SECTION II

SCOPE OF LINE PIPES FABRICATION, LAYING & INSTALLATION

1.0 INTRODUCTION
This requisition, along with, all relevant attachments defines the minimum requirements for
pipeline fabrication, laying, installation, testing and commissioning of our clients production
facilities.
2.0 SCOPE
2.1 This document covers the details of work tendered, scope of work, scope of supply and other
requirements pertaining to pipeline fabrication, laying, installation testing and commissioning of
our clients production facilities.
(a) Pipe line work in Kwale, delta State
Details of works and other requirements pertaining to pipeline and associated facilities are also
covered elsewhere in this tender.

2.2 The scope of work and details mentioned in this document shall be read in conjunction with job
specific requirements for pipeline laying works Document No. JSP (Job Specific Procedure)
attached with this document, Scheduled of rates, Specifications, Drawings and any other
documents forming a part of Tender documents.

3.0 WORK DETAILS

Work under this Contract document consists of the following:
3.1 Laying of pipe line from size 20” – ½” OD at Kwale.
3.2 Laying of Pipe line from Sch. 40, Sch. 80, Sch. 120 & Sch. 160 at Kwale
3.3 Supply of all materials required for completion of the Works except the Company supplied
items.
3.4 Carrying out associated mechanical, civil, structural, electrical and instrumentation works.
3.5 All works related to pre-testing, flushing, gauging, hydro testing and swabbing and tie-in with
adjoining pipeline section/piping facilities.
3.6 Pre-commissioning of pipeline sections, including providing commissioning assistance
/support. Company shall carryout final commissioning of the entire Pipelines and associated
facilities.
3.7 Idle time preservation of pipeline, if required.
3.8 Carrying out all such works which though specifically not indicated here but will otherwise is
required to complete the Work in all respects.
4.0 SCOPE OF WORK
4.1 The Contractor’s Scope of Work under the Contract consists of, but not limited to fabrication,
installation, testing, pre- commissioning of pipelines and associated facilities complete, with all
associated mechanical, civil, structural, Instrumentation works including providing
commissioning assistance required and carrying out all such works which though specifically
not indicated here but will otherwise be required to complete the work in all respects. The scope
indicated below shall be read in conjunction with job specific requirements the schedule of
rates, drawings, specifications and other requirements forming part of the Bid/Contract
document.
4.2 The COMPANY shall supply the line pipes and the accessories such Valves, Flanges, Bends,
Bolt & Nuts and gaskets etc.. to be used for the pipeline laying from its stock yards. The
Contractor shall collect and transport the required material from Company’s warehouse to the
work site.
4.3 All the procedures for execution of this job is attached in Annexure-1, document no. JSP (Job
specific procedures). Contractor has to comply with the procedures mentioned in that
document.
4.4 The scope of work and procedures provided in this tender document is for the guidelines only.
However the Contractor shall execute the job as per the International standards &
specifications. Also Contractor shall suggest best engineering practice to suit the site conditions
while executing the job.
4.5 The contractor shall provide the following but not limited to:
a. Company will make available an area of land for the Contractor’s construction facilities.
If this is not sufficient for Contractors requirement with respect to the Work, then the
Contractor shall find and provide additional areas at his own cost
b. The Contractor shall be responsible for providing and maintaining any office
accommodation, workshops, storage facilities and lay down area, etc. permanent or
temporary access roads required for the Work.
c. The Contractor shall be responsible for the supply, installation, hook-up and maintenance
of all facilities and services required to enable him to carry out the Work. These shall
include office accommodation, messing facilities, laundry, medical and first aid facilities,
workshops, warehouses, pre-fabrication sheds, power, water, all temporary utilities,
waste and sewage disposal, communications (IT, Telecoms/Fax) and any other
associated equipment, consumables, tools, materials etc necessary to complete the
Work within the Project Schedule.
d. The Contractor will also be responsible for provision, design, installation or erection of
any temporary facilities required to assist with the work including weather protection,
lighting. Scaffolding, etc, and removes/uninstall these temporary facilities on completion
of the Work.
e. The Contractor shall be responsible for the provision and maintenance of all plant,
consumables and materials. This shall include all construction plant, tools, any special
tools, all consumables, and specialized lifting equipment, heavy duty equipment’s
necessary to install, test and execute the job.
f. The Contractor shall comply with the requirements of providing necessary equipment’s
for excavation, pipeline laying, testing and commissioning during rainy season in the
water logging areas.
5.0 PROJECT PROGRAMME SCHEDULE
The contractor shall ensure to complete the work as advised in Call out notice within from the
date of mobilization notice.
6.0 THE CONTRACTOR IS REQUIRED TO MOBILISE Minimum RESOURCES as below ON
BOARD:

Sr. No. Item Description Quantity Remarks

1 Excavator 2 Nos.
2 Welding machine with all accessories 12 Nos.
3 Self Loader 2 Nos.
4 Trailor 1 No.
5 Radiography Testing Equipments 2 Units
6 Hydro test unit with Water filling pump, Foam 1 Complete unit
pigs, Dead weight tester with chart recorder with calibration
of temperature and pressure, pressure certificate
gauges etc.
7 De-watering pump 2 Nos.
8 Motorised Pressure Pumps 2 Nos.
9 Air Compressor 1 No.
10 Crew 4 Crew Each crew comprises of 2
welder, 1 Grinder, 1 Fitter
and 4 skilled workers.
 11 Maintenance Crew 2 No. 1 Electrician, 1 Mechanic
12 Store Keeper 1 No.
13 Project Manager 1 No.
14 Site Engineer 2 Nos.
15 QA-QC Engineer 1 No.
16 Documentation Controller 1 No.

NOTE: The contractor is required to give execution plan with the mobilization resource list for
achieve work completion as required by Company from date of mobilization.

1) No. of weld joint production and RT per day : Min 50 joints

2) Contractor have to follow welding, RT, Joint Painting, Excavation and lowering
simultaneously so complete work can be completed as per the time schedule agreed
with Company prior to Mobilization.

7.0 RESPONSIBILITY MATRIX

The overall responsibilities of Contractor and Company under the proposed Contract are
detailed hereunder:
Item To be Provided By At the Expense of
Description
No. Contractor Company Contractor Company
CONTRACTOR Equipment &
1.0
Transportation between locations
Provision of trucking services during
1.1 √ √
transportation
Provision of additional equipment,
manpower, material or consumables
1.2 √ √
during transportation of contracted
equipment.
Power, Fuel and Lubricants for the
2.0
equipment and portable camp
2.1 Power for carrying out the work √ √
2.2 Fuel storage tanks √ √
2.3 Fuel, lubricant etc. √ √
3.0 Food and accommodation
3.1 For CONTRACTOR Personnel √ √
3.2 For Company’s Personnel √ √
4.0 Water Supply
4.1 Water supply to the contractor camp √ √
Water supply to the CONTRACTOR for
4.2 √ √
pipeline pressure testing
5.0 Vehicles
5.1 Contractor crew’s vehicle √ √
6.0 Safety equipment & Services
6.1 First aid services at the work site √ √
6.2 Ambulance services √ √
6.3 Safety Gears √ √
7.0 Maintenance
Workshop facility and mobile
7.1 √ √
maintenance truck
All repair and replacement work to
7.2 CONTRACTOR Equipment including √ √
spare parts and consumables
Maintenance of all CONTRACTOR
7.3 equipment in accordance with the √ √
CONTRACT
8.0 PERSONNEL
 Travel time and any associated personal
expenses for CONTRACTOR personnel
8.1 √ √
during travel between point of origin to
work site
Visa, work permit and related
8.2 documentation, if required, to maintain √ √
CONTRACTOR personnel in Nigeria
Telecommunications, CONTRACTOR
need to provide communication link
8.3 √ √
between crew truck, supervisor truck
and CONTRACTOR base camp.
9.1 SECURITY
9.1 Security for personnel √ √
9.2 Security for equipment and materials √ √
10.0 SUPPLY OF MATERIALS
Supply of any equipments,
consumables, materials etc to complete
10.1 √ √
the work and services other than
company supplied items
Transportation of company supplied
10.2 items from company’s warehouse to √ √
work site

Job Procedures for pipeline Installation

20”, 16”, 12”, 10”, 8”, 6”, 4”, 3”, 2”, 1” & 1/2” Dia. Gas Pipeline

INDEX

i. Welder Qualification & Procedure Qualification

ii. Job Procedure for Handling, Hauling and Stringing of Pipes
iii. Job Procedure for Mainline Welding
iv. Job Procedure for Radiography
v. Job Procedure for Excavation
vi. Job Procedure for Lowering and Backfilling
vii. Job Procedure for Tie-in
viii. Job Procedure for Pre-Hydro Testing
ix. Job Procedure for Horizontal Direction Drilling
x. Job Procedure for Hydro Testing of Pipeline
xi. Job Procedure for Dewatering and Swabbing
xii. Job Procedure for Exposed Pipeline section Painting
xiii. Job Procedure for Marker Installation
xiv. Job Procedure for ROU RESTORATION

1. Welder Qualification & Procedure Qualification

1. Equipments/Tools
D.G. Set
Power Generator
Power Tools
Hydra / Lifting equipment / crane / side boom
External Clamp
Temperature tester, thermal check or digital temperature instrument

2. Procedural Steps:

A) WELDING PROCEDURE QUALIFICATION

General
QUALIFICATION OF WELDING PROCEDURES CONTAINING FILLER METAL ADDITIVES
of API 1104 20th edition, 2005 edition, NDT Section 5 & Client specification.

