WORK METHOD STATEMENT

FOR
PIPELINE CONSTRUCTION WORKS

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 Table of Contents
1.0 PROJECT INTRODUCTION
2.0 LIST OF EQUIPMENT/MACHINERY
3.0 APPLICABLE CODES,STANDARD AND SPECIFICATION
4.0 SURVEY AND ROUTING
5.0 RIGHT-OF-WAY GRADING
6.0 DITCHING/TRENCHING
7.0 HAULING AND STRINGING OF PIPE
8.0 LINE-UP AND WELD
9.0 PRODUCTION WELDING
10.0 NONDESTRUCTIVE TESTING
11.0 JOINT COATING
12.0 “POWER Crete-J” FIELD JOINT COATING
13.0 BARE BEND/PIPE COATING
14.0 PIPE COATING REPAIR
15.0 AS-BUILT QUANTITIES
16.0 LOWERING-IN AND BACKFILLING
17.0 CLEAN-UP AND REINSTATEMENT
18.0 DITCH BREAKERS
19.0 TIE-INS TO EXISTING LINE
20.0 TIE-INS
21.0 CATHODIC PROTECTION
22.0 MARKER POST, AERIAL MARKERS AND WARNING SIGNS
23.0 CROSSING
24.0 PAVED ROADS AND HIGHWAY CROSSING
25.0 WATER COURSE CROSSING
26.0 CLEANING, GAUGING, HYDROSTATIC TESTING AND DRYING
27.0 REMOVAL OF PIPELINE SECTION
28.0 APPLICATION OF PIPELINE SET-ON –WEIGHTS, CONCRETES SADDLE
29.0 FINISH GRADING AND CLEANING UP OF ROW
30.0 ENVIRONMENTAL SAFETY
31.0 AS-BUILT DOCUMENTATION

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1.0 PROJECT INTRODUCTION
Roads and Highways Department is committed to construct a multilevel road interchange at
Hatikamrul intersection under South Asian Subregional Economic Cooperation (SASEC) Road
Connectivity Project-II. The construction of the interchange renders relocation of all utility services
from the interchange area. Upon request of Roads and Highways Department Gas Transmission
Company Limited has agreed to relocate the 30” OD x 1000 psig x 1.32 Km Nalka-Hatikamrul Gas
Transmission Pipeline from Dhopakandi (near Aristocrat hotel) to south side of Hatikumrul scraper
trap station from the interchange area. The pipeline relocation works will be implemented by the Gas
Transmission Company Ltd. [the Employer], a company of Bangladesh Oil, Gas and Minerals
Corporation (Petrobangla). The cost of the relocation of pipeline works would be met up from Roads
and Highways Department (SASEC Road Connectivity Project-II).

1.1 SCOPE OF WORK

The Pipeline Engineers And Associates Limited shall construct approximately 1.32 Km X 30" dia. High
Pressure Natural Gas Transmission pipeline from Dhopakandi (near aristocrat hotel) to south side of
Hatikumrul scraper trap station according to alignment sheets, typical and individual drawings and
Technical Specifications. The scope of works is as follows but not limited to:

(i) Requisition of land, Preparation, Clearing, Grading and Development of Right-of-Way (RoW),
Development of Works Site, Transportation of Line Pipe and Pipeline Materials, Carrying &
Hauling and Stringing of Line pipe & Induction Bend , Welding of Pipes, NDT, Joint Coating,
Digging the Trench, Lowering the Pipes, Civil Works (including of all civil materials), Tie-in, Road
Crossing by Thrust Boring, Metalled & Unmetalled road crossing by open-cut method, Crossing
of Khal, Canal, Pond etc., Fabrication and Placement of Set-on-Weight, Aerial and Rout Marker
post, Warning Sign, Backfilling, Cleaning Gauging & Hydrostatic Testing, Dewatering & Drying
and Clean up & Reinstatement of Row, Mitigation Environmental Policy (MEP), Remedy of Defect
etc.

