JOB PROCEDURE FOR UNDERGROUND MDPE PIPE NETWORKS

DOC:- TGSPL/IOCL/COIMBATORE/C-5/QCP-JP-01 Rev. No. 00 P a g e 1 of 12

PROJECT : LAYING OF MDPE PIPELINE AND ASSOCIATED WORKS FOR

COIMBATORE GA (GROUP C-5) FOR CGD PROJECT
CLIENT : M/s INDIAN OIL CORPORATION LTD

PMC : M/s TRACTBEL ENGIEERING PVT LTD

CONTRACTOR : TECHNO GLOBAL SERVICES PRIVATE LIMITED.

WO. NO : 26238679 DATED:20.12.2019

JOB PROCEDURE FOR UNDERGROUND MDPE PIPE NETWORKS

DOC:- TGSPL/IOCL/COIMBATORE/C-5/QCP-JP-01, Rev-00

Rev Descript Prepared by Checked by Reviewed & Approved by

Date
. ion TGSPL TGSPL TEPL/IOCL

Review &
00 13-05-2020
Approval RAJA CHAKRABORTY SUMAN MONDAL
 JOB PROCEDURE FOR UNDERGROUND MDPE PIPE NETWORKS
DOC:- TGSPL/IOCL/COIMBATORE/C-5/QCP-JP-01 Rev. No. 00 P a g e 2 of 12

TABLE OF CONTENTS

Sr. No Description Page No

1. Purpose 4

2. Scope 4

3. Reference 4

4. Responsibilities 4

5. Methodology 5

5.1 Excavation 5

5.2 Laying 6

5.3 Jointing of Polyethylene Pipe 7

5.4 Backfilling 7

5.5 Moiling 8

5.6 Boring/Ramming/Directional Drilling 9

5.7 Casing Pipe 9

5.8 Restoration 9

5.9 Testing 10

5.10 Purging 10

5.11 Valve and Valve pit 11

 JOB PROCEDURE FOR UNDERGROUND MDPE PIPE NETWORKS
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5.12 Permanent Markers 11

6. Assistance in Commissioning 11

7. Standard of Work 11

8. Appendix / Formats 12
 JOB PROCEDURE FOR UNDERGROUND MDPE PIPE NETWORKS
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1.0 PURPOSE

The purpose of this procedure is to lay guidelines and requirements and to establish a method or
system to control LAYING OF MDPE PIPELINE AND ASSOCIATED WORKS FOR
COIMBATORE GA (GROUP C-5) FOR CGD PROJECT

2.0 SCOPE

LAYING OF MDPE PIPELINE AND ASSOCIATED WORKS FOR COIMBATORE GA (GROUP C-

5) FOR CGD PROJECT

3.0 REFERENCES

1. AS PER TEPL Specification

4.0 RESPONSIBILITIES

Project Manager - Shall report to Project Director

Shall be responsible for providing resources for
- the implementation of this procedure.
Shall be responsible for control, supervision
-
and direction for implementation and execution
- -
of construction plans using calibrated measuring
and test equipments.

Resident Construction - Shall report to the Project Manager

Manager - Construction Manager shall provide adequate
resources (manpower, machineries, tools etc) to
implement the procedure and should also ensure
quality and workmanship.
- Responsible for overall monitoring,
implementation and control of construction
activities
QA/QC Manager / QA/QC - QA/QC Manager Shall be responsible for overall
Engineer quality management in accordance with ISO 9001-
latest edition. He shall also be responsible for
 JOB PROCEDURE FOR UNDERGROUND MDPE PIPE NETWORKS
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establishment of procedures and custody all

documentation and control, calibrations of
instruments.
- Shall check and verify all construction activities.

HSE Officers - Reports to Site Project Manager.

- Manages the implementation of all
Safety requirements during operations.

5.0 METHODOLOGY

5.1 EXCAVATION

Trench shall be excavated by using manual/machine on the cleared, graded and center tine marked
right of use as per alignment sheets. In case of rocky area/RCC floor area separate procedure has to
prepared and submitted to IOCL /TEPL for their approval.

