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e Pipeline Replacement Project In Gujarat


Region Ankleshwar - Baroda (Part-A)
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Job Procedure For HOPE Duct Laying, Jointing & Testing


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Document No. : JSIW-GAIL-ABGL-ML-JP-012

Pipeline Replacement Project In Gujarat Region Ankleshwar - Baroda (Part-A)

; Client GAIL ( India) Limited


4' Limited

Contractor i JSfW Infrastructure Pvt Ltd

Job No
23PH (GR)
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FOANo GAIL I NOIDA I C&P I PROJ I LAYING I GUJARAT I 01S.017 141, Ot-20.01.2016

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~ WlTHOUTPREJODICETO CONtRA'·
OBIJGATlONS AND UABlunl
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Date Description JSIW JSIW MECON MECON
Sign I Name Sign I Name Sign I Name Sign { Name
Pipeline Replacement Project In Gujarat : r;(fi) 4if!in :
Region Ankleshwar - Baroda (Part-A) 6 ~) ........... .....,_'_'_ _

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Job proce~ure For HD~,=_~uct Laying, ,~~~~~:~ &, Testing _ ,,_,~


I Document No. : JSIW·GAIL-ABGL-ML-JP-012 I Rev. No. 00 1 P age 2 of 7 ;
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TABLE OF CONTENTS
1.0 PURPOSE 3

2.0 SCOPE 3

fit 3.0 REFERENCES 3

4.0 RESPONSIBILITY 3

5.0 METHODOLOGY 4

6.0 HEALTH, SAFETY AND ENVIRONMENT 7

6.0 QUALITY ASSURANCE I QUALITY CONTROL 7

6.0 APPENDICES AND FORMATS 7

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I Pipeli."e Replacement Project In Gujarat ! r/.i0. t1i/1it.\


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Job Procedure For HOPE Duct Laying, Jointing & Testing


i Document No. : JSIW..GAIL-ABGL.ML.JP.012
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1.0 PURPOSE
This Procedure covers the work method for laYing & jointing permanently lubricated HOPE duct
for OFC & its documentation for Pipeline Replacement Project in Gujarat Region Ankleshwar
• Baroda (Part-A) by JSIW.

2.0 SCOPE
The scope covers Laying, Jointing & Testing of HOPE duct for construction of Pipeline
Replacement Project In Gujarat Region Ankleshw.. r - Baroda Gas PipeHne Project.

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3.0 REFERENCES
• Specification for OFC installation and associated works MECiSJ05/ES/T/001
• Design and Col"lstruction ReqUiremer'lts for CrMS Country Hydrocarbon Plpeline!'\ OISO­
STD-141
• Gas Transmission and Distribution piping system ASME B 31,8,

3.0 RESPONSIBILITY

Project Manager - Shall report to Project Director.


- Shall be provided all necessary resources to
implement this procedure.

ReSident Construction Manager - Shall report to the Project Manager,


- Shall be responsible for quality of the job and shall be
providing adequate resources tools & infrastructure to
implement this procedure
- Shall be responsible for overaJi Implementation

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monitoring and control of construction activities.

Site Engineer - Shall report to Resident Construction Manager


- Preparation of HOPE Duct laying schedules
addressing speCific issues and characteristics,
Overall control and safety management and for the
implementation of procedure and supervises the
activity,
- Generation of report dunng the actIvity
Explaining all other persons Invorved in laying of the
OFC to be done prior to start the activity,

HSE Officers - Shall report t::> Project Manager I Resident


Construction Manager
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- Implementation of an safety requirements as per SOP
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.D. Pipeline Replacement Project In Gujarat . ~ ~l


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Region Ankleshwar - Baroda (Part-A) 6 ~~
l Job Procedure For HOPE Duct Laying, Jointing & Testing
~qcument ~o:': JSIW-GAIL.ABGL.ML-JP.012~'."'.~m." _ _ _ ._","'.p~~: o~ Page Sof7

Trench bottom for HOPE Duct shalf be clean, smooth and free from stones Proper care shall
be taken so that there should be no kinks, loops, twist in the duct while laying. Feed the HOPE
Pipes directly into the trench without mess so that HOPE ducls are laid WIthout criss-crossing,
HOPE duct ends should be cut with the help of HOPE duct cutter and after proper coupling;
coupler should be tighten with C-spanner

Before blowing of Optical Fibber Cable in the laid HOPE duct. will be tested for proper laying.
crush, deformity and pressure testing, JSIW shall be fully responsible f()r any obstruction and
deformity in the laid HOPE duct and shall have to remove the obstrlJction I deformity 6f any kind

-- before blowing Optical Fibber Cable into the duct.

