ABU DHABI CRUDE OIL PIPELINE PROJECT

(ADCOP)

30-99-90-1653
CASED CROSSING PROCEDURE

EPC CONTRACTOR: PROJECT MANAGEMENT CONSULTANT:

China Petroleum Engineering ILF Consulting Engineers
& Construction (Group) Corporation P.O.Box 73250
Abu Dhabi Branch
Abu Dhabi, UAE
P.O. Box 127345 CONSULTING
EN GI N EERS

PROJECT: ABU DHABI CRUDE OIL PIPELINE PROJECT

EPC Contractor Doc. No.: PAGE: 1 of 19
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DOCUMENT No.: 30-99-90-1653 Rev. 0 Project No: E 30153 DATE: Aug. 4 08
CONTENTS PAGE

1 GENERAL ..................................................................................................................................................4
2 CONSTRUCTION METHOD ......................................................................................................................4
2.1 Construction Equipment and Tools.............................................................................................................4
2.2 Construction Method...................................................................................................................................4
3 TECHNICAL REQUIREMENTS.................................................................................................................5
4 MAIN CONSTRUCTION METHOD AND MEASUREMENT......................................................................5
4.1 Construction Flow Chart Specifically for Auger Boring Techniques............................................................5
4.2 Construction Flow Chart Specifically for Manual Boring Techniques .........................................................6
4.3 Preparation, Taking over Stakes, Surveying and Setting out .....................................................................6
4.4 Access ........................................................................................................................................................6
4.5 Excavation of the Launching Pit and Receiving Pit ....................................................................................7
5 POSITIONING THE EQUIPMENT .............................................................................................................8
6 PIPE JACKING WITH HYDRAULIC JACK EQUIPMENT ........................................................................8
6.1 Installation of Casing Pipe ..........................................................................................................................8
6.2 Operation Methodology ..............................................................................................................................9
7 CROSSING WITH AN AUGER ................................................................................................................10
8 INSPECTION AND DEVIATION RECTIFICATION..................................................................................12
9 DISASSEMBLE THE EQUIPMENT .........................................................................................................12
10 FABRICATION AND HYDRO-TESTING OF CARRIER PIPE .................................................................12
11 CARRIER PIPE INSTALLATION .............................................................................................................13
12 END SEALING .........................................................................................................................................13
13 BACKFILLING AND RESTORATION......................................................................................................14
14 SAFETY MEASUREMENT ......................................................................................................................14
15 LAYOUT OF THE JACKING/AUGER DRILLING CROSSING ...............................................................15
APPENDIX A QC PLAN .................................................................................................................................16
APPENDIX B CHECK LIST............................................................................................................................19

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1 GENERAL

Abu Dhabi Crude Oil Pipeline Project (ADCOP) comprises of 48” dia mainline pipe 402km. Pipeline starts

from HABSHAN, ends in FUJAIRAH.

1.1 Scope of application

This procedure applies to the jacking or augering for casing pipe for crossings of road, rail and lined

canal and/or other non-specified crossings in ADCOP.

The following jacking/auger methods may be applied:

a) Normal soft soil

In this case, auger boring technique is the prevailed method;

b) Rock

In this case, the rock jacking technique is the prevailed method;

c) Stony dry soil

In this case, the pipe jacking system (manual boring) up to a maximum of three pipe length is the

preferred method.

Any longer crossings in stony dry soil will be executed by the rock jacking method.

2 CONSTRUCTION METHOD

2.1 Construction Equipment and Tools

Jack with high pressure hydraulic pump, casing pipe, jacking parts and equipments for soil

transportation.

An auger may be used to move and transport the soil backwards out of the casing pipe

2.2 Construction Method

2.2.1 Prior to start of construction, a launching pit and a receiving pit shall be prepared.

2.2.2 Position the equipment and install the jacking parts.

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 2.2.3 For the method which will be applied, see 1.1 for detail. For manual boring crossings, workers

enter the casing pipe to dig and move the soil out. And then continue to jack until the first casing

pipe is finished. When the jacked casing pipe reaches the other side the road, rail or liner canal,

disassemble the equipment and clear up the soil inside the casing pipe.

Finally insert the pre-tested carrier pipe string with insulators.

2.2.4 For auger cased crossing, the surplus soil is transported along the spiral drill stem of the auger to

the launching pit. Workers will move and transport the soil to designated location or the soil may

be used at other locations along the pipeline.

