Majnoon Sour Gas Treatment Facility Project: MGP1-GP2-CPC-LA-7880-1501 003

Majnoon Sour Gas
Treatment Facility
,
Project
Specification for Pipeline Construction
003 Approved for Construction 8-MAR-2021 Lu Chao Zhao Furui Yang Qiang Chen Junwen
002 Issued for Approval 19-FEB-2021 Lu Chao Zhao Furui Yang Qiang Chen Junwen
001 Issued for Review 31-DEC-2020 Lu Chao Zhao Furui Yang Qiang Chen Junwen
Rev. Reason for Issue Date Author Checker Reviewer Approver
Rev.
MGP1-GP2-CPC-LA-7880-1501
003
Specification for Pipeline Construction Majnoon Sour Gas Treatment Facility Project
Revision History
Revision Revision
Approver Summary of Changes
Date Number
31-DEC-2020 001 Chen Junwen Issued for Review
19-FEB-2021 002 Chen Junwen Issued for Approval
8-MAR-2021 003 Chen Junwen Approved for Construction
Holds
Hold Ref. Description / Reason for Hold Ref. Section
Reference Documents
Ref. Document Number Rev. Document Title
1 MGP1-GP2-CPC-AA-7704-0001 - Basis of Design
2 MGP1-GP2-CPC-LA-5507-5101 Pipeline Design Criteria
3 MGP1-GP2-CPC-LA-3331-5101 - Pipeline Design report
4 MGP1-GP2-CPC-LA-3328-1501 - Typical Details for Road, Track Crossing
5 MGP1-GP2-CPC-LA-3328-1502 - Typical Details for Existing Pipeline/Cable Crossing
6 MGP1-GP2-CPC-LA-3328-1503 - Typical Details for Pipeline Construction
7 MGP1-GP2-CPC-LA-3328-1504 - Typical Details for Marker Post and Sign Boards
8 MGP1-GP2-CPC-RA-7754-0005 - Specification for Painting and Coating
9 MGP1-GP2-CPC-RA-7754-0003 - Specification for Buried Pipeline Cathodic Protection
10 MGP1-GP2-CPC-LA-4024-1501 - Field Layout for New Pipelines
11 MGP1-GP2-CPC-QA-6180-0001 - Welder Evaluation Procedure
12 MGP1-GP2-CPC-AA-5798-0002 - Construction Execution Plan
MGP1-GP2-CPC-LA-7880-1501 Page 2 of 32 Rev.: 003
Uncontrolled when printed or stored locally

Table of Contents
REVISION HISTORY 2
HOLDS 2
REFERENCE DOCUMENTS 2
TABLE OF CONTENTS 3
1.0 INTRODUCTION 6
1.1 Project Background 6
1.2 Purpose 6
1.3 Scope 6
2.0 ABBREVIATIONS 7
2.1 Definitions 7
2.2 Abbreviations 7
3.0 ORDER OF PRECEDENCE 8
4.0 CODES & STANDARDS 8
5.0 GENERAL REQUIREMENTS 9
6.0 TECHNICAL REQUIREMENTS FOR CONSTRUCTION 10

6.1 Route Delivery and Centreline Paying Off 10
6.2 Right of Way (ROW) 10
6.3 Grading, Handling, Stringing and Storing 10
6.3.1 Grading 10
6.3.2 Handling 10
6.3.3 Stringing 11
6.3.4 Storing 11
6.4 Trench 12
6.5 Pre-Padding 13
6.6 Bend 13
6.6.1 General 13
6.6.2 Elastic Bends 14
6.6.3 Hot Induction Bends 14
6.6.4 Cold Bends 14
6.6.5 Rejection of Bends 14
6.7 Welding and Inspection 14
6.7.1 General 14
6.7.2 Pipe Alignment 15
6.7.3 Cutting on Site 16
6.7.4 Welding Consumables 16
6.7.5 Preheating 16
6.7.6 Hardness Inspection 17

6.7.7 Post-weld Heat Treatment (PWHT) 17

6.7.8 Welding Procedure Specification (WPS) 17
6.7.9 Welding Procedure Qualification (WPQ) 17
6.7.10 Welder Requirements 20
6.7.11 Inspection and Acceptance of Welds 20
6.7.12 Repair and Removal of Defects 21
6.8 Coating 22
6.9 Cathodic Protection 22
6.10 Lowering-In 22
6.11 Backfill 23
6.11.1 General 23
6.11.2 Backfill Material 23
6.11.3 Excess Material 23
6.11.4 Berm 24
6.12 Clean-Up 24
6.13 Pigging 24
6.14 Gauging 24
6.15 Final Tie-ins 25
7.0 PRESSURE TEST, DRYING AND PURGE 25

7.1 Basic Requirements 25
7.2 Pre-testing of Assemblies 25
7.3 Air content determination 26
7.4 Temperature Recorder 26
7.5 Water Quality Requirement 26
7.6 Temperature Stabilisation 26
7.7 Strength Test 26
7.8 Leaktightness Test 27
7.9 Testing of Special Sections 28
7.10 Depressurising 28
7.11 Dewatering 28
7.12 Drying 29
7.13 Preservation 29
7.14 Safety Requirement 30
7.15 Internal Cleaning 30
7.16 Cleaning Scraper Tools 30
7.17 Dirt and Debris Containment 30
8.0 TREATMENT FOR SPECIAL SECTIONS 30

8.1 Road Crossings 30
8.2 Underground Utilities Crossing 31
8.3 OHTL Crossings/ Parallel 31
8.4 Construction Access Road 31

9.0 MARKERS AND SIGN BOARDS 32
10.0 SAFETY 32

1.0 INTRODUCTION
1.1 Project Background
The Sour Gas Treatment Facility (SGTF) is a new facility as part of the Majnoon Growth Project
(MGP) which will gather associated sour gas from oil processing facilities across the concession
for export. The facility will dehydrate and compress gas to export specifications.
The Majnoon field is currently producing at a consistent rate of 200-220 kbopd via the processing
facilities at CPF 1 (Central Processing Facilities) and DS2-DS1 (Degassing Stations 1 & 2). These
facilities are currently being debottlenecked to a combined capacity of up to 250 kbopd.
The Majnoon Growth Project covers the expansion of the current facilities by an additional 200
kbopd in the Majnoon concession area with the addition of CPF2. Thus, there will be greater than
420 kbopd oil production capacity in the concession area once implemented. The Majnoon
Growth Project will also add a Sour Gas Treatment Facility (SGTF) within concession to gather,
compress and dehydrate sour gas collected throughout the field. In total the SGTF should be able
to accommodate up to 155 MMscf/d of sour gas at the inlet of the facility and compressor
discharge pressure shall be adequate to meet sour gas pressure export to pipeline of 50 barg.
These facilities are envisaged whilst a longer-term sour gas solution is matured as the field is
further developed. As such, preference will be made for SGTF equipment that is highly
modularized and fit for re-use and incorporation into the longer-term sour gas solution.
Current gas facilities at CPF1 include capture of 1st stage sweet gas from sweet oil separators.
All other gas in CPF1 & DS2 are currently flared but will be recovered as part of the Majnoon
Growth Project. Gas capture within CPF1 & DS2 will be handled in a separate scope of work to
the functional specification due to the high-level of brownfield work, but is included in the SGTF
sizing basis and gathering lines from the fence of the existing facilities. This includes 1st, 2nd,
3rd stage sour gas.
The Project intends to leverage replicated standard, pre-engineered gas treatment facilities,
modularized to a high degree, as widely used in Industry & Iraq. The aim is to stay within the
limits of catalogue or “already used” designs and maximize the use of industry standards.
1.2 Purpose
The purpose of this document is to provide technical requirements for construction of Raw Gas
&Condensate Pipelines envisaged in Sour Gas Treatment Facility project.
This specification provides the requirements that shall be followed for the construction of pipelines.
This specification defines the minimum requirements for the construction of all below listed
Pipelines.
Method of Statements shall be provided before to start activities.
1.3 Scope
PL-1: A 14” sour gas pipeline of 1.8km length from DS2 battery limit to CPF1 battery limit.
PL-2: A 24” sour gas pipeline of 5.4km length from CPF1 battery limit to SGTF.
PL-3: A 28” sour gas pipeline of 9.9km length from CPF2 battery limit to SGTF
PL-4: A 6” sour condensate pipeline of 5.4km length return from SGTF to CPF1 battery limit.