Contractor shall submit the proposed welding procedure specification to client for review and
for releasing the procedure for procedure qualification tests. The procedure qualification test
shall be carried out by contractor in welding shop and is to be witnessed by client. A complete
set of parameters and data’s shall be recorded jointly by contractor and client. Procedure
qualification test shall be carried out by using the external clamp as per approved WPS.

Once welded specimens cleared visually it shall be subjected to radiographic testing and
subsequently to destructive testing. Destructive testing shall be done as per Specification and
Article 5.6 for manual welding of API 1104 20th edition, 2005.
A complete set of test results shall be submitted to client for approval immediately after
completing the procedure qualification tests.

Non Destructive Examination:

Non-destructive examination shall mainly consist of examination using X- ray radiography.
Welds shall meet the standards of acceptability as set forth in API 1104 20th edition,2005 .
Destructive Testing:
Having passed the visual and the non-destructive testing, the test weld shall be subjected to
mechanical test.
Test specimen shall be taken from the position as given in the Client spec & API 1104 from
areas as free from defects as possible, for this reason it is necessary to take the previous NDT
reports into account.
The test shall be carried out at laboratory approved by client. Test specimens shall be prepared
in accordance with relevant specifications, which refer to the individual test.
Type, no & pipe dia. Test Specimens for Procedure Qualification
Subsequent to successful completion of all tests the values and parameters shall be
documented in the form of Procedure Qualification Record and shall be submitted to client for
approval. Based on the values and parameters noted during these tests the “as welded or
approved” welding procedure specification shall be prepared and shall be submitted for
approval by client.

B) WELDER QUALIFICATION

General
Welder shall be selected by client based on the certificates of previous experience and on
conducting trial test at site. The Welder Performance Qualification Test shall be carried out in
accordance with the qualified WPS, which shall be made available to welder.
The Welder Performance test shall be carried out in accordance with SECTION 6
QUALIFICATION OF WELDERS of API 1104 20th edition 2005.
On acceptance of non-destructive test results each welder shall be assigned a unique
identification number. All butt joint welder (SMAW) should be qualified by virtue of radiographic
test as permitted by Section 6.6 (Radiography – Butt Welds only) unless otherwise specified
by Client.
Welder qualification records as per the approved format shall be maintained. Each welder shall
be provided with identity card (Photo copy) duly signed by client.
The qualification validity of any welder is subject to the satisfactory performance during
production welding. Also welder performance will be assessed based on the production
radiography results.
Material Identification and traceability of WQT materials and consumables shall be
documented and should be of the similar type and grade as those of production welding.
It shall be ensured by QC Inspector that all welders have previous experience and are capable
of performing qualification test.
 Site QC Inspector shall ensure that welding Plant and equipment are in prime condition and
are similar to be used in production welding.
All measuring & test Equipment such as Clamp Meter, Amp/Volt meter, weld gauge etc. are
available.

Visual Examination of Welds

For Qualification of welder, the qualification test welds to meet requirements of Visual
Examination as defined in Section 6.4 of API 1104 20th edition. Failure to meet requirements
of this subsection shall be adequate cause to eliminate additional testing.

Retest
A welder who fails to pass qualification test may be upon the discretion of client be retested.
Further retest shall be given only after the welder has submitted proof of subsequent training,
sufficient to accept him for re-testing.

Extent of Testing
Extent of testing shall be performed as per Section 6.4, 6.5 6.6 and 12.6 API 1104 ,20th edition.

Approval of Welder/operator Qualification Test

WQT shall be qualified in the presence of client and shall approve the same. Records of it shall be
maintained and be made available for reference to client as and when required.

Approval of Welder Qualification Test

Welder shall be qualified in the presence of client records of same shall be maintained same
shall be approved and be made available for reference to client and Auditors as and when
required.

3. HSE
o All personnel shall have proper P P E
o All equipments / tools shall have valid TC.
o All portable grinding machines shall have proper secured guard.
o All grinders and personnel working around grinding area shall have face shield
/ safety goggles.
o There shall not be any temporary electrical connections. All extensions of cables
shall be throw proper sockets and pins arrangement. No damage cable shall be
used.
o All grinders shall have proper training and familiar with speed of grinding machine
and rated compatible speed of grinding discs.

2. Job Procedure For Handling, Hauling and Stringing of Pipes

1. Equipment
Side Boom/Crane /Hydra
Trailer
Rigging tool i.e. Sling, Lacing Belts, Skids

2. Procedural Steps

 All work shall be carried out as per method statement.

 Inspection of all pipes shall be carried out by loading supervisor/QC supervisor and client jointly
for the defects in pipe and same shall be reported. Register shall be maintained for recording
the necessary information i.e. Manufacturer, Pipe no, Heat no., Dia, thickness and Tailor no.
 Pre- damaged pipes shall be stacked separately and to be taken for work only after repairing
and inspection the same.
 Utmost care shall be exercised during handling of pipes.
 Lifting Hook when used shall be equipped with a plate curved to fit the curvature of pipe.
 Hooks to be covered with soft material like rubber, Teflon or equivalent.
  In loading pipe on trailer, each length shall be lowered to position without dropping from the
height and special supports of wood shall be used to avoid the damage of pipe during
transportation of pipe.
 After loading chain and padding or lacing belt shall be used to tie to the load securely to each
bolster. Care shall be taken to avoid the point concentration on pipe.
 Non- metallic/ non- abrasive belts of proper width (Min. 60mm) may be used. Use of round
sectional slings is prohibited. If belts are used, pipe to be stacked shall be separated by row by
row to avoid damages. Slings/ Belts shall be cleaned to remove hard materials such as stone,
sand, gravel etc. Spacer to be provided between each pipe sections.
 Pipes shall be carefully unloaded from trailers by means of cranes/ side booms/Hydra with
suitable lifting device and stringed on sand or wooden sleepers.
 Rolling, Skidding or dragging shall be strictly forbidden. The pipe shall be stacked at a slope so
that during rain water doesn’t collect inside the pipe.
 Stacks must be properly secured against sliding and shall consist of pipes of the same diameter
and the same thickness.
 The stringing of pipe in ROW the bottom of pipe minimum 400 mm from natural ground level.
 Stringing of pipes will be as per approved drawing or alignment sheet for the proper placement
of pipes by thickness, grade.
 Pipe no., Heat no. & Length of pipes to be transferred at above of pipes by paint, and all
information this shall be legible wherever stenciling is not visible and same to be verified by
Material Test Certificate.
 Pipes lengths must be properly spaced in order to make easier the handling during welding
phase.

3. HSE

● All equipments & tools / tackles shall have valid test certificates.
● No other than one man will go on trailer.
● After hooking up the pipe he will be staying off from swing line of pipe.
● Lifted pipe will be guided by two guide ropes handled by two persons.
● No person other than rigger (4 persons) will be staying near the swing area of
the pipe.
● ROU will be flagged while unloading / stringing the pipes.

3. Job Procedure for Mainline Welding

1. Equipments (Minimum Per crew)
1. Welding machine
2. External clamp
3. Grinding machines (angle grinder AG-7, AG-5, GQ-4)
4. Welding hut
5. Hand tools i.e. chipping hammer, wedges, cable, gloves, welding shield etc
6. Hydra
2. Procedural Steps

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 inspected for any dent / damage
or improper machining.

Dents in bevels with a depth of less than 1 mm shall be removed by contractor during cleaning,
grinding. If the depth of bevel dent / defect is between 1 mm and 3 mm. contractor shall re bevel
the pipe end by grinding . If the depth of bevel dent / defect is more than 3 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% DPT or UT & visually inspected to ensure
freedom from laminations and record shall be maintained.
 Pipes shall be checked for correct thickness, dia. and spec. With respect to the approved drawing.
The first pipe shall be positioned on skids of appropriate height from the ground supports shall be
minimum two per pipe, 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 Hydra and shall be aligned with the
first pipe and the External clamp shall be actuated. The root gap shall be checked. Weld seams of
the pipes shall be staggered in the top 900 of the pipe or at 2 & 10 O’Clock / 300-mm whichever is
less. For pipe of same nominal wall thickness the off set shall not exceed 1.6 mm.

The offset may be checked from outside by dial gauges or hi-lo gauge. No hot dressing shall be
permitted. 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 site. Alignment and fit-up shall be checked before
welding.

Before starting of welding works contractor shall submit and keep it for record batch Certificates of
the electrodes for review. All electrodes shall be kept in close container is avoid any damage of
electrodes & shall be taken out, during use only. Different grades of electrodes shall be carried in
separate container.