3 TECHNICAL REQUIREMENTS

Utility Crossing Minimum cover

Highways / Major road crossing 3D

Notes:
1. D is pipeline outside diameter.
2. Cover depth refers to undisturbed ground to top of pipe.

4 MAIN CONSTRUCTION METHOD AND MEASUREMENT

4.1 Construction Flow Chart Specifically for Auger Boring Techniques

Excavation of the Pits Grading the

Preparation Surveying
Pit Bottoms

Assemble Together Auger Installation of guiding rail

Positioning and equipment

Assemble the Casing Pipe and the Auger Stem

Check the Correctness Start to Augering Soil Removal

of Alignment

Draw Back the Stem to Assemble Another

Casing Pipe and Repeat Augering

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4.2 Construction Flow Chart Specifically for Manual Boring Techniques

Excavation of the Grading the

Preparation Surveying
pits pit bottoms

Casing pipe Installation of guiding

Digging Measuring installation rail and equipment

Jacking Reset jack Adding jacking part

Soil removal Hoist soil Soil removal

4.3 Preparation, Taking over Stakes, Surveying and Setting out

Prior to commencement, the following works will be carried out:

Site investigation; check the local hydrology, geology and meteorological information; understand the

construction drawings, technical requirements and specifications; check the construction drawings and

prepare detailed installation drawings, resolve any problem appearing in the drawings; obtain the

construction permit with Owner’s assistance; Resolve any outstanding issues.

Taking over the survey points including: control posts (turning posts, kilometer posts etc.), temporary

markers and permanent markers. Pipeline survey points should strictly comply with the approved for

construction drawings.

According to the design drawings and relating documents, markers and control stakes, pipeline

centerline stakes and boundary should be marked out clearly.

4.4 Access

According to the site condition, access will be prepared by CPECC to the launching pit and receiving pit

to facilitate entrance of vehicles and equipments. The access should connect to the pipeline ROW

smoothly.

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4.5 Excavation of the Launching Pit and Receiving Pit

According to the design requirement, pits will be excavated at both side of the crossing, one side is the

launching pit, and the other side is the receiving pit.

The size of the launching pit depends on the size and length of casing pipe, jack and backup board, and

the method of jacking.

In case of uncontrolled groundwater in the pits and at crossing locations, dewatering equipment (well

pointing or deep wells) shall be deployed to control the ground water levels.

The depth of the launching pit depends on the design elevation of the pipe bottom. If the bottom of the

pit is firm and free of ground water, a wooden foundation shall be installed at the bottom; if there is

groundwater in the pit, 200mm thick C20 concrete shall be applied. Guiding rail will be laid on the

bottom, and fixed by anchor bolt or welded to the steel plates embedded inside the concrete. The

distance between the two rails shall make the included angle in the sketch below in the range of 70-90°.

Center of the pipe

Rail

70-90

In case an auger machine is used for crossing, the special rail will be installed as recommended by the

manufacturer.

The pit will be excavated by machine combined with manual work.

During excavation, the back wall should not be broken, detail requirement as follows:

(1) The back wall shall be sufficiently designed to withstand the maximum counterforce anticipated

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 during jacking.

(2) The back wall should also have angular rigidity. It should not deform too much when the jack is

pushing.

(3) The back wall should be straight and perpendicular to the axis of the casing pipe.

(4) Depending on the soil characteristic, the back wall will be reinforced by, such as sleepers and/or

steel plate

5 POSITIONING THE EQUIPMENT

5.1 Prior to commencement, survey and grade the launching pit bottom in accordance with the

requirements and specifications. In general, this is in the same straight line as that of the crossing.

5.2 After survey and grading of the pit bottom, install the back pushing board with mobile crane, support

and guiding rail will also be installed, adjust the guiding rail to ensure that its centerline is the design

centerline.

5.3 In case an auger is used, the machine body shall be positioned on the rail at first. Then the drilling stem,

which has been put into a casing pipe in advance, will be positioned and connected to the drilling

machine.

6 PIPE JACKING WITH HYDRAULIC JACK EQUIPMENT

6.1 Installation of Casing Pipe

Visual inspection will be executed before the casing pipe was positioned on the guiding rail, including

surface inspection and alignment inspection.

The jack is lower than the casing pipe, so supports under the jack might be needed. If more than one

jack is used, they should be distributed evenly around the axis of the casing pipe.

The jacking parts include ring jacking plate, rectangle part and horizontal part.

