TITLE: 03501-1 - Underground Piping Installation

DATE; June 18, 1993

REV.: 0

UNDERGROUND PIPING INSTALLATION

1.0 PURPOSE

To provide guidelines for the inspection and testing of underground piping.

2.0 SCOPE

The procedure covers inspection and testing activities for receiving, hauling, trenching,
stringing, bending, joining, coating, laying and backfilling, operations during underground
piping construction.

When preparing the inspection check lists, refer to the pipeline construction
specifications and alignment sheets.

3.0 DEFINITIONS

None

4.0 REFERENCES

None

5.0 RESPONSIBILITIES

None

6.0 REQUIREMENTS

6.1 Receiving, Hauling and Storage

6.1.1 Care should be exercised in all loading, unloading, hauling and stringing operations so as
to avoid damage to the pipe ends and coatings.

6.1.2 Handling hooks should be protected or of soft metal type so as not to cause out of round
or deformed bevels.

6.1.3 Inspect yard storage of pipe, valves, and coating materials for proper protection. Ensure
large diameter pipe is not stacked too high (with suitable soft packing if prewrapped) to avoid
deformation and to reduce accident risk.
6.1.4 Where special coatings have been applied, ensure that transport carriers are properly
buffeted to prevent damage.

6.1.5 Check bevel and coating cutback.

6.2 Trenching

6.2.1 Check that the trench width and depth is not less than the minimum specified.

6.2.2 Check for proper clearance between the pipeline and any other underground pipeline or
structure.

6.2.3 Ensure drainage ditches are provided when necessary.

6.2.4 Check that bottom of the trench is graded as specified. (As a minimum, it must provide a
uniform support for each joint of pipe).

6.2.5 Where rock is encountered, check that the trench depth and width is sufficient to provide
at least the minimum of "earth padding" specified.

6.2.6 If "earth padding" is not available, check that rock shields are used when specified.

6.2.7 Where drainage tiles are used, check for proper clearance between the pipe and the tiles.

6.2.8 Ensure the proper construction technique at roads, railways, ditches, canals, and river
crossings are in accordance with design documents.

6.2.9 If casing is used, check that the joints are sealed

6.2.10 In general, pipe is strung end to end along the right-of-way. In some cases, it may be
placed in piles for welding or coating. Monitor these activities to ensure correct procedure is
followed to alleviate damage.

6.2.11 Valves, casing and other materials may be hauled and strung along the right-of-way.
Monitor these activities to ensure against loss or damage.

6.2.12 Monitor, to ensure that small materials, or materials easily lost or damaged are properly
stored.

6.2.13 All welding shall be done in accordance with specification requirements.

6.2.14 Check interior of pipe for foreign matter prior to aligning for welding. Swab clean if
necessary.

6.2.15 Check that the open ends of lines are securely closed at the end of each day's work to
prevent the entrance of small animals or introduction of foreign matter.. Do not re-open until
work is resumed at that point.

6.3 Bending

6.3.1 Where seam-welded pipe is used, check that:

 a. The longitudinal seam is placed on top for side bends, and on the side for sag and
overhead bends.

b. The seams on adjacent pipe lengths are off-set so as not to be in line with each
other.

6.3.2 When spiral-weld pipe is used, extra care must be taken to prevent buckling, particularly
if it is thin wall pipe.

6.3.3 Check that the pipebends are free from buckling, out of round, cracks, thinning of pipe
wall or any other evidence or mechanical damage.

6.3.4 Check that the bent pipe conforms to the profile of the bottom of the completed trench or
bedding.

6.3.5 Check that cold-pipe-bends are smooth and uniform.

6.3.6 The maximum permanent deflection of a pipe bend depends on the pipe diameter and
wall thickness, the particular code in use and Design-Document. Ensure that the maximum
deflection specified is not exceeded. This should be checked by pulling a gauging plate through
the bend prior to stringing in the line.

6.3.7 Check that the difference between the maximum and minimum diameter at a pipe bend
does not exceed the specified amount.

6.3.8 Check that bending does not occur within the minimum distance specified from a joint.

6.3.9 Check that suitable precautions are taken to prevent deformation at the end of the pipe
joint due to bending activities and pipe handling.

6.3.10 Where the pipe is double-jointed prior to bending, ensure that the weld is not placed
within the bending shoe. In no case should a bend occur at the circumferential weld, nor should
a completed weld come in contact with the surface of the bending or holding shoe, or the clamp
of the machine.

6.4 Coating and wrapping

For coating and wrapping activities refer to the specific coat and wrap specifications.

