1.

GENERAL QAP
2. MRIR
3. WPS
4. WQT
5. EQT
6. ROU CLEANING AND GREADING
7. TRENCHING
8. STRINGING
9. MAINLINE WEALDING
10. RADIOGRAPHY TESTING.
11. YLTRASONIC TESTING
12. LEQUIED PENERATION TEST
13. WELD REPAIR
14. FIELD JOINT COATING
15. LOWEARING.
16. TIEIN WELDING
17. BACKFILLING
18. CROSSING (OPEN CUT)
19. CASED CROSSING
20. PRE- HYDRO STATIC TEST
21. POST HYDRO STATIC TEST
22. SWABBING
23. DRYING
24. PRE- COMMISSIONING & COMMISSIONING
25. HORIZONTAL DIRECTIONAL DRILLIN7654321`5RIR
26. PIPE BOOK

1 WPS (WELDING PROCEDURE QULIFICATION)

1. REFERENCE

 API 1104, Latest Edition

 CLIENT Specification
 ASME B 31.8
 ASME Sec.-V

General

Welding procedure qualification shall be carried out in accordance with the relevant requirements Section
5 QUALIFICATION OF WELDING PROCEDURES CONTAINING FILLER METAL ADDITIVES of API-1104, latest
edition and CLIENT Specification.

CONTRACTOR shall submit the proposed welding procedure specification to TPIA/ CLIENT for review and
for releasing the procedure for procedure qualification tests. The procedure qualification test shall be
carried out by CONTRACTOR under welding shop and is to be witnessed by TPIA/ CLIENT. A complete set
of parameters and data’s shall be recorded jointly by CONTRACTOR and TPIA/ CLIENT
Once welded specimens cleared visually it shall be subjected to radiographic testing and subsequently to
destructive testing. Destructive testing shall be done as per CLIENT Specification and Section 5.6 for
manual welding of API 1104, Latest edition.
 A complete set of test results shall be submitted to TPIA/ CLIENT
for approval immediately after completing the procedure qualification tests.
2. EQT ( ELECTROD QULIFICATION TEST
REFERENCE
API 1104, Latest Edition
CLIENT Specification
ASME B 31.8
ASME Sec.-2 PART C

3. SURVEY, ROU CLEANING & GRADING

REFERENCES

 CLIENT Specification No.

 Route Maps
 Alignment Sheets

4. TRENCHING
REFERENCE
 Construction Drawings / Alignment Sheets
 CLIENT Specification No.

5. STRINGING OF PIPES
REFRANCE
During stringing, pipes should be supported completely clear from ground at a suitable height (500 mm)
using sand or saw dust bags placed at suitable intervals (minimum two supports in one length of pipe
should be provided).

The pipes shall be strung parallel to the centre line of the trench at a suitable & constant distance from
Entry pit. Stringing of pipes on ROU shall be done in daylight & shall be done in such a manner so as to
cause the least interference with the normal use of the land crossed.

6. MAINLINE WELDING
CLIENT SPECIFICATION
Approved WPS & PQR
ASME: B31.8
API 1104
ASME Sec-II C
MEHTODS
Prior to start of fit-up bevel cleaning shall be carried out using power brush for a width of 25 mm from the
edge of bevel for inside and outside of pipe. Bevel shall be visually inspected for any dent/damage or improper
machining.

1.1 Before start the welding full weld joint if required it should be cover with temporary booth which
contains fire resistance cloth to protect welding space from weather until the weld completed.

1.2 Dents in bevels with a depth of less than 0.5 mm shall be removed by CONTRACTOR during
cleaning, grinding. If the depth of bevel dent/defect is between 0.5 mm and 1 mm. CONTRACTOR
shall re bevel the pipe end by grinding. If the depth of bevel dent/defect is more than 1 mm,
CONTRACTOR shall cut the defective bevel end and re bevel the pipe end. The beveling shall be
done using a beveling machine. Such new bevels shall be examined by 100% visually & by LPT
method, inspected to ensure free from laminations and record shall be maintained. The cut
bevel shall be checked with bevel gauge before fit-up of the joint.

1.3 Pipes shall be checked for correct thickness, dia. and spec, with respect to the approved
alignment sheets. The first pipe shall be positioned on skids of appropriate height from the
ground Supports shall be minimum two per pipe and skid shall have soft pads placed over them
 to avoid damage to the PE coating, Pipes shall be locked to prevent their rolling from the skids.
External clamp shall be loaded outside. The second pipe shall be held by side boom/ crane and
shall be aligned with the first pipe and the external clamp shall be actuated. The root gap shall
be checked as per qualified WPS.

1.4 For welded pipes, circumferential weld seam and longitudinal weld seams of adjoining pipes
shall be staggered such that a minimum distance of 100 mm is maintained along the
circumference and both longitudinal welds or at top 90ºC quadrant of the pipeline whichever is
lesser (Except for bends). A longitudinal joint shall pass an appurtenance of a structural element
at a minimum distance of 50 mm.

1.5 The alignment abutting ends shall minimize the offset between surfaces. For pipe ends of the
same nominal thickness, the offset should not exceed 1.6 mm, larger variations are permissible
provided the variation is caused by variation of pipe end dimensions within the pipe purchase
specification tolerance, and such variations have been distributed essentially uniformly around
the circumference of the pipe. Hammering of the pipe to obtain proper lineup should be kept to
a minimum.

1.6 The branch connection sleeve, etc. shall be minimum 150 mm from any other weld. The welds
for fittings shall be so located that the toe of the weld shall not come within 50mm of any other
weld. Cold dressing is permissible only in cases of slight misalignment and may only be carried
out with a bronze headed hammer. Hot dressing shall not be permitted.

1.7 The offset may be checked from outside by dial gauges or hi-lo gauge. When different thickness
are involved, the thickness of higher pipe shall have a taper of minimum 1:4 by grinding or any
other means at inside of pipe at site, alignment and fit-up shall be checked before welding and
the welds shall be subject to both ultrasonic and radiographic inspection.

1.8 Before starting of welding works CONTRACTOR shall submit batch Certificates of the electrodes
for review & approval.

1.9 Pipe shall be pre-heated using open flame heating. Preheat temperature of 100ºC Minimum
shall be maintained prior to commencement of root run and subsequent runs.

1.10 Preheating shall extend to at least three times the thickness of the joint but not less than 50 mm
on both sides of the weld preheating shall be checked by using temperature-indicating crayons /
Thermo pens.

1.11 Maximum inter pass temperature shall be 250°C.

1.12 Earthing clamp shall be used for connecting pipe to welding machine terminal.

1.13 Welding shall be done as per the approved welding procedure specifications (WPS). Only
qualified welders shall be engaged and each welder shall bear an identity card during welding
operation.

Process SMAW.
When an external line-up clamp is used, all spaces between bars or minimum 60% of the root pass length
shall be welded before the clamp is released. The remaining pipe shall be adequately supported on each
side of the joint.
The root pass of butt joints shall be executed properly so as to achieve full penetration with complete
fusion of the root edges. Welding shall not be interrupted during a pass and shall be completed as early as
possible. Penning shall not be permitted.
The time lapse between second and third pass shall be as stated in the procedure specification, normally
not exceeding 4 to 5 minutes. Welding can be suspended, so as to allow the joint to cool down, provided
that the thickness of the weld metal deposited is at least 50% of the pipe thickness. Upon restarting,
 Pre-heating to at least of 100°C shall be carried out. Subsequent passes tip to weld completion shall be
protected to avoid rapid cooling, if meteorological conditions so dictate. Cleaning between passes shall be
done carefully so as to reduce the possibility of inclusions.
Only one welder shall be used for main line welding work up to the 8”φ pipeline & two welders shall be
used for main line welding work above the 8”φ pipeline.
In case of two welders to be used, Welder No. 1 shall start from 12'O' clock position and proceed towards
6'O' clock, In respect to Anti-clock wise direction Welder No.2 shall start from 3`O`clock position and
proceed towards 6`O`clock and then start from 12 o’clock to 3 o’clock, in respect to clock wise direction.

7. WELD REPAIR
2. REFERENCES

1. API- 1104
2. ASME B 31.8
3. APPROVED WPS/PQR
4. ASME SEC 9
5. ASME section part-C
3. METHODOLOGY

A separate welding procedure specification sheet shall be formulated and qualified for repair welds
simulating the proposed repair to be carried out. Separate procedures are required to be qualified for

(a) Full thorough thickness repair

(b) Partial thickness repair.

Welders shall be qualified in advance for repairs and in accordance with "Qualification and
Procedures of Welders". The root pass, for repairs opening the root, shall be done by the vertical up
technique. The procedure shall be proven by satisfactory procedure tests to API 1104 including the
special requirement of the specification, and shall also be subject to metallographic examination,
hardness surveys and Charpy tests to determine the effects of repair welding on the associated
structure.

Location:

With respect to radiography or other NDT method, location shall be marked on the weld with
reference to marking of ref. Points (markers).
Method of evaluation
1. Partial repair (External):

Each layer will be thoroughly checked for this type of discontinuity shown in NDT reports. Smooth
grinding will be done to make ‘V’ Groove and clean all surfaces. This is limited to 30% of weld length
only. Minimum 2 runs shall be made for partial repair. After cutting the repair area, CONTRACTOR
shall be checked and ensure that the defect has been removed, by LPT on cutting area.
2. Thru repair / Root Repair