2.0 ABBREVIATIONS
2.1 Definitions
PROJECT Majnoon Sour Gas Treatment Facility Project (SGTF)
COMPANY Basra Oil COMPANY (BOC)
EPCM Kellogg Brown and Root (KBR)

CONTRACTOR/EPC China Petroleum Engineering & Construction Corporation
CONTRACTOR (CPECC)
VENDOR/SUPPLIER Manufacturers/Supplier of Goods & Equipment
Part of Manufacturers/Suppliers of goods/equipment Ven
SUB VENDOR
dor
The party(s) which carries out all or part of the design,
SUB CONTRACTOR/
procurement, installation and testing of the system(s) as
CONSTRUCTION CONTRACTOR
specified by the CONTRACTOR
2.2 Abbreviations
Specific abbreviations used for this Project:
Table 2‑1 Abbreviations
Abbreviation Detail
SGTF Sour Gas Treatment Facility
API American Petroleum Institute
ASME American Society of Mechanical Engineers
ASTM American Society of Testing and Materials
CPF Central Processing Facility
DS Degassing Station
MMSCFD Millions Standard Cubic Feet Per Day
NDT Non Destructive Testing
NACE National Association of Corrosion Engineers
PQR Procedure Qualification Report
ROW Right of Way
AWS American Welding Society
PWHT Post-weld Heat Treatment
WPQ Welding Procedure Qualification
WPS Welding Procedure Specification
SMAW Shielded Metal Arc Welding
GTAW Gas Tungsten Arc Welding

Abbreviation Detail
GMAW Gas Metal Arc Welding
GSFCAW Gas Shielded Flux-Core Arc Welding
RT Radiographic Test
PT Penetration Test
MT Magnetic Test
3.0 ORDER OF PRECEDENCE

In the event of any conflict or contradiction between the specifications and standards, in
accordance with Section X Functional Specification of the CONTRACT, the CONTRACTOR shall
comply with the following mandated Engineering Standards and Codes, listed in order of
precedence:
a. Process Safety Basic Requirements

b. Mandatory Iraqi Statutory and Regulatory Requirements
c. International Standards
d. CONTRACTOR standards
e. Mandatory requirements stated in APPENDIX D in view of H2S presence in gas.
In the event of non-compliance with the above requirements CONTRACTOR shall seek
guidance from COMPANY to give direction against its own standards set.
Compliance with Iraqi Laws and Regulations is mandatory.
4.0 CODES & STANDARDS

Pipeline for the project shall be constructed primarily in accordance with the requirements of this
specification. Unless otherwise stated, they shall meet the requirements of the current issue (at
contract award date) of the following industry standards:
Table 4‑1 Codes & Standards
Codes & Standards

Title
No.
ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and Others
Liquids
ASME B31.8 Gas Transmission and Distribution Piping Systems
ASME IX Qualification standard for welding, Brazing, and Fusing Procedures;

Welders; Brazers; and Welding, brazing, and Fusing Operators
API 5L Specification for Line Pipe
API STD 1104 Welding of Pipelines and Related Facilities
API RP 1110 Recommended Practice for Pressure Testing of Liquid Petroleum

Pipelines
API RP 1102 Steel Pipeline Crossing Railroads and Highways

Codes & Standards

Title
No.
ASTM E92-2017 Standard Test Methods for Vickers Hardness and Knoop Hardness
of Metallic Materials
ISO 6506-1:2014 Metallic materials — Brinell hardness test —Part 1:Test method
ASTM A370-20 Standard Test Methods and Definitions for Mechanical Testing of
Steel Products
NACE TM 0284-2016 Standard Test Method - Evaluation of Pipeline and Pressure Vessel
Steels for Resistance to Hydrogen-Induced Cracking
ISO 7539-2:1989 Corrosion of metals and alloys - Stress corrosion testing - Part 2:
Preparation and use of bent-beam specimens
ASTM G39-99 (2016) Standard Practice for Preparation and Use of Bent-Beam Stress-
Corrosion Test Specimens
NACE TM 0177-2016 Laboratory Testing of Metals for Resistance to Sulfide Stress

Cracking and Stress Corrosion Cracking in H2S Environments
NACE MR 0175 / ISO Petroleum and natural gas industries - Materials for use in H2S
15156 containing environments in oil and gas production
5.0 GENERAL REQUIREMENTS

The CONTRACTOR / SUB CONTRACTOR shall complete all works associated with the Pipeline
scope and ensure it is built to the design, specifications and as per project requirements.
CONTRACTOR shall carry out all construction activities associated in compliance with local laws,
by-laws, ordinances and regulations.
CONTRACTOR / SUB CONTRACTOR shall be liable for damage to any and all above or below
grade existing manmade structures or natural features that may be located within or adjacent to
the working area. Caution and due consideration shall be given to the protection and support of
such properties and structures.
The CONTRACTOR shall protect the roads from damage caused during construction, and shall
repair any damage in time according to the COMPANY's instructions. Unless the COMPANY and
local authorities advise otherwise, open-cut methods should be used to cross roads.
SUB CONTRACTOR shall submit for approval individual construction procedures/Method

statements and ITPs including all relevant report sheets to CONTRACTOR and COMPANY for
review for all pipeline activities.
Draining of pollutants onto the land or into water bodies is not permitted. All waste material must
be collected and removed by the CONTRACTOR / SUB CONTRACTOR to an approved disposal
area on an ongoing basis.

6.0 TECHNICAL REQUIREMENTS FOR CONSTRUCTION

6.1 Route Delivery and Centreline Paying Off
The proposed pipeline route is shown on the pipeline route maps and AFC pipeline alignment
sheets. CONSTRUCTION CONTRACTOR shall be responsible to conduct a construction survey
of the entire pipeline and place pipe center line pegs at a maximum distance of 100 meters for
straight sections and a maximum of 10 meters where horizontal bends are required – pegs should
be located at the center of the bend. Pegs should be made from wood and shall be visible by
means of painted tops or wrapped in red and white safety tape.
6.2 Right of Way (ROW)

For construction spread space, the width shall be reduced as much as possible to facilitate the
transportation and arrangement of the pipeline.
Width of construction spread space in general section shall be 12~20 m for the pipeline.
CONTRACTOR shall locate and identify all existing buried facilities, such as cables, pipelines,
water mains, sewers, etc., including those not shown on the construction drawings, crossed or at
close proximity with the pipeline. The facilities underground if ascertained shall be marked, and
labelled in the alignment sheet. The corresponding protection measures shall be taken during
construction.
6.3 Grading, Handling, Stringing and Storing

6.3.1 Grading
The clearing of the ROW shall be carried out in conjunction with the construction of the access
roads in the ROW’s. After clearing the ROW and when grading has been performed so as to allow
passage of loaded trucks and equipment without undue wear and tear thereon, the
CONTRACTOR / SUB CONTRACTOR may commence his scheduled work.
The CONTRACTOR shall grade off high points and fill low points to allow the pipe to be bent and
laid within the limits set forth herein with due regard to the minimum radius of bends allowed and
shall excavate rock or other material which cannot be graded off with ordinary grading equipment
in order to provide an adequate working space along the pipeline route. The banks resulting from
cutting and filling must be sloped and or terraced sufficiently so as not to present hazards to
persons, livestock and wildlife.
Spoil banks from grading operations shall not be placed where drainage will be affected, and
such spoil banks shall be placed in locations acceptable to COMPANY. Grading shall be done so
as to prevent any erosion and right-of way instability during and after construction.
6.3.2 Handling
Pipe shall be handled in a manner to prevent possible damage to pipe walls and pipe ends.
Boomers shall always be used in cross-country or rough road handling. Pipe shall not be dropped
or rolled off or onto vehicles but shall be handled with suitable slings. Pre-coated pipe shall be
handled at all times with wide non-abrasive canvas or nylon belts, or other equipment designed
to prevent damage to the coating. Rope shall not be used. Pipe stockpiled shall be carefully
stacked and blocked to avoid damage to pipe or pipe coating. Pipe loaded out shall have suitable
tie downs, supports and blocking to prevent shifting. Tie-down, supports, and blocking shall be of
such material and construction to provide adequate protection to pipe and to pipe coating. Pre-
coated pipe requires tarpaulin protection when being hauled on gravel roads.

CONTRACTOR / SUB CONTRACTOR shall ensure that all construction materials consigned to
any part of the work shall be properly stored to prevent theft, damage or deterioration.
CONTRACTOR shall contain all forms of debris from its operation, such as cans, bottles,
containers, welding rods, excavated material etc., and dispose of such debris at waste disposal
sites approved by COMPANY.
6.3.3 Stringing
CONTRACTOR / SUB CONTRACTOR shall string pipes on the right-of-way in preparation for
bending and welding in a manner that prevents damage to pipes and coatings. To minimize the
risk of damaging the line pipe, proper lifting method should be considered by the CONTRACTOR
/ SUB CONTRACTOR for handling purposes.
Pipe shall be lifted from transporters using an approved type of pipe hook. Pipe shall be placed
directly onto sand bags or other approved supports to ensure that it is held clear of the ground
surface and maintained in a secure position against movement due to rain or settlement.
Stringing vehicles shall have installed suitably padded supports to prevent pipe coating damage.
Pipe shall be strung alongside the trench on supports properly spaced with the pipe clear of the
ground. The trench is to be completely excavated and the area cleared of all debris and the
requisite base pre-padding placed before stringing of the pipes. However the CONTRACTOR /
SUB CONTRACTOR shall note and make allowance for sand drift into the trench in sandy areas.
The pipe shall be strung parallel to the trench at a suitable and constant distance from the
centreline of the trench. The stringing on the ROW shall be done in such a manner as to cause
the least interference with the normal use of access by trucks, side-booms, etc. Gaps shall be left
at intervals or wherever requested by other users to permit the passage for traffic or equipment
across the ROW or along public roads or highways. Pipe stringing shall be done in such a manner
as not to cause a hazard or possible damage by traffic.
All coated pipe strung on the ROW shall be supported in such a manner that the pipe is free from
contact with the ground at all times. Sand bags are permissible for use as pipe supports except
in wet areas. In wet areas, sand bags with wood pads shall be used.
6.3.4 Storing
Materials supplied by the CONTRACTOR shall be properly stored in a safe & secure area and
shall not be stored on the ROW. When required the materials shall be transported onto the ROW
in covered vehicles and delivered directly to the desired location.
The pipe stacking site should not be in low-lying terrain to prevent water accumulation. In case of
continuous rain causing ground subsidence, diversion ditch should be made to avoid
accumulation of water.
CONTRACTOR / SUB CONTRACTOR shall record the pipe numbers, steel heat numbers, pipe
lengths, wall thickness and location of each piece of pipe, as strung.
These records shall be amended “as laid” to include the weld numbers and the welding operator’s
identification numbers, and maintain the records.
The length of the welded pipe string shall be planned with due consideration of thermal expansion
and other expected or accidental movement of the pipe string. Special attention shall be paid to
strings with one or more bends, in view of the inherent increased risk of failure of sand bags due
to the above movements of the pipe.