(ii) Highway/Metalled Road crossing by thrust/augur boring method using casing and other crossing
conduits, cables, utilities and other facilities.
(iii) Metalled/unmetalled road crossing by open cut method without casing.
(iv) The khal/canal/pond by open cut method complete in all respect.
(v) Installation & Commissioning of Mg Anode system (vertical ground bed) for casing pipe at each
road crossing as per design and drawing and instruction of site Engineer.
(vi) Crossing of existing pipeline/facilities as per design and drawings.
(vii) Fabrication and installation of RCC concrete Set-on-Weight (SOW) for buoyancy control.
(viii) Fabrication and installation of required nos. of temporary Test Head for cleaning, gauging and
hydro test purpose.
(ix) Hook-up/Tie-in newly constructed pipeline section with the existing 30” OD Nalka-Hatikumrul
Gas Transmission Pipeline. Contractor has to supply necessary materials required for total
completion of Hook-up works. During Hook-up existing pipelines shall be cut-out by using cold
cutting machine. For Hook-up welding shall be required. All construction works including
destructive & non-destructive testing of welds.
(x) The entire pipeline to be hydrostatically tested with cleaning, gauging, pigging, and drying as

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 well as required amount nitrogen charging. During pressure testing the contractor shall ensure
presence of representative(s) of explosive department.
(xi) The pipeline shall have a minimum cover of 1.2 meter from the top of pipeline surface.
(xii) The pipeline shall have a minimum cover of 2.5 meter from the top of pipeline surface in
khal/canal/pond area as per technical specification and drawings.
(xiii) Fabrication and installation of route marker and aerial post, warning sign, identification sign etc.
(xiv) Remedying of defects during the defects liability period.
(xv) Supply of Employer’s facilities.
(xvi) Preparation and supply of As-Built Drawings, Radiographic Films including weld book and
interpretation sheets in the form of bounded dossiers, Materials Balance Sheet and return of all
unused and scrap materials to Employer.
(xvii) Supply of all consumable such as welding electrodes, paints, POL, skids, water, electricity,
Nitrogen, vent & drain pipe support, all civil works materials (sand, cement, rod, stone bricks
etc.) etc.
(xviii) Pigging and Commissioning complete in all respects, of around 07 kilometer X 30” OD Pipeline
including supply of required no. of Commissioning Pigs.
(xix) Select store yard near to ROW.
(xx) Carryout ROW survey and submit report before commencement of construction (marshy land,
existing utilities, SOW & CWC probable location, electric pole, high-tension cable, khal/pond/
road etc.).
(xxi) After Hook-up with existing 30" OD Nalka-Hatikumrul pipeline section, the abandoned section
of Pipeline shall be cut at the joint locations and removed the Pipes from trench and transport
to GTCl’s store yard at Bonpara with maintaining all kinds of safety precautions. After removal
of pipes contractor shall backfill with proper compaction.

2.0 LIST OF EQUIPMENT/MACHINERY

2.1 Side Boom
2.2 Back Hoe/ Excavator/Long arm excavator
2.3 Crane
2.4 Road Boring Machine
2.5 Cold cutting Machine (Upto 30’’ OD pipe)
2.6 Air Operated Internal Clamp with compressor
2.7 Welding Generator
2.8 Chain Dozer
2.9 Rotary Pipe Cutting & Beveling Machine
2.10 Holiday Detector with rechargeable Battery
2.11 Pipe carrier
2.12 External Clamp
2.13 De-watering Pumps
2.14 Mud-Pumps
2.15 Hydrostatic Testing Pump and other Accessories

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 2.16 Heavy duty air compressor
2.17 Gas Detector
2.18 Pipe and Cable Locator
2.19 Sand Blasting Machine
2.20 Radiography Facility

3.0 APPLICABLE CODES, STANDARDS, AND SPECIFICATIONS

All equipment and materials supplied and work performed shall conform to the following applicable
codes, standards, and specifications:

ASME B31.8 Gas Transmission and Distribution Piping System

ASME B31.3 Process Piping.
ASME Section VIII Unfired Pressure Vessels
API Spec 5L Specification for Line Pipe (Latest edition)
API Std. 1104 Standard for Welding Pipelines and Related Facilities (Latest edition)
API RP 1102 Recommended Practice for Liquid Petroleum Lines Crossing Highways
NACE RP0169 Control of External corrosion on Underground or Submerged Metallic Pipelines
NACE RP0177 Mitigation of Alternating Current and Lightning Effects on Metallic Structures
and Corrosion Control Systems
NEMA National electrical Manufacturers Association, USA.
API 2201 Procedures for Welding or Hot Tapping on Equipment Containing Flammables
SSPC-SP-1 Solvent Cleaners
SSPC-SP-11 Power Tool Cleaning
SSPC-SP-10 Near-White Blast Cleaning
BS 1722: Part 1 Chain Link Fences
AGA Report #3 Standard Gas Fluids Measurement

Pipeline Right of Way Terms and Conditions

BIWTA/Railway/Highway and Waterway/DoE/BTRC/Forest/Other pipeline related Permit Requirements
(Terms and condition applicable)
Bangladesh Natural Gas Safety Rules 1991 amendment in 2003
Local and Regional Building Codes
Safety Requirements

In case of conflict between this specification, drawing and its associated specifications and the above
codes and standard, contractor shall bring the matter to the Employer’s attention for resolution and
approval in writing. In all cases the most stringent requirement shall be applied.

4.0 SURVEY AND ROUTING

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 4.1 During taking over of ROW from the Employer, PEAL will stake the entire alignment of the pipeline(s).

4.2 If in the course of establishing the alignment of the pipeline or any part thereof, PEAL determines a
realignment from the defined route, in a particular area or section, could result in a better installation
at no additional cost or at cost savings to Employer, then PEAL will, by providing sufficient time, seek
Employer’s approval through a change order to proceed. In the event the Employer makes significant
change in the pipeline route, during the course of implementation of the project that will involve
additional costs then PEAL will seek prior approval of the Employer as per provision of the Contract.

4.3 PEAL is responsible for taking reasonable efforts in working around foreign obstructions as described
below:

4.3.1 Work around existing pipelines and other buried facilities.

4.3.2 The proposed pipeline will cross some existing pipelines at different locations, cables,
power lines, conduits, structures (above and underground), or facilities either owned by
the Employer or others. Where pipeline construction work parallels or crosses existing
pipelines, cables, power lines, conduits, structures, or facilities either owned by Employer
or others, extreme care will be exercised by PEAL at all times. PEAL will be responsible for
contacting authorities and owners, and locating such facilities before excavating. . In the
event such obstructions requires PEAL to lay the pipeline with a greater depth of cover,
than what is specified, requiring additional work at additional costs then PEAL may seek
prior approval of the Employer as per contract provision.

4.3.3 Although Employer will use its best efforts to provide PEAL with such information as
Employer has available as to locations of existing pipelines, power lines, conduits, cables,
structures or facilities not otherwise apparent, Employer will not be responsible for the
accuracy or completeness of such information. Employer may have its surveyor mark
certain crossed facilities for PEAL's convenience, but in no way does Employer or its
surveyor assume any liability in so doing.

5.0 NONDESTRUCTIVE TESTING

5.1 Radiographic inspection will be performed by PEAL in accordance with the latest
Editions of API 1104 and ASME B31.8.

5.2 100 percent of field welds will be radio graphed.

5.3 PEAL will submit to Employer a daily report of the welder symbols of ail welders responsible for
weld defects. The report will identify the welder symbol, number of weld defects by the welder

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 for each work day, total weld defects in the last 50 joints welded, and total weld defects welder
has been responsible for on the job. This report will be required for both pipeline and
fabrication production welders.