Earthing clamp shall be used for connecting pipe to welding machine terminal.
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.
Joint shall be checked for moisture deposition & shall be cleared of any moisture is present. Joint
shall be preheated if temperature is less than 30 or (Max. 100 degree) C in cold weather.
The root gap shall be checked .The use of external clamp is mandatory and shall not be released
before 60% completion of the root pass.
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.
Welder shall be follow direction of welding as per approved WPS / PQR.
Cleaning / removing the flux craters, welding irregularities slag etc. by power brush.
Removal of Clamp shall be disengaged and taken out of the second pipe. The pipe shall be lowered
on pre-positioned skids.
Hot Pass and fill pass Process by SMAW Welding progression shall be as qualified welding
procedure.
Two weld beads shall not be started from the same location, if required, welding may be suspended
after the completion of the third pass so as to allow the joint to cool down, provided that the thickness
of the weld metal deposited shall be atleast 50% of the thickness of the pipe.
Arc strikes outside the bevel surface shall not be permitted. The skids used in during welding shall
be removed only, after completion of full welding.
Every pass shall be cleaned by power-brush, grinding machine and chisel, starting and finishing
points shall be staggered for every pass.
Capping shall be max 1.6 mm over the surface of the pipe. Spatters shall be removed and cleaning
shall be done by power brush and any remedial grinding necessary, shall be performed limited to
dressing.
Further subsequent pipe alignment, joints shall be welded in the same manner as explained
above.
For weather protection, windshield made of metallic frame covered by. G.I sheets/canvas shall be
provided to cover the welders and joint during welding, if necessary to protect against
rain/drizzling/wind.
Visual Examination
 All finished welds shall be visually inspected for excessive reinforcement, concavity of welds,
shrinkage, cracks, undercuts, dimensions of weld surface porosity and other surface defects. If any
such defects are noticed they shall be rectified.
All finished weld shall be Examined for NDT by 100 % Radiography Test.

3. HSE
1. All equipments, tools / tackles shall have valid T.C.’S.
2. It is to be noted that the machine operators Involved shall be an experienced / competent
person.
3. PPE shall be used in this activity.
4. Trained rigging personnel shall be deployed for this activity.
5. During fit up operation special care to be taken to avoid personal injury.
6. Personnel around the machine should be cautious about frequent handling of pipes.
7. During the movement of equipment the operator should blow horn to caution the people around.
8. All Measuring & Test Equipment used shall be well maintained.
9. Grinding machine guards shall be always in place.
10. All electrical connection for powering the tools shall have industrial sockets & pins.
11. Person working around / near to welding place shall have eye protection always on.
12. All lifting devices & Tools used shall be well maintained.

4. Job Procedure for Radiography

PERSONNEL QUALIFICATION:
The qualification of NDT Personnel to carry out Testing should be minimum, ASNT Level I in
accordance with documents ASNT SNT-TC-IA & ANSI CP 189, in Radiography Testing method.
The Personnel shall satisfy any certification requirements from local authorities (Radiation
Regulatory Authority of country of Operation) .The Level I inspector shall always carryout the
testing under the supervision of NDT Level II Inspector and the Interpretation of Radiography
Testing shall be carried out only by an ASNT RT level II Inspector.
EQUIPMENT,CONSUMABLES & ACCESSORIES:

☼ X ray Crawlers with Module/ Battery packs & Drive Assembly.

☼ X-ray Machine with Control panel & cables.
☼ Pilot Command
☼ Survey Meter
☼ Dosimeter
☼ Densitometer.
☼ Film reviewing facility.
☼ Dark Room Accessories & Consumables.
☼ Films.
☼ Chemicals.
PROCEDURE:

Radiography shall be carried out using any one of the following Techniques with X-Radiation.

 SINGLE WALL SINGLE IMAGE:

This Technique is ideal for plates, & Pipelines or Vessels, Tanks Structures & Components.
In this technique the radiation penetrates through single wall of Test Object & image of the
Single wall is recorded on the Radiograph. In the case of Pipelines the Radiography
Equipment with Panoramic X-ray source fitted with a crawler, is placed at the center of the
Pipeline.

 DOUBLE WALL SINGLE IMAGE:

 This Technique is ideal for pipes of diameter 2 ½” and above & components (where the single
wall single image is not possible). In this technique the Radiation penetrates through both the
walls of test object (Pipe) and single image of the part closest to the film is recorded on the
Radiograph.

 DOUBLE WALL DOUBLE IMAGE:

This Technique is ideal for small bore pipes of diameter below 2 ½” & components (where the
Single wall single image or double wall single image is not possible). In this technique the
radiation penetrates through both the walls of test object (Pipe) and the images of both the
walls are recorded on the Radiograph.

PRECAUTIONS:

 Ensure that the film cassettes are in close contact with the weld seam.
 Ensure that a lead number belt is placed along the side weld seam.
 Ensure that lead nos. and letters properly identify each weld.
 Ensure that proper penetameters are used and they are correctly positioned.

INTERPRETATION:
All indications that are equal to or greater than rejection level, be described in acceptance/
rejection criteria in section 10 of this procedure or as agreed by client’s inspector, shall be
considered representing defects and may be cause of rejection or repair of the weld or base
metal. All Radiographs showing film marks in the area of interest shall be reshoot in accordance
with this procedure.
ACCEPTANCE OR REJECTION CRITERIA:
Acceptance or rejection criteria shall be in accordance with API 1104 field piping or ANSI B 31.3
for station piping as specified in client’s specification. All defect location shall be marked & / or
recorded for repairing.
RETESTING:
Retest of the repaired area and reshoot joints for defective films shall be carried out in accordance
with this procedure. Only single time repair is admitted again the repair come joint need to be cut
out and reweld.
HSE:
Safety in this NDT method is first priority, hence all technicians must work as per radiation safety
guide & all local rules and regulations. All Technicians should use TLD personnel Badge /
Dosimeter while carrying out Radiography. Survey meter to be used to check Radiation level. As
far as possible area to be cordon off with Radiation Warning Flags.

5. Job Procedure for Excavation

1. Equipment

Excavators as required.
Dumpy level and survey equipment and accessories as required.
( for trench center and depth of trench )
Measuring tape as required.
Hand tools

2. Procedural Steps

 All work shall be carried out as per approved procedure

 Excavation shall only be done on the staked center- line of the pipeline.
 At the crossing like road, before start of trenching, trench and near by area use for heavy
equipment, area shall be check with cable locator and pipe locator and also identify the all
under ground exiting utility and obstacle. The areas to be identify and mark them with the
temporary painted post. And expose / uncovered them by manually / hand digging. Using an
 excavator bucket is not allowed. In any case of damage of any cable or pipeline, work shall
be halt immediately and inform to the client and concerned company or owner without any
delay.
 During Excavation if found any unforeseen obstacle like old foundation, post, bunkers etc ,
these must be remove with consultation of client.
 Need to be take permission from related authority or concerned party for remove (
temporarily) or shifting of cables, pipeline, poles or pylons, for carry out the work with
professional and experienced personal
 In cultivated land and other areas specifically designated by company, top 100mm of the
arable soil on the pipeline trench shall be excavated and stored separately on the extreme
end of the ROU for restoration in the original position after back- filling and compacting rest of
the trench.
 Suitable crossings shall be provided and maintained on ROU for access for general public,
Owner’s etc.
 Fresh excavated soil should not be mix with foreign material, loose debris etc.
 All rivers, sewer, drains, ditches and other natural waterways shall be maintained open and
functional.
 If Blasting is required at some hard rocky area , the work shall be carried out as per approved
procedure .and check the near by utility should not effected and be sure that in this area
stringing shall be done after trenching .
 The foot of Trench Width shall be minimum equal to outside diameter plus at least 150 mm
either side of pipe.
 Trench shall be made wider to accommodate two pipeline. Cover shall be maintained at all
the places.

Open Cut Trenches:

Wherever it’s permitted by the company to open cut trench across paved roads etc, the operation
shall be carried out only after the section of pipeline to be laid is complete in all the respect. After
laying of pipeline, back- filling shall be immediately performed and all the area shall be temporarily
restored. Barricades, warning sign boards/ traffic lights or lantern shall be provided. The paving
shall be restored as per authority acceptance after the installation of pipeline.
 Extra depth to be excavated to fit the min. radius of bends as specified as per the slope terrain
of ground where bends are provided at various crossings etc.
 When pipeline will be crossing the existing underground facilities the min. clearance of 300mm
or as specified in the drawing or as per statutory requirements whichever is stringent between
the two shall be kept and accordingly the depth of trench shall be increased.
 If the depth of trench specified is more than the normal in the ROU requirement, the excavation
shall be done accordingly.
 Minimum depth of cover shall be measured from top of pipe as applicable to the top of
undisturbed surface of the soil or top of graded working strip or top of rail or top of road
whichever is lower.
 Bottom of Trench should be as square as possible. Manual dressing/ drag behind the trenching
machine/ adjusting and adopting the crumbing shoe and digging teeth of the trenching machine
may be adopted to achieve this.

Bedding of Trench underneath Pipe:

 Required in all cases where rock or gravel or hard soil is encountered in the bottom of the
trench.
 The thickness of compacted padding shall not be less than 200mm.
 Bedding/ Padding material shall be SOFT soil/ sand or other materials containing no gravel/
lumps/ hard soil.

Permitted reduction of the minimum trench depth

If, exceptionally, the minimum depth of the trench can not be achieve due to local reasons, the
pipeline cover may be reduced, provided prior approval of client. The method of excavation and
special protection must be approved by client.
3. HSE

a) All area to be excavated shall be checked thoroughly for existing U/G. utilities or any foreign
pipeline. If required “Trial holes” are to be made along the alignment centre line to ensure there
is no other facility or utility along the alignment route of pipe line.
b) After excavation near to crossing, area should be proper barricaded and use the reflected sign
board for night purpose.
c) During blasting at rock area, nearby area should be barricaded and keep the signal man
around 50meter all side. Blasting should not be carry out without permission of HSE in charge
of contractor, client and local authority and it is the responsibility of the HSE Personal of
contractor to check the area personally and allow the blasting.
d) Use proper signed board during operation. And take care of the work if any village or any
house is there.
e) Care shall be taken while working the existing overhead power lines. Minimum 5 mts.
Clearance shall be maintained.
f) Banks man shall be provided at all excavators position, shall have radium stripped jacket.
g) All equipment shall have valid T.C’S.
h) First aid boxes shall be available at working location.
i) Trench shall have stabilized slope according to soil conditions.
j) Open trench shall be barricaded properly to warn the local personnel & avoid any accidents.

