Duqm Refinery Project – EPC Package 2 Drainage Material and Workmanship

Revision History

Amendment Revision Amender

Amendment
Date Number Initials

Incorporation of FEED Amendment Notes, EPC2 Design Notes

15-May-2018 O1 HSN
and Accepted VE

21-JUN-2018 A1 HSN Client comments incorporated

18-JUL-2018 B1 HSN Code A for revision A1, Next stage issue

24-NOV-2018 B2 HSN Client comments incorporated

Related Documents

Document Number Document Name Description of Content

Holds

Section Number Short Description of Hold

Definitions and Abbreviations

Term Comment

DRP001-OUF-SPE-C-000-008 Page 2 of 15 Rev: B2

Duqm Refinery Project – EPC Package 2 Drainage Material and Workmanship

CONTENTS

1 PURPOSE ..................................................................................................................................................... 5

2 SCOPE .......................................................................................................................................................... 5

3 CODES AND STANDARDS ......................................................................................................................... 5

4 REFERENCE DOCUMENTS ........................................................................................................................ 6

5 DEFINITIONS ................................................................................................................................................ 7

6 QUALITY ASSURANCE AND QUALITY CONTROL .................................................................................. 7

7 DESIGN ......................................................................................................................................................... 7

8 MATERIALS .................................................................................................................................................. 7
8.1 Design Parameters ......................................................................................................................... 7
8.2 Materials for Concrete and Reinforcing Steel ............................................................................. 7
8.3 Pipework .......................................................................................................................................... 8
8.4 Pipe Bedding Materials .................................................................................................................. 9
8.5 Manholes, Catchbasins, Sumps & Pits ........................................................................................ 9
8.6 Manhole Covers and Catchbasin Gratings .................................................................................. 9
8.7 Manhole Step Irons ........................................................................................................................ 9
8.8 Water Stops ..................................................................................................................................... 9
8.9 Concrete Protective Coating ........................................................................................................ 9
8.10 Cement Mortar .............................................................................................................................. 10
8.11 Keys ............................................................................................................................................... 10

9 SAFETY....................................................................................................................................................... 10

10 CONSTRUCTION EXECUTION.................................................................................................................. 10

11 HANDLING AND STORAGE OF MATERIALS .......................................................................................... 10

11.1 General .......................................................................................................................................... 10
11.2 Material for Concrete.................................................................................................................... 10
11.3 Pipework ........................................................................................................................................ 10

12 WORKMANSHIP ......................................................................................................................................... 11
12.1 Trench Excavation ........................................................................................................................ 11
12.2 Bedding ......................................................................................................................................... 11
12.3 Pipe laying ..................................................................................................................................... 11
12.4 Trench Backfill .............................................................................................................................. 12
12.5 Manholes and Other UG Structures ........................................................................................... 12
12.6 Bedding of Manhole cover Frames ............................................................................................. 12
12.7 Temporary Manhole Covers ........................................................................................................ 12
12.8 Sealing Open Pipe Ends .............................................................................................................. 12

13 TESTING ..................................................................................................................................................... 13
13.1 Drainage and Sewer Pipework .................................................................................................... 13

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Duqm Refinery Project – EPC Package 2 Drainage Material and Workmanship

13.2 Water Test ..................................................................................................................................... 13

13.3 Air Test .......................................................................................................................................... 14
13.4 Manholes ....................................................................................................................................... 14
13.5 Clear and Flush all Drains ........................................................................................................... 14
13.6 Test Programmes ......................................................................................................................... 14
13.7 Records of Tests .......................................................................................................................... 14

14 INSPECTION ............................................................................................................................................... 14

15 DISPOSAL OF MATERIALS AND TEST FLUIDS ..................................................................................... 15

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Duqm Refinery Project – EPC Package 2 Drainage Material and Workmanship

1 PURPOSE
The purpose of this specification is to prescribe the minimum requirements for the
gravity piped drainage system that is installed underground with the necessary fittings,
manholes, inlets, catch basins, valve pits and appurtenances as shown on the contract
drawings and specified herein.

2 SCOPE
This specification provides rules for the furnishing, installation, inspection and testing of
the gravity piped drainage system installed underground.