All pipe ends shall be protected / covered to prevent sand from entering the pipe by using weather
resistant material.
Coating and primer shall be unloaded from cars at destination points in such a manner as to
prevent damage to containers. Containers of coating materials shall not be handled with hooks
at any time and shall be stored with tops of containers up.
Valves, fittings, and other materials shall be unloaded in a manner to prevent damage, loss or
deterioration and permit easy access for checking of quantities. Valves, flanged fittings, or other
materials with finished surfaces shall always be placed on sand bags to prevent the finished
surfaces from coming into contact with the earth. Small fittings, fiberglass wrapping material, and
supplies shall be kept in suitable warehouses.
6.4 Trench
Before any trenching commences, CONTRACTOR / SUB CONTRACTOR shall obtain the
approval of COMPANY. CONTRACTOR / SUB CONTRACTOR shall excavate the pipeline trench
in the pipeline corridor as per Project Typical Drawing No. MGP1-GP2-CPC-LA-3328-1503 -
Typical Details for Pipeline Construction.
Trenching shall include all excavation, whether by trenching machine, power shovel, by hand, or
by other methods which may be necessary (after grading has been completed) to prepare a
trench for the pipe with the minimum of cover between top of pipe and immediate ground level as
specified in alignment sheets.
The depth of the trench shall be measured from the level of the original ground on each side of
the trench. It shall be necessary to provide additional depth trench at certain locations such as
roads, highways, drainage trenches, ravines, and other water courses, crossings of other
underground structures, etc. The trench depth is determined according to the regulations of B31.8
and Pipeline Design Report, detailed in the Pipeline Alignment Sheet
The trench shall excavate and grade the trench to a depth and in such a manner that the
separation of the pipeline will be a minimum of 500 mm below/above the bottom/top of the
underground structure crossed. Refer to Typical Details for Pipeline Construction, Doc # MGP1-
GP2-CPC-LA-3328-1503.
The bottom of the trench shall be square cut as neatly as possible to avoid unnecessary handwork.
Handwork will be required however, to remove rocks, and protruding roots from the sides or
bottom of the trench or as required by COMPANY.
Mechanical excavation shall not take place within 2 meters of an existing service; only manual
excavation shall be permitted within this distance. In all cases where the trench has been cut
across private or public roads, the CONTRACTOR / SUB CONTRACTOR shall provide
Temporary bypass (diversion) road as not to disrupt traffic flow.
As per recommendation from INTERPRETATIVE REPORTFOR GEOTECHNICAL

INVESTIGATION, Layer① lean clay is classified as Type B soil, layer ②lean clay is classified as
Type C soil as defined by Occupational Health and Safety Act (OSHA). Within Type B soils,
temporary open cut excavations muse be slope at 1 horizontal to 1 vertical from the base of the
excavation per the requirements of OHSA. Within Type C soils, temporary open cut excavations
muse be slope at 1.5 horizontal to 1 vertical.
The CONTRACTOR / SUB CONTRACTOR shall, whenever possible, complete the trenching,
laying and backfilling of roads before the end of the work day so as to avoid hazards to night
traffic. Adequate signage shall be placed informing of road works. Hard barricade and battery
powered lighting to be placed if road shall be closed during night hours.

Rocks, gravel or other hard materials in the trench, which will damage the pipe or pipe coating,
shall be covered with soft earth or sand as project drawing.
The trench shall be kept in good condition until the pipe is laid and inspected. All lumber, jacks,
or other materials used to brace the trench shall be furnished and removed.
6.5 Pre-Padding
CONTRACTOR / SUB CONTRACTOR shall provide trench bottom pre-padding in areas of rock
trench, or other areas where material in the bottom of the trench has potential to damage the
pipes or external coating following pipes installation. Where trench is on slopes, CONTRACTOR
/ SUB CONTRACTOR shall install soft plugs to avoid soil run off.
Rock free excavated soil shall be used for pre-padding. The maximum size of solid particles of
pre-padding should not exceed 20mm.
Trench bottom material shall be placed to a minimum compaction thickness of pre-padding

material to a minimum depth of 150 mm and on top of pipe to a minimum depth of 300 mm as
specified in the relevant Project typical drawing ‘’MGP1-GP2-CPC-LA-3328-1503-Typical Details
for Pipeline Construction’’, above the highest point in the ditch bottom prior to pipe being lowered
into the trench and pre-padding shall be placed across full trench width to ensure the pipelines is
evenly supported.
All bush, sand bags, pipe, metal of any kind, rocks, large clods, sticks, projecting rocks, and other
hard objects shall be removed from the trench into which the pipeline is to be lowered so that the
protective coating shall not be punctured or abraded.
The trench shall be made wide enough where slack loops are lowered into the trench so that no
coating will be rubbed off for pipeline.
Whenever the bottom of the trench contains rocks which might damage the pipe or coating, the
bottom of the trench shall be padded with sand or soft soil.
The pipe shall be lowered into the trench as soon as the coating has hardened sufficiently so that
the lowering will not cause holidays. This shall be checked by picking the pipe up after it has been
lowered in and checking with a holiday detector. If this check shows holidays, the pipe must be
lowered to sand bags until it has had sufficient time to properly harden.
Wide non-abrasive slings, belts, or rubber tire and cradles shall be used in all lowering of the
pipeline. The CONTRACTOR / SUB CONTRACTOR shall lower line in such a manner as to
provide sufficient slack. The line shall not be dropped or subjected to impact. Only slings, belts
or cradles approved by COMPANY shall be used.
Where trench is excavated in rock, pre-padding will be provided with sand or soft soil..
6.6 Bend
6.6.1 General
CONTRACTOR / SUB CONTRACTOR shall provide all bends and make all field bends required
for the laying of the pipelines in accordance with requirements for minimum cover, vertical profiles,
and horizontal alignment.
Hot Induction bends are preferred for this project. However Elastic bends and Cold bends will be
used if required.

6.6.2 Elastic Bends

The minimum allowable radius for elastic bend in the buried pipeline or above ground pipeline is
based on a maximum allowable bend stress specified in Pipeline Design Report Document No.
MGP1-GP2-CPC-LA-3331-5101. The elastic bend shall be continuously supported over its full
length. The elastic radius is at least R=1000D, meanwhile, for the section of pipeline lay in the
same trench; the elastic radius should meet the large diameter pipeline.
6.6.3 Hot Induction Bends

For all horizontal and vertical angles greater than or equal to 3 degrees of the project’s pipeline,
the CONTRACTOR / SUB CONTRACTOR should use prefabricated thermal induction bending.
It is prohibited for cutting induction bends in site.
6.6.4 Cold Bends

CONTRACTOR shall, before the start of the Work, submit and demonstrate to COMPANY a
bending procedure, which shall conform with the recommendations of the manufacturer of the
bending machine. This procedure shall be subject to COMPANY`s review.
Bends shall be made such that the pipe, when laid, conforms to the bottom of the trench without
the use of external force to hold it in place.
For cold bending, the individual gauging check is made at 97.5% of the cold bent pipe internal
diameter
6.6.5 Rejection of Bends

Bends with wrinkles, buckles, flat spots or other mechanical damage and bends with excessive
ovality as per bending limits shall be rejected. CONTRACTOR / SUB CONTRACTOR shall
salvage usable straight pipe from any rejected bend. The entire bending operation shall be
conducted so as not to damage pipe coating.
6.7 Welding and Inspection

6.7.1 General
Pipeline welding techniques includes SMAW, GTAW, GMAW, GSFCAW or any combination of
these techniques. Manual, semi-automatic or automatic welding is acceptable and semi-
automatic welding is recommended for large-diameter pipeline. The specific welding technique
shall be determined according to the terrain conditions and the CONTRACTOR / SUB
CONTRACTOR's equipment conditions.
The performance of the welding equipment should meet the welding procedure and safety
requirements, and should be in a good working condition and suitable for field application.
Before welding, a detailed welding procedure instruction should be drafted according to the
design requirements, and the WPQ should be carried out accordingly. Based on the qualified
welding procedure, the WPS should be compiled.
When the pipe joint adopts a different welding techniques or different welding consumable from
that of the trunk line, a new WPQ shall be carried out.
In view of the local environmental conditions, wind-shielding equipment should be installed at the
upwind or construction in a wind-proof shed to prevent wind and sand from affecting the pipeline
welding.
Welding shall not be carried out in any of the following environments without taking effective
protective measures:

1) Rain, snow and blowing sand (with high wind);
2) The relative atmospheric humidity is greater than 90%;
3) Arc welding with low hydrogen electrode, wind speed is greater than 5m/s;
4) Arc welding with acid electrode, wind speed is greater than 8m/s;
5) Semi-automatic welding with self-shielded flux cored wire, with wind speed greater than 8m/s;
6) Gas-shielded welding, wind speed is greater than 2m/s;
7) The ambient temperature is lower than the temperature specified in the welding procedure
specification.
6.7.2 Pipe Alignment

The pipe alignment should meet the requirements of Table 6.7-1.
Table 6.7-1 Pipe Alignment Requirements
Check List Requirements

Internal cleaning Free of contaminants
Nozzle cleaning (within 20mm range) The pipe end is intact, free of rust, oil, paint, and
and trimming burrs
Straight seam distance between two pipe
Greater than or equal to 100mm
ends
When the pipe wall thickness is less than 16mm,
the misalignment should be less than 1.6mm;
When the pipe wall thickness is greater than or
equal to 16mm, the misalignment should be no
Misalignment and misalignment
greater than 10% of the pipe end wall thickness,
correction
and should be no greater than 2mm; the local
misalignment should be no greater than 3mm,
and the misalignment should be evenly
distributed along the circumference.
1.5 times greater than pipe diameter and no less
Length of short section pipe
than 100mm
Butt joint deviation No greater than 3°
Other requirements include:
1) The inspection and acceptance of the pipe groove quality shall be performed by foreman.
Except for joints and elbows, internal alignment devices should be adopted for pipelines with
diameter equal to or greater than 350mm.
2) The pipes and equipment should be steadily fixed if in the longitudinal slope. The
construction method should be determined according to terrain, topography and geological
conditions.
3) Misalignment, if exists, should be evenly distributed along the circumference. Hammering to

correct misalignment is strictly prohibited. After root welding is completed, misalignment
correction is prohibited. When internal alignment devices are used, it should be detached upon
the completion of root welding. During detachment of alignment device, the pipes should be kept
in balance. When external alignment devices are used, the installation and detachment should
be according to the WPS.

4) When straight pipes and hot bends are connected, the straight seams must be staggered
and kept distant for at least 100mm.
5) When hot bends are butt-welded, the welding seams near the centreline of the elbow should
be on two sides of the butt elbow. If it is not possible, the two straight seams shall be staggered
and kept distant for at least 100mm.
6) No circumferential welds are allowed when crossing highway and railway with a width less
than 10m.
7) Mechanical cutting of straight pipeline should be perpendicular.
8) All longitudinal and planar changes are connected by hot bends.
6.7.3 Cutting on Site

For pipelines, if cutting is required on site, hot-cutting methods such as oxy-acetylene should not
be used, unless it is guaranteed that heat affected zone can be completely removed with machine
cutting (such as cold cutting) after hot cutting. Cold cutting shall be adopted for cutting on site.
Cutting of hot induction bends is prohibited at site.
6.7.4 Welding Consumables

Welding consumables shall meet the following requirements:
1) Welding filler materials shall be selected in accordance with characteristics of the base metal.
The mechanical properties of the weld shall match that of base material. The chemical
composition of the welding metal shall be similar to that of the base metal.
2) Low-hydrogen welding consumables shall be used, and the diffusible hydrogen content shall
not exceed 10ml/100g. Low hydrogen welding consumables should be adopted and comply with
the requirements of AWS specification and API STD 1104.
3) The welding of feed gas and condensate pipes in sour service shall not adopt procedures and
welding consumables that may cause the nickel content in the deposit metal to exceed 1%.
4) The handling, storage and use of welding consumable should be in accordance with its
production specification and WPS.
5) The welding operations of feed gas and condensate pipes shall use the same welding
consumable type and the same manufacturer as the WPQ. Any modification or changes need to
be re-evaluated.
6.7.5 Preheating
All preheating requirement should be in accordance with ASME B31.8, ASME B31.4 and ASME
IX, and meet the following requirements.
1) Pipeline welding area shall be preheated when it is required in the WPS, or when the ambient
temperature is lower than 5°C or the atmospheric humidity is greater than 90%. The preheating
shall be in accordance with WPS. The preheating temperature should not be lower than the
temperature specified in WPQ and should not exceed this temperature by 50°C.
2) The preheating range should be no less than 3 times of the wall thickness on both sides of the
groove, and should not be less than 25mm. The heating should be uniform, and local overheating
is strictly prohibited. During welding, the temperature between the weld layers shall not be lower
than its preheating temperature.

6.7.6 Hardness Inspection

Each pipeline weld and heat affected zone of the feed gas and condensate should be tested for
hardness. A portable Brinell hardness tester or Leeb hardness tester should be used. For portable
Brinell hardness tester, the hardness result should be the average of 3 readings. For Leeb
hardness tester, weekly calibration should be conducted and the hardness results should be the
average of 5 readings.
Sanding, filing or other surface preparation work for hardness testing is allowed providing that
depth shall not exceed 0.5mm. The hardness results shall not exceed 200HBW.
6.7.7 Post-weld Heat Treatment (PWHT)

PWHT shall be carried out if required as per WPS/PQR. PWHT is not mandatory in the project.
However, when on-site hardness results exceed 200HBW, PWHT shall be carried out according
to WPS with a minimum temperature at 620°C. Hardness shall be retested after PWHT. The weld
shall be removed if the hardness requirement is still unqualified.
6.7.8 Welding Procedure Specification (WPS)

All welds including weld repairs shall be supported by a relevant WPS. WPS shall be defined
according to ASME IX. All WPS shall be in writing and shall be qualified and certified in
accordance with the applicable code. All supporting PQR shall be witnessed, or at least certified,
by a recognized inspection authority.
Each WPS shall be identified by a unique document number.
The CONTRACTOR / SUB CONTRACTOR shall develop welding procedures, and the completed
WPS for a welding process addresses all essential variables. When any of the essential variables
and supplementary essential variables of ASME IX is changed beyond what the reference code
paragraph allows for the process, the welding procedure must be re-established as a new WPS.
The WPS shall state the actual consumable or flux trade name and type as well as the code
designation. All WPS’s specifying PWHT should indicate maximum heating rate, holding
temperature range, holding time and maximum cooling rate.
WPQ shall use the same welding consumables or flux as onsite welding. Any change of
manufacturer or welding consumables classification from the same manufacturer, re-qualification
shall be required.
6.7.9 Welding Procedure Qualification (WPQ)

6.7.9.1 General Requirements
WPQ in sour service shall be in accordance with ASME IX, and the WPS should be prepared
according to the qualified WPQ.
In addition to the critical factors specified in ASME IX, the qualification of post-weld heat treatment
conditions (If applicable), raw materials and welding consumable shall be supplemented as
critical factors. Any modification and changes of these critical factors should be re-qualified.
The qualification scope is limited to the same strength level and the same heat treatment condition
of the material used in the trial welding.
6.7.9.2 Supplementary Performance Requirements
1) Charpy impact test

The welds and the heat-affected zone shall be subjected to charpy impact test in accordance with
ASTM A370. The test temperature and results shall meet the requirements specified in Table 6.7-
2.
Two sets of charpy V-notch impact samples shall be collected by machining on each test block.
One group of notches shall be on the vertical centre of the weld, and the other group shall be on
the fusion line. The direction of the notch shall be perpendicular to the surface of the material.
Table.6.7-2 Requirements of Charpy Impact Toughness
Minimum Charpy Impact
Energy Test
Position Grade （J） temperature
（℃）
Single Value Average
Weld seams
and heat X52MS 30 40 -29
affected zone
Weld seams
and heat X52QS 30 40 -29
affected zone
2) Hardness test
Hardness inspection shall be carried out in WPQ for pipelines in sour service. The hardness test
method shall be Vickers hardness in accordance with ASTM E92. The test section shall be taken
along the circumferential direction. The maximum single hardness reading shall not exceed
250HV10. Brinell hardness of cap weld shall be measured in accordance with ISO 6506-1. The
maximum single hardness reading of cap weld shall not exceed 200HBW.
The hardness test results shall be included in the WPQ report, as well as the schematic diagram
of the hardness test location and the corresponding hardness readings.
The Vickers hardness of the WPQ shall be measured according to Figure 6.7-1 (butt weld), Figure
6.7-2 (fillet weld) and Figure 6.7-3 (repairing weld and partial penetration weld).
Figure 6.7-1 Vickers Hardness for Butt Weld
A —— Heat affected zone (visible after etching);
B —— The measuring line.