Grinding will be done up to the root, opening will be done by chisel, hacksaw blade. The entire vol.
will be ground smoothly to ‘V groove, root gap will be achieved using blades, thin grinding wheels and
filing. Maximum repair length is 20% of weld. The minimum length of a repaired area shall be 100mm
as measured over the recapped length.
Die-penetration test shall be done during and after removal of defective weld metal by grinding to
ensure that the defect has been removed. After removing of the same, welding for repair should be
carried out.
Welding
Welding shall be done as per approved WPS and PQR (for repair of weld) after identifying the defects.
Care shall be taken to ensure that no grinding marks are made on pipe surface anywhere. Repair weld
deposition shall be smooth, free from burrs, cuts and other surface irregularities. The root gap shall
 be made carefully and shall conform to the welding procedure. The welded area shall be thoroughly
cleared.
The repair welding shall have a minimum preheat of 1500C and shall be preheated for at least 50mm
on either side of repair.
Any repaired area that is irregular shall be rejected and a full cut out and re-beveled to make a joint
Repairs opening the root shall be carried out in the presence of experienced Supervisor. All repairs
shall be carried out during the day after initial radiography. Weld shall be cut at zone of at least 5cm
at pipe material on both side of the welds & new bevel shall be made & checked by LPT. Shallow
crater crack or star crack shall not ne repaired by welding. Crack must be removed by cutting. RT & UT
as per CLIENTshall re inspect weld repair.
The reports of all repairs shall be maintained by CONTRACTOR, and shall be submitted every day to
client for review. CONTRACTOR shall identify the welders giving repairs more than acceptable limit
and that particular welder shall be warned by CONTRACTOR.
In case the percentage of repair is not reduced within acceptable limits after issuing 1 warning letter,
welder shall be rejected by CONTRACTOR.
Cleaning
Each pass will be thoroughly cleaned using power brush / grinder.
No. of Welders
A Qualified welder for the appropriate process, consumable and direction alone will be envisaged.
Welding carried out in accordance with approved PQR.
Parameters
As per WPS & PQR (approved)
NDT
1. Liquid Dye Penetrant test for repair area after cutting.
2. Radiographic inspection which covering the repair weld length.
3. Ultrasonic Examination which covers the repair weld length.
8. FIELD JOINT COATING
1 REFERENCE
 Sleeve Manufacturer Application Procedure
 DIN EN-12068 code/standard & DIN-30671
2 MATERIALS FOR FIELD JOINT COATING AND REPAIR:
 Heat Shrinkable Sleeves of Raychem HTLP-80
 Primer Part A Type S1301
 Primer Part B
 Applicator kits
 PERP 80 (for repair )
 PERP Filler / mastic filler
3 INSTRUMENTS FOR FIELD JOINT COATING AND REPAIR:
 Digital Thermometer 1Nos
 Hygrometer 1Nos
 Coat Meter/Elco-meter 1Nos
 Aluminum / rubber / Teflon hand roller 4Nos
 Micrometer 1Nos
 Press-O-Film/Comparator
 Holiday detector with 6”φ ring 1set
 Portable Peel Tester Kit 1Nos
 D.C. voltmeter (calibrated for holiday detector)

4 METHODOLOGY OF FIELD JOINT COATING

General
Procedure qualification shall be carried out in the field in the presence of vendor’s representative and
shall be approved by CLIENT.

All insulators shall be qualified by RAYCHEM/CLIENTand only such qualified insulators shall be put on the
job. All qualified insulators shall be provided with identity cards.
 Materials shall not be older than their period of validity at the time of application. The coating material
used Heat Shrinkable Sleeve and epoxy primer, shall be supplied by CONTRACTOR & shall be procured
from approved vendors. Test certificate for each batch of materials shall be submitted to CLIENTprior to
use on the job. Material supplied shall be tested in accordance with the requirement of CLIENT All
materials shall be duly inspected by CONTRACTOR & CLIENT.

Prior to start of surface finishing or joint coating, the welded joint shall be cleared / accepted in NDT (RT/
UT) as per QAP.

CONTRACTOR shall confirm that before that cooling of coating, backfilling or lowering shall not be done. In
hot climate provide shedding from sunlight. Water quenching shall be allowed only when permitted by the
coating material and manufactured recommendation.

Surface Preparation

Any oil, grease, salt or other material detrimental to the finished coating shall be removed completely in
accordance with ISO 8503-1 and shall be calibrated prior to the start of the work in accordance with ISO-8503-
03 or ISO-8503-04.
White Spirit/Turpentine/Kerosene shall not be used for this purpose.

The mechanical cleaning must be continued to at least 10 cm beyond the existing intact coating, in such a
way that all dirt is removed and the coating is roughened to ensure good adhesion. The intact coating will
be chamfered at the extremities to an angle of 15 to 30° in order to form a perfect joint.

Each field joint shall be blast cleaned using a closed cycle blasting unit or open expandable blasting
equipment. With the first equipment type, steel or chilled shot and iron grit shall be used. During blast
cleaning the pipe surface temperature shall be simultaneously more than 5°C and more than 3°C above
ambient dew Point,

Prior to surface cleaning the surfaces shall be completely dry. The surface shall be cleaned to a grade SA 2½
in accordance with Swedish Standard SIS-055900 with a roughness profile of 50-70 microns. While during
blasting activity the ambient relative humidity shall not be greater than 85%.

Surface roughness profile shall be measured using an approved profile comparator in accordance with ISO
8503-1 and shall be calibrated prior to the start of the work in accordance with ISO-8503-3 or ISO – 8503-4.
The blast cleanliness shall be checked on every joint and the roughness profile shall be checked for 1 out of
every 10 joints.

The ends of existing pipe protective coating shall be inspected and chamfered. Unbounded portions of the
coating shall be removed and then suitably trimmed. Portions where parent coating is removed shall be
thoroughly cleaned as specified. The adjacent chamfered areas of the line pipe coating shall be cleaned and
abraded, to expose a clean uniform fresh surface of uncontaminated factory applied coating.

Application Procedure of Heat Shrink Sleeves

i) The wrap around sleeve shall be of a size such that a minimum overlap of 50mm is ensured
(after shrinking) on both sides of the yard applied corrosion coating of pipe.
ii) Immediately after blast cleaning surface shall be wiped to remove the particles left over from
cleaning.
iii) Pre heat joint area using blow heating torch to 70C, CONTRACTOR shall ensure the correct
temperature is reached on steel and line coating using a pyrometer.
iv) Apply mix (shall be with ratio 3:1 for part A part B) epoxy to a smooth finish on all exposed
bare metal, including the line coating edge. Minimum wet film thickness for epoxy shall be
maintained 100 micron.
v) Wrap the HTLP 80 sleeve loosely around pipe, centering it over the weld area and evenly
overlapping the adjacent pipe coating by minimum 50 mm on each side & sleeve and closure
patch shall be min 100mm.
 vi) Press the closure in position (in 10 or 2 O’ Clock position) centering over the exposed steel
end.
vii) Flame of LPG torch shall be adjusted to produce yellow flame. Heat the closure evenly till the
pattern of fabric reinforcement is visible. Run a small hand roller over the closure to push out
any trapped air.
viii) Using LPG torches heat the sleeve, as recommended by manufactured circumferentially
around the pipe beginning at the center using a roller up and down motion.
ix) Continue heating towards one end of the sleeve, followed by the other.
x) When sleeve has been shrunk on to the joint area and is still hot and soft, run a small hand
roller over the sleeve to push out any trapped air. Particular attention shall be paid to the
weld and cut back area and if necessary some areas may be re heated to roll out air.
xi) The installed sleeve shall not be disturbed until the adhesive has solidified.
xii) All materials shall be stored in sheltered storage and protect from direct sunlight and the
storage shall be as per the recommendations of manufacturer.

5 INSPECTIONS AND TESTING

Procedure qualification testing:-

CONTRACTOR shall furnish the procedure qualification at site as instructed by manufactured

representative and in front of CLIENT representative.

The parameter shall be record during qualification of procedure.

Manufacturer representative shall be qualified the insulator be insure that the qualified insulator are
suitable for the job as requirement.

Manufactured shall issue the identity card with photograph of insulator.

The insulator shall be qualified in presence of Manufacturer Representative & CLIENT.

Visual Inspection

CONTRACTOR shall ensure the following: -

i) Mastic extrusion on either ends of the sleeve shall be examined.

ii) There shall be no sign of punctures, pinholes or bond failure.
iii) The external appearance of the sleeve shall be smooth, free of dimples/wrinkles, air
entrapment or void formations.
iv) Weld bead profile shall be visible over the sleeve.
v) The entire closer patch shall have changed colour uniformly.

Holiday Inspection
The entire surface of the coated field joint shall be inspected by means of a full circle holiday detector
approved by CLIENT. The test voltage shall be 5 KV + 5 KV/mm of total thickness of coating at the time
of lowering, subject to a maximum of 25KV. Inspection of the sleeves shall be conducted only after
the joint has cooled below 50ºC. At the time of holiday test CONTRACTOR shall arrange the Jeep
Meter for calibration of holiday detector.
No. segment of pipeline shall be covered or lowered in the trench until the field joint coating have
been approved by the CLIENT
Peel Test
Peel test shall be carried out on one of every 50 joint coating or one joint coating out of every day’s
production as per DIN EN-12068 CODE.
From each test sleeve, strip of size 25 mm x 200 mm shall be cut perpendicular to pipe axis and slowly
peeled off. The required peel strength shall be as per Standard and after removal of strip, the
adhesive layer that remains on the pipe surface shall be essentially free of voids. CONTRACTOR shall
undertake repair/replacement of all defects/defective coatings.
 The adhesive layer that remains on the pipe surface shall be free from voids resulting from air and gas
inclusion. Repair shall be carried out with PERP-80 as per Joint Coating Repair Procedure. If sleeve
taken away failed, then two adjacent sleeves shall be tested. If the adjacent two sleeves are not
accepted then the coating operation shall be stopped and further investigation shall be done and
necessary corrective action shall be taken, to the satisfaction of client. Coating thickness shall be
checked on either side of the girth weld & on weld at 3, 6, 9 & 12 O clock positions by non distractive
method for each field joint.
Thickness Measurement
The thickness of field joint coating materials shall be such that an average thickness of 2.3 mm & with
minimum thickness 2.0mm is guaranteed on the completed field joint coating on pipe body. The
minimum permissible thickness at the apex of weld seam shall be 1.6mm & average shall be 2.0mm.
6 METHODOLOGY FOR COATING REPAIR
Surface Preparation
a) Repairing of small defects

The 3LPE surface around the point faults has to be roughening with a brush disk. The 3LPE surface over
the entire pipe surface has to be dried with propane burner at about 30°C. Adhesive plastic wrapping tape
has to be applied over the entire pipe circumference, in accordance with supplier’s specification.

b) Repairing of other defects.

Cut out the damaged 3LPE surface around the defect to the point where the coating is adhered properly.
The edges of the existing coating have to be chamfered and roughened. The whole surface has to be
cleaned with a brush disk to a degree of cleanliness S.T.2 1/2. Primer has to be applied to the cleaned steel
surface and the PE coating after drying the entire part at 30°C.The hole has to be filled with mastic filler.
Adhesive wrapping tapes over the entire pipe circumference has to be applied as per approved supplier’s
specification.
c) Repairing of 3LPE damage

The method can be applied to all 3LPE damage up to a maximum size of 350 x 350mm except for
directional drilling.
Cut out the damaged 3LPE surface around the defect to the point where the coating is adhered
properly. The edges of the existing coating have to be chamfered and roughened. The whole surface
has to be cleaned with a brush disk to a degree of cleanliness as per S.T.2 1/2.
The entire part has to be dried with a propane burner at 60°C. The uneven holes and spots are to be
filled with mastic filler. Correct size of adhesive plastic repair patch has to be applied. The same to be
heated until the pigment is disappeared.
The material must comply with DIN 30672 classes C-70 (Raychem –PERP-80 or equivalent).
Application Procedure of PERP 80
Pre heat the repair area by using torch heating to approximately 60C to 70C and chamfer the repair
portion.