5.4 Employer will review the daily weld defect report and undertake the final interpretation.
Subsequently Employer will instruct PEAL of remedial action following the criteria given below:

Weld Defects Action

1 to 2 weld defects in 50 welds Defects recorded

3 weld defects in 50 welds PEAL advised

4 weld defects in 50 welds Second notice

5 weld defects in 50 welds Welder removed from project

PEAL will carry out Radiographic testing and inspection. 100% of the welding will be radio graphed by
using of X-ray crawlers. The tie in welds and fabrication welds may be inspected by gamma ray. PEAL or
GTCL’s approved sub PEAL will carry out Radiography testing, developed radiography films, and submit
acceptable films to Employer after carrying out preliminary interpretation in accordance with approved
radiography procedure. The final interpretation will be carried out by Employer. All fitting welds, fillet
welds will be examined by MPT or Ultrasonic testing. “All golden welds” the final closure weld between
hydrostatic test section, will be subjected to 100% radiography and 100% MPT or UT inspection.

The Employer will have the right to call up other NDT method such as UT, MPT etc. to assist the location
and or evaluation of defects.

6.0 JOIN COATING

6.1 Installation of Field Joint Coating and Repairs

Before starting of joint coating activities, PEAL will submit joint coating procedure for approval.
Prior to initial field joints coating or making repairs to damaged coating, GTCL will provide
representative for a site demonstration session for all PEAL personnel who will perform joint
coating or coating repair work.

6.2 Weather Conditions

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 Application of coating, field joints, and repairs, and holiday detection testing will not be done
during inclement weather, unless weather protection and other measures approved by Employer
are provided by PEAL.

6.3 Heat Shrink Sleeve Field Joints

PEAL will install wrap-around heat shrinkable sleeves for all field welds on coated pipe not
installed in bored crossings. Sleeve application procedures and personnel will be qualified. All
sleeve materials, supplied by Employer, will be stored in accordance with manufacturer’s
recommendations.

6.3.1 Surface Preparation

Bare pipe and 75 mm of corrosion coating beyond the cutback will be wiped clean of any
dirt, oil, or grease per SSPC-SP-1. Solvents such as gasoline, kerosene, diesel, and similar
degreasers that leave any oily film will not be used.

Bare pipe surfaces will be blast cleaned as per SSPC-SP-10 to an anchor pattern of 1 to 3
mils. Areas which cannot be blast cleaned will be prepared using power wire brushes per
SSPC-SP-3 to remove dirt, scale, foreign debris and all but tightly adhering rust.
Sleeves will be installed only after the weld is cooled to ambient. All weld spatter will be
removed and the bare metal prepared by sand blasting. Where necessary, the mill-
applied corrosion coating will be feathered back to avoid a ridge. The bare metal surface
will be preheated using propane torches, ring burners, or induction heaters to a minimum
temperature of 75C as verified by Tempil Sticks or contact pyrometer.
6.3.2 Application
The sleeve will be applied with the lap facing down and centered over the girth weld. Heat
will be applied to one free end (side) or as specified by manufacturer's recommended
practice using propane torches with billowy flame, heating the work from top to bottom
until a complete band is shrunk onto the pipe. Heating will continue toward the opposite
end until the entire sleeve is shrunk on. Immediately after beating, hand rollers will be
used to remove all entrapped air.
7.0 “POWERCRETE-J” FIELD JOINT, IF REQUIRED
Application of powercrete-J coating compound to all field joints installed in drilled or bored
crossings. This compound will be applied in accordance with the manufacturer’s instructions.

12.1 Surface Preparation

Powercrete-J is a two-part compound which is designed for application directly onto pipe whose surface
has been prepared as described in 10.3.1 above to SSPC-10 specifications. The pipe must be dry before
application and should be pre-heated to at least 55C to enhance cure times.

12.2 Application

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 Once the two parts have been properly mixed, the liquid should be applied using a Powercrete-J
troweling tool or equivalent. The first layer should be applied to a minimum wet film thickness of 15
mils, as verified with a wet mil gauge. The second 15 mil layer should be applied no sooner than 20
minutes after completing the first layer. Thickness should be checked around the weld seam to verify
total wet film thickness of 30 mils.