2, 3, 6, 7, 10, 11, 14, 15, 17 and 19 indentation should be completely in the heat-affected zone,
and as close as possible to the fusion line between the deposited metal and the heat-affected
zone. The upper measuring line should be in a suitable position so that the 2 and 6 indentations
are consistent with the outline of the heat-affected zone or the fusion line of the last weld.
Figure 6.7-2 Fillet Weld
A —— Heat affected zone (visible after etching);
B —— The measuring line;
C ——The measuring line, parallel to the measuring line B and passing through the fusion
boundary between the weld metal and heat affected zone.
The hardness indentations of 3, 6, 10 and 12 should be completely in the heat-affected zone and
as close as possible to the fusion line between the weld metal and the heat-affected zone.
Figure 6.7-3 Repairing Weld and Partial Penetration Weld
A —— The initial heat affected zone;
B —— Repair welding heat affected zone;
C —— The dashed line is parallel to the measuring line.

The upper measuring line should be in a suitable position so that the indentation of the heat-
affected zone is consistent with the outline of the heat-affected zone or the cap weld fusion line
of the last weld.
3) Corrosion resistance tests
(a) HIC
Hydrogen-induced cracking (HIC) test shall be carried out in accordance with NACE TM 0284,
test solution: solution A. Test duration: 96 hours. The maximum allowable rate of any section in
each sample should not exceed the following indicators:
Crack length rate (CLR)≤15%,
Crack thickness rate (CTR) ≤5%,
Crack sensitivity rate (CSR)≤2%.
The test report should include macroscopic photos of all cracks, and photos or drawings of
hydrogen blistering on the surface of the test piece should also be provided.
(b) SSC
The sulfide stress cracking (SSC) test should be carried out in accordance with ISO 7539-2 or
ASTM G39 using four-point bending specimens, and the test shall be carried out according to
NACE TM0177 solution A.
Loading stress: 80% AYS (the actual yield strength of the base material on the lower yield strength
side).
Test duration: 720 hours.
Acceptance criteria: The tensile surface is inspected under a microscope with 10X magnification
and no cracks or any surface damage should be observed.
6.7.10 Welder Requirements

The CONTRACTOR / SUB CONTRACTOR shall provide effective welders or welding operators'
qualification certificate. CONTRACTOR shall be responsible for conducting tests to qualify the
performance of welders and welding operators in accordance with qualified WPS. Welder shall
use the same welding technique and proceed at the same welding speed as he/she passes the
test and is permitted for welding. Copies of the welder and welding operation qualification test
records shall be available for review by the Company's representative.
All welding, including pipeline welding, repair welding and tack welding, shall be performed by
qualified welders using qualified welding procedures. Welders or welding operator shall be
qualified and scope of welder’s qualification shall be in accordance with API STD 1104.
6.7.11 Inspection and Acceptance of Welds

Unless other specified, the all requirements of acceptance shall be according API 1104 and
followings.
6.7.11.1 Visual Inspection
Welds shall be visually inspected first and meet the following requirements:
No cracks, pores, depressions, slag inclusions and fusion spatter shall be observed on the
surface of the weld.
The width of the weld on each side should exceed the groove by 1.0mm～2.0mm.

The surface of the weld should not be lower than that of the base metal and should meet the
following requirements:
(a) When upward welding is adopted, the weld reinforcement shall not exceed 3mm.
(b) When downward welding is adopted, the weld reinforcement shall not exceed 2mm, the partial
length shall not exceed 3mm, the continuous length shall not exceed 50mm. When the weld
reinforcement exceeds 3mm, the weld reinforcement shall be grinded. The grinded weld
reinforcement shall be smoothly transitioned to the base metal without any damage to the base
metal.
The undercut depth should not be exceed 12.5% of the wall thickness and should not exceed
0.5mm. In any continuous weld length of 300mm, the cumulative undercut length shall not exceed
50mm.
6.7.11.2 Non-destructive Test (NDT)
NDT is allowed to proceed when visual inspection is accepted. The test results should meet the
requirements of API STD 1104. The inspection ratio and qualified levels of NDT of welds are as
follows:
1) 100% RT for circumferential weld shall be performed with the acceptance of API STD 1104.
2) 100% PT or MT for fillet weld shall be performed with the acceptance of API STD 1104.
3) Cracks and incomplete foot fusion are not allowed in all welds.
4) For the unqualified welds of gas and condensate pipelines, only one repair is allowed on the
same position (crack defects must be removed and repairs are not allowed). The repaired weld
shall allow the use of original inspection methods, and shall be re-inspected using original
methods.
5) When 100% radiographic test is adopted on the circumferential welds, crawlers shall be used
whenever possible.
6) When two adjacent construction sections (golden weld) are joined and welded, the ambient
temperature should controlled at 20°C to reduce stress due to temperature difference.
6.7.12 Repair and Removal of Defects

As for the welding seams unqualified for the inspection, the removal and rework shall be carried
out according to the relevant requirement prescribed in the Section 10 removal and rework of
defects in API 1104, including:
The welded joint with cracks shall be cut away from the pipeline according to the relevant
regulation. For non-crack defects, the repair of the same welding seam shall not exceed twice.
Inspection and acceptance standard: the reworked area shall be inspected with the original
inspection method before rework.
The penetrant inspection shall be conducted to the reworked welded joints according to Welding
of Pipelines and Related Facilities (API 1104); the reworked welded joint without any defect shall
be deemed as qualified. If the welded joint is not qualified after repairs, the welded joint with
cracks shall be cut away from the pipeline.
The repaired welded joint that was once regarded as unqualified during inspection shall be
determined whether the repaired welded joint needs to be heat treated or not according to the
WPQ test report through project assessment. If it needs to be heat treated according to the WPQ,
the hardness test shall be performed to the repaired welded seam.

The inspection unit shall carry out the inspection works according the following rules on the basis
of the WPQ and material requirement:
Except when the special requirement is made to the time of butt welding joint, the NDT shall be
carried out 4 hour after the completion of welding, and the NDT for the rest parts shall be carried
out 24 hour after the completion of welding.
NDT shall be carried out for the repaired welded joints, and the joints between existing pipeline
and new pipeline.
Cracked welds shall be removed from the line unless permitted by Section 6.8 in API STD 1104
or when the repair is authorized by the company. Cracks may be repaired provided the length of
the crack is less than 8% of the weld length and a qualified repair welding procedure is used.
Defects in the root and filler beads may be repaired with prior company authorization. Defects in
the cover pass may be repaired without prior company authorization. A qualified repair welding
procedure is required to be used whenever a repair is made to a weld using a process different
from that used to make the original weld or when repairs are made in a previously repaired area.
Repair procedure should be complied with the Section 10.2 in Welding of Pipelines and Related
Facilities (API 1104).
Repaired areas shall be inspected by the same means previously used. Repairs shall meet the
standards of acceptability of Section 6.8 in API STD 1104.
Welder evaluation, repair rate, etc are defined in Welder Evaluation Procedure, Doc No. is MGP1-
GP2-CPC-QA-6180-0001_004.
6.8 Coating
Coatings for all buried pipes, hot bends and field joints shall as per “Specification for Painting and
Coating”, Doc # MGP1-GP2-CPC-RA-7754-0005.
The coating used for underground line pipes is 3LPE coating, detailed in “Specification for
Painting and Coating”, Doc # MGP1-GP2-CPC-RA-7754-0005.
The coating used for underground induction bends is Double Layer FBE+ Polyolefin tape, detailed
in “Specification for Painting and Coating”, Doc # MGP1-GP2-CPC-RA-7754-0005.
The coating used for field joints is HSS, detailed in “Specification for Painting and Coating”, Doc
# MGP1-GP2-CPC-RA-7754-0005.
The coating used for above ground pipe and hot bend is epoxy rich zinc + MIO epoxy + acrylic
polyurethan, detailed in “Specification for Painting and Coating”, Doc # MGP1-GP2-CPC-RA-
7754-0005.
The coating of monolithic isolation joints shall as per “Specification for Painting and Coating”, Doc
# MGP1-GP2-CPC-RA-7754-0005, table 7.1-1, notes-5.
6.9 Cathodic Protection

During pipeline construction Temporary CP system shall be installed to provide cathodic
protection to the pipeline during the construction stage until the permanent CP system is
commissioned. The minimum design life of the temporary CP system shall be at least 3 years, or
the maximum period when the permanent CP are installed and operational. Refer Specification
for Buried Pipeline Cathodic Protection (MGP1-GP2-CPC-RA-7754-0003) for details.
6.10 Lowering-In
This shall include all work necessary to lower pipe into trench.