Wrap the PERP 80 on defect portion centering it over the defect area and evenly overlapping the
adjacent pipe coating by minimum 75 mm on each side.

Using torch, run a small hand roller over the closure to push out any trapped air.

The installed PERP 80 shall not be disturbed until the adhesive has solidified Holiday Inspection

Repair portion shall be checked with full circle Holiday Detector with voltage 5KV + 5KV/mm of total
thickness of coating, subject to a maximum of 25KV or as specified by Manufacturer

9. LOWEARING.
1 METHODOLOGY

All work shall be carried out as per below mentioned step:-

 A. Lowering shall start only after obtaining approval from CLIENT in part A of pipe book. Pipe book
part A shall be submitted to CLIENT in advance.
B. In all cases where rock is encountered in the bottom of the trench, at least 150mm sand / soft
soil bedding shall be done.
C. After satisfactory completion of trench bottom, the level shall be checked to get the required
minimum cover. If the required further dressing of the trench shall be done to get the desired
cover. Minimum cover shall be meeting specified requirement as per approved trenching method
statement.
D. Where water is present, no lying shall be permitted. However, water shall be removed to the
extent and for the time necessary to make visual inspection possible of the bed on which the
pipeline is to be laid. Following such inspection the presence of water is permitted provided it is
not so high as to cause cave-in of the walls of the trench or floating of the pipeline before
backfilling, when weighting is not provided for the pipe. Care shall be taken to prevent the
floating of pipe section before backfilling.
E. Standard pipe cradle can be used and a demonstration shall be carried out that pipe coating is
not damaged. Alternatively non-abrasive pipe belts shall be used and care must be taken while
removing the belts. Wire rope slings or other material which may damage the PE coating shall not
be used to the lift the pipes. No slings shall be put around the field coated joints.
F. Before lowering in a complete check by a circle holiday detector for pipe coating (PE Coating) and
for field joint coating (HTLP 80 Sleeve) shall be carried out at 25KV, the damages if any observed
during the examination shall be repaired as per the approved procedure.
G. Hydra/Cranes as required minimum numbers shall be used for holding the pipeline in gentle S
curve maintaining the minimum elastic bending radius as specified in the job standard. The
pipeline must be laid without interruption of whole section length available.
H. Immediately after lowering level of pipe to be checked with level machine, same to be recorded
for as –built.
I. Night caps to be provided at the end of the open ends of the lowered pipe section.
J. When ever the pipe sections are left open at intervals to be tied in at a later date under road,
marshy locations etc shall be capped with a securely closed metal caps to prevent entry of dirt,
water or any foreign matter into the pipe section.
K. Immediately after lowering back-filling shall be started as per approved procedure.
L. The widening and depth shall be maintained as per approved Trenching Procedure.
M. After completion of the Lowering activity, The Backfilling activity shall be start as per approved
Job procedure.
N. Widening or deepening of the trench shall be done as specification and approved procedure.
O. The trench shall be made as per surveyor detail at the poisoned of bend or bend shall be made as
per profile of terrain.
P. If necessary the complete adoption of the section concerned in all cases where rock or gravel or
hard soil is encountered the bottom soil bedding.

10 TIEIN WELDING
REFERENCES

API 1104, ASME B 31.8, ASME Sec IIC and Approved WPS/PQR
METHODOLOGY

 All work shall be carried out as per Specification No.11-0299-02-07-02-011, API 1104, ASME B
31.8, ASME Sec IIC and Approved WPS/PQR.
 Tie-In shall be made without stresses in the pipes.
 Bell Holes with sufficient size shall be made to facilitate for welding and provide adequate
clearance to the welders to make sound weld.
 External line-up clamp shall be released only after 60% of root weld.
 Pipe pup piece length for Tie-In shall be minimum 1M. In no case more than three (3) welds
shall be permitted on a 10 meter length of pipeline.
  Tie-in Welded joints shall be 100% tested by Radiography testing. UT shall be checked on
pipes which have been cut to an extent of 20mm at the new bevel to ensure it is free from
laminations. X-rays shall be carried out in accordance with the provisions of API 1104.
Radiographic test shall be carried out using X-ray radiation. Gamma rays may also be allowed
in case of inaccessible joint. The new bevel shall be 100% visual and DP tested & report shall
be prepared for all above test. Before any pipe length is cut, the painted Pipe No., Heat No.,
shall be transferred to either side of the pup lengths of the cut pipe. Also recorded and
painted with pipe no. & heat no.

 Where different wall thickness pipe are to be welded and for difference wall thickness, 1:4
taper internal grinding on the higher thickness shall be done.

11. BACKFILLING
METHODOLOGY

Backfilling shall not be done until the pipe and appurtenances have the proper fit and the pipe is
following the ditch profile at the required depth that will provide the required cover and has a bed which
is free of extraneous material and which allows the pipe to rest smoothly and evenly.

Backfilling of trench in water courses shall be carried out as per the relevant specification issued for the
purpose.

Backfilling shall be carried out immediately after the pipeline has been laid in the trench, inspected by
the CLIENT, so as to provide a natural anchorage for the pipeline, thus avoiding long exposure of coating
to high temperature, damaging actions of adverse weather conditions, sliding down of trench sides and
pipe movement in the trench. If immediate filling is not possible, a covering of at least 200mm of earth,
free of rock and hard lumps shall be placed over and around the pipe and coating.
On no account the top soil from the ROW be used for this purpose, In general, the trench shall be dry
during backfilling and deviations there of must have prior approval of the CLIENT.
The backfill material shall contain no extraneous material and/or hard limps of soil which could damage
the pipe/coating or leave voids in the backfilled trench. After the initial backfill has been placed in to the
trench to a level slightly above the surrounding ground, CONTRACTOR shall compact the backfill material.
The crown shall be high enough to prevent the formation of a depression in the soil when backfill has
settled in to its permanent position. Surplus material, including rock, left from this operation shall be
disposed of the satisfaction of land owner or authority having jurisdiction.
Rock, gravel, lumps of hard soil or like materials shall not be backfilled directly onto the pipe unless
'padding' and/or rock shell has been provided as per specification. When "Padding" of this specification is
to be used the following shall be applicable.
Where rock, gravel, lumps of hard soil or like materials are encountered at the time of trench excavation,
sufficient earth, sand or select backfill materials shall be placed around and over the pipe to form a
protective cushion extending at least to a height of 150mm above the top of the pipe.
Select backfill materials for padding that are acceptable to CLIENT shall be soil, sand, clay or other
material containing no gravel, rock or lumps or hard soil. Whether such padding material would be taken
from the adjacent spoil bank or imported from elsewhere shall be directed by CLIENT.
Loose rock may be returned to the trench after the required selected backfill material has been placed,
provided the rock placed in the ditch will not interfere with the use of the land by landowner or tenant.
When the trench has been dug through drive ways or roads, all backfills shall be executed with sand or a
suitable material and shall be thoroughly compacted.
In certain cases, special compaction methods, such as moistening or ramming of the backfill in layers may
be required.
Trenches excavated in dykes which are the property of railways or which are part of main roads shall be
graded and backfilled in their original profile and condition. If necessary, new and/or special backfill
materials shall be supplied and worked-up.
 The trench in irrigated and paddy fields shall be backfilled to within 300 mm of the top then rammed and
further backfilled until the trench is completely backfilled. Surplus material remaining after the operation
shall be' spread over the ROW.

At the end of each day's work, backfilling shall not be more than, 500 meters behind the head end of
lowered-in pipe, which has been padded and approved for backfill.
CONTRACTOR shall furnish materials and install breakers in the trench in steep areas (stopped generally
10% and more) for the purpose of preventing erosion of the backfill.
When backfilling the trenches in sloping terrains or steep areas, the backfill may be washed out of the
trench, sheet piling or other effective water breakers across the trench shall be provided. This is to divert
the flow of water away from the trench into normal drainage followed before laying the line.
CONTRACTOR shall leave the pipe uncovered at certain location to allow survey of the center line of the
pipe and the level of the pipeline in the backfilled trench. Within 48 hours after backfilling, CLIENT shall
have carried out such survey and informed CONTRACTOR of any realigning if required. Thereafter
CONTRACTOR shall compact the backfill.
The maximum allowable deviation from the centre line for land sections as staked out by CLIENT and as
referenced by CONTRACTOR after backfilling is limited to 200 mm.
Backfilling shall be preferably carried out at the highest ambient temperature.
Before backfilling the trench it shall be made sure that all the required work has been completed (CP,
MDPE Pipe Laying, warning mat, mechanical protection etc.) as per specification.
First 300 mm backfilling shall be done by manually / by JCB/ excavator. Once post padding / backfilling is
complete surplus excavated soil should be placed over the trench so as to avoid setting of the earth at
the pipeline trench which may affect proper covering of the pipe.
For existing utilities like underground cable or pipelines, CONTRACTOR shall place protection devices in
accordance with requirements of the public services & authorities.

12. CROSSING (OPEN CUT)

REFERENCES

 Alignment sheets
 API 1104, Latest Edition
 API 1102, Latest Edition
13. METHODOLOGY

Approval from authorities and preparations

Open cut crossings shall be done only with prior permission of CLIENT. The work to be carried out for
crossing shall meet the minimum requirements of API 1102. Prior approval from the statutory
authorities shall be obtained to lay the pipeline.
CONTRACTOR shall submit the following documents to CLIENT for perusal and approval, prior to the
commencement of the works.
 Time schedule for the crossings to be executed.
 Equipment deployment list.
 Manpower deployment list.
 Construction proposed drawing.
 Working methodology.
 Calculation of temporary works.
CONTRACTOR shall make all necessary arrangement (if required) for diversion of traffic by making a
temporary by pass road. The bypass road shall be well compacted for moment of vehicle & proper
lighting shall be provided.
during the night time and suitable warning signs shall be provided.
An initial survey, with the help of relevant authorities, shall be made for the presence of utilities and
service pipelines and cables in the area based on the construction drawings and their approximate
locations clearly marked.
A temporary-crossing layout (sketch) shall be developed showing the positions of various entities and
the diversion plan.
Preparation of pipe string
The pipes string of suitable length and of proper wall thickness, with bends if any at the ends shall be
prepared beforehand the operations. The pipe string shall be welded, NDT performed, joint coating
completed and holiday test done as per the relevant approved procedures.
The pipe string shall be ready in all aspects for lowering.
Equipment and Method
The operation shall use excavators as the equipment. Suitable lifting accessories shall also be used.
Sufficient numbers of the lifting equipment shall be used so that the pipe string is lifted comfortably
not to cause inordinate deflection of the pipe and induce stresses on it.
Excavation and Pipe laying
The open cut operation shall be scheduled during the daytime, if the traffic on the particular road is
thin, giving more weight age to the safety during the operations. The operation may be scheduled
during night if the road is having heavy unavoidable traffic during the daytime. In such case more
attention is to be given to the safety aspects for the working groups as well as the public and
environment.
The alignment of the trench shall be set out from the nearest IP’s/bench marks.
The trenching shall be performed manually, initially, near the location of suspect utilities and service
pipelines and cables. Once they are exposed, the excavation may be continued using the excavators
without damaging the utilities.
Once the trench is completed to meet the requirements of depth and cleanliness, the pipe string will
be lowered slowly into the trench without disturbing the utilities and service lines and cables,
Padding shall be done, where ever applicable as per specification. Pipeline lowering shall be done as
per approved procedure.
The pipe string will be positioned in its desired place, the as built levels and positions recorded.

