections 10
points 5 and 6.
13.24 Dye penetrant inspections shall be performed on the root bead and hot pass for all welds. No linear
indications are allowed.
13.25 Dye penetrant inspections shall be performed on small carbon steel welds that cannot be inspected
by other techniques. No linear indications are allowed.

14 DOCUMENTATION

The inspection reports for structural steel works will be the verification documents for meeting
the requirements of the Project specification.

QC inspectors shall be responsible for completing Inspection Reports for these activities.

- Risk Assessment
- Report Forms for NTD Procedure –
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APPENDIX
A
CURRENT LIST OF COMPANY
PIPELINES

length
Dia of the PL / FL
(m)
6" Dia 28810

8" Dia 83290

10" Dia 5850

12" Dia 2050

16" Dia 12350

20" Dia 17300

28" Dia 38000

32" Dia 24000

15 ATTACHEMNT

RA - Radiography
Revision Number: 0 Assessed by: Date:
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Task/operation and location [including any tools/equipment in use]

Exposure to radiation
Hazards Risk ratings
Without controls With controls

Exposure to ionizing radiation High Medium

Unsealed sources of radiation can be inhalation, ingestion, High Low
absorption through broken skin or injection.
Other:
Harm
Cancer
Dermatitis
Radiation Poisoning
Persons in danger
NDT workers
Other workers
Member of the public
Control measures
Employees working with the radiation source should be competent and fully trained.
Employees to wear appropriate personnel protective equipment supplied.
Warning signs must be erected at each entrance of where work is being carried out to prevent other
employees entering area.
Appropriate warning signs will be displayed and restrictive bunting tape will be erected to cordon off the
area where work is being carried out.
Keeping as far back as possible from the radiation source and constantly monitoring the restricted area to
prevent other employees entering.
Any employees working with ionising radiation sources must be equipped with personnel film badges
(dosimeter badges) which record the amount of exposure an employee has received over a given amount
of time.
Prior to use the radiography equipment must be checked.
Flashing lights and acoustic warning alarm shall be used during night work if required.
Care must be taken to ensure maximum distance between the operator and X-ray tube and no
unauthorised personnel is within the controlled area before work starts.
When work is ended, all equipment shall be collected and taken back to the store.
Personal protective equipment
Safety helmet, safety boots and hi-visibility vest
Light eye protection
Personal Dosimeter

Specific Job Safety Analysis required? Yes, to be developed together with the subcontractor actually
carrying out the Radiography activities: Radiation Safety, Emergency procedure, Recovery procedure, etc.
Information, instruction and training
Workers informed of the control measures and instructed to wear the required PPE
Refresher training undertaken in the form of toolbox talks
Emergency procedures
Recovery and Emergency procedure to be developed with Radiation Site Representative.
Monitoring procedures
It is responsible of the NDT crew supervisor to check that at all times the effectiveness of the barriers in
place (barricade, lights, and alarms).
Regular reviews of control measures undertaken to ensure that they are effective and that workers are
adhering to them; where necessary, procedures should be updated
Inspections of all equipment before use
During site radiography the appropriate personnel protective equipment must be worn, including dosimeter
Other items
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APPENDIX – B – INSPECTION AND TESTING PLAN FOR PIPELINE

CONSTRUCTION
H - Hold point
W – Witness
R – Review
A – Approval
S – xxxxx

Supplier’s Responsibility
Sl Reference Acceptance Verifying Extent of
Activity Description verification
no Documents criteria Document inspection CONTR COMP
Personnel ACTOR ANY
Preliminary survey & site
preparation including the
requirement of Permit,
1 ERW clearance certificate
1.1) Co-ordinates & initial
level: H H
Transfer /Protection of
bench Marks
1.2) Point of intersection H W
2 Right of way
2.1) Clearance / Width of
Right of Way (ROW) and
access road H H
2.2) Soil stripping H W
2.3) Right of way H W
2.4) Filling and Grading H W
Excavation /Earth works for
3 trenching
3.1) Excavation Permit H W
3.2)Dimension & location H W
3.3) Pipeline Routing &
Chain age H W
3.4) Trail Excavation to
detect underground utilities H W
3.4.1) Cable /Road
/Pipeline H W
3.4.2) Road Crossing H W
3.4.3) Pipeline Crossing H W
3.4.4) Pipeline
characteristics H W
3.5)Trenching H W
3.6) Back Filling
3.6.1) Soft & Bedding (
Before Pipe laying ) H H
3.6.2) Soft & Padding (
After Pipe laying) H H
3.6.3) Back filling H W
3.7) Berm Construction H W
4 Materials
Pipes ( Dia, Thickness &
Grade) W W
Fittings ( Size, Class and
identification stamp) W W
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Gaskets( Size, Class and

Serration Protection) W W

Valves ( Type ,Class and

adequate Protection of
Valve ends) W W
Pipe line sectional
5 replacement
5.1) Marking of Heat no.,
Pipe no. & length H R
Arresting of leak by
6 clamping H W
Coating removal and
7 recoating of pipes H W
8 Line up/Main line Welding
8.1) Line pipe traceability (
Pipe book) and weld map H W
8.2) WPS/PQR Approval H H
8.3) Qualification of welder H W
8.4) Electrode & dry
condition inspection H S
8.5) Weld joint Fit-up H S
8.6) Pre-heating ( If
required) H S
8.7) Marking for welder ID
no./Joint no. H S
8.8) Visual inspection for
surface defect H S
8.9)NDE- Radiographic
testing, UT, MPT, PT H W
8.10) Hardness Testing H W
8.11) Lamination check &
Thickness check & PT
/MPT on the cut-back. H W
9 Weld Repair
9.1) WPS/PQR H H
9.2) Qualification of Welder H W
9.3) Electrode & dry
condition
Inspection H S
9.4) Weld Joint Fit-up
(For Cutout joints) H S
9.5) Pre heating(If required) H S
9.6) Visual Inspection for
surface defect H S
9.7) Radiographic Testing H R
9.8) Hardness Testing H W