The Clean Water Storm Sewer (CSS) System is covered in DRP001-OUF-SPE-C-000-

007.

All drawing text, dimensions etc. shall be expressed in the English language and all the
units in the SI system.

3 CODES AND STANDARDS

The applicable parts of the following codes and standards and references shall be
considered to be an integral part of this specification. The edition in effect on the date
of the contract award shall be used, except as otherwise noted. If there is, or appears
to be a conflict between this specification and the referenced document, the matter
shall be referred to the Company. The most stringent requirement shall govern until
written clarification is provided by the Company.

American Society for Testing and Materials (ASTM)

ASTM A36 Standard Specification for Carbon Structural Steel

ASTM A48 Standard Specification for Gray Iron Castings

ASTM A185 Standard Specifications for Welded Steel Wire Fabric for Concrete
Reinforcement

ASTM A615 Standard Specification for Deformed and Plain Carbon-Steel Bars for
Concrete Reinforcement

ASTM C150 Standard Specification for Portland Cement

ASTM C206 Standard Specification for Finishing Hydrated Lime

ASTM C33 Standard Specification for Concrete Aggregates

ASTM C478 Standard Specification for Precast Reinforced Concrete Manhole

Sections

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Duqm Refinery Project – EPC Package 2 Drainage Material and Workmanship

ASTM C913 Standard Specification for Precast Concrete Water and Wastewater
Structures

ASTM D1784 Standard Specification for Rigid PVC Compounds and Chlorinated
CPVC Compounds

ASTM D2996 Standard Specification for Filament-Wound Fiberglass Pipe

American Water Works Association (AWWA)

AWWA C900 Polyvinyl Chloride (PVC) Pressure Pipe 4” to 12” for Water
Distribution

AWWA M45 Fiberglass Pipe Design

4 REFERENCE DOCUMENTS
Project Specifications

DRP001-OUF-SPE-U-000-002 Project Design Data

DRP001-OUF-PRO-Q-000-001 Project Quality Plan

DRP001-OUF-SPE-C-000-001 Civil Engineering Design Criteria

DRP001-OUF-SPE-C-000-011 Structural Design Criteria

DRP001-OUF-SPE-C-000-007 Storm Sewers and Culverts

DRP001-OUF-SPE-C-000-002 Concrete Mix Design Criteria

DRP001-OUF-PRO-Z-000-003 Project HSE Plan Document 4 Environmental

Plan

DRP001-OUF-SPE-P-000-004 Pipe Class Service Index

Project Standards Drawings

DRP001-OUF-000000-C-CVL-001-1 Concrete Works General Notes

DRP001-OUF-000000-C-CVL-002-1 Civil Works Standard Details Sheet 1

DRP001-OUF-000000-C-CVL-002-2 Civil Works Standard Details Sheet 2

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Duqm Refinery Project – EPC Package 2 Drainage Material and Workmanship

5 DEFINITIONS
For the purpose of this specification, the following definitions shall apply:

Company - Duqm Refinery & Petrochemical Industries Company (Duqm

Refinery)

EPC Contractor - Person appointed by the Company pursuant to the EPC

Contract to carry out the works

Works - All works and services provided by the EPC Contractor in

order to construct, install, erect, commission, test and
complete the Facilities

6 QUALITY ASSURANCE AND QUALITY CONTROL

References shall be made to DRP001-OUF-PRO-Q-000-001 Project Quality Plan for
Quality Assurance & Quality Control requirements.

7 DESIGN
Criteria for the design of the gravity pipes drainage system is provided within the
Clause 12 of Civil Engineering Design Criteria (DRP001-OUF-SPE-C-000-001).

8 MATERIALS

8.1 Design Parameters

In the selection of suitable materials for use in the relevant drainage systems,
consideration shall be given to the relevant material to withstand the effects of its
contents, e.g. scouring chemical acid attack and the temperature of the effluent. The
aggressive nature/conditions in the soil and the potential for movement of the soil, or
the drainage structures shall also be considered in the final choice of material to be
used, and the method of jointing.