Include method of HDPE duct laying as "Tensioning of HOPE duct after laying" as per tender
specification.

5.2.3 TenSioning of the HOPE duct after laying:

• Determine the direction or installation and set the reel. Ouct should be unrolled from the
bottom of the coil,
• Place the duct inside the trench.
• ,Let two workers stand on the duct at start point and two other worker stretches the duct.
thereby giving tension, upto of 30-40 meters:
• After covering the 30-40 meter backfill the trench at that point to hold the duct in position
and to avoid loss of tension.
• Repeat the above procedure till the entire duct length of 1 KM laid with proper tensioning,
• Backfill the entire trenches

To lay the next HOPE duct drum length. couple the laid HOPE ducts to the new drum to be laId
with the help of a coupler with same procedure explains above,

@ 5.2.4 Jointing of HOPE Duet:

In case of crossings there may be the possibility that laid HOPE section length may have to be
joined to other laid HOPE section length. The jointing of two ends of HOPE duct should strictly
be done with the help of Coupler, which will be made of similar material. InstaiiaHon of HOPE
coupler to join laid HOPE duct should strictly been done ,vith the help of C-spanners for proper
tightening of Coupler. Joints may also likely to come up due 10 Roadl River I Nalla t Railways
crossing. All efforts shall be made to minimize joints. The coupling should be water and airtight
and should be able to withstand minimum pressure of 10 bar. Following procedure should be
followed for jointing HOPE duct:

• Cut the two ducts that are to be joined at the same place where they overlap Cutting
should be done in such a way that the duct ends match with the coupler perfectly because
is very important that coupling jomts be airtight Prt.>per pipe shears or cutler must be l..tSed
for smooth cutting HackS8w should not t)e used to cut the dueL
• Debar both the inside and the outside edges of the duct with a debarrmg tool
• Apply a smail amount of proper lubricant for better lnstallat.lon of plastIC coupler.
• Tighten the plastiC coupler with c-spanner~-;:::'--:;:;:I'=d_::~l~~t~,., '.

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Pipeline Replacement Project In Gujarat

Ankleshwar - Baroda (Part~A) ~


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Job Procedure For HOPE Duct Laying, Jointing & Testing
Document No. : JSIW·GAlL·ABGL-ML~JP·012 Rev. No. 00

5.2.5 Sealing of HOPE Duct:

The Contractor shall supply and put end plugs to seal the end of HDPE ducts after laying of

same to prevent ingress of sit, dust etc. prior to back filling. The end plug should be made of
similar material as that HDPE duct does not change its position due to heavy impact of soils or
due to any other cause.

5.2..6 Crossings

e Crossing By Boring

For pipeline crossing executed through uSIng pipes or by boring I jacking I HOD I Thrust Boring
methods.

In case of crossing to be done with boring I jackinq I HDD I Thrust Boring the OFC be laid in
HDPE duct which shall be sub ducted in stoel duct. Ensy.. to·jn5tu!l Cubic scaling plug shall be
used to seal the ends of the duct to prevent the ingress of water, dirt and rodents, which may
damage Optical Fibber Cable. The two ends of each duct shall be sealed immediately after
installation of Sub·ducts and re-sealed when the cable has bean installed inside the duct.

Open Cut Crossings

For these crossing JSIW shall lay the cable through the HDPE Duct Length of HOPE Duct shall
be estimated with the help of survey documents & alignment sheets. For water crossings.
HDPE duct shall be used till -5m of the normal underground trench depth on either side. The
bank protection measure being provided for pipe shall also be extended to take care of Optical
Fibber Cable For Road crossings. the HOPE duct shall be extended for minimum 3 meters on
either side of the road.