6. Job Procedure for Lowering & Backfilling

1. Equipment
Hydra/Crane/Side boom
JCB
Backhoe
Theodolite / Dumpy level

2. Procedural Steps:
a) Lowering
 Lowering shall start only in the presence of client, after submission of section pipe book and
acceptance of the section to be lowered. Entire trench bottom shall be checked for the presence
of off cuts, pipe supports, stones, roots, debris, stakes, rock projections, underside of pipe and
any other materials.
 Bottom padding shall be done at all places where rock is encountered. The thickness of the
padding shall be at least 150 mm all around the pipe with fine soft soil. Initially a layer of 150
mm shall be spread in the trench before lowering.
 The pipeline shall be lifted and laid using, necessary, suitable slings. Care shall be exercised
while removing the slings from the pipe, after it has been lowered into the trench.
 Laying shall be carried out under safe conditions so as to avoid stresses and temporary
deformations, which may cause damage to the pipeline itself. In all localized points where the
ROW is restricted to the minimum, the laying shall be carried out using other suitable means.
The pipe section shall be placed on the trench bed without jerking, falling, impact or other similar
stresses. Minimum 3 no of Side Booms / Hydra Crane shall be deployed for lowering if the
section consists of more than 3 pipes. It shall be ensured that the pipe is laid gently following
the S’ curve within its elastic limit.
 Lowering shall not be permitted in night.
 Wherever the pipeline is laid under tension, as a result of undue stresses at specific points, the
trench shall be rectified to the satisfaction of client, so that it fits in the excavated trench bed.
 Pipe cover shall be checked immediately after lowering at every joint.

b) Back Filling
 Backfilling shall be carried out with in 24 hours after the pipeline has been laid in the trench,
inspected and approved by the client, so as to provide a natural anchorage for the pipeline,
sliding down of the trench sides and pipe movement in the trench. If immediate back filling is
not possible, a covering of atleast 200mm of earth shall be placed over and around the pipe.
 Where rock or like materials are encountered at the time of trench excavation, sufficient 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 300 mm above the top of the pipe. 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.
 When the trench has been dug through roads, all backfill shall be executed with sand or a
suitable material as approved by client and shall be thoroughly compacted. In certain cases,
special compaction methods, such as moistening or ramming of the back fill in layers may be
required by client. Client and any public or private authority having jurisdiction over a road,
street or drive way may require that the surface of the backfill be graveled with crushed rock or
some other purchased material and the road shall be repaved. In such instances, Contractor
shall comply with said requirements at no extra cost to client.
 Trenches excavated in dikes which are the parts 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 at no extra cost to client. The materials required may include gravel,
special stabilization materials or stabilized mixtures. Moreover, special processing and/or
compacting methods shall require the approval of client and/or competent authorities.
 The trench in irrigated and paddy fields shall be backfilled to within 300mm 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 as specified in “Clean up and
Restoration of ROW, of this specification.
 CONTRACTOR shall furnish materials and install breakers in the trench in steep areas (slope
generally 40% and more) for the purpose of preventing erosion of the back fill. The type of
breakers installed shall be as per the approved drawings. Breakers shall be constructed of grout
bags filled with a mixture of 4:1 Sand: Portland cement at client direction. Such works shall be
done at no extra cost to client. CONTRACTOR shall pay attention to the direction of back filling
in such steep areas.
 CONTRACTOR shall leave the pipe uncovered at certain locations to allow client to survey the
centerline of the pipe and the level of the pipeline in the backfilled trench. Within 24 hours after
backfilling, client shall carry such survey and informed CONTRACTOR of any re-aligning, if
required. Thereafter CONTRACTOR shall compact the backfill material.
 Finishing shall be carried out on backfill making a crown of about 300 mm on Dia. Of pipe line
for settlement of loose soil in the trench during the raining.
 Reinforced concrete slabs of size 1600mmX500mm and thickness 10cm shall be provided for
mechanical protection of pipeline. Concrete slabs or HDPE Sheet 6mm thk. shall be at utility
crossings and overhead power lines as per site conditions and instructions of client. The PVC
MAT shall also be used for the same as per instructions from client.

3. HSE
• All equipment’s / tools tackles shall have valid T.C.
• Trench shall be checked before lowering in operation, no person shall be inside the trench during
operation.
• Only designated man will give the signals to the equipment’s.
• All riggers, & other persons working around the lowering equipment’s shall have flourscent
jackets.
• Signal man will be positioned himself in such a way that he should be visible by all operators of
lowering equipment’s.
• End of pipeline shall be hold tightly till last pipe is lowered – in and moved in synchronize way.
• All the area shall be blocked & barricaded for unauthorized persons entry till operation is over.

7. Job Procedure for Tie-in

1. Procedural Steps

 Welds, joining the restricted movement sections of the pipeline, valve installation or similar
welds are classified as Tie-ins, which shall be made in the trench. Alignment of all Tie-in joints
shall be done utilizing external alignment clamp.
 External Clamp shall be used for all Tie Ins Joints and the same shall be removed after 60% of
root run.
 Direction of welding for root pass is uphill whereas other all passes are carried out downhill.
 The lowered section and other unconnected sections of the pipeline at various locations to be
tied in, shall have over lapping ends, and uncovered pipe of sufficient length (approx. 2 pipes
on either side) facilitating small displacement necessary for perfect alignment/ connection of
the ends without excessive stresses in the pipe line.
 A Tie-in pit of enough area for free movement of working personnel shall be cut to enable free
work access in the trench. Proper precaution shall be taken so as not to allow collapse or caving
in, which shall include the use of suitable shoring. An angle of repose of at least 100 at such
area is preferred according to soil condition.
 Contractor shall then carry out Tie-in welding operation, the excess pipe lengths are cut and
pipe end are prepared with proper bevel. 25mm length of both bevel ends shall be checked by
DPT & UT. All reports of Tie-ins along with NDT reports shall be submitted to client for review
and approval.
 Tie-ins shall be done in such a way as to leave minimum pipeline stress, which is feasible.
Realigning of the pipe shall be done to eliminate unnecessary force and strain in the pipes as
necessary to the respect with the trench profile. If any pup pieces are required for Tie-ins, the
minimum length shall not be less than 1 Mtr, more than one pup piece shall not be welded
together. Tie-in with two or more pups of length more than 1 Mt. may be used providing a space
of entire length of pipe. In no cases more than 3 welds shall be permitted in a 10 Mt. length of
main line.
 In connecting pipe, special items, fittings of differing material thickness, a special transition
piece shall be provided with 1:4 taper, those welds shall be subjected to both DPT &
radiography examination.
 Seam orientation of welded pipe (when applicable) shall be selected to ensure that at the
circumferential welds, the longitudinal welds shall be staggered in the top 900 of the pipeline.
 The root gap shall be checked and shall confirm to the qualified welding procedure parameters.
All spaces between line up clamp bars or at least 60% of root pass shall be welded before the
external clamp is released with the pipe remaining adequately supported on each side of the
joint.
 Segments thus welded shall be equally spaced around the circumference of the pipe. Slag etc
shall be cleaned off and the ends of the root pass shall be prepared for subsequent welding by
grinding, so as to ensure continuity of the weld bead. Qualified welders shall carry out welding
as per qualified welding procedure and, whilst welding is in progress, care shall be taken to
avoid any kind of movement of the component, shocks, vibration and undue stress, to preclude
possible occurrence of weld crack.
 Electrode starting (start) and finishing (stops) shall be staggered from pass to pass. Arc strikes
outside the bevel on the pipe surface shall not be permitted. Inter pass temperature shall be
maintained as per the qualified welding procedure.
 All finished welds shall be visually inspected for parallel and axial alignment of the work,
excessive reinforcement, and concavity of welds, shrinkage, cracks, under cuts, dimensions of
welds, surface porosity and other surface defects, which shall meet contract specification
requirements.
 Parts being welded shall be protected by windshields made of metallic frame covered by
Canvas, if necessary, to protect the welding operation from any adverse environmental or
weather effects. 100% RT shall be conducted on all Tie-in welds, the reports shall be submitted
to inspection agency for review and approval.
 For Tie-in of adjacent section of pipeline already pressure tested, a single pup or off cuts, which
have been hydraulically pre-tested shall be used. Contractor shall keep sufficient stock of
hydraulically pre-tested pipes.
  All golden joints are completely DP Tested after completion of root, 100% UT of both bevel
ends and after completion of joint UT and RT clearance should be required.