Lowering in the pipelines into the trench shall be based on COMPANY's approval of the lowering-
in certificate. The lowering-in certificate shall certify that the welding, NDT and coating in that
section meet the specifications. No lowering-in will take place prior to approval by COMPANY of
this certificate.
Before lowering-in the pipe, the trench bottom shall be visible and the trench depth shall be
checked to ensure that the specified depth of cover shall be maintained, taking into account any
pre-padding that may be required. Holiday shall be performed before pipe lower in.
All coated and wrapped pipe, which has been supported in any manner, shall be subjected to
close inspection and checked with a holiday detector to see that the coating is undamaged and if
found damaged shall be patched.
CONTRACTOR shall furnish sufficient proper equipment during the lowering-in operation to
prevent excess bending of the pipe or damage to coating.
6.11 Backfill
6.11.1 General
This shall include all work necessary to backfill excavated material in the trench, and restore
creek banks, hillsides, or other places where the right-of-way has been graded. Immediately after
the pipe has been lowered, it shall be weighted by filling the trench over the pipe with backfill
material.
The laying of warning tapes should meet the following requirements:
1) The materials, specifications, colours, terms and fonts that should be used for laying the
warning tape should meet the design requirements.
2) The warning tape should be laid flat on the top of the pipe, and the distance from the top of the
pipe should be 0.3m, with the word face up when laying.
3) The laying of the warning tape should be continuous, and there will be missed connections
during intervention.
No backfilling work shall be executed and prior approval or acknowledgement by CONTRACTOR

/ SUB CONTRACTOR and COMPANY representative is required.
Upon completion of backfill, the pipeline alignment will be temporarily pegged to ease the
installation of permanent marker and signage.
6.11.2 Backfill Material

Initial backfill of trench or post padding shall be from excavated soil free from rocks, large lumps,
wood or other extraneous materials. The remaining backfill and capping shall be constructed
using the remaining excavated material.
The maximum size of granulocytic of sand material should not exceed 20mm.
6.11.3 Excess Material

Excess material which cannot be used for backfill shall be removed from right-of-way to a location
approved by COMPANY.
All surplus rock removed from the trench shall be disposed of to the satisfaction of the COMPANY.
All roads, pavements, hillsides, creek banks, terraces, and other places where the
CONTRACTOR / SUB CONTRACTOR has moved earth to facilitate the movement or operation
of its equipment shall be restored by CONTRACTOR / SUB CONTRACTOR to their original
profile and condition.

6.11.4 Berm
After the trench backfill is completed, in order to prevent insufficient burial depth of the pipeline
caused by wind erosion, berm should be laid on the ground. The specific specifications of berm
should refer to Typical Details for Pipeline Construction, Doc No. MGP1-GP2-CPC-LA-3328-1503.
6.12 Clean-Up
This shall include all work necessary to remove surplus material from the right-of-way and to finish
grading the back-fill and right-of-way and to repair fences.
Before the work is finally accepted, CONTRACTOR / SUB CONTRACTOR shall remove all
surplus blasted or excavated material from the right-of-way and adjacent property, as well as from
public and private roads, and the channels of streams and trenches. All underbrush, broken sand
bags, and other such debris shall be disposed of as specified by the COMPANY. Oil drums, sheet
metal from paint barrels, and other objects shall be gathered up and removed from the right-of-
way. Sheet metal or other material shall not be placed in the pipeline trench and covered up as a
means of disposal.
On sections of pipeline where there is rock excavation, all loose rock deposited by such operation,
both on right-of-way, and on land adjacent to right-of-way, shall be picked up and disposed off by
CONTRACTOR / SUB CONTRACTOR. The backfill shall be piled over the trench and then
smoothed down with a grader or harrow. In all areas, all spoil from side hill cuts will be returned
to its original position.
Where the pipeline has been laid within improved roadway rights-of-way, the surface of such
improved roadways shall be restored using new materials of like quality with those found in the
original improvement to the satisfaction of the COMPANY and the governmental authority having
jurisdiction over that portion of the work.
6.13 Pigging
All pipelines shall, before pressure test, be cleaned no less than 2 times using a brush pig or foam
pig.
After pressure test, additional pigging shall be conducted to ensure cleanliness within the pipeline,
i.e. no free water and impurity in the pipe. This will be repeated until the pipeline is deemed clean.
Temporary pig launcher and receiver shall not be installed in densely populated areas. Pigging
discharge shall meet environment protection requirements. Safe channel must be set put at pig
outfalls so to prevent from flooding surrounding areas, and the outfall shall be higher than
surrounding ground to prevent from back flow of ponded water.
As for the pigging between stations, the builder shall connect all the pipelines between stations
within its specific bid section, and then conduct the pipe pigging using compressed air to drive
the pig.
Pigging between stations shall adopt pig launcher and receiver.
All the cut-off valves of the pipelines passed by the pig shall be open.
Pigging between stations adopts compressed air, and the dirt cleaned out shall be drained into
the blow down sump so to prevent from pollution. The pigging can be stopped only after the
pipeline is considered sufficient clean.
6.14 Gauging
After pigging is completed, the internal diameter of the pipeline shall be measured before
pressure test in order to check internal wall defect.

Gauging disc may be installed in the middle part of the pig to check whether such defects as pit
and deformation exist in the internal wall or not. The gauging disc shall be commonly made of
aluminium plate with 12-15mm thick and its diameter shall be 95% of inner diameter of the
pipeline. The gauging shall be made with guage plate diameter equal to 97.5 % of inner diameter
for cold bends, induction bends, MIJ and special sections or components at respective workshops
after manufacturing/fabrication. Pigging and diameter measurement shall be according to the
following procedure: Before pigging and diameter measurement, install temporary receiver and
launcher at both ends of the pipeline firstly, and then install the pig in the launcher, start the air
compressor to fill compressed air into the launcher to push the pig to move forward until the pig
pushes such sundries as soil, sand and welding slag in the pipeline into the receiver, and then
stop filling compressed air into the pipeline and open the exhaust valves in the receiver and
launcher for exhaust. Open the receiver when pressure in the pipeline lowers down to the
atmospheric pressure and inspect effect of pigging and diameter measurement. Pigging shall be
done not less than twice to remove all sundries in the pipeline. After pig reaches the receiver,
remove the gauging disc from the pig. Diameter measurement meets relative requirements if the
gauging disc has no distortion or fold.
6.15 Final Tie-ins

If insufficient overlap of pipe exists at final tie-ins (tie-ins between hydrostatic test sections) such
that extra pipe is required, only appropriate pre-tested pipe shall be used. The tie-in weld between
hydrostatic test sections shall be tested by other accepted non-destructive methods, should PT
in addition to radiography inspection.
7.0 PRESSURE TEST, DRYING AND PURGE

7.1 Basic Requirements
The test pressure shall be the lower of the below two values, unless otherwise specified by the
COMPANY:
(I) The test pressure as required in ASME B31.4 (ref 437.4) or B31.8 (ref table 841.3.2-1 and
A847.2) as applicable.
(II) The test pressure value of the weakest component in the pipeline system (other than line pipe,
e.g. Flange, isolation joint, .etc.)
During the hydrostatic pressure test, the combined stress shall not exceed 100% SMYS of line
pipe material based on minimum wall thickness. The combined stress shall be calculated. In no
case the test pressure at the lowest point in the system, shall be more than 95 % SMYS.
The elevation profile shall be plotted to assist in checking that the test pressures at the low and
high points and shall not result in pressures or combined stresses outside the limits specified
above.
7.2 Pre-testing of Assemblies

CONTRACTOR shall hydrostatically test assemblies following fabrication and installation but prior
to tying into the completed pipeline system. Wherever the CONTRACTOR elects to fabricate
temporary spool pieces for use during assembly piping hydrotesting, the applicable spool
drawings shall be submitted to COMPANY for approval. All assemblies shall be hydrostatically
tested to a minimum test pressure as specified by COMPANY, for a minimum period of 4 hours
without a loss in pressure. Any variation in pressure shall be explained (e.g. temperature
fluctuations). All test certificates shall be furnished by the CONTRACTOR for approval by
COMPANY.

7.3 Air Content Determination

The air content of the filled line shall be determined during initial pressurisation by using the
pressure/ added volume plot. The linear section of the curve shall be extrapolated to the volume
axis, which shall correspond to static head pressure. The volume of air can be read from the
intersection of the line with the volume axis and shall be used to calculate the air content thus:
Percentage air content = (Volume of air / Volume of line) x 100%
If the air content exceeds 0.2 % of the line volume, testing shall be terminated and the cause
investigated. If further venting does not bring the air content within acceptable limits, the test
section should be emptied and refilled at the discretion of the Principal.
7.4 Temperature Recorder

A temperature recorder shall be installed by CONTRACTOR on each test section a minimum of
500m back from the exposed pipe at one end of the test section. One sensing element shall be
placed against the pipe wall, suitably insulated and backfilled. The second element shall be
installed in the pipe backfill material a minimum of 0.3m from the pipe wall and suitably insulated
and backfilled.
Temperature recorders shall be checked every three hours during filling and testing to ensure
they are functioning properly.
7.5 Water Quality Requirement

To ensure that the water for pressure test is clean water, the water source shall be sampled for
chemical analysis to ensure that the water for pressure test is indeed the clean water whose PH
value is neutral and harmless to the pipeline. The index of PH value, salt content and total
suspended solid as following:
a. PH value of 6～9
b. Salt content of ≤1800mg/l
c. Total suspended solid of ≤50 mg/l.
When the water quality cannot meet the requirements, chemical treatment should be used.
7.6 Temperature Stabilisation

The water shall be allowed to rest for a thermal stabilisation period before commencing the
pressure test. This period shall be either a minimum of 72 hours or such time when the pipe
temperature variation does not exceed 1 ℃ over a 24 hours period. During the stabilisation period,
pressures and temperatures shall be recorded every hour. This shall include measurement of
ambient and ground temperature conditions.
7.7 Strength Test

The clean water shall be used as the medium of the pipeline strength test. The pressure of clean
water applied to the strength test is 1.5 times as much as the design pressure for gas pipeline,
and for condensate pipeline, it should be 1.25 times of design pressure. The pressure test scheme
shall be prepared in advance and the water sources relay and drainage measures shall also be
considered. Pressure test sections along the pipeline shall be divided by the construction units of
specific bid section according to the topographies and water source conditions etc.; for sections
with heavier undulating terrain, water relay shall be considered when necessary. All instrument
connections shall be blinded off. In-line ball valves shall be in partially opened position.