Field joint Heat Shrink

10 sleeve Application
10.1) Approval of Coating
Application Procedure,
Field Repair Procedure,
Coating applicator & Site
trial qualification H A
10.2) Heat shrink sleeve
material, primer H w
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10.3) Weather conditions

Relative Humidity, Dew

point, substrate
Temperature, Air
temperature, Dry Bulb, Wet
Bulb etc. H W
10.4) Surface preparation
Checking Grit material,
Degree of Cleanliness,
Roughness, chloride test
once on everyday
production H W
10.5) Heat Shrink sleeve
Application
Preheating H W
Primer application H S
Tape to overlap H S
Overlap to PE Coating H S
Visual Inspection of applied
Heat
shrink sleeve H W
10.6) Heat shrink sleeve
repair
Defective sleeves shall be
removed, replaced or
repaired and then re-
examined H H
10.7) Repair on supplied
coated pipes
For surface defect without
Holiday
(by polyethylene sticks) H W
For surface defect with
holiday H W
For holes about 1/2" dia
(by polyethylene sticks)
H W
For holes above 1/2" dia
(by patch work)
H W
10.8) Heat shrink sleeve
Testing Peel Test(once per
working shift) H W
11 Lowering and Laying
11.1) Holiday testing of
Lowering section H W
11.2) Lowering of Pipeline
section H W
12 Tie-in of Pipeline sections
12.1) Line pipe
Traceability(Pipe book) H W
12.2) WPS/PQR H H
12.3) Qualification of welder H W
12.4) Electrode & dry
condition Inspection H W
12.5) Weld joint Fit up H W
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12.6) Pre heating & PWHT

(If required) H H
12.7) Marking of welder ID H W

no./Joint No.
12.8) Visual Inspection for
surface defect H W
12.9) Radiographic Testing H W
12.10) Hardness Testing H W
12.11) Field joint Heat
shrink sleeve application H W
12.12) Holiday test of Tie in
joint Heat shrink sleeve H W
13 All crossings :
13.1) Crossing of existing
facilities H W
Road Crossing
13.2) Survey works
including the Permission &
authorisation H W
13.3) installation of
diversion Roads.
13.4) Excavation of
crossings H W
13.5) Welding Inspection H W
13.6) NDE & Hydro-testing. H H
13.7) Field joint HSS
Application H W
13.8) Holiday testing H W
13.9) Lowering H W
13.10) Spacer Installation,
insertion, vent pipe H W
13.11)Backfilling &
Reinstatement H H
13.12) Installation of
diversion Roads. H W
14 Pipeline Pigging
14.1) Cleaning Pig
inspection H H
14.2) Cleaning operation H H
Inspect the Pig before
loading H W
Inspect the Pig After
Removal H W
15 Pipeline Gauging
15.1)Gauging Plate
inspection H W
15.2) Gauging Plate outside
Dia. H W
Gauging plate material H W
Gauging Plate thickness H W
15.3) Gauging Operation H W
16 Pipe line Filling & inhibition
16.1) Water analysis H R
16.2) Inhibitor Inspection H R
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16.3) Test Equipment

inspection H W
Pumps , Valves,
Instruments ,Dead Weight
tester, Pressure &
temperature ,Recorder etc.
16.4) Pigs inspection
Bidirectional Pig H W
16.5) Pipeline Flooding
Operation H W
17 Hydrostatic Test
17.1) Pressurisation up to
50 % test pressure H H
17.2) Measurement of air
content after reaching 50%
test H W
Pressure
17.3) Pressurisation up to
100 % test pressure H H
17.4) Temperature
stabilization H W
17.5) Pressure Monitoring H W
17.6) Readings
Pressure & temperature
recorder H W
Dead weight tester &
pressure gauge ( Maximum
,Minimum & average
values) H W
Ambient temperature
readings H W
Water temperature
readings H W
17.7)Acceptance of test H H
18 Dewatering
18.1) De-Pressurisation H S
18.2) Dewatering Pigs
Bi directional Pig H H
18.3) Dewatering operation H W
18.4) Inhibited Water
Disposal H S
19 Swabbing H W
20 Drying
Air Drying & Nitrogen
Purging (If applicable) H H
Temporary Cathodic
21 Protection System
21.1) Material Receiving
Inspection W H
21.2) Installation of
Sacrificial Anodes &
Testing H H
Permanent Cathodic
22 Protection System
22.1) Material Receiving
Inspection W H
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22.2) Bore well /Cashing

Pipe Installation H H
22.3) Installation of H H

Cathodic Protection
Rectifiers
22.4) Installation of Lead
Junction Boxes H W
22.5) Installation of Wires &
Cable, Negative cable and
test lead attachment H W
22.6) Permanent Reference
CELL
22.6.1) Placement H W
22.6.2) Backfill H W
22.6.3) Wiring H W
22.7) Post Installation
Testing of CP System H H
Review /Compile
24 Documentation H R