2. HSE
o It is to be noted that the special care to be adopted against snake / insects bite.
o PPE is a must in this activity.
o Only trained rigging personnel to be deployed for this activity,
o All Measuring & Test Equipments used must be well maintained.
o All lifting devices & Tolls used shall be well maintained and approved by a
competent authority.
8. Job Procedure for Pre-Hydrostatic testing
1. Procedural Steps
Water filling and pressurization
 All weld joints in test loop / section shall be radio graphically cleared and accepted before
water filling.
 Chlorine free 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 two bar/min to a test pressure.
 Pressure shall be applied by means of a suitable test pump, which shall not be connected
to a system until ready to test. A pressure gauge shall be provided at the pump discharge
for guidance, 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 30 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.
 During the test, care shall be taken that the hydrostatic test pressure never exceeds 5 bar
more than the actual pressure. 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 out 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.
HSE:

Provision shall be made for the installation of no-admittance signs to unauthorized personnel
from the roads to the R.O.W.

Process area shall be barricaded.

9. Job Procedure for Horizontal Directional Drilling
1. Procedural Steps
Pre Construction Activities
 The following steps should be undertaken by Contractor in order to ensure safe and efficient
construction which minimum interruption of normal, everyday activities at site.
1. Obtain all necessary permits or authorizations to carry construction activities from client.
2. The proposed drill path should be determined and documented, including its horizontal and
vertical alignments from the alignment sheet submitted by the contractor.
The size of excavations for entrance and exit pits should be of sufficient size to avoid a sudden
radius change of the pipe, and consequent excessive deformation at these locations. Sizing the
pits is a function of the pipe depth, diameter and material. All pits over 5’ depth must be shored
properly or side wall shall be given proper slope.

 Contractor to walk the area prior to the commencement of the work and visually inspect
potential sites. The following should be addressed.
1. Contractor to establish stability of soil conditions for HDD operations (The HDD) method is
ideally suited for soft sub-soils such as clays and compacted sands.
Installation requirements
 Contractor shall ensure that appropriate equipment is provided to facilitate installation; in
particular the drill rig shall have sufficient pulling capacity to meet the required installation loads.
The drill rig should have the ability to provide pull loads, push loads; torque. Contractor shall
ensure the drill rod can meet the bend radii required for the proposed installation.
 During construction continuous monitoring and plotting of pilot drill progress shall be undertaken
to ensure compliance with the proposed installation alignment and allow for appropriate course
correction to be undertaken that would minimize “dog legs” should the bore start to deviate from
the intended path.
 Monitoring shall be accomplished by manual plotting based on location and depth readings
provided by the locating / tracking system.
 Contractor shall ensure that all drilling fluids are disposed of in a manner acceptable to the
appropriate local authority. While drilling in contaminated ground the drilling fluid shall be tested
for contamination and disposed of appropriately.
 To minimize heaving during pull back, the pull back rate shall be determined which maximizes
the removal of soil cuttings and minimizes compaction of the ground surrounding the bore hole.
The pull back rate shall also minimize over cutting of the borehole during the back reaming
operation to ensure excessive voids are not created resulting in post installation settlement.
 The carrier section to be pulled should be pre hydro tested.

Contractor Responsibilities.
 Contractor shall identify in the construction plan:
1. Location of entry and exit pits
2. Working area and their approximate size.
3. Proposed pipe fabrication and layout areas.
4. Pproperty lines, utility drawings :

Contractor shall coordinate with the local agencies and utilities for identification of any other utility
on the route mentioned / not mentioned in the alignment sheet/ drawings by client with no additional
cost to client.
Locating & Tracking
 Contractor shall submit an as built data sheet for locating and tracking the drill head during the
pilot bore. The locating and tracking system shall be capable of ensuring the proposed
installation can be installed as intended.
 The locating and tracking system shall provide the following information
o Clock and pitch information
o Depth
o Battery status
o Position (x, y)

Safety
 The drilling unit should be equipped with an electrical strike safety package; the package
should include warning sound alarm.

Drilling Operations
 Contractor shall deploy only experience operators to operate the drilling equipment. And also
to ensure the following points strictly during drilling.
o The drill path alignment should be as straight as possible to minimize the fractional
resistance during pull back and maximize the length of the pipe that can be installed during
a single pull.
o It is preferable that a straight tangent section be drilled before the introduction of a long
radius curves. Under all circumstances, a minimum of one complete length of drill rod
should be utilized before starting to level out the borehole path.
o Entrance angle of the drill string should be between 8 and 20 degrees, with 12 degrees
being considered optimal. Shallower angles may reduce the penetrating capabilities of the
drilling rig, while steeper angle may result in steering difficulties, particularly in soft soils. A
recommended value for the exit angle of the drill string is within the range of 5 to 10 degree.
Whenever possible, HDD installation should be planned so that back reaming and pulling
for a leg can be completed in the same day, if necessary, it is permissible to drill the pilot
hole and pre-ream one-day, and complete both the final ream and the pull back on the
next day.
Pipe installation should be performed in a manner that minimizes the over-stressing and
straining of the pipe.
Equipment Setup and Site Layout.

 Contractor shall ensure that there is sufficient space required on the rig side to safely set up
and operate the equipment. A working space of similar dimension to that on the rig side shall
be allocated on the pipe side, in case there is a need to move the rig and attempt drilling from
this end of the crossing.
 If at all possible, the crossing shall be planned to ensure that drilling proceed down hill allowing
the drilling mud to remain in the hole. Minimize inadvertent return.
 Sufficient space shall be allocated to fabricate the product pipeline into one string, thus enabling
the pullback to be conducted in a single continuous operation. Tie-ins of successive strings
during pullback may considerably increase the risk of an unsuccessful installation.
Drilling & Back Reaming.

 Drilling mud shall be used during drilling and back reaming operations. Using exclusively water
may cause collapse of the borehole in unconsolidated soils. While in clays, the use of water
may cause swelling and subsequent jamming of the product.
 Heaving may occur when attempting to back ream too large of a hole. This can be avoided by
using several pre-reams to gradually enlarge the hole to the desired diameter.
  A swivel shall be attached to the reamer, or drill rod, to prevent rotational torque being
transferred to the pipe during pull back.
 In order to prevent over stressing of the pipeline during pullback, a weak link, or breakaway-
pulling head, may be used between the swirl and the leading end of the pipe.
 The pilot hole must be back-reamed to accommodate and permit free sliding of the pipeline
inside the borehole. A rule of thumb is to have a borehole 1.5 times the pipeline outer diameter.
This rule of thumb should be observed particularly for larger diameter installation (> 250 mm
O.D)
 The pipeline must be sealed at either end with a cap or a plug to prevent water, drilling fluids
and other foreign materials from entering the pipe as it is being pulled back.
 Pipe rollers, slates or other protective devices should be used to prevent damage to the pipe
from the edge of the pit during pull back, eliminate ground drag or reduce pulling force and
subsequently reduce the stress on the product.
 The drilling mud in the annular region should not be removed after installation, but permitted to
solidify and provide support for the pipe and neighboring soil.

Tie-ins and Connections

 Trenching may be used to join sections of pipeline installed by the directional boring method.
 An additional pipe length, sufficient for joining to the next segment, should be pulled into the
entrance pit. This length of the pipe should not be damaged or interfere with the subsequent
drilling of the next leg.
Alignment & Minimum Separation
 The product should be installed to the alignment and elevations shown on the drawings within
the pre-specified tolerances (tolerance values are application dependent for example, in a major
river crossing, a tolerance of + 4m from the exit location along the drill path centerline may be
an acceptable value).
Site Restoration and Post Construction Evaluation
 All surfaces affected by the work shall be restored to their pre-construction conditions.
Performance criteria for restoration work will be similar to those employed in traditional open
excavation work.

 If required, Contractor shall provide a set of as-built drawings including both alignment and
profile. Drawing should be constructed from actual field readings. As part of the “As-Built”
document Contractor shall specify the tracking equipment used, including method of
confirmatory procedure used to ensure the data was captured.