All sewers, drains, ditches and other natural waterways, encountered while trenching shall be
maintained open and functional by providing proper temporary installations if required. Suitable
dewatering pumps shall be deployed to dewater, if required.

The trench shall be excavated to a minimum width to provide clearance on both sides of the pipe as
indicated in the Client Specifications relevant to trench dimension and to a depth sufficient to provide
the minimum cover.

In those areas where rock or gravel or hard soil is encountered in the bottom of the trench compact
padding is required. The thickness of the compacted padding shall not be less than 150 mm all
around the pipe. Padding material approved by TEPL/ IOCL. Shall be graded soil/sand and/or other
materials containing no gravel, rock or lumps of hard soil.

When permitted to open cut a paved road crossing by authorities and/or TEPL/ IOCL the paving shall
be removed in accordance with restrictions and requirements of the authorities having jurisdiction or
as directed by TEPL/IOCL.

Trench gaps shall be provided as necessary to permit land owners or tenants to perform their work on
both sides of construction right-of-way.

The paving shall be restored to its original position after the pipeline is installed,
 JOB PROCEDURE FOR UNDERGROUND MDPE PIPE NETWORKS
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Where the contour of the ground may require extra depth to fit minimum radius of bends Customary
to good pipeline practice or where deep trench is required at approaches to roads, Railways, or water
courses additional depth shall be excavated after obtaining permission from concerned authorities
and or TEPL/ IOCL.

M/s TGSPL shall excavate to additional depth where the pipeline approaches and crosses other
pipeline, sewers, drain pipes, water mains, telephone conduits and other underground structures, so
that the pipeline may be laid with at least 30 cms free clearance from the obstacle or as specified in
the drawings or such greater minimum distances as may he required by authorities having
jurisdiction.

Necessary care to be taken to protect the underground utilities/structures and shall excavate the
trench manually where use of trenching machine/excavator may result in damage to the property and
sub-surface structures likely to be encountered during excavation M/S TGSPL has to obtain all
existing and planned underground services from relevant authorities and shall follow these plans
accordingly.

Wherever necessary soil dams and dewatering of trench etc. to be carried out to avoid up floating of
pipes to the satisfaction of Consultant / Client.

5.2 LAYING

Laying of MDPE pipelines shall commence only after ensuring proper dimensions and clean surface
of the trench. The trench bottom shall he free from the presence of cuts, stones, roots, debris, stakes,
rock projections up to 150mm below underside of pipe and any other material which could lead of
perforation/ tearing of the pipe wall.

After ensuring above the MDPE pipe coil shall be uncoiled smoothly through proper equipment's/
care inside the trench ensuring no damage to pipe coil during laying. We must ensure that pipe caps
are provided before lowering of pipeline. The trench after this can be released for back filling leaving
adequate lengths open at the ends, for jointing.

Where given specific approval by the Engineer In-Charge a pipe may pass through an open drain or
nalla. Where this is permitted the pipe shall reinstalled inside a concrete or steel sleeve for protection.
The sleeve material shall be procured and laid by M/s TGS. In general the GI Sleeve and MS sleeves
material specification shall be confirming to IS 1239 (Heavy Duty) specification of reputed make.
 JOB PROCEDURE FOR UNDERGROUND MDPE PIPE NETWORKS
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Valves shall be installed at locations shown on the Design Plan or as directed by the Engineer In-
Charge and joined with PE pipes by electro-fusion techniques. The valves shall be supported on a
bed of fine fill of grit size not greater than 5mm to achieve equivalent support as the incoming and
outgoing pipe work.

Laying graphs with details of depth, length, offsets from fixed references, other utility crossings,
fittings, size of casing pipe used for the pipeline shall be prepared on daily basis and submitted to Site
Engineers of the Owner for approval. These details will be further incorporated into As-Built Drawings.

5.3 JOINTING OF POLYETHYLENE PIPE

The procedure for jointing of PE pipe and fittings is enclosed. Only Bar coded electro-fusion machine
(Automatically Readable) that can read the bar code of the fittings automatically shall be used for
jointing of MDPE pipe / fittings. Manual feeding electro-fusion machines are not acceptable for jointing
purpose.