8.2 Materials for Concrete and Reinforcing Steel

Unless otherwise specified, all materials employed in the production of concrete and
the use of reinforcing bars shall comply with the requirements of DRP001-OUF-SPE-C-
000-011 Structural Design Criteria.

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Duqm Refinery Project – EPC Package 2 Drainage Material and Workmanship

8.3 Pipework
8.3.1 General

All pipework supplied by the EPC Contractor that will be used in the works shall be
obtained from an approved Manufacturer. EPC Contractor shall forward to the
Company, certificates from the Manufacturer certifying that the pipes and fittings have
been tested and comply with the appropriate standard, before despatch.

8.3.2 Sanitary Sewer System

Material for sanitary wastewater system shall be Reinforced Thermosetting Resin Pipe
(RTRP) - Epoxy and shall be in accordance with the standard specification for RTR
Pipe (ASTM D2996).

8.3.3 Oily Water Sewer System (OWS)

Material for OWS system shall be Reinforced Thermosetting Resin Pipe (RTRP) –
Epoxy and shall be in accordance with the standard specification for RTR Pipe (ASTM
D2996).

8.3.4 Accidentally Oil Contaminated Sewer System

Material for AOC system shall be Reinforced Thermosetting Resin Pipe (RTRP) –
Epoxy and shall be in accordance with the standard specification for RTR Pipe (ASTM
D2996).

8.3.5 Closed Drain System

For closed drain pipe material refer to Piping Material Index ( DRP001-OUF-SPE-P-
000-004).

8.3.6 Chemical Drain System

For chemical drain pipe material refer to Piping Material Index ( DRP001-OUF-SPE-P-
000-004).

8.3.7 Acid Drain System

For acid drain pipe material refer to Piping Material Index ( DRP001-OUF-SPE-P-000-
004).

8.3.8 Piping Jointing Materials

The method of installation and the material used for jointing shall be in accordance with
the relevant Manufacturer’s recommendations and instruction, and shall be suitable for
the expected operating conditions, temperature range, differential settlement and
wastewater expected within the system.

8.3.9 External Corrosion Protection

All buried steel pipes and fittings shall be provided with external corrosion protection in
accordance with Coating and Wrapping for Buried Pipework Specification (DRP001-
OUF-SPE-W-000-016).

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Duqm Refinery Project – EPC Package 2 Drainage Material and Workmanship

8.4 Pipe Bedding Materials

For concrete pipe, the bedding material shall comprise of a well graded readily
compacted broken stone, crushed rock or gravel. All granular material shall be single
sized or graded in accordance with ASTM C33 / C33M-13.

Pipe bedding for carbon steel, RTRP and uPVC pipes shall comprise of well graded
natural sand and shall be free from contamination and deleterious material.

For U/G drainage piping material specifications see DRP001-OUF-SPE-P-000-004

Piping Class Service Index.

8.5 Manholes, Catchbasins, Sumps & Pits

Manholes, catchbasins, sumps and pits shall be constructed utilising precast concrete
rings and cover slabs which shall comply with the requirements of ASTM C913 and
ASTM C478.

Alternatively manholes, catch basins, sumps and pits may be constructed from in-situ
concrete. Reinforcement size, spacing and location shall be indicated on the respective
drawings.

8.6 Manhole Covers and Catchbasin Gratings

Covers and gratings shall comply in all respects with the requirements of ASTM A48
and shall be of the type, class and material indicated on the drawings or manhole
schedule. Catch basin grating frames may either be a manufactured item or site
fabricated. Proposed design and free flow area shall be submitted for Company’s
approval prior ordering or fabrication.

8.7 Manhole Step Irons

Manhole step irons may be castings or bent steel rod. Steps shall be plastic
encapsulated or galvanised to protect from corrosion.

The manufactured manhole step irons shall be true to pattern in form and dimension
and free from defects that would affect the service value. Castings, which have defects,
shall be rejected. The casting shall be filleted boldly at angles and arises shall be sharp
and true. The Vendor shall paint or dip the frames and covers in a commercial quality
asphalt paint approved by Company if not pre-coated by the manufacturer.

8.8 Water Stops

Water stops installed in concrete structures shall be a proprietary PVC or rubber
material to provide permanent liquid-tight seal. The type of water stop shall be selected
in consultation with the manufacturer.