10. Job Procedure for Hydro Testing Of Pipe Line

1. Procedural Steps
The procedure shall strictly comply with the requirements of this specification and shall be
submitted to client for approval. The procedure manual shall include all temporary materials
and equipment, but not limited to the following items.
 For the systems to be tested, a diagram indicating all fittings, vents, valves temporary
connections, relevant elevations and ratings. The diagram shall also indicate injection locations
and intake and discharge lines. Approved Pipe Book shall also be made available.
 Estimated amount of test water, water sources, including required concentration of corrosion
inhibitors and additives, procedure for inhibitor injection and control of concentration.
 Filling and flushing procedures, including a complete description of all proposed equipment and
instruments (including spares), their location and set-up.
 Procedures for stabilization after filling & pressurization to allow for temperature stabilization.
  Pressure testing procedure including a complete description of all proposed equipment and
instruments (Including spares), their location and set-up, and proposed system for observation
and recording of data during the pressure test.
 Procedure for detection and location of leaks.
 Procedure for de-watering the pipeline section(s) after testing, including a complete description
of all proposed equipment and instruments (including spares), their location and set-up, type
and sequence of pigs & pig tracking system along with the pig specifications.
 Forms for recording the test data.
TEST DURATION AND PRESSURE
 The duration of hydrostatic test shall be minimum 24 hours after stabilization and the test
pressure shall be as indicated in the approved hydrostatic test diagram.
 Pre-Test Water Pressure and final hydrostatic water test pressure shall be as specified in
specification.
EQUIPMENT AND INSTRUMENTATION
 The CONTRACTOR shall furnish all necessary equipment for performing the work as stated in
cleaning, flushing, filling, leveling, stabilizing, testing and de watering procedures.
 This shall include, but not be limited to, the following equipment and instruments.
 Pigs in filling, cleaning and water filling.
Contractor shall provide sufficient number of pigs for cleaning, gauging, water filling, swabbing
and for drying of Pipeline.
 Fill pumps:
The CONTRACTOR shall determine the type and number of fill pumps in order to guarantee
the following:
Differential head 20% greater than the maximum required. If single pump is used a standby
unit must be available.
 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.
 Two positive displacement meters to measure the volume of water used for filling the line.
These meters shall be provided with a calibration certificate not older than one month.
 Portable tanks of sufficient size to provide a continuous supply of water to the pump during
pressurizing.
 Bourdon pressures gauges of suitable pressure range (1.5XTest Pressure) and
accuracy.(+0.1%of FCV)
 Dead weight tester with an accuracy of 0.01 bar and sensitivity of 0.05bar shall be provided
with a calibration certificate not older than one month, which shall be traceable to National
Physical Laboratories. The pressure range of dead weight tester shall be 1.5 times the hydro
test pressure
 Two 24 hours recording pressure gauges with charts and ink gauges tested with dead weight
tester prior to use. These shall be installed at the test heads.
 Pressure recording charts of 24Hours.
 Two temperature recorders with an accuracy of +0.1%of FCV and sensitivity shall be 0.1 oC.
for fill water.
 Thermocouples for measuring the pipe wall temperature & soil temperature with an accuracy
of +0.2 oC.
 Two laboratory thermometers 0oC to 60oC range, accuracy + 0.1 degrees duly calibrated.
  Injection facilities to inject anti-corrosion additives into the test medium in the required
proportions.
 Communication equipment suitable for a continuous communication 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.
 The temporary scraper traps shall be installed according to the testing sections agreed in the
test procedure manual. Proper piping and valve arrangements shall be available to allow
launching and receiving of each pig independently. The test heads shall be sized in conformity
with ASME specification Section VIII, Division 2 with particular reference to Appendices 4 and
5.
Thermocouples (Surface Type Contact) for measuring the temperature of the pipe wall shall be
installed on the pipeline to be tested:
 1 thermocouple at about 500 m distance from the one end.
 1 thermocouple every 2500 m of the pipe.
 1 thermocouple at about 500 m distance from the other end.

Thermocouples shall be attached on the external surface of the pipe.

 A well maintained test cabin shall be made available at pumping head site by contractor. The
test cabin shall include all instrumentation & their controls and proper communication & safety
facilities.

PROCEDURES

 Equipment and / or parts which need not or must not be subjected to the test pressure, or
which must not be tested with water, must be disconnected or separated from the pipeline to
be tested.

 If the difference of minimum and maximum atmospheric 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.

 The test medium shall be soft non-aggressive water furnished by the CONTRACTOR. 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 provide client approved corrosion inhibitors, oxygen scavengers and bactericides to be
added to the test water. The CONTRACTOR shall furnish and install all temporary piping
which may be necessary to connect from source of water to its pumps and manifolds /
tankages.
Air Pigging:
Before filling operation, Contractor shall clean the pipeline by air driven pigs to be carried out
as per client specifications. Air pigging shall be preferable in sections. of thickest pipe internal
diameter.
Note: - Cleaning of line shall be evaluated by client.
If the pig stuck up in the line. Contractor shall locate the pig / identify the cause and should
rectify the damage of pipe without any additional cost to client.
WATER FILLING:
The section, which is planned for water filling, shall be cleared from NDT, air cleaning. A
detailed pipe book for the section to be tested shall be submitted by Contractor to client for
review before commencement of water filling activity. Filling header shall consist of Minimum 3
pigs and the headers are to be pre-tested before welding to main line. During filling the pipeline
is to be flushed with minimum 1km of pipeline volume and water shall be filled with corrosion
inhibitor by propelling minimum two pigs with water column of 100meters the volume of water
used for filling shall be measured by turbine meter / flow meter at every one hour interval.
THERMAL STABILIZATION:
 After a check has been made to confirm if the pressure has attained at least 1 bar (g) 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.
 Temperature readings shall be made at 2 hours - intervals. Thermal stabilization shall be
considered to have been achieved when a difference not higher than 1OC is attained between
the average values of the last two readings from pipe to soil Thermal stabilization completion
shall be approved by client.

PRESSURIZATION

The pressurization shall be performed in the presence of client at moderate and constant rate
not exceeding 2 bars / min. One pressure recorder shall be installed in parallel with the dead
weight tester. Volume of water used to reach the test pressure shall be recorded periodically
throughout the pressurization by recording no of stroke. The pressurizing shall be cycled
according to the following sequence:
 Pressurize to 50% of test pressure, hold pressure for 1 hour and collect water for air volume
calculations.
 Drop pressure to static head of test section at test head.
 Pressurize to 75% of test pressure, hold pressure for 1 hour and collect water for air volume
calculations.
 Drop pressure to static head of test section at the test head.
 Pressurize to test pressure.

In case, during the hold periods indicated above, a decrease in pressure is observed, the above
operations shall not be repeated more than twice, after which the line shall not be considered
capable of test, until the CONTRACTOR has isolated and eliminated the cause for the lack of
water tightness.

AIR VOLUME CALCULATION PLOTTING

In order to check the presence of air in the pipeline, two separate consecutive pressures
lowering of 0.5bar shall be carried out.
For calculation of air in the pipeline the second pressure lowering shall be used, and the
relevant drained water shall be accurately measured (V1). This amount measured shall be
compared to the theoretical amount (V2) corresponding the pressure lowering that has been
carried out, by using the procedure outlined in the specification.
If no air is present in the length under test:
V1
--- =1
V2
In order that the above ratio is acceptable, it shall not differ from 1 by more than 6%
(i.e.1.06).
If ratio is find within limits, pressurization can continue, If not, water refilling shall be carried
out by passing of another pig.
Testing:
After the section has been pressurized and the air volume test has given acceptable results the
test pressure shall be held for a minimum of 1 Hours after stabilization. After temperature and
pressure has stabilized, the injection pump shall be disconnected and all connections at the
test heads shall be checked for leakage. The pressure recorders shall then be started with
 the charts in a real time orientation for continuous recording throughout the test. 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 pressure measurements from dead weight testers.
- Every two hours the ambient temperature and the pipe temperature at the
thermocouples.
All data shall be recorded on appropriate forms attached to the hydrostatic Test procedure
manual. Care shall be taken that the maximum test pressure is not exceeded.
Bleed off water shall be accurately measured and recorded.

ACCEPTANCE
 The hydrostatic test shall be considered as positive, if pressure has kept a constant value
throughout the test duration, except for change due to temperature effects

 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 the initial value and the test shall be considered as acceptable if the difference
is less than or equal 0.3Bar. 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 searching the location of leakage or failure. All leaks and failures within the pipe
wall or weld seam shall be repaired by replacement of entire joint 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 instructions of the client whether to replace a section of the
line pipe that includes the line leak or whether to repair the circumferential weld. Where failures
occur in pipeline field bends, bends shall be replaced with same degree of bends. After
completion of repairs, the hydrostatic test shall be repeated in full, as per this specification.
 The cost of repairs or replacements, followed by refilling and re-pressurizing the line, due to
poor workmanship, shall be borne by the CONTRACTOR. In the event of leaks or failures
resulting from faulty client furnished materials, CONTRACTOR shall be reimbursed for
furnishing all labor, equipment, materials, except those materials furnished by the client and
transportation necessary to repair and re pressurize the section of the pipeline to the pressure
at the time of recognition of leak or line failure.
 CONTRACTOR shall be entitled for compensation as per the provisions of the CONTRACT.
 All work of reinstalling line pipe, to replace failures, shall be done in accordance with the
relevant Specifications included in the CONTRACT..

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

DEPRESSURIZATION AND DEWATERING

The pipeline shall be slowly depressurized at a moderate and constant rate as instructed by
client.
 CONTRACTOR shall de-water the tested line as per the following requirement after test
acceptance.
 Using four-cup pigs (polycups) and foam shall carry out the de-watering. Pigs shall be
driven by compressed air.
 The detailed dewatering procedure shall be developed by the CONTRACTOR in such a
way as to provide adequate control of pigs during de-watering.
  Pigs and equipment required for dewatering the line shall be furnished by CONTRACTOR
and shall be approved in advance by the client.
 Four-cup pigs shall first be passed through the line to displace the water. Foam pigs shall
then be passed in order to complete the line de-watering.
 CONTRACTOR shall use a number of foam pigs each in different colors / numbered for
this purpose.
 The line shall be considered de-watered when a negligible amount of water is flushed out
by the last foam pig and approval is given by the client.

 During de watering, care shall be taken to properly dispose the discharging water in order to
avoid pollution, damages to fields under cultivation and / or existing structures and interference
with the traffic. As chemical have been added to water, dewatering shall be done in such a way
that the composition of the efficient water does not exceed the limit set in IS 2490 (Part-I)
tolerance limits for industrial effluents discharged into in land surface water. Hence, dewatering
circuit shall include chlorination before letting the water out of the pipe section to the
environment.

 Upon completion of the testing and dewatering operation, any provisional traps for pigs and all
other temporary installation relating to the test shall be removed. Subsequently, the individual
sections of the line already tested shall be joined in accordance with the requirements of
relevant specifications issued for the purpose. Upon completion of dewatering, swabbing shall
be followed by using foam pigs. Weight of last pig received, shall not be more than 25% of initial
weight.