We shall flush the Pipeline (with air to remove dust, water, mud etc. before fusing the joints. Before
joining, the M/s TGSPL shall place packing sand under the pipes on both sides of the joint to keep the
pipes in line and at the correct alignment during the jointing process. Alignment clamps with the
correct size shells should be used to align the pipe during the electro-fusion cycle.

Only, Approved Jointers shall carry out fusion of all joints. M/s TGSPL shall provide the list of jointers
to be used on the job and make arrangements for qualification Testing of the jointers in presence of
Owner / Owner's representative. All approved Jointers shall bear Identity cards signed by
Owner/Owner's representative.

5.4 BACKFILLING

Backfilling shall be done after ensuring that appurtenance have been properly fitted and the pipe is
following the ditch profile at the required depth that will provide the required cover and has a bed
which is free of extraneous material and which allows the pipe to rest smoothly and evenly.
Dewatering shall be carried out prior to backfilling. No backfilling shall be allowed if the trench is not
completely dewatered.

Prior to backfilling it should be ensured that the post padding where required of compacted thickness
150mm is put over and around the pipe immediately after lowering.
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The backfill material shall contain no extraneous material and/ or hard lumps of soil, which could
damage the pipe and/ or coating or leave voids in the backfilled trench. In case, it is required and
directed by Engineer In-Charge, screening of the backfill material shall be carried out with specified
equipment before backfilling the trench.

Where small pieces of rock, gravel, lumps of hard soil or like materials are encountered at the time of
trench excavation, sufficient earth or select backfill materials shall be placed around and over the pipe
to form a protective cushion extending at least to a height of 150mm above the top of the pipe. Select
backfill materials for padding that are acceptable shall be screened soil, containing no gravel.

After laying of PE pipe lines, back filling with available soft soil up to depth of minimum 300mm,
placing brick as per given drawing or instruction of IOCL / TEPL, back filling with available soil up to
minimum depth of 200 mm above bricks, putting approved warning mat of 0.5mm thick and 250 mm
wide with traceability provision (as per attached specification), The warning mat is to be unrolled
centrally over the pipe section and ther6after further backfilling will commence. Backfilling activity
shall include proper compaction by jumping jack compactor and watering in layers of 150mm above
the warning mat.

Proper crowning of not more than 150mm shall be done. All the excavated material required to be
used during the Restoration process shall be stacked and kept separately and properly. Wherever
Road cutting/ Tiles removal/ PC cutting has been done during excavation for laying, the area shall be
back filled and compacted immediately so that no inconvenience is caused to the general public.

5.5 MOLING

The Moiling shall be carried out as per the requirement specified by IOCL/ TEPL, and approved
procedures. The M/s. TGSPL has to carry out thorough survey of the underground utilities before
going for the Moiling, to avoid the damage to the other utilities.

For manual Moiling the M/s TGSPL shall ensure that the size of the hole shall not be more than 20%
of the size of the casing / carrier pipe whichever is applicable. After completion of Manual Moiling the
hole shall be properly compacted / filled with soil by watering and by approved procedures, the pits
shall be backfilled, compacted & restored.

The length of the Hole (excluding the sizes of the pits on both ends) shall be considered for the
measurement of moiling length. However, intermediate pits will consider in the moiling length.
 JOB PROCEDURE FOR UNDERGROUND MDPE PIPE NETWORKS
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5.6 BORING/RAMMING/DIRECTIONAL DRILLING

One of the above techniques is required to be carried out by the M/s TGSPL where conventional
trenching/Moiling is not possible viz. railways, major waterways, highways, roads etc. Details of such
crossings shall be obtained by the M/s TGSPL and construction drawings shall be prepared by the
M/s TGSPL in consultation with TEPL/IOCL. Execution of the work shall be based on the TEPL/ IOCL
approved drawings. The M/s TGSPL has do the thorough survey of the underground utilities before
commencement of BORING/ RAMMING/ DIRECTIONAL DRILLING to avoid the damage to the other
utilities.

The type of HDD to be carried out i.e. conventional (with or without casing) shall be at the discretion
of IOCL/TEPL. And prior approval is to be taken before starting the HDD.