Subsequent layers to obtain the required minimum 30 mils wet film thickness may only be applied after
the 20-minute interval between layers.

Only after the joint coating has reached a minimum Shore D hardness of 65 may the coating be checked
for holidays and the pipe buried.

Cure time may be accelerated by using a heat gun or shrink sleeve torch, provided flames do not touch
to Powercrete-J surface AND the surface temperature is limited to not more than 70C.

8.0 BARE PIPE/BEND COATING

13.1 Surface Preparation

Bare pipe/Bend surfaces shall be prepared using power wire brushes as per SSPC-SP-3 to remove dirt,
scale, foreign debris and all but tightly adhering rust.

13.2 Application

Bare pipe/Bend surfaces shall be coated manual/semi-automatic process with applying primer and poly ethylene
tapes. HD 50 mils poly ethylene tapes and cold primer shall be used for coating. The first layer of coating
shall be 55% overlap and the second layer of the coating shall be 50% overlap.

9.0 PIPE COATING REPAIR

9.1 General
PEAL will do the visual and holiday detector inspection for pipe coating damage before lowering
the pipe into the ditch. PEAL will provide suitable approved holiday detectors with the proper
settings for testing of the coating and sleeves. All fittings, valves, and piping will also be examined
for coating damage. The holiday detector must be calibrated in accordance with NACE Standard,
and used carefully since voltages required to cheek the sleeves will burn the coating. The test
voltage will be set calibrated to detect a pinhole defect

 The pipe surface to be re-coated will be cleaned to remove all dirt and damaged or disbanded
coating. The pipe surface and the surrounding coating will be roughened using a file or wire
brush.

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  The patch will be made using heat shrinkable sleeves or wraps with a suitable hot melt
adhesive layered on the inner side. If the pipe surface temperature is below 50° F at the time
of patching, the pipe surface and surrounding coating will be warmed using a torch prior to
applying the coating.
 PEAL may propose to use a compatible, adhesive lined, polyethylene tape in lieu of heat shrink
sleeves if approved by Employer.

10.0 AS-BUILT QUANTITIES

PEAL will provide EMPLOYER three (3) days prior notice to the backfill of pipe in the trench to allow
EMPLOYER to inspect and confirm the quantity of “As-Built” welds, linear footage, laid, depth of trench,
etc.

11.0 LOWERING-IN AND BACKFILLING

11.1 Preparation
11.1.1 Prior to lowering-in, any loose rock, debris, metal of any kind and hard objects will be
removed from the ditch. In areas where the native material, in the opinion of Employer,
would damage the pipe coating, clean sand beams will be set in the ditch bottom every 6
meters or less to support the pipe a minimum of 150 mm above the ditch bottom after
allowing for settlement and the full pipe load. Sandbags or polyurethane foam supports
may be used as an alternative to the sand berms provided that adequate support and
bearing area are provided for the pipe.
11.2 Lowering In
11.2.1 Pipe will properly conform to the ditch profile. External force will not be used to make the
pipe conform to the ditch. Pipe not conforming to the ditch will be removed and either
re-bent or the ditch re-dug to provide the correct profile.
11.2.2 PEAL will use sufficient and proper equipment for lowering-in to prevent damage to the
coating and the pipe and to ensure control and Safety in handling the pipe strings. Wide
nonabrasive belts or cradles will be used. Upon lowering-in, the depth of cover and pipe
profile will be recorded so that cathodic protection test leads can be installed.
11.3 Backfilling
11.3.1 Backfilling of the pipeline in the ditch will be completed as soon as practical after
lowering-in, and that the coating has not been damaged. If, during the course of the work,
a section of the pipeline is backfilled prior to Employer review and approval.
11.3.2 Initial backfilling or shading will consist of completely covering the lowered in pipeline