The pipe strength test shall be slowly progressed, the rate of pressurisation should be constant
and should not exceed 1 bar/minute (15 psi/minute) until a pressure of 35 bar (500 psi) or 50 %
of the test pressure, whichever is lower, has been attained. During this period, volume and
pressure readings should be recorded at 1 bar (15 psi) intervals.
when the pressure is separately increased to 30% and 60%, the pressure shall be respectively
stabilized for 30min and all potential leakage points shall be checked. After the pipe has been
checked without problems, the pressure shall be continuously increased to strength testing
pressure and stabilized there for 4 hours at least;
The pipe is considered as qualified, after being checked by eyes and confirmed to be free from
deformation, rupture and seepage, and with a pressure drop less than or equal to 1% of the
testing pressure.
Table 7.1-1 Strength Testing Pressure for Newly Built Gas and Condensate Pipelines
Specified
Strength Strength
Design Minimum Selected
O.D. Test Test Test
Pressure Yield W.T. Material
(mm) Pressure Pressure Duration
(barg) Strength, (mm)
(barg) (h)
δs (MPa.g)
18 360 711 12.7 L360MS 1.5×DP 27 4
18 360 610 11.91 L360MS 1.5×DP 27 4
18 360 355.6 9.53 L360QS 1.5×DP 27 4
18 360 168.3 7.92 L360QS 1.25×DP 22.5 4
7.8 Leaktightness Test

Leaktightness test can only be carried out after the strength test of the pipelines is passed, with
a medium of water and a testing pressure of 1.1 times of the design pressure.
After the satisfactory completion of the strength tests, the test section shall be depressurised to
leaktightness test pressure. Pressure let-down valves shall be opened slowly and depressurising
continued at a rate that does not generate vibrations in associated pipework. Under normal
circumstances, no fitting of any type should be attached to the pressure let-down valve. If fittings
or drain lines are attached, they shall be adequately braced and tied down to prevent movement.
The depressurisation rate should not exceed 1 bar (15 psi) per minute until the pressure has been
reduced to 40 % of the strength test pressure. Then depressurisation should continue at a rate of
less than 2 bar (30 psi) per minute to the leaktightness test pressure.
The leaktightness test shall be passed if no seepage happens and clean water pressure drop is
not more than 1% of test pressure after 24 hours under stable pressure. The pressure test is
unnecessary for the welded joints at the connecting point of two pressure test sections after the
sectional pressure test has been passed. However, the straight nipple used for the connector
shall be qualified pipeline sections upon the pressure test, otherwise it cannot be used. The weld
crater at the connection point also shall be subject to 100% X-ray inspection and 100% ultrasonic
examination.

Table 7.1-2 Leaktightness Testing Pressure for Newly Built Gas and Condensate Pipelines
Specified
Design Minimum Selected Leaktightness Leaktightness
O.D. Test
Pressure Yield W.T. Material Test Pressure Test Duration
(mm) Pressure
(barg) Strength, (mm) (barg) (h)
δs (MPa.g)
18 360 711 12.7 L360MS 1.1×DP 19.8 24
18 360 610 11.91 L360MS 1.1×DP 19.8 24
18 360 355.6 9.53 L360QS 1.1×DP 19.8 24
18 360 168.3 7.92 L360QS 1.1×DP 19.8 24
7.9 Testing of Special Sections

In some test sections, it is difficult to correlate the pressure changes with the temperature
fluctuation, because the temperature fluctuations of the test section are difficult to measure, e.g.
in above-ground test sections (effects of the sun, rain and wind). In such cases, the leak test
should be carried out, wherever possible, on the basis of a visual examination to check the
leaktightness of the test section after the satisfactory completion of the 4-h strength test. The
visual examination shall not commence before the pressure has been reduced to the leak test
pressure and held for a minimum of 4 h. The results of the visual examination shall be
documented by the test supervisor.
If it is not possible to check the leaktightness of the test section by visual examination, the
leaktightness shall be demonstrated by a 24 h leaktightness test. The influence of the
temperature fluctuation should be considered in specifying the location and number of
temperature measurements. It may be necessary to protect above-ground or above-water test
sections against sun radiation.
A 24-h leaktightness test for pre-tests of assemblies is not necessary. The influence of the
temperature fluctuation should be considered in specifying the location and number of
temperature measurements and the stabilisation period.
Contractor shall execute the special section test only after approval from COMPANY.
7.10 Depressurising
After the satisfactory completion of the strength and leaktightness tests, the test section shall be
depressurised to hydrostatic head plus 1 bar (15 psi) so that air does not enter into the test section.
Pressure let-down valves shall be opened slowly and depressurising continued at a rate that does
not generate vibrations in associated pipework. Under normal circumstances, no fitting of any
type should be attached to the pressure let-down valve. If fittings or drain lines are attached they
shall be adequately braced and tied down to prevent movement.
The depressurisation rate should not exceed 1 bar (15 psi) per minute until the pressure has been
reduced to 40 % of the test pressure. Then depressurisation should continue at a rate of less than
2 bar (30 psi) per minute.
Test pressure shall not be used for transfer of water from one test section to another.
7.11 Dewatering
CONTRACTOR shall dispose of water in a manner satisfactory to the authorities having
jurisdiction over these matters, and COMPANY. Prior to dewatering, all drain lines and test
manifolds shall be firmly tied down and braced to prevent movement.

Care shall be taken so that water is disposed of without causing excessive erosion or flooding.
The polyethylene pigs shall be propelled by compressed air. A pressure recorder shall be
connected to the test manifold to record the air pressure while dewatering.
CONTRACTOR will purge the entire section of water by using a pig driven by compressed air.
Multiple runs may be required ensure that all of the water has been removed from the test section.
Pigging with foam or brush foam pigs shall continue until they arrive without free water in front.
7.12 Drying
All pipelines shall be dried after pressure test.
Before drying, the pipelines that have passed the pressure test should be swept inspection. If
brush pigging is used for inspection, it shall be qualified that there is no clear water at the end. If
a foam pig is used for inspection, the qualification standard is that the water content of two
consecutive foam pigs is not more than (1.5DN/1000) kg. The interference of the pig can be 3%
to 8% of the pipe inner diameter.
Dry air can be used to dry the pipeline. The water dew point at the end of the pipeline does not
exceed 3°C after 4 hours of the airtight test, and it is qualified if it does not exceed -20°C.
7.13 Preservation
1) The replacement of the air in the pipeline should be carried out after the strength test, the
leaktightness test, the cleaning of the pipe, and the drying pass. Nitrogen or other non-corrosive,
non-toxic inert gas should be used as the isolation medium.
2) The mixed gas should be discharged to the vent system during the replacement process. Vents
should be far away from traffic lines and residential areas, and an isolation area with a radius of
300m should be established around the vents. Pyrotechnics and static sparks are not allowed in
the empty isolation area.
3) The end of the replacement pipeline should be equipped with gas content detection equipment.
When the oxygen content of the vent pipe at the end of the replacement pipeline is not more than
2%, the replacement can be considered qualified.
4) If the owner cannot confirm that the pipeline (or pipe section) can be put into production
immediately after the completion of the pipeline, in order to ensure the safety and life of the
pipeline, the pipeline section or the entire line completed in advance should be timely used to
effectively protect the inner wall of the pipeline with nitrogen. It should be filled with dry nitrogen,
and keep the internal pressure of the pipe greater than 0.12MPa~0.15MPa (absolute) in a dry
state to prevent external moisture from re-entering the pipe, otherwise it should be dried again.
5) If the CONTRACTOR cannot confirm that the pipeline (or pipe section) can be put into
production immediately after the completion of the pipeline, in order to ensure the safety and life
of the pipeline, the pipe section or the entire line completed in advance should be timely used to
effectively protect the inner wall of the pipeline with nitrogen. It should be filled with dry nitrogen,
keep the internal pressure of the pipe greater than 0.12MPa~0.15MPa (absolute), and seal the
pipe ends to prevent external moisture from entering the pipe, otherwise it should be dried again.