Minimum cover between existing buried facilities and pipeline shall be 500mm.
Minimum pipe top cover of pipeline shall be maintained as per specification should not less than
normal laying top cover at any point during open cut method in addition to above mechanical
protection(like RCC slab, HDPE sheet) shall be provided if required or as suggested by CLIENT.

Location Minimum cover

a) Industrial, commercial, residential, agricultural rocky and other areas 1.20m
b) Minor water crossings, Nala, Drains/ditches, lined and unlined canals 1.5m
c) Uncased / cased road crossings 1.5m
d) Rail road crossings 1.80m
e) River Crossings 2.0m

Backfill and Restoration

The backfill will soon commence once the as built readings are completed. The backfill material shall
be approved by CLIENT. The backfill material will be filled into the position in layers of 300mm with
ramming for compaction of each layer if required special compaction methods such as moisturizing of
the backfill material shall be done.

The surface of the road will be restored to the original condition as soon as possible. The diversion
and other barricades will be removed and the bypass road will be dismantled and restored back to
the original / near original form.

Minor Watercourse Crossing

 Minor water crossings are crossings of ditches, canals, water courses, rivers, streams etc. whether the
bed contains or not, and not being specified as “Major Water Crossings” in the contract / approved
alignment sheet .

For minor water crossings a standard drawing or a separate detailed approved drawing for individual
crossing shall be applicable, whenever minor water crossings in the ROW are to be crossed,
CONTRACTOR shall install bridges.

In crossings of water courses with either moderate flow rate or of torrential nature with marked and
unpredictable flooding, an adequate survey shall be carried out before starting the work with the
object of determining what precautions are necessary and the most favorable period for executing
the work.

In case of crossings of water courses for which no special methods of laying are required, a pipe
section of a size as per the approved drawings shall be assembled and subsequently laid. Bends shall
be of cold field type.

The depth of the existing bottom of a minor water course crossing shall be determined in relation to
the adjacent ground level by taking the average of four measurements. CONTRACTOR shall take
special care to check with the responsible authorities for special conditions applying to working on,
over, under or through minor water crossings and CONTRACTOR shall comply with any such
conditions.

The minimum cover over the pipe shall be as specified in the relevant approved drawing and job
standard. The pipe section shall be made in such a way that it conforms to the existing or future bed
as indicated in the approved drawings.

Whenever the crossing requires a straight section of pipe between the lower beds coinciding with
riverbed, this section shall be laid at a single horizontal level.

CONTRACTOR shall arrange temporary installation of diversions as may be necessary, to ensure the
effective functioning of these watercourses crossed.

Banks and trenches of minor water crossings shall be backfilled with soil and shall be thoroughly
compacted to prevent soil and bank erosion. Rock, gravel and other hard objects shall not be placed
directly on the pipe. Sufficient earth, sand shall be backfilled initially around and over the pipe to
provide a protective padding.

After the trench has been backfilled and during the cleanup works also, the minor water crossing
shall be cleaned across the whole width of the ROW.

The crossing of any embankments shall be carried out strictly in accordance with approved drawings.

14. CASED CROSSING by HDD MATHOD

Reference:

 API 1102 Steel Pipeline Crossing Railroads and Highways

 ANSI B 31.8 Gas Transmission and Distribution Piping System
 ANSI B 31.4 Liquid Petroleum Transportation Piping System
 Route Maps.
 Alignment Sheets
 Crossing Drawings (IFC) and site Survey reports.

1. Equipments:
  Boring/HDD Machine with accessories
 Excavator/JCB
 Welding DG Sets.
 Hydra
 Dewatering Pump

2. Material:
 Casing Insulator.
 End Seals.
 Vent Pipes.
 Carrier & Casing Pipe

3. Method:

All work will be carried out as per WGEIL Specification, Route Maps, Alignment Sheets, Crossing drawings
(IFC) and site survey reports. Before start of any work, permission to be obtained from authorized
agencies having jurisdiction. Before starting of the work the following documents to be submitted for
individual crossing for approval.

 Time Schedule (Start and End)

 Working Method with Equipment to be deployed.
 Working and Test Procedure.
 Man Power Deployment.
 Detailed Drawing.
 Test certificate of all materials (Casing pipe, Insulators, Stud & Nut, and End Seal Etc.
 Highways, Main Roads, Railways etc. will not be used for loading, unloading or stacking of
material.
 Prior to start of work barricades, temporary bypass and adequate warning signals will be
provided.
 Material, size & wall thickness of the casing pipe will be as per STD & approved drawing.
 All civil and mechanical works related to pipeline Crossings will be done as per CLIENT
 The cover of casing pipe will be checked from the drain of the Road or lowest point of ROW will
be as per CLIENT If statutory requirement for cover is more than specification, the same shall be
followed. The cover for cased Crossing shall be as per given in specification.
 Carrier Pipe section after fabrication and NDT clearance will be pre- tested at 1.4 times of MOP
for a duration of 6 hours for all major crossings like railways, express way, national highways and
line canal as per approved procedure and visually examined for leakages/defects etc, prior to
joint coating.
 During Boring operation the ground water table will be lowered and maintained 0.5m below
bottom of pipeline.
 The described profile, direction lines and level marks must be checked in particular as per site
condition.
 Size of Boring pit will depend on the length of Boring, machine capacity etc. Necessary
precautions according to site condition will be taken to safe guard the stability of the bore pit.
Before placing the boring machine into the pit, necessary compaction has to be laid according to
the site condition. The minimum slope of the casing pipe will be as per CLIENT
 While welding of casing & vent pipes internal high low is not permitted. Root gap will be kept as
narrow, so as to avoid excessive root penetration inside which may damage the insulators while
inserting the carrier pipe. Before welding every single length of pipe will be checked for out of
roundness (OVALITY), dents etc and necessary rectification will be done or defective portion will
be cut out.
Welding of casing and vent/drain pipes need not be radiographed. However, only normal visual
inspection shall be carried out.
 No NDT is required for the casing pipe welding. Only visual check shall be done. Epoxy Primer
apply on casing pipe & check by CLIENT before insertion.
 Before insertion of the carrier pipe, vent and drains will be welded to the casing pipe ends by
direct insertion without any protrusion inside. (Flush to the ID of Casing pipe.)
 If the carrier pipe insertion is not done immediately then the ends of casing pipe will be sealed
suitably to avoid entering of foreign materials inside. Before insertion of carrier pipe inside of
casing pipe will be thoroughly cleaned.
 After pre-hydro test of the carrier pipe section, all the weld joints will be field coated and 100%
Holiday checked before fixing the insulators.
 End seal and Casing insulators will be arranged as per CLIENT Standard drawing and specification.
 While inserting the carrier pipe care will be taken to ensure that carrier pipe is centered in the
casing and that an even push/pulls are applied. The front end of carrier pipe must be equipped
with a slider shoe and drawn by cable through the casing.
 MEGAR test shall be conducted and recorded before Tie- In and back- fill to ensure the electrical
resistance between carrier and casing pipes & carrier and soil which will be at least 1Mega Ohms.
(106 Ohm)
 After mechanical completion of cased crossing, backfilling work will be performed.
 Casing pipe will be 14”Φ and shall be installed by boring/ jacking/HDD/Moiling or specified by
concerned authorities. Casing pipe will be extended minimum 600mm beyond the width of ROU
of the crossing or 900mm beyond the bottom of the drainage ditch on the either side, whichever
is greater. During Boring 1:250 slope shall be maintained. Before installation of the boring
machine over the rails, slope of rails will be checked and offered for inspection.
 The bottom of the trench will be graded and backfilled with clean sand or approved material for
minimum 12m at the approach to each end of casing.
 Compaction will be carried out to at least 95% proctor density to be achieved to ensure
continuous support to the pipeline.
 A no objection certificate from concerned authorities shall be submitted by CONTRACTOR for
review of CLIENT.
 Warning marker will be installed on casing crossing as per specification.
 A sketch showing position & levels of carrier and casing pipe will be submitted by CONTRACTOR
for review and approval of CLIENT with placement of insulator.
 After completion of both side tie-in welding NDT, CONTRACTOR shall be installed end seal and
bentonite filling as per CLIENT

15. PRE- HYDRO STATIC TEST

Applicable Codes & Specification

 CLIENTNo. 11-0299-02-07-02-019(Rev-00)
 ASME B 31.8 Gas Transmissions and Distribution Piping Systems.
 API RP 1110 Pressure Testing of Liquid Petroleum Pipelines.
 ASME Sec. VIII Boiler & Pressure Vessels Code. Div.1

Method

 Water filling and pressurization

 All weld joints in test loop/section shall be radio graphically cleared and accepted before
water filling.
 Water Test Certificate of water used for filling shall be submitted to CLIENT.
 Clean, not salty, with PH 6 to 8 and non corrosive water shall be used for test. Water tank
shall be deployed for filling operations in view of smaller length of strings.
 Main and rear headers shall have provision for water filling, pressurization, venting,
drainage and installation of pressure gauges.
 The strings shall be filled in full and ensured that there is no air entrapment. For all bolted
fittings spiral wound gasket shall be used.
 Only calibrated pressure gauges and temperature gauges shall be used.
 Pressurization shall be done in the presence of the CLIENT at a moderate and constant rate
not exceeding 2 bar/min and pressurize up to the final test pressure as per CLIENT
  Pressure shall be applied by means of a suitable test pump, which shall not be
connected to a system until ready to test. In bringing the system up to the test
pressure. An authorize operator shall attend to the pump constantly, during the test.
The pressure shall be allowed to stabilize for a period of 15 min after attainment of
test pressure during which pressure shall be established i.e. checked and test pump
shall be disconnected the test section shall be completely isolated and all connections
shall be checked for leakage. The test pressure ‘hold period ‘shall be 4 hours. Test
section shall be visually examined for leaks/defects etc.
 Pressurize to test pressure i.e. 75 Kg/cm2
 Pressure gauge of suitable pressure range (1.5 x pressures to be measured) and
accuracy.
 One laboratory thermometers 00C to 600C range accuracy ± 0.1 degrees.