6.5 Lowering of Pipe into the Trench

6.5.1 Ensure proper lowering sequence and procedure.

a. Side bends and sag bends should be lowered first and weighted to serve as
anchorage.

b. Side bends should be made to bear on the outside wall of the trench.

c. Sag bends should bear firmly on the bottom of the trench.

d. Check that overbends have at least the minimum specified space between the
bottom of the pipe and the bottom of the trench.
6.5.2 Ensure that if the pipe is cradled-in, it is done in such a manner as to secure proper slack
and does not injure the pipe coating, and that the minimum radius of bending is observed.

6.5.3 Check that cooling of the pipes with a wetting-agent is carried out when necessary during
hot weather cradling-in operation.

6.5.4 Check for damage to coating by bumping or scuffing during lowering in operation.
Initiate any repairs necessary and check that they are performed in accordance with Design
Documents.

6.6 Mechanical Jointed Pine

6.6.1 Ensure pipe is free from cracks (including lining if applicable).

6.6.2 Ensure gasket or seal lubricants are kept in dirt free condition.

6.6.3 Ensure offsets at joints do not exceed t he angle stipulated by the manufacturer.

6.6.4 Check that gaskets or seals are the correct specification (especially in sour systems).

6.6.5 Normally jointed pipe is installed with bell end facing up the slope when used on gravity
drainage systems utilizing slopes.

6.6.6 At flanged connections (especially on cast and ductile iron systems) ensure that mating
flanges of valves and/or equipment are compatible. (Normally flat faced) to avoid risk or
fracture during bolt-up.

6.6.7 Ensure, during pressure tests, that anchors, stops or sufficient backfill has been placed.
Care should be exercised on part tests to ensure temporary plugs, caps or flanged connections are
adequately shored and braced.

6.6.8 Any sand bags used for installation expediency should be burst prior to compaction and
testing activities. Use of temporary wood cribbing in trenches should be avoided. Since there is
a tendency for these to be buried and not removed.

Note: Where epoxy cements are used in bell and spigot pipe to afford zero leakage, the
joint manufacturers recommendation regarding cleanliness, mixing and placement must be
rigidly adhered to.

6.7 General

6.7.1 Ensure weights are installed where specified.

6.7.2 Check that the concrete mix and pouring procedures for any blocks, weights,
foundations, valve boxes, supports and anchors are in accordance with design documents.

6.7.3 Check that all necessary drips, valves, farm taps, tie-ins, and other connections are
properly installed.

6.7.4 Check that any damaged or removed drain tile is replaced with the correct material.
6.7.5 Check that troughs or conduits are placed so as to adequately support the drainage
tile, e.g. they should penetrate sufficient solid ground to ensure that alignment and correct
grade are maintained when backfill settles.

6.7.6 Check that cleaning and blowing activities are carried out in accordance with design
document requirements.

6.7.7 Ensure correct installation of cathodic protection when required.

6.8 Backfilling

6.8.1 Monitor backfilling operations to ensure that they are carried out in accordance with
design document requirements.

6.8.2 Check that backfilling operations do not damage the pipe's protective coating or fittings.

6.8.3 Where rock is the backfill material, check that rock shields are installed where required.

6.8.4 Where backfilling is omitted due to installation of boxes, farm taps, tie-ins, foundations,
etc., ensure it is completed after such installations have been approved.

6.8.5 Ensure adequate compaction of open-cut highway or railway crossings. Where the pipe
is not cased, check that rock-shields are installed if required, and proper permits have been
secured. Ensure proper inspection and completion notices have been distributed.

6.8.6 Inspect cathodic protection installation prior to backfilling.

6.8.7 For general pipe-testing refer to specifications and procedures.

6.8.8 Ensure that testing of pipe line meets all applicable Codes and is witnessed by proper
inspectors, and that all questionable welds have been repaired and documented prior to the test.

6.8.9 Ensure that the proper leak detection equipment is on hand in case of leaks.

6.8.10 If water is the test medium, check for suitable Ph, and that the water is filtered if
required.

6.8.11 Ensure that the test segment is backfilled throughout its length, except for necessary bell
holes or open valve settings.

6.8.12 Check that all valves are in the correct open/closed position.

6.8.13 At river or canal crossings, the pipe is tested before laying.

6.8.14 Witness and record all test procedures and results.

6.8.15 Ensure correct repair of any ruptures or leaks.

6.8.16 When testing has been completed, ensure proper cleaning and dewatering of the pipe
system.

Copyright 1993 Bechtel Corporation

First Edition. All Rights Reserved.

No parts of this publication may be reproduced in any form without the prior written or
expressed permission of the publisher.

Printed in the United States of America.