Pipes cast into or passing through drainage structures shall have a hydrophilic water
stop bonded to the external face of the pipe and integral puddle flange to stop capillary
action along potential leak path. The puddle flange material shall be the same material
with the pipe. Hydrophilic water stop and puddle flange shall be located at the midpoint
of the wall or slab.

8.9 Concrete Protective Coating

Coating membranes used for secondary linings to effluents collection or treatment
sumps, manholes, catch basins and retention ponds shall be resistant to the

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Duqm Refinery Project – EPC Package 2 Drainage Material and Workmanship

wastewater properties and ground conditions. For concrete protective coating

specification, refer to DRP001-OUF-SPE-W-000-0009 (Coatings – Internal Lining).

8.10 Cement Mortar

Cement mortar used for benching, filling lift holes, joints, patching and anchoring
castings shall consist of one part Portland cement, Type II ( ASTM C150), one-quarter
part hydrated lime (ASTM C206) and 2½ parts clean, sharp well-graded sand and
water free of suspended matter, alkali and containing no industrial or domestic waste.

8.11 Keys
EPC Contractor shall provide and hand over to the Company at completion of the
works, two sets of lifting/locking keys to suit each specific pattern of installed manhole
cover/grating.

9 SAFETY
The EPC Contractor shall establish a safety program that includes but is not limited to
the handling, shipping and storage of contract materials present onsite as well as
maintaining all necessary documentation/material data specifications of contract
materials containing known hazardous or toxic substances.

10 CONSTRUCTION EXECUTION
The EPC Contractor shall produce the procedure and work plans for the construction
and installation of all constituent parts of the underground gravity pipe drainage system
for Company approval prior to commencement of the Work. The procedure and work
plans are to be submitted to the Company for review.

11 HANDLING AND STORAGE OF MATERIALS

11.1 General
All materials shall be stored in such a manner as to protect them from deterioration and
contamination from whatever source.

11.2 Material for Concrete

All materials used in the production of concrete shall be handled and stored in the
manner described in Specification for Concrete Works (DRP001-OUF-SPE-C-000-005).

11.3 Pipework
All pipes and fittings shall be thoroughly inspected on delivery and again before being
placed in position. Throughout the operations of delivery, handling, storing and
transporting on or about the site, EPC Contractor shall use such methods, plant and
equipment as will prevent damage to the pipes and to any coating. Impacts shall be
avoided. Ropes, cables and hooks shall not be used during handling. Instead, wide
straps shall be used and shall be of a length suited to the diameter of the pipes.

During storage, the pipes shall not be placed directly on the ground and shall not be
stored one on top of another. They shall be placed on wide timber bearers with
suitable interplacing of a protective material.

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Coated and wrapped carbon steel, uPVC and PE pipework shall be protected from the
direct rays of the sun. To avoid damage to linings or pipes and fittings special care and
attention shall be taken when lifting, moving and placing pipe on site.

12 WORKMANSHIP

12.1 Trench Excavation

Excavation for underground pipework shall be carried out in accordance with Site
Preparation, Excavation and Backfill (DRP001-OUF-SPE-C-000-500).

12.2 Bedding
A bed of selected bedding material as specified in Section 8.4 shall be laid and
compacted to 100mm minimum thickness over the full width of the trench, where the
bed thickness is measured from the bottom of pipe to the trench bottom. The bed
thickness shall be increased to 150mm in rock or hard soil conditions. The bed shall be
scooped out locally at pipe sockets where socketed pipes are used. The bed thickness
under sockets shall not be less than 50mm.

Alternative bedding types shall be considered where required by specific site

conditions.

Pipes shall be adjusted to line and level within tolerances specified in the design to
ensure that pipe barrels rest uniformly on the bedding along their whole length. Where
side fill is required, further selected backfill material shall be laid and compacted
uniformly by hand halfway up each side of the pipe.

12.3 Pipe laying

Before installation and prior to lowering into the trench the pipe shall be inspected for
defects. Any pipe or fitting found to be defective before or after laying shall be
replaced at no additional cost.