During the test, care shall be taken that the hydrostatic test pressure never exceeds 119 Kg/cm2.
Water shall be bleed off, if required.

 Acceptance:

Hydrostatic test shall be considered as positive if no abrupt drop in the pressure is observed through
the test duration, except for a change due to temperature effects as per the applicable specifications.
It should also be observed that there is no evidence of sweating before, during and after the ‘hold
period’ on all the weld joints.

 Termination:

After recording the results, test shall be terminated with the consent of the CLIENT, and the loop shall
be depressurized.
The line and equipment shall be completely drained by suitable means after completion of
hydrostatic test of the system. Vent shall be opened before draining the section. Subsequently, de-
watering operation shall be carried out. Water shall be disposed off at suitable location with the
approval of the CLIENT.

Precautions during Hydro Test

Before start of work CONTRACTOR shall take safety clearance from CLIENT.
The testing team shall not leave the premises until the pipe section is de pressurized after the test.
All personnel working on hydrostatic testing shall be appraising of the possible dangers connected
with high pressure air and water. Local authorities shall be advised as to the timings of test period and
relevant phone numbers used in emergency.
The Test Engineer shall be nominated, who shall be responsible to ensure that all personnel working
on hydro-test are fully aware of their individual responsibilities.
Provision shall be made for the installation of no admittance signs to unauthorized personnel from
the roads of the ROW.
Signs stating “PIPE UNDER TEST- KEEP AWAY” with local language, translations shall be placed where
the pipeline is uncovered, and particularly where the provisional traps, all valves and flange
connections and stations are located. Such areas shall be suitably fenced in such a way as to prevent
access of unauthorized personnel.
Provisional scrapper traps shall be installed in compliance with methods and locations so that any
rupture cannot cause any injuries to the personnel and third parties.

16. POST HYDRO STATIC TEST

Reference

 ASME : B 31.8 Gas Transmission and Distribution piping system

 ASME: B 31.4 Pipeline transportation systems for liquid hydrocarbons and other liquids.
  API 5L
 ASME SEC VIII DIV. 1 Rules for Construction of pressure vessels
 API-1110 Pressure testing of liquid petroleum
Methodology

 Hydrostatic test shall be performed on the entire length of the pipeline. Hydrostatic test shall be
performed In accordance with approved Hydrostatic Test diagrams for each test section. The
maximum length of each test section shall not exceed 25 km.
 All buried steel pipelines shall be pressure tested after installation using water as a test medium
minimum test pressure shall be equal to 1.4 times Maximum Allowable Operating Pressure.
 Before start of Hydro test activities, PART-A + PART-B of pipe book shall be cleared by
CONTRACTOR and approved by CLIENT and CONTRACTOR shall give the details of estimated
amount of test water, water source, result of test sample shall be as per CONTRACTOR‘s
procedure approved by CLIENT Hydro-testing of mainline shall exclude SV, valves at tap off
stations, terminals etc. Temporary test header shall be provided and the mainline shall be
hydrostatically tested between the temporary test headers only.
 Before start up hydro test, test plan with elevation sketches & mechanical clearance certificate
shall be submitted for approval to CLIENT concern authority.
 Hydrostatic test shall be performed on the entire length of pipe line in accordance with approved
hydrostatic test diagrams for test sections.
 Hydro test section length shall be decided based on :-
Geographical profile (elevations) of the pipe line so that the highest point of the test section shall
be subjected to the minimum test pressure specified below and the maximum test pressure shall
not be higher than the test pressure of the pipes in the factory corresponding to 95% of SMYS of
pipe material based on the min. wall thickness in the test section.
 Location of stations.
 Other site conditions.
 HT section shall be 25000m (approximate), if the section length is to be increased then prior
approval must be taken from CLIENT.
 Test duration shall be minimum 24 hrs (24 hours for strength test and 24 hours for leak test) after
stabilization and the test pressure shall be as indicated in the approved hydrostatic test diagram.
 Test pressure shall be as follows.

Type of Test & Holding Minimum Test Maximum Test

Pipe line Size (min) Remarks
time Pressure in Kg/cm2 Pressure in Kg/cm2

6” OD x 6.4mm thk Strength test and (1.5 x MOP or Design 499.17 MOP = 49
(API 5L Gr. X52) strength test (24 Hrs) Pressure) (95 % of SMYS) Kg/cm2
Total 24 hours 73.5 (P=2ST/D)
Kg/cm2
=75 Kg/cm2

 Design pressure shall be as per TEPL design data

 Subsequent to separate hydro-testing of pipeline and facilities, tie in/hook up shall be carried out
by CONTRACTOR.
Pipes/pre fabricated assembly used for such tie in shall be pre tested to a test pressure specified
for the pipeline.

1.0 Equipment’s & Instruments :

The CONTRACTOR shall furnish all necessary equipment for performing the work as stated in cleaning,
flushing, filling, leveling, stabilizing, testing and dewatering procedures. This shall include the
following:
A. Hydro testing cabin with air-condition
B. Pigs for filling, cleaning including
 Cleaning pigs shall be a Foam Pig of high & low density pigs.
The CONTRACTOR shall provide sufficient number of pigs including spares.
C. Fill Pumps:
The CONTRACTOR shall determine the type and number of fill pumps in order to guarantee the
following.
A. Differential heads 20% greater than the maximum required.
B. Flow rate min 40 m3 per hour & max 60 m3 per hour.
C. Portable tanks during filling should be of sufficient size to provide continuous water supply to
pressurizing pump.
D. Variable speed positive displacement pumps equipped with a stroke counter to pressurize the
line with a known stroke and capable of exceeding the maximum test pressure by at least 20 bar.
E. Flow meter (2” turbine type) to measure the volume of water used for filling with calibration
certificate.(Not older than six months)
F. Injection facilities (dosing pump) to inject anti corrosion additives in to the test medium in the
required proportion.
G. Digital pressure gauge with suitable pressure range (1.5 x Pressure to be measured) with an
accuracy of ± 0.1% of full –scale value. The pressure gauge shall be installed at both end of the
test section.
H. Dead weight tester with the accuracy of 0.01 bar measuring in increments and sensitivity of 0.05
bar shall be provided with a calibration certificate no older than within one month duration.
I. Pressure recorder (0 – 250 Kg/cm2) with sufficient charts for recording up to 24 hours and ink
gauges tested with dead weight tester prior to use. These shall be installed at the test heads.
J. Pressure recording charts.
K. Two Temperature recorders for fill water with an accuracy of ± 1% of full scale range shall be 0 to
60º C and the sensitivity shall be 0.1º. The temperature shall be recorded throughout filling stage.
L. Recording thermometer accuracy shall be ±0.1°C (Duly Calibrated). The scale range should be 0 to
60°C. Environmental temperature recorder accuracy shall be 0.1°. The scale range should be 0 to
60°C.
M. Two laboratory thermometers of 0 to 60ºC range, with an accuracy of ±0.1ºC to be used in
thermowells.
N. Thermocouples for measuring pipe wall temperature with an accuracy of ±0.2%.
O. Means to measure the volume of water necessary to drop the line pressure by 0.5 bar (container
on scale or graduated cylinder)
P. Communication equipment suitable for continuous connection between the beginning and the
end of the test section and with the inspection team along the line in accordance with the
requirements of local authorities.
Q. The temporary scrapper traps shall be installed according to the testing sections fixed in the test
procedure manual. Proper piping manifolds and valve arrangements shall be available to allow
for launching and receiving of each pig independently.
The test headers shall have sufficient length to accommodate the required number of pigs.
R. Thermocouples for measuring the temperature of the pipe wall shall be installed on the pipeline
to be tested,
1 thermocouple at about 500m distance from the pumping head and receiving head.
1 thermocouple at up to 2500m of the pipe the spacing depending on the terrain and nature of
sub-soil along the alignment of section.
1 thermocouple at about 500m distance from the terminal head.

2.0 Procedure:

2.1 Equipment and/or parts which need not or must not be subjected to the test pressure must
be disconnected or separated from the pipeline to be tested.
2.2 If the difference of minimum and maximum atmosphere temperature should cause thermal
instability on the pipe section directly exposed to atmospheric condition, the scraper traps
and above ground pipeline shall be properly protected.
2.3 The test medium shall be soft non-aggressive water. The water to be used shall be filtered,
shall not be contaminated, and free from sand or silt. CONTRACTOR shall submit laboratory
test reports of water used for testing. CONTRACTOR shall furnish and install all temporary
 piping which may be necessary to connect from source of water to its pumps and
manifolds/tankage.
2.4 Before filling operation the CONTRACTOR shall clean the pipeline by air driven foam pigs to
remove all mill scale rust sand from the inside of pipe section. For this purpose temporary
header for air cleaning shall be attached to the pipeline. The number of pig runs is depending
upon the cleaning results and shall be determined by the CLIENT at site.
After completion of cleaning gauge plate (size of 95% of nominal internal dia of the heavy
wall thickness pipe) shall be passed through the section to check the possibility of out of
roundness along the pipeline.
After receiving the gauge plate it shall be presented to the owner`s representative for
approval.
After acceptance of cleaning operation, air header shall be cut and removed protested test
headers loaded with three numbers of foam pigs shall be welded to test Section. Un-
inhibited water equal to 10% of the volume of test section shall be introduced in front of the
first pig. The first pig shall be launched by introducing about 10% of pipeline length un-
inhibited water. Then the second pig shall be launched by pumping the inhibited water till
the second pig is received at the other end. The thermal stabilization and pressurization can
now the started.

3.0 Thermal stabilization

After a check has been made to confirm if the pressure has attained at least 1 bar on the highest
section, the thermal stabilization can be started.

Thermal equilibrium between the pipeline and environment shall be checked through the
thermocouples installed on the pipeline. Thermocouples shall be attached to mainline pipe by
ensuring proper contact. Pipe coating and the pipe surface shall be thoroughly cleaned with wire
brush and rough sand papers.

Temperature reading shall be made at 4 hours-intervals. Thermal stabilization shall be achieved

when a difference not higher than 1c is attained between the average values of the last two
successive readings. Thermal stabilization completion shall be approved by CLIENT.

4.0 Pressurization

The pressurization shall be performed in the presence of CLIENT at a moderate and constant rate. The rate
shall not exceed 2 BAR/min during pressure cycling. One pressure gauge and pressure recorder shall be
installed in parallel with the dead weight tester. Dead weight tester shall be monitored in a controlled
atmosphere test cabin. Volume of Water required to be added to reach the test pressure shall be
calculated periodically. The DWT pressure readings shall be recorded periodically throughout the
pressurization as follows:

 Each 5 bar increments up to 80 % of test pressure as recorded by the dead weight tester.
 Each 2 bar increment between 80 % to 90% of test pressure as recorded by the dead weight
tester
 Each 0.2 bar increments between 90% of the test pressure to full test pressure as recorded
by the dead weight tester.
The pressurizing shall be cycled according to the following sequence
 Pressurize to 50% of test pressure, hold pressure for 1 hour collect water and carry out air
Volume calculation.
 Drop pressure to static head of test section at test head.
 Pressurize to 75% of test pressure, hold pressure for 1 hour and carry out air volume
calculation.
 Drop pressure to static head of test section at the test head.
 Pressurize to 100% test pressure and carry out air volume calculation.
The pressurization to each test pressure as above i.e. 50%, 75% and 100%, two tests shall be
 carried out for the calculation of air volume in the pipeline under test.