MEASUREMENTS
WATER AMOUNT MEASUREMENT
The water volume added to the section to be tested shall be measured during the filling stage
through a positive displacement meter (a turbine meter may also be used). Calibration
certificates shall not be older than one month. Satisfactory performance on site to be
established.
In the calculation, as per this specification, use shall be made of the geometrical volume of the
section. The water amount that has been let into the section shall be measured during the
pressurization stages through positive displacement meters or turbine meters.

PRESSURE MEASUREMENT
Pressure shall be measured with a dead weight tester that shall permit readings of at least 0.05
bar.
During the test the pressure shall be recorded by means of a recording pressure gauge
featuring the following specifications:
Accuracy : + 0.1% of the full scale vale
Recording : Continuous on tape or disk, graph width 100 mm
Feed : 20mm/h for tape diagrams, 7.5o/h for disk diagrams.
Recording range : To be such as to record pressure between 50% and 90% of the Diagram
width.
The recording pressure gauge shall be checked by means of dead weight test at the beginning,
during and at the end of the hydrostatic test.
TEMPERATURE MEASUREMENT:
Water temperature shall be taken at every 4 hours through the thermocouples that have been
installed along the section under test on the pipe wall.
Further, the temperature measurement shall be taken:
 During the thermal stabilization stage
 During the hydrostatic test
 The thermocouples’ sensitivity shall enable temperature readings with accuracy of + 0.2oC.

Water temperature shall be recorded from the beginning of pressurization to the end of the test
by means of a recording thermometer featuring the following characteristics:
Accuracy : + 1% of the scale range
Scale : 0oC to + 60oC
CALCULATIONS
The theoretical water amount that is necessary for filling the section to be tested shall be
obtained from the geometrical volume of the section considering the pipe tolerances.
The theoretical water amount that is necessary for pressurizing the section shall be calculated
by means of the following formula:
ri
Vp = (0.884 ----- A) X 10-6 x Vt x P x K
ti
Where:
Vp = Computed water amount required to rise by P the Pressure in the section to

be tested (m3).
Vt = Geometrical volume of the section (m3).
P = Pressure rise (bar).
ri = Nominal inner radius of the pipe (mm).
ti = Nominal pipe thickness (mm).
A = Isothermal compressibility value for water at The Pressurization temperature
in the P range (bar-1) x 106. (Refer water compressibility factor Vs pressure
and Temperature chart).
K = A dimension less coefficient that is equal to A value of 1.02 for
longitudinally welded pipe.

The pressure change due to a water temperature change shall be calculated through the
following
Formula:
B X ΔT
ΔP = ——————
0.884 ri + A
ti
Where,
ΔP = Pressure change resulting from a temperature change (bar)
ΔT = Algebraically 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 the test and that of steel (oC-1) x
106.
A = Isothermal compressibility value of water as estimated at the pressure and
temperature values obtained at the end of test (bar-1) x 106.
ri = Nominal inner radius of the pipe (mm).
ti = Nominal pipe thickness (mm).

PRECAUTIONS DURING THE TEST

In addition to all that has been expressly described in the procedures for carrying out the tests,
the following additional requirements shall be complied with:
 Provision shall be made for the installation of no-admittance signs to unauthorized personnel
from the roads to the R.O.W.

Signs stating “PIPE UNDER TEST KEEP OFF” with local language translation shall be placed
where the pipeline is uncovered, and particularly where the provisional traps and stations are
located. Such areas shall be suitably fenced in such a way as to prevent access of unauthorized
personnel. No unauthorized personnel shall be closer than 40 m to the pipeline or equipment
under test.

Provisional scraper traps shall be installed in compliance with methods and suitable locations
so that their rupture cannot cause any injuries to the personnel or third parties.

The test station shall be placed in such a location as to prevent it from being affected by a
catastrophic failure in the test head.

Once dewatering is over, the sectionalizing valves and other valve assemblies tested
previously shall be installed at locations shown in the drawings and in accordance with the
procedures contained in the relevant specifications. All thermocouples installed in the pipeline
shall be removed.

PRESERVATION OF PIPELINE
When so stated in the CONTRACT, to preserve / conserve the pipeline for a specified duration,
CONTRACTOR shall completely fill the pipeline with water, with sufficient quantity of corrosion
inhibitors depending upon quality of water and the period of conservation, at a pressure to be
agreed upon with the client at a later stage. CONTRACTOR shall obtain necessary approval
from the client’s of the procedure and the type and quantity of the inhibitors used before
commencement of the works.

DOCUMENTATION
Contractor shall provide following as minimum
 Schematic layout of cleaning, filling and testing facilities.
 Calibration certificate of measuring instrument and testing equipment.
 A profile of the pipeline that shows the test sites, all instrument and injection connection.
 Pipe filling logs and records.
 Additive specification, required concentration and additive injection records.
 Pig inspection records including photographs of the damages.
 Records of gauging pig and photograph.
 Quality records.
All the reports identified mentioned in this procedure.
Inspection and Test Plan
Test procedure for cleaning, flushing, filling and testing.
 Air-volume calculation
 Pressure change due to temperature change calculation.
 Records and photograph of all leaks.

11. Job Procedure for Dewatering & Swabbing

1. Equipment
i. Compressor
ii. Batch Pig / Foam Pig
iii. Pressure Gauges
iv. Spring Balance

2. Procedural Steps

Dewatering
i. Dewatering operation shall consist of number of dewatering pig runs when air is used as
propellant for pig trains.
 ii. Bi-directional cup pigs, which are designed to prevent damage to pipeline, shall be used
for dewatering.
iii. Minimum speed and backpressure of the pigs will be defined for continuous operation.
iv. All calculations to be submitted regarding this procedure and contingency plan for
implementation in case the pigs get stuck.
v. A pig at the receiving end should be removed in the presence of Engineer In-charge.

Swabbing
i. Air pigging headers shall be used for launching the foam pigs. Weighing arrangements
shall be available at launching and receiving ends. There shall not be any traces of oil in
the compressed air used for launching the pigs.
ii. After de-watering the hydro test water, Swabbing shall be carried out as per following
procedure.
iii. Remaining water if any shall be removed by four cup batch pig and high density foam pig.
iv. One no. of low density foam pig shall be launched after ensuring that all water has been
removed.
v. Then approx. 1 km of compressed air shall be injected into the pipe.
vi. After this low density foam pig shall be launched.
vii. During the running of the pig train pipe line pressure shall be recorded.
viii. The swabbing operation shall involve the weighing of the pigs before launch & immediately
after their removal. The swabbing operation shall be considered to be complete when it is
established that there is no free water left in the pipeline and the pipeline is ready for drying.
The Swabbing operation shall be repeated till the weight of the last received foam pig does
not increase by more than 25%.
.
3. HSE

i. Use of PPEs
ii. Compressor is properly grounded
iii. Cordoning the work place by the cordoning tape
iv. Minimum persons to be kept at site
v. Skilled workers to be allowed to do job.
vi. Use of Standard and Calibrated Gauges

12. Job Procedure for Exposed Pipeline section Painting

1. Equipments
Equipment and consumables required for painting as follow:
i Compressor & sand blasting unit
ii Spray unit & painting brush
iii Elco meter
iv Profile Gauge
v Oil and Water Separators

2. Material:

All painting materials shall conform to client Specification. The paint manufacturer’s instructions
shall be followed as far as practicable at all times. Particular attention shall be paid to the following:

i. Instructions for storage to avoid exposure as well as extremes of temperature.

ii. Surface preparation prior to painting.
iii. Mixing and thinning and shelf life of paint materials.
iv. Application of paints and the recommended limit on time intervals between coats.
v. Primer should be use Zinc Anode 304 & Epilux 610 and finish Paint should be Epilux
04 & Thane Enamel 41 (Golden yellow) for from the same manufacturer.

3. Procedural Step:
 SURFACE PREPARATION, SHOP COAT, COATING APPLICATION & REPAIR AND
DOCUMENTATION

General:

i. All painting works shall be commenced only after Line/system/ tests have been
completed and cleared for painting .However primer application may be started prior to
fabrication works except welding joints.
ii. In order to achieve the maximum durability, one or more of following methods of surface
preparation shall be followed.

Blast cleaning:

i. Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure that a
clean and dry surface is obtained in blast cleaning it shall be SA 2½ or equivalent as
per Swedish Standard SIS-05-5900-1967. Where highly corrosive conditions exist, and
then blast cleaning shall be SA 3 as per Swedish Standard.
ii. Remove all other contaminants, oil, grease etc. by use of an aromatic solvent prior to
surface cleaning.
iii. Blast cleaning shall not be performed where dust can contaminate surfaces undergoing
such cleaning or during humid weather conditions having humidity exceeding 85%.
iv. Irrespective of the method of surface preparation, the first coat of primer must apply on
dry surface. This should be done immediately and in any case within 4 hours of cleaning
of surface. However, at times unfavorable weather conditions client shall have the
liberty to control the time period, at their sole discretion and/or to insist on reclining, as
may be required during unfavorable weather conditions, blasting and painting shall be
avoided.
v. Screen off each flange collar, any openings not sealed off, all non metal structures such
as rubber, filter against blasting no blasting grains or grits, metal fillings or paint should
get into the pipes, valves, operators & other devices.