The length of the HOLE (excluding the sizes of the pits on both ends) shall be considered of HDD
length.

5.7 CASING PIPE

The tentative sizes of the HDPE casing pipe for Moiling/ HDD shall be as follows:-

Size of MDPE pipe Size of HDPE pipe

32 mm 63 mm
63 mm 125 mm
90mm 180mm
125mm 250mm

5.8 RESTORATION

Wherever the restoration is required, the roads, footpaths (including roads and footpaths inside
colonies) shat be restored to original condition, and the same shall be done as per concerned local
authorities norms and to the satisfaction of the concerned local Authority. To retard curing of the
installed concrete, wet sack cloth is to be placed on the finished surface and kept damp for a period
of 36 hours.

5.9 TESTING
 JOB PROCEDURE FOR UNDERGROUND MDPE PIPE NETWORKS
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Pressure testing will be carried out with compressed air. Compressed air will be provided by M/s
TGSPL for testing purposes.

For main line the test duration shall be 24 hrs. With these tests, the pressure should be allowed to
stabilize for a period of 30 minutes after pressurization. The holding period may then commence and
continue for 24hours. For secondary pipeline network and service lines measuring instruments shall
have been calibrated and their accuracy and sensitivity confirmed. For testing of Network, calibrated
pressure gauges of suitable range shall be supplied by the M/s TGSPL. The pressure gauges shall
be calibrated from time to time as desired, by Engineer-in-Charge. All testing shall be witnessed and
approved by the EIC or his delegated representative. Tie-in joints may be tested at working pressure
following commissioning.

Only, The service line for connectivity of PE pipelines from secondary network to tertiary network,
depending on case to case basis testing will be carried out independently and shall be pneumatically
pressure tested at 6-10 kg/cm2 for reduced test duration of 4hrs. The service testing in this case will
be performed after the service installation is complete but before the service tee has been tapped.
Also in some cases the tapping of the service tee will be delayed pending the completion and purging
of the main pipelines.

Test procedure with sketches showing the pipeline got to be tested, vent points, gauge location, and
inlet pressure point is to be prepared & approved by TEPL/IOCL site engineers as the same shall
depend on the location & the extent of laying of PE Connectivity pipeline.

5.10 PURGING

Nitrogen purging shall be carried out prior to commencement of gas charging. Gas charging &
commissioning shall be carried out when purging has been successfully completed and test records
are available with line under positive nitrogen pressure of at least 0.3 to 0.5 kg/cm2.
 JOB PROCEDURE FOR UNDERGROUND MDPE PIPE NETWORKS
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5.11 VALVE AND VALVE PIT

The valve pit shall be constructed in accordance with location and drawings provided by M/s
TEPL/IOCL.

5.12 PERMANENT MARKERS

Permanent Marker (As per typical Drawings Placed at Tender) shall be Installed at regular intervals
as per the instructions of the Engineer In-Charge immediately after laying of the pipeline. The
installation of the type of the Permanent Marker shall be decided by the EIC depending on the site
condition.

6. ASSISTANCE IN COMMISSIONING

M/s TGSPL shall provide the required personnel, Vehicles, labor, supervision, tools, equipment,
instruments and technical assistance for performance tests and commissioning activities as per
requirement of IOCL/TEPL.

7. STANDARD OF WORK

All work carried out under this contract shall be to standards, codes of practice; construction
procedures and other technical requirements as defined in the technical specifications.
 JOB PROCEDURE FOR UNDERGROUND MDPE PIPE NETWORKS
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8. APPENDIX AND FORMATS:

Appendix: 1 Inspection and test plan

(TGSPL/IOCL/COIMBATORE/C-5/QCP-ITP-01Rev 0)

Appendix: 2 PNEUMATIC TESTING Report

(TGSPL/ IOCL/COIMBATORE/C-5/QCP-IR-01Rev 0)

Appendix: 3 Fusion welding Checklist

(TGSPL/ IOCL/COIMBATORE/C-5/QCP-IR-01A Rev 0)

Appendix: 4 HDD LOG SHEET

(TGSPL/ IOCL/COIMBATORE/C-5/QCP-IR-01B Rev 0)