@)) 5.3 DUCT CLEANING I DUCT INTEGRITY TEST

The following procedure to be followed for Duct Cleaning, Duct Integrity test and Air Pressure
Test:
• Compressed -air should be blown through the duct in order to remove any dirt and water that
has accumulated inside the duct with the help of air compressor short blast of air of about 1
bar shall be blown through the duct for about 1 minute

• Spongers will be blown through the duct to further remove any dirt and water from the ducl
segments. Sponges should be blown in to the duct wltil clean and dry sponge come~ out of
the duct A semi Hexible shuttle (rubber) 75mm long and 0.8 x 0 mm. where 0 is inner dia of
HOPE duct shall be passed through the duct confirming duct integrity.

• Static pressure tests are to be carried out in order to verify air tightness for the purpose of
cable blowmg'as well as to prevent Ingress of water or dirt during the life lime QLQt~ct To
verify the air tightness, pressure Inside the duct should be brought lip to@%f1Of 2
minutes. A pressure drop of 0 \0 0.5 bar per minute of the test IS acceptatAo if a higher
pressure drop is detected No further test should be conducted until the lea i< Itas beer·
located and repaired No leakage is accePtable',J's~

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Pipeli.ne Replacement Project In Gujarat I.
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Job Procedure For HDPE Duct Laying, Jointing & Testing J
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I Doc~-;ent No. : JSIW·GAIL·ABGL.ML·JP.012
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• After pressure testing duct ends should be sealed with the help of duct plugs,

6.0 HEALTH, SAFETY AND ENVIRONMENT

• All PPE is a must in this activity,


• Only trained personnel to be deployed for thIs activity,
• Personnel around must be informed evacuated 10 a safe distance.
All measuring & Test Equipments used must be well maintained,
e •


Regular awareness program shall be arranged',
JSIW shall arrange first aid box,

7.0 QUALITY ASSURANCE I QUALITY CONTROL

Quality Assurance and Control shall be maintained by systematic implementation of this


procedure and generating necessary quality records

8.0 APPENDICES AND FORMATS

Appendix: 01 Inspection and test plan (lTP) for OFC & HOPE Duct Laying
(JSIW-GAIL-JHPL-1A-B-ML-JP-012-ITP-012 Rev 00)

Appendix; 02 Inspection Report for HOPE Duct Lay!ng


(Format No. JSIW-GAIL-ABGL-ML-JP-012-IR-01 Rev 00)

A Appendix: 03
• Inspection Report for HDPE Duct Integrity Test
(Format No. - JSfW-GAIL-ABGL-ML-JP-012-IR-2 Rev aD)

Note: In case on any ,conflict between the above procedure and project Specification the
later shall govern, without any prejudice to the terms and conditions of the contract. i
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Pipeline Replacement Project In Gujarat Region !

Ankleshwar - Baroda (Part-A)

Inspection & Test Plan for HOPE Duct Laying, Jointing & Testing
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Client : Mis GAIL ( India) Limited Appendix-1

Consultant : Mis MECON limIted Document No : JSIW·GAIL·ABGL·ML-JP·12·ITP·01


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Contractor : JS1W Infrastructure Pvt Ltd Rev.; 00 1
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SrNo ActIvities ByJSIW I By MECON


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Ii 7 Duct Integrity Test 'iN \V


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Review of Oocurl1enis

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PROJECT : PIPELINE REPLACEMENT PROJECT IN GUJARAT REGION ANKHLESWAR - BARODA (PARJ..Aj

CLIENT ; MIS GAIL INDIA UMrTED. I Append1l"':r'


CONSULTANT : MIS MECON UMITED IReport No.: /' / .
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PIPELINE REPLACEMENT PROJECT IN GUJARAT REGION ANKHLESWAR - BARODA (PART-A)

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CLIENT ; MIS GAIL INDIA LIMITED, 1 ~-~-Appendh(.3 , / I

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