In case, during the hold pressure periods indicated above, a decrease in pressure is observed, the
above operation shall not be repeated more than twice, after which the line shall not be
considered capable of test, until CONTRACTOR has isolated and eliminated the cause for pressure
drop.
5.0 Air volume calculation

In order to check the presence of air in the pipeline, two separate consecutive pressures lowering of 0.5
bar shall be carried out by slowly bleeding water from the test section after each pressurization as
mentioned above. Calculation of air in the pipeline the second pressure lowering shall be used, and the
relevant drained water shall be accurately measured (VA). This amount measured shall be compared to
the theoretical amount (VT) corresponding to the pressure lowering that has been carried out, by using
the procedure obtained in specification.
If no air is present in the length under test:

VA/VT = 1

In order that the above ratio is acceptable, it shall not differ from 1 by more than 6 % (i. e.1.02+)

VA/VT < = 1.02

If the air found in the pipeline is within the above established tolerance, then the pressurizing can
continue. If the ratio VA/VT exceeds 1.06, Then test shall be repeated as per the above procedure until
above estimated tolerances are satisfied. The pressurizing can then be continued to reach the test
pressure.

The theoretical amount of water that is necessary for pressurization of the section shall be calculated by
means of the following formula:

Vp = (0.884 x ri/ti + A) x 10-6 x Vt x ∆P x K.

Where
Vp = Compound water amount required to raise by P the pressure in the section to be tested (m3) or
amount to reach the test pressure (m3).
Vt = Geometrical volume of the section including the pipe traps (m3)
∆P = pressure change (bar)
ri = Average nominal inner radius of the pipe (mm)
ti = Average nominal pipe thickness(mm)
A = Isothermal compressibility value for water at the pressurization temperature in the P range (bar-1)

K = A dimensional coefficient that is equal to a value of 1.02 for longitudinally welded pipe.

ri = (r1 x l1 + r2 x l2 +………………….+ rn x ln)/(l1 + l2 +…………+ ln)

ti = (t1 xl1 + t2 x l2 +………………….+ tn x ln)/(l1 + l2 +…………+ ln)

Where rn = Nominal internal radius of the definitive segment (mm)

tn = nominal pipe thickness of the definitive segment (mm)

ln = length of the definitive segment (mm)

6.0 TESTING :
STRENGTH TEST & LEAK TEST
After the section has been pressurized and the air volume test has given acceptable results the test
pressure shall be held for minimum 48 hours (24 hours for strength test and 24 hours for leak test) after
thermal stabilization for 24 hours. After temperature and pressure has stabilized, the injection pump shall
be disconnected and all connections at the test heads shall be checked for leakages. The pressure
recorders shall then be started with the charts in a real time orientation for continuous recording
throughout the test. No further pumping is permitted during the test period.
During testing all ball valves in position shall be in partially OPEN condition.
During the testing period the following measurements shall be recorded / reported.
 Every one hour ambient temp shall be recorded continuously.
 Every one hour pressure measurement from dead weight testers
 Every two hours the soil temperature and the pipe temperature at the thermocouples

All data shall be recorded on appropriate forms attached with this procedure. Care shall be taken that the
maximum test pressure is not exceeded. If the water temperature increases resulting in increased test
pressure above, maximum test pressure limits then Bleeding of water shall be done to bring the test
pressure within limits. Bleed-off water shall be accurately measured and recorded.

When a pressure drop is noticed during hold period the pressured shall be lowered down to the operating
pressure and the leak shall be searched for as detailed below.

a. Visual observation (Walk over survey)

b. Sub dividing the section & retest till the leak is detected.
c. By any other suitable method

7.0 ACCEPTANCE OF TEST:

The hydrostatic test shall be considered as passed if pressure has kept a constant value through out
the test duration, except for change due to temperature effects. Such changes shall be evaluated as
described under

After the completion of the test periods the collected data shall be used to evaluate the Hydro test.

The pressure change due to water temperature change shall be calculated through the following
formula.

∆P = B x ∆T/(0.884 * (ri/ti) +A)

Where
∆P = Pressure change resulting from temperature change (bar)

∆T = algebraic difference between water temperature at the beginning of the test and water
temperature as measured at the end of the test (ºC)

B = value of the difference between the thermal expansion of water at the pressure and
temperature as measured at the end of test and that of steel (0°C-1) x 10-6

A = Isothermal compressibility value of water as estimated at the pressure and temperature values
obtained at the end of the test (bar –1) x 106

ri = average nominal inner radius of the pipe (mm)

ti = average nominal pipe thickness (mm)

The pressure change value as a function of temperature change shall be algebraically added to the pressure
value as read on the meters. The pressure value thus adjusted shall be compared with initial value and the
test shall be considered as acceptable if unaccountable pressure loss is less than or equal to 0.19 bar. In
case of doubt the testing period shall be extended by 24 hours.
If test section fails to maintain the specified test pressure after isolation, CONTRACTOR shall determine by
search the location of leakage of failure. All leaks and failures with in the pipe wall or weld seam shall be
repaired by replacement of entire joints or joints in which leakage or failure occurs. In those cases, where
leaks occur in circumferential welds the method of repair shall be determined by the CLIENT. CONTRACTOR
shall comply with instruction of CLIENT whether to replace the section of the line pipe that includes the line
leak of whether to repair the circumferential weld. This repair shall be done as per approved procedures.
Where failure occurs in the pipeline bends, the same shall be replaced with a new bend of same degree.
After completion of repairs, the hydrostatic test shall be repeated in full as per the specification.

8.0 TERMINATION:

After the positive results of testing and all the data have been gathered, the test shall be terminated upon
written approval given by CLIENT.

9.0 DEPRESSURIZING & DEWATERING:

The pipeline shall be slowly depressurized at a maximum rate of 2.0 bars per minute. Necessary
arrangement shall be made by CONTRACTOR for safe disposal of hydro-test water by making suitable
drains.

a. Dewatering of test section shall be started after obtaining permission from CLIENT.

Dewatering shall be carried out by using foam (HD & LD) pigs driven by compressed air.

Pigs and equipments required for dewatering the line shall be furnished arrange. High density foam
pig first to be passed through the line to displace the water then low density foam pig shall be
passed in order to complete the line dewatering. CONTRACTOR shall use required number of foam
pigs for this purpose. The line shall be considered dewatered when a negligible amount of water is
flushed out by the last foam pig and approval is given by CLIENT.

b. During dewatering, care shall be taken to properly dispose and discharge of Water in order to
avoid pollution, damages to field of cultivation and/or existing structures and interference with
the traffic.

c. Upon completion of testing and dewatering operation, any provisional trap for pigs and all other
temporary installations relating to the test shall be removed. Subsequently, the individual section
of the line already tested shall be joined in accordance with the requirement of relevant
specification issued for the purpose.

d. Thermocouples shall be removed and coating shall be repaired and holiday to be checked
accordingly.

10.0 FINAL TEST DOCUMENTS

The complete report signed by CONTRACTOR/CLIENT shall be submitted upon completion of hydrostatic
test for each test section.

This report shall contain as minimum.

 The cleaning, flushing, filling and testing procedures used.

 The schematic layout of cleaning, filling and testing facilities.
 Instrument calibration certificates
 A profile of the pipeline that shows the test site, all instruments and injection connections by
filling logs and records.
 Additive specification required concentration and additive injection record.
  Pig Specifications
 Pig inspection record including photographs of the damages
 Pipe water filling logs & records.
 Pressurization and stabilization record.
 Pressure and temperature recording charts with appropriate information’s inscribed there
on.
 Temperature data along the pipeline
 Dead Weight tester logs and recordings
 Air volume calculations
 Pressure change due to temperature change calculation.
 Depressurization logs and records.
 Dewatering procedure and schematic layout of relevant facilities.
 Dewatering logs and records.
 Records and photographs of all leaks if any.

17. SWABBING
METHOD:

The swabbing operation is meant to reduce the remaining water in the pipeline into touch dry condition.
Swabbing operation shall be carried out to ensure that there is no free water left inside the pipeline. This
is done by driving number of swabbing pigs so that the weight increase in low density pig before and after
the swabbing operation is not more than 25%.

 Following steps shall be taken for Swabbing/drying,

Schematic Drawing of swabbing operation will be submitted before start of work.
 High and Low density foam pigs shall be propelled with compressed / dry air for removal of
Residual water for swabbing operation.
 For checking the contents of water, each pig shall be weighed before launching and after
receiving and recorded.
 The difference in weight of receiving foam pig shall not be more than 25% of initial weight of
same foam pig to ensure that there is no physical water in line. If more than one foam pig is
launched at same time then at least one of the received low density pigs shall qualify the weight
criteria for satisfactory swabbing.
 During the above operation log of pigging shall be maintained at site.
 CONTRACTOR shall provide communication facility at both launching and receiving ends.

Acceptance Criteria

The Contractor shall ensure that the swabbing operation is considered to be completed when it is
established that there is no free water left in the pipeline and tile pipeline has achieved a touch dry
condition. This shall be subject to CLIENTapproval/acceptance.

18. DRYING
METHOD:

Super Dry Air Method:

A schematic drawing to be submitted before start the job.

 Draying operation shall be carried out after successful completion of swabbing.
 Drying of the pipeline is done -40ºC dew point temperatures at inlet by air compressor to absorb
residual water content moisture present in the pipeline.
 The air drying operation shall be carried out continuously by blowing compressed dry air which shall
be of free from oil, dust, moisture etc.
  The air drying operation shall be carried out continuously by blowing compressed dry air at -40º C
(inlet) dew point temperature until a constant dew point of -8º C is measured at outlet (at
venting).
 Dew point reading shall be checked at both ends at every 4 hrs. Interval by using digital dew point
meter.
 The pipeline is considered as dry if several consecutive reading of dew point is found constant
after 24 hours achieved a dew point of -8º C.
 Drying operation shall be carried out until complete satisfaction of TPIA / CLIENT.
 End of section shall be shield immediately after the acceptance of drying.

Methodology for Shield Dry:

The pipeline section to be cleaned and dried is to be sealed at the ends by means of welded testing
pig traps. These end station are equipped with instruments for permanent measurement of the
temperature, pressure and dew point. After Dewatering, foam pigs shall be run through the pipeline
many times as necessary until internal surface is free of dirt, such as welding slags, rust, oil and dust
practical`s.