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1. Backup Wall ,2. Jacking Pipe, 3.Jacking Plate, 4. Longitudinal Jacking Part,5. Transverse Jacking Part
6.Jack 7.Water Collection Pit 8.Sleeper 9. Foundation
Jacking Crossing Scheme

6.2 Operation Methodology

6.2.1 Forward Moving

(1) Forward moving is to push the casing pipe into the void, which has already been dug in advance;

the key is to “dig first, and then moving forward”.

(2) After one stroke, reset the jack, change another appropriate longitudinal jacking part, and repeat

jacking. The installation of longitudinal jacking parts should be in a line with the original one.

Deviation should be strictly avoided because it may cause injury to people. Attention should be

paid to oil pressure gauge. Stop moving forward if abnormality is observed to find out the reason.

The piston of the jack should not extend beyond the specified limit, which may cause damage to

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 the jack. The advancing process should be continuous and the stoppage should not be too long,

otherwise the friction may increase. Moving forward progress should be controlled during jacking

progress to prevent the road from bulging

6.2.2 Digging

(1) Excavation must be made in the specified scope; no over digging is tolerated. The general profile

of the soil will be dug as the shape shown in the follow sketch.
Casing Pipe

120-135° Undisturbed Soil

Undisturbed Soil

Undisturbed Soil

(2) For manual digging, the bottom soil should not be disturbed. See above sketch for detail.

(3) Depending on the soil characteristic, when the digging has completed 0.2-0.5 meter. Move the

casing pipe forward.

(4) Moving forward should be immediately done when digging was finished, measuring of the moving

forward distance and the correctness of the alignment will also be done.

6.3.3 Soil Transportation

Soil will be removed by small cart inside the casing pipe, and then hoisted out of the pit.

7 CROSSING WITH AN AUGER

7.1 Visual inspection will be executed before the casing pipe was positioned on the guiding rail, including
surface inspection and alignment inspection.

7.2 A reference marker for pipe alignment shall be located on the bottom of the launching pit. Pipe
alignment during boring shall be checked by sighting reference markers at the top of the casing
pipe/cutting head using a survey instrument. Any deviation from the alignment shall be corrected by
using hydraulic jacks to adjust the lead head guide tracks.

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7.3 Hydraulic jacks shall be provided with easily readable pressure gauges and scalable pressure limits.
Their proper operation shall be demonstrated before the work is started.

7.4 The bore diameter shall be as close as practicable to the outside diameter of the casing pipe (in case
of cased crossing) but in no case larger than 50mm. Depending on site conditions, the auger diameter
may be adjusted. The diameter of the cutting ring at the front of pipe to be bored through shall be
selected accordingly. A lubricating pipe with nipples not protruding from the cutting ring may also be
used. However, lubricating pipe shall not be fixed to the pipe or casing and only biodegradable
lubricants shall be used (e.g. an emulsion of bentonite).

7.5 Removable of soil from the pipe during boring and jacking shall be by mechanical or manual (in certain
cases) means utilizing a standard, locked auger, which shall be safeguarded against jacking ahead of
the pipe. During jacking the progress of the pipe to be jacked and the cutting capacity of the auger
shall be mutually adjusted by regulating the speed of auger, to prevent the road from bulging (rpm too
low) or cave-ins (rpm too high).

7.6 Casing pipe shall be installed with a single slope not exceeding 1: 200 for ease of carrier pipe
installation and draining of casing pipe.

7.7 In case of jacking failure for rock auger, e.g. resulting in pipe buckling or the equipment being unable to
push the pipe further, the pipe shall be left in the hole, filled with sand and plugged at both ends. In
order to facilitate the removal of auger cutter tool shall be of collapsible type of which OD gets reduced
when rotated in reverse direction and can be taken out easily leaving Casing pipe intact.

7.8 Size and length of casing pipe shall be as per approved drawings. Unless insisted by authorities, the
weld joints of casing pipe and associated vent / drains will not be required to be radio- graphed.

7.9 Once the casing pipe has been jacked and checked for alignment, the vent/drain pipes shall be
installed, DN 40(2”), galvanized carbon steel pipe and fittings shall be used for fabrication of casing
vent and drain. The vent shall be installed on higher end and drain at the lower end of the casing. The
vent pipe shall be installed by direct insertion and welding. Care shall be taken to prevent contact
between carrier pipe and vent pipe. Pipe for casing drain shall not extend inside the casing pipe.

7.10 Casing insulators shall be firmly bolted on to the prepared carrier pipe string. Unless shown otherwise
on approved drawings, spacing between the insulators shall not exceed 2.5 m center-to-centre. At
the ends of the casing, a double set of insulators shall be installed.