7.14 Safety Requirement

The safety of employees and mass people during the pressure testing period shall be considered,
the safety plan shall be formulated. The pipe strength test pressure shall be boosted progressively
and slowly; when the pressure is separately boosted to 30% and 60%, the pressure boosting
shall be stopped respectively and the pressures shall be stabilized for 30min; after the system
has been checked without any abnormal situation, the pressure shall be continuously boosted to
the strength test pressure. In the meantime, within the period of boosting the pipeline’s hoop
stress from 50％s to the maximum test pressure for the first time and later reducing the pressure
to the maximum operating pressure, appropriate procedure shall be adopted. The staff who does
not involve into the pressure testing shall evacuate from the pressure testing area.
7.15 Internal Cleaning

Once backfilling has been completed the pipeline shall be cleaned and gauged to ensure there
is no deformation and the line is clear from any obstructions.
Prior to hydrostatic testing CONTRACTOR / SUB CONTRACTOR shall remove all dirt, loose rust,
mill scale and construction debris from the inside of the pipeline.
7.16 Cleaning Scraper Tools

CONTRACTOR / SUB CONTRACTOR shall propel cleaning scraper tools through all sections of
the pipeline using compressed air. The pig shall be new or any used pig shall be in an acceptable
condition. Multiple runs of scraper tools with polyethylene (PE) pig shall be done to clean the
pipeline internal to the satisfaction of COMPANY.
The removal of the cleaning scraper tool shall be witnessed by COMPANY. Extra cleaning
scraper tool runs shall be made if, in the opinion of COMPANY, a proper level of internal
cleanliness has not been achieved.
7.17 Dirt and Debris Containment

CONTRACTOR / SUB CONTRACTOR shall provide means for containing dirt and debris
generated by the cleaning operation. Dirt and debris shall not be allowed to blow over adjacent
land.
No visible debris at the outlet of the pipeline after Internal Cleaning is considered qualified.
8.0 TREATMENT FOR SPECIAL SECTIONS

8.1 Road Crossings
Road crossings shall be installed in accordance with requirements of API RP 1102 Steel Pipelines
Crossing Railroads and Highways and as per relevant Project typical drawings and in a manner
which satisfies all requirements of the authorities having jurisdiction over the crossings. Impact
on users of the highway or road shall be minimised and the safety of the road shall not be
adversely affected.
CONTRACTOR / SUB CONTRACTOR shall obtain all permits necessary for all road crossings.
CONTRACTOR / SUB CONTRACTOR shall also monitor post construction reinstatement to

ensure the condition is technically acceptable and no further damage. Any damage shall be
repaired immediately.
CONTRACTOR / SUB CONTRACTOR shall provide and maintain signs, barricades, detours,
flagmen, or watchmen as required by the authorities to ensure the safe execution of the work.

Road crossings shall be done in accordance with Project typical drawing No. MGP1-GP2-CPC-
LA-3328-1501 - Typical Details for Road, Track Crossing respectively.
8.2 Underground Utilities Crossing

The pipeline under construction is normally to be installed below the existing buried facilities, such
as pipelines, cables, etc. When the existing facilities have been laid at a depth that allows the
passage of new pipeline respecting the foreseen minimum cover, it may pass above.
Cable and pipeline crossings shall be done in accordance with Project typical drawing No. MGP1-
GP2-CPC-LA-3328-1502 - Typical Details for Existing Pipeline/Cable Crossing respectively.
CP test post shall be installed at each buried foreign steel pipeline crossing. For detail refer DWG.
No. MGP1-GP2-CPC-RA-2309-0022.
When the buried depth of the existing pipeline/cable is too deep, it is acceptable to cross the
existing pipeline under the premise of meeting the requirements of the buried depth of the pipeline
and the crossing distance.
In all cases, whatever buried service is to be crossed on the ROW, proper measures and
precaution shall be taken for its safeguard.
The location of buried services shall be exactly located on site.
Where existing facilities are to be crossed, they shall be exposed by hand digging prior to
trenching pipeline operation is performed.
Mapping survey shall be executed onto the identified crossing in order to avoid damage, before
the manual excavation for exposure. An area of 2m x 2m shall be proposed for hand digging of
the crossing section.
Protection/segregation between new pipeline and existing facilities shall be as detailed on the
typical drawings.
The minimum vertical or horizontal clearance between the pipeline and any underground facility
shall allow the easy installation the new pipeline and the existing pipeline or other facility, as
shown on the typical drawing.
8.3 OHTL Crossings/ Parallel

Contact with overhead electric lines could be lethal. Overhead power lines are not normally
insulated and if direct contact or near contact is made with them (i.e. by a crane boom, scaffold
pole or similar conductive material) the electrical current shall arc to earth across any person or
persons in the immediate vicinity causing serious injury or death. Power lines may automatically
switch off resulting in claims for loss of revenue from the utility owner.
For pipelines welding shall not be executed under high voltage power lines and the section to be
installed under them shall be prepared 10m minimum away, and then carried in position when
ready to install.
Each piece of equipment utilized to handle pipe in any way, such as unloading picking up,
transporting, bending or “lowering in” shall be grounded and may be equipped with a cable
assembly capable of grounding the joints of pipe to the piece of equipment handling that pipe.
8.4 Construction Access Road

Temporary bypass (diversion) road placed as not to disrupt traffic flow. The road shall be of good
standard and maintained throughout the activity as required.

9.0 MARKERS AND SIGN BOARDS

The location of buried pipelines shall be clearly identified by markers. Pipeline markers and
signboards shall be as per Doc MGP1-GP2-CPC-LA-3328-1502 - Typical Details for Marker Post
and Sign Boards In areas where the risk of interference or disturbance by mechanical excavators
is high, additional warning signs should be installed to lower the risk. Pipeline markers should be
installed at the locations along buried pipelines as indicated in
10.0 SAFETY
On all pipelines, these safety rules and specifications shall apply:
All construction shall comply with health and safety regulations of the local authority having
jurisdiction.
Corresponding personal protective equipment should be equipped according to the type of work
and operation content. The CONTRACTOR / SUB CONTRACTOR will provide his personnel with
the necessary protective equipment.
CONTRACTOR / SUB CONTRACTOR is to supply two fire extinguishers whenever tie-ins to

existing lines are being made.
All tie-ins to existing lines will be done according to a written tie-in procedure approved by
CONTRACTOR / SUB CONTRACTOR and COMPANY. Hot-Work Permits are required for all
tie-ins.
Well pads and existing pipeline rights-of-way are not to be used as storage or parking areas
without approval of the COMPANY.
CONTRACTOR / SUB CONTRACTOR is to ensure that all foremen are in possession of pipeline
drawings before start of work.
Cable crossings shall be handled in a similar manner as foreign pipeline crossings.

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Majnoon Sour Gas

Specification for Pipeline Construction

Rev. Reason for Issue Date Author Checker Reviewer Approver

MGP1-GP2-CPC-LA-7880-1501 Page 2 of 32 Rev.: 003

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3.0 ORDER OF PRECEDENCE 8

4.0 CODES & STANDARDS 8

5.0 GENERAL REQUIREMENTS 9

6.0 TECHNICAL REQUIREMENTS FOR CONSTRUCTION 10

MGP1-GP2-CPC-LA-7880-1501 Page 3 of 32 Rev.: 003

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6.7.7 Post-weld Heat Treatment (PWHT) 17

7.0 PRESSURE TEST, DRYING AND PURGE 25

8.0 TREATMENT FOR SPECIAL SECTIONS 30

MGP1-GP2-CPC-LA-7880-1501 Page 4 of 32 Rev.: 003

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9.0 MARKERS AND SIGN BOARDS 32

MGP1-GP2-CPC-LA-7880-1501 Page 5 of 32 Rev.: 003

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Method of Statements shall be provided before to start activities.

MGP1-GP2-CPC-LA-7880-1501 Page 6 of 32 Rev.: 003

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PROJECT Majnoon Sour Gas Treatment Facility Project (SGTF)

COMPANY Basra Oil COMPANY (BOC)

EPCM Kellogg Brown and Root (KBR)

SGTF Sour Gas Treatment Facility

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASTM American Society of Testing and Materials

CPF Central Processing Facility

MMSCFD Millions Standard Cubic Feet Per Day

NDT Non Destructive Testing

NACE National Association of Corrosion Engineers

PQR Procedure Qualification Report

ROW Right of Way

AWS American Welding Society

PWHT Post-weld Heat Treatment

WPQ Welding Procedure Qualification

WPS Welding Procedure Specification

SMAW Shielded Metal Arc Welding

GTAW Gas Tungsten Arc Welding

MGP1-GP2-CPC-LA-7880-1501 Page 7 of 32 Rev.: 003

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GMAW Gas Metal Arc Welding

GSFCAW Gas Shielded Flux-Core Arc Welding

3.0 ORDER OF PRECEDENCE

a. Process Safety Basic Requirements

Compliance with Iraqi Laws and Regulations is mandatory.

4.0 CODES & STANDARDS

Codes & Standards

ASME IX Qualification standard for welding, Brazing, and Fusing Procedures;

API STD 1104 Welding of Pipelines and Related Facilities

API RP 1110 Recommended Practice for Pressure Testing of Liquid Petroleum

MGP1-GP2-CPC-LA-7880-1501 Page 8 of 32 Rev.: 003

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Codes & Standards

NACE TM 0177-2016 Laboratory Testing of Metals for Resistance to Sulfide Stress

5.0 GENERAL REQUIREMENTS

SUB CONTRACTOR shall submit for approval individual construction procedures/Method