Appendix: 5 MDPE Backfilling Report

(TGSPL/ IOCL/COIMBATORE/C-5/QCP-IR-01C Rev 0)

Note: In case on any conflict between the above procedure and project specification the
later shall govern, without any prejudice to the terms and conditions of the contract.
PROJECT :LAYING OF MDPE PIPELINE AND ASSOCIATED WORKS FOR COIMBATORE GA (GROUP C-5) FOR CGD PROJECT

CLIENT : M/s INDIAN OIL CORPORATION LTD

CONSULTANT : M/s TRACTEBEL ENGIEERING PVT LTD

CONTRACTOR :TECHNO GLOBAL SERVICES PVT LTD. Appendix-1

Document No : TGSPL/IOCL/COIMBATORE/C-5/QCP-ITP-01, Rev.:00

INSPECTION TEST PLAN FOR MDPE LAYING

Docs to be
S.NO Activities BY TGS BY TEPL/IOCL Remarks
submitted by TGS

1 Submission and Approval of Work Procedure P A Approved Procedure

Trench cleaning, Dewatering,MDPE pipe

2 straightning and laying, Bottom P RW
Padding,Lowering,Backfilling
MDPE Jointing as per approved electro
3 P RW
fusion technique.
4 Pneumatic Testing P W
5 Purging & Commisioning P W
LEGENDS
"A" ; Approval
"R" Review of Documents.
"W" Witness.
"RW" Random Witness. "P" : Perform.

TGSPL TEPL/IOCL
Sign.: Sign :
Name: Name :
Date : Date :
 Project: LAYING OF MDPE PIPELINE AND ASSOCIATED WORKS FOR COIMBATORE GA (GROUP C-5) FOR CGD PROJECT

FUSION WELDING JOINT REPORT

Doc No.: TGSPL/ IOCL/COIMBATORE/C-5/QCP-IR-01A Rev.:00

Dia. Of Pipe Loop No. Joint no. _

Joint Type:
Client : M/s INDIAN OIL CORPORATION LTD
CONSULTANT : M/s TRACTEBEL ENGIEERING PVT LTD
Contractor : M/s TECHNO GLOBAL SERVICES PVT LTD
Location:
Joining Check Details

Sr. No. Description Requirement Remarks

Bar coded electro-fusion

1 Fusion Machine machine (Automatically
Readable)
2 Coupler Type
3 Whether Pipeline is free from dust, water, mud etc.
4 Whether Alignment Clamp available
Whether approved pipe cutting tool available
5
6 Availability of DG set
Whether Jointer is having ID card signed by IOCL/TEPL
7
8
Whether Removal of oxidized surface (0.1 to 0.4 mm from outer SAMPLE
surface of PE pipe)
9 Whether Pipes Faces are parallel & aligned through proper
alignment clamp
10 Whether bar code reading done
11 Fusion completed as per required time through automatic bar
12 code reading
Joint hold immobile under fusion force for 5 minutes
13 Avoided of any activity near or on joint for
30 minutes
14 Avoided of any activity near or on joint for
30 minutes

FOR TGSPL FOR TEPL/IOCL

NAME NAME
SIGN SIGN

Page 1 of 3
 Project: LAYING OF MDPE PIPELINE AND ASSOCIATED WORKS FOR COIMBATORE GA (GROUP C-5) FOR CGD PROJECT

FUSION WELDING JOINT REPORT

Doc No.: TGSPL/ IOCL/COIMBATORE/C-5/QCP-IR-01A Rev.:00

DATE:-
REPORT NO.:-
LOCATION:-
Contractor Name:- M/s.TECHNO GLOBAL SERVICES LTD

Fittings Amb. Fusion Cooling

Joint
Sr. No. Site Name & Joint Location Type & Temp Time Time Remarks
No
Size (Deg C) (Sec.) (Sec.)