Pipe laying should commence at the downstream end of the system. Immediately
following the excavation of the trench, the pipe shall be laid and jointed in accordance
with the Manufacturer's recommendations and as detailed on the EPC Contractor’s
drawings. Joints shall be undamaged and clean. Brick or other hard blocks, etc shall
not be placed under the pipes for temporary support.

Cutting of pipe shall be carried out with manufacturer’s recommended tools and
procedures. Damage to internal and external coatings and or linings shall be repaired
in accordance with manufacturer’s instructions.

The full length of each section of pipe shall rest solidly upon the pipe bed. A pipe that
has the gradient or joint disturbed after laying shall be taken up and relaid. Pipes shall
not be laid when trench conditions are unsuitable for the work. When work is not in
progress open ends of pipes, fittings and valves shall be securely closed so that no
water, sand or other substance will enter the pipes or fittings. Pipe ends left for future
connection shall be valved, plugged or capped.

Each length of pipe shall be laid in a dead straight line both in the horizontal and
vertical planes, the levels and/or gradients shown on the EPC Contractor’s drawings
being rigidly adhered to, unless otherwise approved by the Company. Permanent
adjustments to line and/or level shall not be achieved by local packing. As the work
progresses the interior of the pipe shall be cleared of all superfluous materials. As
soon as possible after the joint is made, sufficient backfill material shall be placed
along the pipe to prevent pipe movement of line or grade and the invert level checked.
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Duqm Refinery Project – EPC Package 2 Drainage Material and Workmanship

12.4 Trench Backfill

Selected fill shall be laid in 100mm layers and hand compacted to a level 300mm
above top of pipe followed by main backfill material placed and compacted in 300mm
layers. On completion of backfilling, surface finish shall be installed / reinstated as
indicated on EPC Contractor’s drawings. Any trench sheeting should be withdrawn as
the work proceeds. Mechanical compactors shall not be used until there is at least
450mm hand compacted cover over the crown of the pipes.

Where necessary, temporary bridges or additional surface protection shall be provided

over trenches to carry construction traffic and prevent damage to pipework after
backfilling.

12.5 Manholes and Other UG Structures

Manholes, valve chambers, catch basins, pump chambers etc., shall be constructed at
locations indicated on the EPC Contractor’s drawings and details

Bases to manholes etc shall be cast in concrete, minimum grade of concrete shall be in
accordance with Concrete Mix Design Criteria (DRP001-OUF-SPE-C-000-002). The
minimum size of the base shall be equal to the external dimensions of the manhole
chamber.

Concrete manholes shall be constructed with precast concrete sections complying with
the relevant requirements specified in section 8.5 with ogee or similar approved joints.
A chamber ring with openings for the drain inlets and outlets shall be set vertically in
the manhole base, and subsequent sections added, as required, and set vertically, to
build the manhole up to surface level.

Care shall be taken to locate step irons in succeeding precast units vertically above
step irons in proceeding units.

All spun concrete manhole sections shall be supplied with mastic fillets at the joints to
provide watertight seals.

Bed the top pre-cast concrete section dry pending completion of surrounding levels.
Replace or adjust as necessary to give accurate and even final levels.

12.6 Bedding of Manhole cover Frames

Manhole cover frames shall be bedded as shown in the detail drawings.

All frames shall be solidly bedded so that the manhole cover is even with the
surrounding finished surface. Any installed cover or frame not level or that allows
rocking of the cover, shall be made level or replaced at EPC Contractor's expenses.

12.7 Temporary Manhole Covers

Partly constructed manholes shall be provided with timber or metal temporary covers.
Building debris being allowed to accumulate in chambers shall require the associated
pipe runs to be rodded out at EPC Contractor's expense.

12.8 Sealing Open Pipe Ends

All pipe open ends and terminations for later connections of pipes shall be securely
sealed, plugged or capped during progress of the works to prevent entry of foreign
matter. Plastic, shaped hardwood, metal plugs or drain plugs shall be used. Screwed-
up paper or cloth pushed into pipe ends will not be acceptable and shall not be used.
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Building debris being allowed to accumulate in drains shall require rodding and clearing
out at EPC Contractor's expense.