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8 INSPECTION AND DEVIATION RECTIFICATION

During jacking, to ensure the quality, centerline and elevation of the pipeline will be strictly controlled. Any

deviation will be rectified; Hydraulic jacks will be used to adjust the jacking direction and alignment. The front

of the casing pipe will also be controlled through adjusting the pushing force among jacks.

9 DISASSEMBLE THE EQUIPMENT

When the casing pipe reaches the receiving pit, jacking of the crossing work is finished. Disassemble the
equipment and clear up the casing pipe, measure any deviation and install casing vent and drains. In case
an auger is used, it is necessary that the spiral drilling stem should be removed from the casing pipe before
the auger machine is disassembled and removed.

10 FABRICATION AND HYDRO-TESTING OF CARRIER PIPE

In accordance with the design requirements, select the carrier pipes of proper thickness as per approved

alignment sheet, stringing and fitting up should be performed on any one side of the road. The carrier pipe

should be at least 4m longer than the casing pipe. Technical requirements for fitting up and welding refer to

Pipeline Welding Procedure. NDT shall be carried out after fitting up and welding. Qualified field coating will

be applied in accordance with the design requirements and approved procedures.

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 When all joints are qualified after NDT, hydro testing shall be carried out in accordance with approved

pre-hydro testing procedure; After successful completion of hydro test, field joint coating work shall be

completed.

11 CARRIER PIPE INSTALLATION

According to the design requirement, Insulator ring will be installed on carrier pipe, which has been

hydro-tested.

The launching trench shall be 3m wide and 1m deeper than the casing pipe bottom and extended to a length

to fit the prefabricated section. Distance holders will be installed in front of pipe and equal spread as pipe

support. CPECC will take necessary measures to prevent damage to the cathodic protection ribbon welded

to the carrier pipe. CPECC will install the HDPE Ducts on the insulator rings and strap the ducts to the

carrier pipe sufficiently, to prevent their sliding down during carrier pipe installation and during pneumatic

pressure testing of the HDPE ducts.

Clear up soil, clay, stone and other foreign material thoroughly. Sufficient quantity of Side booms will be

used to lift the prefabricated section of the carrier pipe and insert it inside the casing pipe. Care must be

taken during insertion to protect the carrier pipe, Insulator Rings, and HDPE Ducts, CP ribbon from distortion

or any kind of damage.

Electrical isolation test：

Immediately after insertion of Carrier pipe and prior to making tie-in with the pipeline and back-filling on both
sides, CPECC, in presence of the owner’s representative, shall carry out testing with a 500 V Megger to
determine the electrical resistance between the casing and carrier pipe. The must show minimum resistance
of 100,000 ohms between carrier pipe and casing pipe.

In case of failure of test, the CPECC shall assess the reasons for lower resistance and make necessary
repair and verify that short-circuiting has been successfully removed.

12 END SEALING

After the installation of carrier pipe, HDPE Ducts and CP etc., the end seals (with special provision for three

HDPE ducts ) confirming to the specification and approved by owner, shall be installed at the ends of Casing

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 pipes in accordance to with the manufacturer’s instructions.

13 BACKFILLING AND RESTORATION

Earth or sand filled bags may be used to firmly support the carrier pipe adjacent to the crossing. In case of

cased crossing, carrier pipe shall be supported with insulators as recommended by the manufacturers in

such a manner that it remains correctly aligned at the casing ends during and after backfilling.

Backfilling shall be carried out when the carrier pipe is installed; backfilling will be compacted, ditch and

drainage shall be restored as well.

Remove all wastes from the construction site.

14 SAFETY MEASUREMENT

There are many equipment on site, and the work shall continue day and night, which will cause the

operators work under stress. So, it is required to deploy two teams of operators and construction personnel

shall take care of each other and all pay attention to safety.

Take precautions against site electricity. Professional electrician shall be designated for the power works;

Electric leakage should always be prevented.

Specific person shall be in charge of hydro-test. The hydro-test plan should be strictly followed; Safety

protection shall be prepared during hydro testing.

Designated instructor shall direct the crossing work.

There should be safety organization in every process and complete safety documents.