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 with 150 mm of padding or suitable backfill material so as to prevent possible coating
damage due to ditch sloughing or collapse and will follow as close as practical behind
lowering-in. Complete backfilling will follow initial backfilling by no more than 48 hours
and will consist of depositing fill material in the remainder of the ditch depth, including a
300 mm settlement beam in normal ditch and a 600 mm high rock beam in rock ditch to
restrict vehicular traffic over the pipeline. Forward progress of lowering-in activities may
be halted by Employer Representative if progress of initial and final backfill operations
are not maintained to specified requirements.
11.3.3 Once padding material is installed, final backfilling will be completed with native material
or native top soil in cultivated agricultural areas. No rock larger than 60mm in any
dimension will be allowed within 300mm of the pipe. For the remaining backfill, all rock
larger than 350 cc in volume or 450 cm in any dimension will be excluded.

12.0 CLEAN-UP & REINSTATEMENT

The pipeline work areas and other sites used by PEAL will be cleaned up to the satisfaction of
Employer. Clean-up activities will begin as soon as the pipe is laid and backfilled. In the performance of
this work, the following will be observed.

12.1 All debris, scrap and other waste material will be collected and disposed of. Existing facilities
which were damaged or altered by PEAL’s activities will be restored to their original condition.
12.2 In cultivated lands and pasture, topsoil will be replaced and loosened after any compaction by
construction activities. Fences, dikes, drainage systems, irrigation systems.
12.3 Temporary access roads, stockpile sites, and camp locations will be cleaned up and restored
To the as-found condition.

13.0 DITCH BREAKERS

13.1 On steep slopes and at other locations where groundwater will be collected and run in the
ditch, breakers will be installed to prevent potential washout of pipe padding and subsequent
slumping of the backfill material. Breaker spacing will be in accordance with the following
table:

Ditch Breaker Spacing

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 Slope Percent Spacing, m.

10% 12

15% 8

20% 7

25% 6

30% 5

40% 4

50% 3

60% 2.5

70% 2

13.2 The construction of breakers will be suitable for Withstanding unbalanced loads imposed
during backfilling and the hydrostatic head established during operation. Breakers will be
constructed from either jute sacks filled with soil/cement mixture or polyurethane foam
sprayed in place. The base of the breakers will be set in undisturbed soil and constructed prior to
pipe installation with the remainder of the breaker completed once the pipe is in place. The sides
of breakers will be keyed into the ditch wall.

14.0 HOOK-UP/TIE-INS TO EXISTING LINE

14.1 De-pressurization of Nalka-Hatikumrul 30" OD pipeline section (approximately 7.0 km) and Cold
Cutting utilizing cold cutting machine using cooling fluid and nitrogen charging with all other
necessary works and Tie-In the new pipeline section with existing 30" OD Nalka-Bogura Gas
Transmission Pipeline maintaining all kinds of safety precautions.
14.2 Hot Work
14.2.1 Tie-ins may involve Hot Work. Authorization which must be obtained from Employer
prior to working on their facilities. All 'Hot Work' requires a daily written “Hot Work”
permit which shall be issued to Contractor by these third parties.
14.2.2 A new permit will be required any time there is a hot work interruption, an operational
change, changes in weather conditions or any other situations which could affect the
safety of the job.
14.2.3 All initial pipeline cuts will be cold cuts using mechanical cold cutters.
14.2.4 A bonding cable shall be used in all cases where existing piping is to be separated. The

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 cable shall consist of No. 10 gauge wire or larger, and of sufficient length to span the
separation in the piping. The ends of the cable shall be securely fastened to the pipe on
each side of the separation.
14.2.5 No "Hot Work" will start until the area has been checked and found to be free of
combustible vapors by the Employer using a combustible gas indicator.
14.2.6 “Bell Holes" will be gas-freed before any hot work is started. All contaminated earth will
be removed or covered with fresh dirt to prevent the escape of combustible vapors.

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