13 TESTING

13.1 Drainage and Sewer Pipework

All drainage and sewer pipework shall be inspected and leak tested by the EPC
Contractor in the presence of the Company’s Representative before haunching of the
pipes and prior to backfilling and again on completion before the EPC Contractor
hands over the system. The initial visual inspection shall include check of line and level,
joints, damage or deformations and linings / coatings.

The leak test shall comprise of either a water test in accordance with clause 13.2 or an
air test in accordance with Clause 13.3 of this Specification. Sections between
manholes shall be tested separately unless otherwise specified. All the necessary
apparatus and attendance for the test shall be provided by the EPC Contractor.

Pipework failing to satisfy the requirements of the water test shall be taken up, re-laid
and re-jointed as necessary and again tested to establish watertightness; at no extra
cost to the Company.

The drainage system shall not be deemed to have failed by means of an air test. A
water test should be carried out prior to the rejection of the system.

13.2 Water Test

Testing of sewers shall be as follows:-

The section of the drain to be tested shall be suitability stoppered or plugged at the end
of connections. The test section shall then be filled with water up to the ground level of
either the downstream or upstream manhole, as appropriate, but with a maximum
pressure of 50 kPa and a minimum pressure of 10 kPa measured at the top of the pipe.
Steeply graded drains shall be tested in stages where the above maximum pressure
would be exceeded if the whole section were tested at once.

Unless otherwise agreed by the Company the test shall commence one hour after
filling the test section, at which time the water level in the feed pipe shall be made up to
produce the required test head. The test shall be continued for sufficient time to allow
the Company to inspect the pipeline and satisfy himself regarding its water tightness
and in any case for not less than one hour.

The pressure shall be maintained within 1 kPa of the test pressure by topping up with
water. The total amount of water added during the test shall be measured and
recorded with the head of water at the required test pressure.

The test requirement is satisfied if the amount of water added is not greater than:

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For clean un-contaminated systems:

0.15 l/m2 during 30 min for pipelines;

0.20 l/m2 during 30 min for pipelines including manholes
Note. m2 refers to the wetted internal surface.
For Hydrocarbon or contaminated drainage systems no detectable loss during the test
shall be allowed, unless otherwise agreed with the Company.

13.3 Air Test

The section of the drain to be tested shall be suitably stoppered or plugged. A
manometer shall be connected to one of the plugs and air pressure source shall be
applied to another plug. Pressure shall be applied either by mouth or with a hand
pump to achieve 100mm water gauge. The test apparatus should be left for a
minimum of five minutes.

The system is deemed to have passed the test if there is no fall in the head of water
during the test period.

13.4 Manholes
Each manhole shall be tested for water tightness in the presence of the Company by
filling with water to a level not exceeding 1.2m above the pipe soffit level or to ground
level. EPC Contractor shall be responsible for locating, making good any leakages and
the work will be accepted as satisfactory only when a visual inspection for water
tightness reveals no leaks or external damp patches. This test is to be carried out prior
to the placing of the backfill material.

13.5 Clear and Flush all Drains

At completion of the works, EPC Contractor shall clear out and flush all drains,
manholes etc with clean water, rodding through drains where necessary to ensure
clearance of debris and leave the system in clean working order with all traps sealed
with water.

13.6 Test Programmes

EPC Contractor shall submit to the Company, for Company’s prior approval, a testing
programme for all underground drainage and sewerage systems.

13.7 Records of Tests

EPC Contractor shall keep a complete record of all tests carried out after installation
and shall supply the Company with a copy of the records as the testing proceeds and
at the end of the Contract, or as otherwise requested by the Company. EPC Contractor
shall submit for approval a test record sheet and his proposal for an underground
drainage and sewerage Construction Records Dossier.

14 INSPECTION
The EPC Contractor shall produce specification for the inspection of all pipes, fittings
and all ancillary concrete structures pertaining to underground gravity pipe drainage

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system. The procedure and work plans shall be issued to Company for approval prior
to commencement of work.

15 DISPOSAL OF MATERIALS AND TEST FLUIDS

EPC Contractor shall leave all parts of the site in a clean, tidy and sound condition.
EPC Contractor shall dispose all materials and test fluids in accordance with local
regulations

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