Procedure for Surface Preparation

Air Blast Cleaning:-

The surface shall be blast cleaned using dry clean river sand at pressure app. 7kg/cm2 at
appropriate distance and angle depending on nozzle size maintaining constant velocity and
pressure.

Compressed air shall be free from moisture and oil. On completion of blasting operation, the
blasted surface shall be clean and free from any scale or rust and must show a gray white
metallic luster. Primer or first coat of paint shall be applied within 4 hours of surface preparation.
Blast cleaning shall not be done outdoors in bad weather without adequate protection or when
there is dew on the metal which is to be cleaned. Surface profile shall be uniform to provide
good key to the paint adhesion.

Necessary precautions shall be taken to ensure the safety of personal and property during
blasting operation. The blasting area shall be adequately barricaded. All the necessary personal
safety appliances like nose mask, ear plug goggles, gloves etc. shall be provided by contractor.

Non compatible shop coat primer

The compatibility of finishing coat should be confirmed from the paint manufacturer. In the event
of use of primer, the paint system shall depend on condition of shop coat. If shop coat is in
satisfactory condition showing no major defects, the shop coat shall not be removed. The touch
up primer and finishing coat(s) shall be identified for application by engineer -in-Charge.

i. Shop coated (coated with primer & finishing coat) equipment should not be repainted
unless paint is damaged.
ii. Shop primed equipment and surfaces will only be ‘spot cleaned’ in damaged areas by
means of power tool brush cleaning and then spot primed before applying one coat of
field primer unless otherwise specified. If shop primer is not compatible with field primer
then shop coated primer should be completely removed before application of selected
paint system for particular environment.
iii. If any damage is there in shop coated equipment, contractor shall obtain information
regarding treatment of surface & quality of paint that was used primer and finish coat/
intermediate coat shall be of same manufacturer.

Procedure and Application:

i. Surface shall not be coated in rain, wind or in environment where injurious airborne
elements exists, when the steel surface temperature is less than 50F above dew point,
when the relative humidity is greater than 85% or when the temperature is below 400F.
ii. Blast cleaned surface shall be coated with one complete application of primer as soon
as practicable but in no case later than 4 hrs. on the same day.
iii. To the maximum extent practicable, each coat of material shall be applied as a
continuous film uniform thickness free of probes. Any spots or areas missed in
application shall be recoated and permitted to dry before the next coat is applied.
Applied paint should have the desired wet film thickness.
iv. Each coat shall be in proper state of cure or dryness before the application of
succeeding coat. Material shall be considered dry for recoating when an additional coat
can be applied without the development of any detrimental film irregularities, such as
lifting or loss of adhesion of the under coat. Manufacturer instruction shall be followed
for inter-coat interval.
v. When the successive coat to the same color have been specified, alternate coat shall
be tinted, when practical, sufficiently to produce enough contrast to indicate complete
coverage of the surface. The tinting material shall be compatible with the material and
not detrimental to its service life.
vi. Brush application of paint shall be in accordance with the following:

a. Brushes shall be of good quality which will enable proper application of paint. Round
or oval brushes are most suitable for rivets, bolts, irregular surfaces, and rough
or pitted steel. Wide flat brushes are suitable for large flat areas, but they shall
not have width over five inches.
b. Paint shall be applied into all corners.
c. Any runs or sags shall be brushed out.
d. There shall be a minimum of brush marks left in the applied paint.
e. Surfaces not accessible to brushes shall be painted by spray, daubers.

vii. Mechanical mixing shall be used for paint mixing operations in case of two pack
systems except that the client may allow the hand mixing of small quantities at his
discretion.
viii. For each coat the painter should know the WFT corresponding to the specified DFT
and standardize the paint application technique to achieve the desired WFT. This has
to be ensured in the qualification trial.

Drying of coated Surfaces –

i. No coat shall be applied until the preceding coat has dried. The material shall be
considered dry for re-coating when another coat can be applied without development
of any film irregularities such as lifting or loss of adhesion of undercoats. Drying time
of the applied coat should not exceed maximum specified for it as a first coat; if it
exceeds the paint material has possibly deteriorated or mixing is faulty. Drying time
shall be as per manufacture recommendation.
ii. No paint shall be force dried under conditions which will cause chocking, wrinkling,
blistering formation of pores, or detrimentally affect the condition of the paint.
iii. No drier shall be added to paint on the job unless specifically called for in the
manufacturer’s specification for the paint.
 iv. Paint shall be protected from rain, condensation, contamination, snow and freezing
until dry to the fullest extent practicable.

5. INSPECTION & TESTING

i. All painting materials shall have manufacturers test certificates. Paint formulations
without certificates are not acceptable.
ii. After surface preparation, the primer should be applied to cover the crevices, corners,
sharp edges etc.
iii. Surface preparation shall be checked visually & incase of blast cleaning, prepared
surface shall be checked with a press o film, comparator or a surface profile
gauge.(Ref. SWEDISH STANDARD ISO 8501-1-1988/ SIS -055900-1967
iv. After each coat of painting, DFT (Dry film thickness) shall be checked and if the DFT is
less than the acceptable limit then a make-up coat shall be applied.
v. The total DFT (225 Micron minimum) shall be checked by decimeter.

6. HSE

i. Use of PPEs
ii. Compressor should be properly grounded
iii. Minimum persons kept at the work place

13. Job Procedure for Marker Installation

 Procedural Steps

 The following are different types of markers to be installed for Pipe Line Project.

1. Pipeline Warning Sign:

Pipeline warning sign shall identify the existence of the pipeline and display the name of Client,
with an emergency telephone number, as shown in Standard Drawing and as specified by
client.
Pipeline Warning sign shall be installed at:-
o Road Crossing - 1 No.
o Minor Water Crossing - 1 No.
o Major Water Crossing - 2 Nos.
o Valve station/stations - 1 No.
o Any other locations as specified by client.
2.0 Kilometer Markers:
Kilometer markers shall in general be installed along the pipeline between the aerial markers at
every one kilometer interval. Markers shall indicate cumulative distance in kilometers from the
reference station, as directed by client.K.M post shall be installed 1000mm to the left of pipe centre
line viewing towards the direction of flow.

3.0 Directional Marker:

Directional markers shall be fabricated and installed to identify significant turning points of the pipe
line during aerial traverse. One directional marker shall be installed at each turning point.
4.0 Navigable Waterway Pipeline Crossing Warning Sign:

Navigable Waterway Pipeline Crossing Warning Sign shall be fabricated in accordance with the
drawing. Such warning sign shall be installed one in each bank of navigable water courses at the
pipeline crossing location.
 Painting and Coloring:
 o Contractor shall pre-cast all boundaries and engrave inscriptions centrally in the mould
on one face.
o Concrete for boundary markers shall be as per approved drawings.
o Above ground part of the boundary markers shall be painted yellow with min 3 coats of
approved quality paint. Inscriptions shall be painted black.
o Approved drawing of fabrication & painting to be provided.

14. Job Procedure for ROU RESTORATION

1. Procedural Steps
 CLEAN-UP AND RESTORATION OF RIGHT OF WAY
Contractor shall restore the ROW and all sites used for the construction of pipelines for Surplus
and Shortage of soil, Temporary and Permanent structure, Repairing of Damages.

 SOIL SURPLUS
If on site, as a result of the work and after careful back filling and compacting, a sub-soil surplus
exists, this shall be worked up by grading and compacting below the sub-soil top layer and as
a rule this shall be done in the same plot of land. It shall not be permitted to remove the surplus
from the plot concerned, unless it concerns rejected soil, which has to be removed. Working up
surplus soil or removal of rejected soil shall be considered to pertain to the ROW. The disposal
of materials shall be to the account of CONTRACTOR.

 SOIL SHORTAGES
If due to unforeseen circumstances during back filling and compacting there should not be
enough soil to fill the trench properly, or to install the crown height as stipulated,
CONTRACTOR shall supply the necessary back fill material. Soil shortages shall be
supplemented and applied before the topsoil is replaced.
The soil to be supplied shall be worked up in those locations and into those layers where a soil
shortage has been established. The quality of the supplemented soil shall be equals to that of
the shortage.

 TEMPORARY STRUCTURES
All auxiliary structures such as bridges, culverts, sheet piling, posts, signs, etc., which were
erected or installed by CONTRACTOR as temporary measure, shall be removed.

 REPAIR OF DAMAGES
Damages to roads, bridges, and private property. All fence and other structures. Slopes,
watercourse sider or banks, which have been partially or totally demolished. All boundary
stones, which have been moved of, removed. All cadastral or geometric markers, The bed of
ditches crossed by the pipeline, open drains All openings in or damage. Crop fields. A sapling
of any plant/tree uprooted or cut during construction and fences shall be carried out to the
complete satisfaction of client, landowner and/or tenant Stringing shall be done in such a
manner, that the `strung pipes are not to be subjected to standing in any ground surface water.
 On completion of clean up, the ROW shall be restored to such stable and usable condition
as may be reasonably consistent with the condition of ROW prior to laying to pipeline.
Client will require from CONTRACTOR signed releases from land owners regarding
satisfactory indemnification and restoration of their lands
 If site and/or climatic conditions should render this necessary, client shall have the right
to instruct CONTRACTOR to suspend certain parts of the WORK related to the clean up
and postpone it to a later date
2. HSE

 PPE is a must in this activity

 Proper stacking of materials is required.