Section shall be kept under positive pressure (0.2 bars minimum) after acceptance of drying till
commissioning.

19. HORIZONTAL DIRECTIONAL DRILLING

Reference:
Reference has been made in this specification to the latest edition/revision of the following codes,
standards and specification.
a) ANSI B 31.8 Gas Transmission and Distribution Piping System
b) ANSI B 31.4 Liquid Petroleum Transportation Piping System
c) API RP 1102 Steel Pipeline Crossing Railroads and Highways
d) Part 192 Title 49 Transportation of Natural and other Gas by Pipeline
(US Department of Transportation - Pipeline Safety Standards)
e) Part 195 Transportation of Liquids by Pipeline
(US Department of Transportation - Pipeline Safety Standards).
f) OISD 141 Design Construction Requirements for Cross Country
Hydrocarbon Pipelines
Equipments:
 HDD Machine
 Excavator/JCB
 Welding DG Sets.
 Hydra
 Dewatering Pump
 Compressor
 Foam Pig
DESIGN & ENGINEERING

The minimum requirement of limits of each river crossing shall be as defined in the preliminary
drawings furnished by OWNER.CONTRACTOR may change the limits slightly to suit his requirement
and installation technique, with prior written approval from OWNER and authorities having
jurisdiction.

Within the entire limits of crasser, as defined in the CONTRACT drawings, the cover to top of
corrosion coated pipe shall be at least 2.5 Meters below the "specified" minimum scour level profile
for the river with normal soil below river bed, and at least 1.5 meters below the "specified" minimum
 scour level per stile for the river with rock sub-strata. CONTRACTOR shall establish the scour depths in
consultation with authorities having jurisdiction and the same shall be approved by the OWNER.

The entry and exit points of the pipeline at ground level shall not come within the limits of crossing as
defined for individual over crossings.
CONTRACTOR shall carry out calculations for determining the maximum permissible overburden on
pipe, to check that the empty pipeline is safe from collapse at any point along the drilled crossing
section.
CONTRACTOR shall submit the detailed calculations for stress analysis, overburden calculations,
coating stresses etc. to OWNER for approval

STRESS ANALYSIS

CONTRACTOR shall determine the minimum allowable elastic bend radius for pipe from the following
considerations.
Pipeline Maximum Longitudinal Stress During Installation.

Total maximum equivalent stress in the pipeline due to tension, bending and overburden pressure
down hole at any location shall not exceed 90% of the SMYS of the pipe material’s yield strength.

CONTRACTOR shall, in order to check this requirement, evaluate the maximum tension forces to
which the pipeline is subjected at any phase of its installation during the pulling operation.
Pipeline Maximum Equivalent Stress during service shall he governed by the requirements of ANSI B
31.8/OISD 141 as applicable.

After installation, the pipeline shall be hydrostatically tested to a pressure of 1.4 times design
pressure in accordance with Specification for Hydrostatic Testing.

According to OISD 141 -the total of the following shall not exceed the SMYS of the pipe material.

 The combined stress due to expansion

 The longitudinal pressure stress

 The longitudinal bending stress due to external loads.

in addition to the above, the sum of (b) and (c) shall not exceed 75% of SMYS

The minimum allowable radius of curvature for the pipeline shall be 1000 times the outside diameter
of the pipeline.

PIPELINE CONFIGURATION ALONG THE SUPPORT STRING BEFORE ENTRY POINT

For each crossing, CONTRACTOR shall determine the required pipeline configuration in order to allow
smooth pull in the crossing entry point and admissible stress in the supported pipeline string. Pipeline
combined stress shall not exceed 90% of the specified minimum yield strength for line pipe material.

CONTRACTOR shall furnish all calculations and specify the number of required supports, description of
the supports, their coordinates and capacity in metric ton. CONTRACTOR shall also furnish a drawing
of the launching ramp indicating the pipeline configuration.

The distance between each roller shall also be specified.

CONRACTOR shall, based on results of design and engineering carried out by him, prepare
construction drawings for each river crossing and shall submit the same for OWNER approval,
Construction drawings shall indicate the pipeline profile with levels furnished at sufficient intervals.
Details such as, entry and exit points and angles, radius of curvature, etc. shall also be indicated.
 CONTRACTOR shall also calculate the total length of pipeline required as well as the maximum tension
required on the pull head of the rig.

All construction works shall be carried out in accordance with the construction drawings, approved by
OWNER.

Before commencement of any installation works, CONTRACTOR shall furnish for OWNER Approval
all design calculations as specified above.

CONSTRUCTION

The method of CONSTRUCTTON shall comply with all the conditions and requirement issued by
Authorities having jurisdiction in the area where the work is to be performed.

If no public road exists, CONTRACTOR shall arrange for access to his work area at no extra cost to
OWNER.

CONTRACTOR shall carry out geo-technical and hydrographical survey and the same shall be
submitted to OWNER for review and approval.

INSTALLATION PROCEDURE

CONTRACTOR shall, before commencing any work at site, submit for OWNER approval a detailed
installation procedure for each river crossing:

The installation procedure as a minimum shall include the following:

a. Project Manpower deployment at site and co-ordination office.

b. Time schedule for construction.

c. Details of equipment: CONTRACTOR shall furnish the complete list of all equipment to be deployed
for preparation of pipe string and installation of crossing including technical characteristics and
capacity of each equipment, instrumentation, monitoring and control equipment.

d. Preparation of fabrication yard and launching areas.

e. Pipeline string preparation (hauling stringing, welding, etc.).

f. Pre- hydrostatic test procedure.

g. Method of installation covering all stages of construction, viz. Rig up, Pilot Hole, Back- reaming,
Pulling. Rig Down, Back filling, etc.

h. Calculations for maximum pulling force on the rig.

i. Hole Collapse & Pipe Buckling Calculation

j. Cold field bending and tie-in details.

The time schedule shall be in accordance with overall time schedule for the project. Approval by
OWNER of the methods used by CONTRACTOR shall in no way relieve CONTRACTOR from the sole
responsibility for safe and satisfactory installation of the crossing,

R.O.W. PREPARATION
CONTRACTOR shall arrange additional land required for pipeline string preparation, rig set-up and
launching operations. CONTRACTOR shall clear and grade the length of ROW required for installation
of the land portion and drilled river-crossing portion. CONTRACTOR shall do such grading on ROW as
necessary and properly to perform the pipeline construction operations, to provide access to the
pipeline construction and to ensure safe construction of pipeline.

CONTRACTOR shall ensure that his construction activities shall not cause inconvenience to public nor
shall there be any undue interference with the normal use of the land and watercourses.

HANDLING, HAULING, STORING AND STRINGING OF PIPES AND OTHER MATERIALS

CONTRACTOR shall be fully responsible for arranging and paying for storage areas. CONTRACTOR shall
load, unload, transport and stock-pile the coated pipes using approved suitable means and in a
manner to avoid damage to the pipe and coating. Transportation and handling of coated pipes shall
also comply with requirements of API RP 5L-1.

PIPE STRING

Complete pipe string shall he pre pared as a single string for pulling:

LINING-UP, WELDING & FIELD JOINT COMPLETION

The lining-up, welding and field joint coating completion shall be in accordance with CLIENT
Specification
INSTALLATION

Installation shall be taken in accordance with approved installation procedures.

The lateral offset of the actual exit point of the pilot hole from the calculated and theoretical exit
point shall not exceed +/- 0.5% of the length of the crossing, however the actual exit point shall not
come outside the ROU limits of the pipeline.

The length tolerance shall not exceed +/- 0.5% of the crossing length, subject to the condition that the
actual exit point shall he within the limits of crossing as defined in the approved drawings.

Back reaming shall be done separately from the pipeline pulling operation. The size of the back-
reamed hole shall be adequate (approximately 1.5 times the pipeline diameter) to allow enough
clearance for smooth pull-back of the pipeline.

CONTRACTOR shall be responsible for maintaining the drilled hole till such time the pipeline is pulled
in.

During pulling operation, the buoyancy of the pipeline shall be controlled by suitable approved
methods so as to maintain the buoyancy as close as possible to zero during pull-back in order to
reduce friction forces of the pipeline in the hole.

Bentonite slurry of specified viscosity shall be pumped into the hole, preventing the wall from
collapsing and protecting the pipeline coating.

CONTRACTOR shall provide suitable facilities to OWNER personnel to witness all stages of
construction.

CONTRACTOR shall be responsible for the integrity of the corrosion coating and shall apply necessary
approved protective coatings.

Coating inspection of the pipeline after completion of pulling operation shall be made by:
 a) Pulling the pipe to the extent possible with normal rig set tip at the exit point;

b) Excavating the adjacent portion tip to and including the first held joint.

The pipeline and joint coating shall be examined visually and with holiday detectors for defect. The length
to be inspected shall, as a minimum, be one pipe length and one joint coating. In case damages/holidays
are detected in the first pipe length/joint, the subsequent pipe length /joint shall be exposed and coating
integrity checks shall be made. If found acceptable by OWNER, the first pipe length/joint shall be repaired
and/or replaced as directed by OWNER. If the coating of second pipe length/ joint is also found damaged,
CONTRACTOR shall propose further course of action and OWNER instructions shall be followed. All such
works shall be done at no extra cost to OWNER.

Before final hydrostatic testing, CONTRACTOR shall prove the diameter of the pipeline by passing a
gauging (caliper) pig through the pipeline. The gauging pig shall have a diameter equal to 95% of the
nominal internal diameter or the pipe. CONTRACTOR shall supply and install all temporary scraper
launchers/ receivers and other equipment, piping and materials and consumables for the purpose.

CONTRACTOR shall obtain plans and full details of all existing and planned underground services from the
relevant Local Authorities and shall be responsible for location and protection of the same. CONTRACTOR
shall execute the work at the crossings as per guidelines of the authorities having jurisdiction and to the
satisfaction of the OWNER.

After pulling the pipeline across the drilled crossing, CONTRACTOR shall cut the extended portion of the
pipeline at the entry and exit points. Thereafter, the drilled portion of the pipeline shall be cut at suitable
location/depth and extended on either bank by installing a cold field bend with minimum bend radius as
specified in the relevant specification and a straight pipe length of 12m, such that at the ends the top of
the pipeline is minimum 1.2m below the natural ground level.

HYDROSTATIC TESTING

Pre- testing
CONTRACTOR shall hydrostatically pre-test the complete pipe string of each river crossing before installation
as per approved procedure.