5 SAMPLE

FOR TGSPL FOR TEPL/IOCL

NAME NAME
SIGN SIGN

Page 2 of 3
MDPE Laying Report No. Date :
DOC. No.: TGSPL/ IOCL/COIMBATORE/C-5/QCP-IR-01C Rev 0)
Project
, R e v: .L: A
0 0Y I N G O F M D P E P I P E L I N E A N D A S S O C I A T E D Society & Street Name:
WORKS FOR COIMBATORE GA (GROUP C -5) FOR CGD
PROJECT
Dia. Of Pipe: Loop No. From Chain age: To Chain age:

Nos. & Type of Joints (Tees & Couplers):

Pipe length payable in Normal Laying: Type of Crossings:

Pipe length Moiling with HDPE casing: Pipe length Moiling without casing:
Pipe length HDD with HDPE casing: Pipe length HDD without casing:
Whether Soft padding& warning mat provided:
Protective cover type (Bricks/ slab): Qty. Of protective cover provided:

TGSPL TEPL/IOCL
Sign Sign
Date Date
Name Name
PROJECT : LAYING OF MDPE PIPELINE AND ASSOCIATED WORKS FOR COIMBATORE GA (GROUP C-5) FOR CGD PROJECT

WORK DETAIL HDD LOG SHEET

Client : M/s INDIAN OIL CORPORATION LTD
Consultant : M/s TRACTEBEL ENGIEERING PVT LTD

Contractor : M/s TECHNO GLOBAL SERVICES PVT LTD

DOC N0. :TGSPL/ IOCL/COIMBATORE/C-5/QCP-IR-01B Rev 0)

DATE: REPORT NO.
STREET LOCATION: HDPE CASING USED: YES / NO
P/L SIZE (mm) 125 90 63 32

REAMER SIZE IF REQUIRED: TYPE AND CAPACITY OF HDD MACHINE:

TIME FOR EACH ROD

NO OF RODS ANGLE DEPTH IN MTR ROT. LOAD (PSI) PULLING LOAD PIPE (PSI)
(MIN)
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

a) Depth at Entry Pit (mtr): g) Max Depth (mtr) :

b)Rod Length (mtr) : h) Minimum Depth(mtr):

c) Coupler used (Nos): i) HDD Machine operator Name:

d) HDD Shot Length ( mtr) : j) HDD Machine Tracker Name:

e)HDD Pulled Length (mtr): k) Attach HDD Bore Plan/ Profile: YES / No

f) End Cap used (Nos):

FOR TGSPL FOR TEPL/IOCL

NAME:- NAME:-

SIGNATURE:- SIGNATURE:-
 Project: LAYING OF MDPE PIPELINE AND ASSOCIATED WORKS FOR COIMBATORE GA
(GROUP C-5) FOR CGD PROJECT

PNEUMATIC TESTING /NITROGEN PURGING & GAS IN-REPORT PE Line

Doc No.: TGSPL/ IOCL/COIMBATORE/C-5/QCP-IR-01Rev.:00

Report No. Date:

TEPL Drawing No:
Client: M/s INDIAN OIL CORPORATION LTD Route Marker/pole marker Installed –Yes / No
Consultant: M/s TRACTEBEL ENGIEERING PVT LTD Location:
Contractor: M/s TECHNO GLOBAL SERVICES PVT LTD. Ward No:
Moiling / HDD Pits Restored/ Debris Cleaning Done
Gas-In/Commissioning Check List: for MDPE Network: Yes / No
S. No. MDPE P/L Approx Executed Inspection Report cross reference no. Date of Inspection
Dia.(mm) Length (m) Report:

1 Flushing Done (Pipe cleared from water /Mud / debris and dust) Date

2 Testing Medium : Compressed air (oil free) Testing Pressure ( Kg/cm2):

3 Pneumatic Testing Start Date:

4 Pressure Gauge Make & No.:
5 Gauge calibration valid up to:
SAMPLE
6 Holding Time (Hr):
7 Pneumatic Testing completed Date
8 Nitrogen Purging Done Date
9 Gas Charging Done Date
10 Gas Pressure observed after Charging at location (Kg/cm2)

Testing Pressure Observation Chart:

S. No. Time Reading (Kg.f/cm²) S.No. Time Reading (Kg.f/cm²)

1. 3.
2. 4.
Test Results :
Remarks If any:
SIG: SIG: SIG:

NAME: NAME: NAME:

M/s TGSPL M/s TEPL (PMC) M/s IOCL

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