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15 LAYOUT OF THE JACKING/AUGER DRILLING CROSSING

Excavator
Hydraulic Pipe Jacking
Operation Pit
Machine or Auger

Back Wall
Receiving Pit Launching Trench

Casing Prefabrication
Excavator Yard
Pipe

Layout of the Jacking/ Auger Drilling Crossing Site

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APPENDIX A QC PLAN

ABU DHABI CRUDE OIL PIPELINE PROJECT

QC PLAN FOR CASED CROSSING

DOCUMENT NO.：30-99-90-1653

OWNER
REV. DATE RIVISION DETAILS PREPARED BY CHECKED BY APPROVED BY
APPROVED BY

0 07/17/2008
 ABU DHABI CRUDE OIL PIPELINE PROJECT

QC PLAN FOR CASED CROSSING

DEFINITION OF INSPECTION AND TEST PLAN SYMBOLS

“H” - HOLD: A point beyond which work shall not proceed without formal approval by appropriate inspectorate. Achievement of “H” points shall be notified to Owner.

“W” - WITNESS: A point beyond which work may proceed without formal documented approval by any of the inspectorate. Achievement of “W” points shall be notified to Owner.

“S” - SURVEILLANCE: A point where CONSORTIUM and others may carry out surveillance of work in progress and documentation associated on an unscheduled basis, with no notification required by any
party and without amendment to the scheduled production programme.

“R” - REVIEW: The documents are to be submitted to the appropriate inspectorate for review by Owner. Note that where a document is subject to Owner approval, work shall not proceed until the Owner’s
approval is given.

“C” - CERTIFICATION: Specific and appropriate certification documentation is to be included in the document package.

“A1” - 100% ACTUAL

“A2” - RANDOM ACTUAL

REMARKS:
 ABU DHABI CRUDE OIL PIPELINE PROJECT

QC PLAN FOR CASED CROSSING

Date: DOCUMENT NO.：30-99-90-1653 PAGE OF

Item Inspection Activity & Specific Acceptance Criteria, Verifying

Contractor TPI Owner
No. Check Point Area Code & Standard Record
1.1 Check the crossing location, depth and length in A1 W W
accordance with the approved drawings, check the soil
structure and hydrology at the crossing areas.

1.2 The centerline of crossing, the elevation of base bed in the 30-78-12-0606 FORM-1653-01 A1 W W
work pit shall be controlled. CROSSINGS
Specification for Pipeline INSPECTION CHECK
1.3 The weld and NDT during crossing shall meet the Construction LIST
requirement of relative standards and regulations. A1 W W

1.4 Inspection on pipe coating and right weld coating,gurrent A1 W W

drain test, backfill inspection, soil compaction, safety signs
1.5 The position of pipe shall meet the requirement of design A1 W W
drawing.
1.6 Pre-post requirements for HDD section prior pull back A1 W W
operation.

Definitions of Symbols : H - Hold Point W - Witness Point S - Surveillance R - Review C – Certification A1 - 100% Actual A2 - Random Actual
APPENDIX B CHECK LIST

No. FORM-1653-01
CROSSINGS INSPECTION CHECK LIST
REPORT NO.: LOCATION/AREA:

DESIGN DRAWING NO.: PIPELINE SEGMENT:

INSPECTION
NO. ACTIVITY DATE
CONCLUSION
CHECK THE CROSSING LOCATION, DEPTH AND
LENGTH IN ACCORDANCE WITH THE APPROVED
1
DRAWINGS. CHECK THE SOIL STRUCTURE AND
HYDROLOGY AT THE CROSSING AREAS.

SELECT THE WORK PIT AND THE POSITION OF

2 THE WORK PIT AND SIZE SHALL BE REASONABLE
IN ORDER TO CONSTRUCT AND OPERATE.

THE CENTERLINE OF CROSSING, THE ELEVATION

3 OF BASE BED IN THE WORK PIT SHALL BE
CONTROLLED.

THE WELD AND NDT DURING CROSSING SHALL

4 MEET THE REQUIREMENT OF RELATIVE
STANDARDS AND REGULATIONS.

INSPECTION ON PIPE COATING AND GIRTH WELD

5 COATING, CURRENT DRAIN TEST, BACKFILL
INSPECTION, SOIL COMPACTION, SAFETY SIGNS.

THE TYPE OF PIPE SHALL MEET THE

6
REQUIREMENT.
CHECK THE CASING PIPE; THE COATING OF PIPE
7 SHALL MEET THE REQUIREMENT OF DESIGN
DRAWING.
THE POSITION OF PIPE SHALL MEET THE
8
REQUIREMENT OF DESIGN DRAWING.

PRE-POST REQUIREMENTS FOR HDD SECTION

9
PRIOR PULL BACK OPERATION.

APPROVALS CONTRACTOR TPI OWNER

NAME

SIGNATURE

DATE