The section of the pipeline corresponding to the river crossing shall, before installation, be subjected to
pre-hydrostatic at 1.5 times of design pressure of pipe as specified in this specification. After the temperature
has been stabilized, the pressure shall be maintained in the pipeline for at least 4 hours and recorded. During
the test, CONTRACTOR shall check all welds for leakage. Failure, if any, during the test shall be rectified by the
CONTRACTOR to the satisfaction of OWNER at no extra cost. The method adopted for pre-hydro testing shall
be in accordance with specification no.11-0299-02-07-02-019.

Post hydro testing for as per approved procedure and JPK Spec.

De watering-Cleaning

Once the tests have been declared satisfactory, the pipeline shall be de watered and properly cleaned and
dried

FINAL CLEAN UP

After completion of construction, CONTRACTOR shall clear the sites of all balance material and debris to the
satisfaction of OWNER and authorities having jurisdiction.
The ground occupied during the work shall be reinstated to its original condition as quickly as possible after
the completion of works.

CONTRACTOR shall take due care in disposing off inhibitor added water so that it doesn't cause any adverse
affect on the surrounding environment.
MARKINGS

The location of the pipe shall be clearly marked by suitable means: conventional yellow markers, overhead
markers, sign etc.

DOCUMENTATION

In addition to the documents specified elsewhere in this specification, CONTRACTOR shall submit to the
OWNER six copies each of the following documents/records.

DURING THE COURSE OF EXECUTION OF THE CROSSING

CONTRACTOR shall generate/compile the following data. It shall be obligatory on part of the
CONTRACTOR to furnish this data to OWNER in the event it is required for.

Detailed drilling log and down hole data, including, but not limited to, the following:

a) Torque and pulling/pushing force

b) Data on drilling fluid consisting of the following:

i. Density
ii. Type of mud and additive employed
iii. Mixing, pumping and cleaning

 Wash and drill pipe data, viz.

a) Dimension and material properties,

b) Data on APT classification,

c) Type of inspection previously carried out on these pipes.

 Topics of the permits obtained from authorities having jurisdiction for the various works.
 Detail profile of the drilled hole along with the water level variations.
 Records of hydrostatic pre-testing and final testing
 Record of Non Destructive Testing of welds.
 Clearance certificates from the land OWNER authorities having jurisdiction regarding satisfactory
clean-up and restoration of pipeline ROU and work areas.
 Test certificate of all calibrated items.

After completion of construction, contractor shall prepare and furnish six sets of copies and two sets of
reproducible of As-Built drawings for the crossings. As built drawings shall, as a minimum include the following
information:

 True profile of the river bed and banks along the pipeline;
 True profile of the pipeline as installed;
 Depth of cover to top of-pipe at regular intervals;
 Location of entry and exit points and angles of entry and exit, along with
 Lateral offset of exit point from the original pipeline alignment;
 Location and angle of field bends; Location of pipeline markers.
 20. RESTORATION
METHODOLOGY

 After completion of pipe laying and backfilling, reinstate all areas disturbed as a result of work
including surface, walls, fencing, drains and other structures within the ROW to the satisfaction level
of GSPC & Concerned authorities.

 Reinstatement of Cultivated Land & Grass Land

 Removal of all remaining and surplus material and equipments.
 The soil strata damaged due to machinery movement such as loss of fertility, permissibility etc. shall
be make to its original condition.
 Removal of all debris whatever the type as well as stones or broken pieces that might hinder the
farming of the land.
 Before replacing the top soil the contractor shall level and break down the sub soil in the working
strip to the agreed depth.
 Top soil which has been stripped and stacked separately shall be replaced over the stripped area in its
original condition.
 If there is shortage of soil to fill trench properly or to install the crown height supplemented soil shall
be placed and compact properly equal to quality as that of the shortage.

Reinstatement of Road
Damages to roads, bridges, and private property shall be repaired by CONTRACTOR. Road surface
through which the trench has been cut shall be restored as soon as possible after backfilling of the
trench at the crossing. All hardcore tarmacs, asphalt and other material required for reinstatement
shall be provided. All access routes shall be reinstated to a condition at least equal to that existing
before the work
Reinstatement of Water Ways
Permanent reinstatement shall be carried out for all waterways, which have been crossed by the
pipeline in accordance with the requirements of the concerned authority. The bed of the watercourse
shall be restored to its original level and contours. The banks shall be stabilized where necessary with
earth filled sacks, rocks or gravels. Slopes / water course slides shall be properly consolidated and
Restored without waiting for their natural consolidation and setting. Contractor shall protect the
banks of major water crossing by using bank protection procedure or accordance with the AFC.
Temporary Structure
All temporary structures such as bridge, culvert, sheet, post, signboards etc that were erected or
installed during execution as temporary measures shall be removed
Renewal of Fences, Wall, Banks & Ditches
The bed of ditches crossed by the pipeline shall be cleaned over the full width of the ROW. Any
subsidence, cave-ins, wash-outs which have been caused during the pipeline construction shall be
repaired by installing new fencing, if required. Bank protection for minor and major water crossing
shall be done as per the respective specifications.

Irrigated Land
- If pipeline runs through permanently irrigated cultivated land, the backfill shall be thoroughly
compacted and finished so that the normal irrigation can continue as soon as possible after
installation.

Boundary Stones
- All boundary stones which have been moved or removed during the work shall be reset in their
original location to the satisfaction of the landowner, concerned authority and GSPC/SGS.

Disposal
- All surplus and defective materials and all trash, and spoiled materials shall be collected and disposed.
The ROW shall be cleared of all rubbish, broken skids, empty cans, cardboard, sacks, stumps, trash
and leftover construction material. All burnable matter shall be burnt or disposed off, in an
 appropriate manner, but never buried in ROW. Surplus soil shall only be removed from the plot after
authorization by GSPL. All loose stone and rock exposed by the construction operations and scattered
over the ROW or adjacent shall be removed and it shall to be transported to a location considered
suitable by the land owner or by authorities having jurisdiction, for satisfactory disposal.
- For the stones, gravel or other hard material, which may be buried in the trench, the provisions of the
specifications shall apply with the understanding that the use of the land by the land owner shall not
be interfered with. On completion of cleanup, ROW shall be restored to such condition which may be
reasonable consistent with the condition of ROW prior to laying of the pipeline. CONTRACTOR shall
furnish to GSPL, NOC from the landowners regarding satisfactory indemnification and restoration of
their lands.

Repair of Damage
- Special precautions shall be taken near step slopes prone to erosion and land slides. Necessary steps
shall be taken to ensure the rapid growth of grass by providing wicker barriers and by regulating the
drainage of surface waters.
- All cadastral or geodetic markers removed during the execution of works shall be restored. This
restoration might contain but shall not be limited to supply and installation of proper materials for
backfill and protection and other precaution to prevent erosion or guarantee the stability as approved
by CLIENT. Other field drains have to be restored by hand and special equipment to be used for that
purpose as soon as possible.
- Damages to roads, bridges, private property shall be repaired by CONTRACTOR. All fences and other
structure which are damaged during construction shall be restored to original condition.
- Slopes, water course sides or banks shall be properly consolidated and restored. The banks and any
excavated areas shall restored to the original levels. The banks shall also be stabilized using barriers,
stone pitching and concrete as per AFC drawing. All boundary stones which have been removed shall
be reset in their location. On completion of clean up, the ROW shall be restored to such stable
condition as may be reasonably consistent with the condition of ROW prior to laying the pipeline.
- Any subsidence, cave-ins, washouts which have been caused during the pipeline construction and
maintenance, caused by whatever reason within the edge of ditches and open drains shall be repaired
by CONTRACTOR.
- The ROW and the backfill trench in particular shall be finished in such a way that the field drains have
to be restored by hand special equipment to be used for that purpose as soon as possible.
- The ROW and the backfill trench in particular shall be finished in such a way that the fields are at their
original level. In case where heavy damage has been caused to the structure of the subsoil as a result
of special circumstances, CONTRACTOR shall carry out special works, if required.
- NOC shall be taken from cultivation land owner and statutory body (Road, Canal, Railway etc) After
restoration and same to be submitted to CLIENT for review.
21. INCOMING MATERIAL INSPECTION
Reference:

 Reference Codes
 Purchase Order
 Approved QAP
Inspection:

The Jointly Inspection report shall be made with TPIA / CLIENT send it at site
as the accepted material for use.

Inspection shall be done with the all necessary tools, measuring instrument
etc. During inspection the MSDS (Material safety Data sheet) shall be check
and ensure that the material to be kept as requirement.
 Method:-
The following actions shall be under taken with regards to the receipt and
inspection of incoming material.

Review of list of material supplied with respect to the packing list and packing.
 Check the availability of release note.

 Check the availability of Test certificate.

 Check the identification mark for co-relation.

 Inspect material visually.

Incase, the material do not pass the acceptance criteria (if found damaged, not
conforming to the specification or having no identification mark etc) then, the
material shall be considered non-conforming. The deficiency shall be
intimated in writing to the vendor/ supplier under intimation to TPIA /
CLIENT

 Generation of material inspection report and record keeping shall be the

responsibility of Store In-Charge/Material engineer.

 No material shall be allowed to be used in the job unless the material

inspection report is received and material incoming inspection report is
generated with the acceptance.

 Non- acceptable/ rejected material shall be stacked separately with proper

identification and disposed off as early as possible.

 CONTRECTOR shall take action for re-procurement/repair/replacement of

the rejected material under intimation of CLIENT

Material such as Welding electrodes, Cement etc. shall be additionally tested

for their properties as per code/ specification requirements before of its use in
the works.

Where incoming material has to be released on urgent basis, it shall be

positively identified and recorded in order to permit immediate recall and
replacement in the event of non- conformance to specified requirements.

Note: - For Brought out Item: - QAP shall be submit for approval.
 CONTRECTOR shall be submit / furnish 3.2/3.1 certificate and MTC
wherever required.

22. PIPEBOOK HANDLING

METHDOLOGY

The format of the Pipe Book shall be duly filled by CONTRACTOR and clearance
obtained from GSPC GAS or its AIA (Authorizes inspection authorities) at three
stages as indicated below.

PART- A: This part of clearance shall be obtained for lowering of pipe section
into the trench. CONTRACTOR shall submit to CLIENTfor checking at least Two
days in advance.
PART- B: This part of clearance shall be obtained for final hydro test of pipeline.
CONTRACTOR shall submit to CLIENT for checking at least one week in
advance.
PART- C: This part of clearance shall be obtained for final clearance after
satisfactory completion of all restoration works. CONTRACTOR shall submit to
CLIENT for checking at least ten days in advance.
All columns of the Pipe Book shall be filled by CONTRACTOR based on the Daily
Inspection Reports signed by the representatives of CLIENT. Any remarks given
in the inspection report shall be reflected / incorporated accordingly in the Pipe
Book.
In the Pipe Book listing, the pipes considered for a joint are the one shown
against the joint number and the next preceding pipe number.