Report No.

: 09
Monthly Report for Quality Surveillance Month:-
September 2019

Monthly Report for Quality

Surveillance of GAIL (India) Limited
Projects Execution from
RINA India Private Limited

Project Name:-JAGDISHPUR-HALDIA-BOKARO-DHAMRA PIPELINE PROJECT (PH-II, SECTION 2A)

GAIL India ltd.:

GM (Projects) : Mr. Santiram Mandal.
DGM (PE) & EIC Mr. Rajesh Gupta.
:

RINA India Pvt. Ltd.

Project Manager : Mr. Sharalsashidharan
Project Coordinator : Mr. Siddharth Singh
Project Coordinator : Mr. Saurabh Mathur

RINA-Surveyors
Name : Mr. Sanjay kumar Bhola
Date of issue : 03.10.2019

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 Report No.: 09
Monthly Report for Quality Surveillance Month:-
September 2019

Executive Summary

GAIL (India) Limited had assigned RINA INDIA PVT. LTD. to provide the Third Party Inspection for
Quality Surveillance for GAIL’s for hiring of third party inspection agency for quality surveillance and
conformity assessment of GAIL’s various Pipeline Projects & LMC Pipeline Projects. As per

FOA No- GAIL/NOIDA/C&P/PROJ/TPIA/TPCA/17-089/027 on dated 31st May 2018.

RINA India Pvt. Ltd. scope of inspection services includes, but is not limited to, inspection during
manufacturing & Coating of Line Pipe, Pipeline construction related activities viz. Welding, NDT and E
& I, Mechanical & Civil jobs at stations on routs as well as at compressor stations.

Objective of Third Party Quality Surveillance

The objective of a TPIA is to assure high quality management standards during the manufacturing,
construction & commissioning of the pipeline system confirmation to design standards in line with the
GAIL's Quality Policy.
The Inspection Agency ensures total conformity of the Project to the specification requirement &
compliance of safe engineering practice during construction & commissioning. The Scope of work
includes the Quality Surveillance at project sites during construction of Pipeline Projects which broadly
includes, but not limited to:

Methodology for Third Party Quality Surveillance

The quality surveillance methodology will incorporate a feed forward and feedback control
mechanism monitored with the help of Coordinators and Field Inspectors posted at Project Office
and site. These Coordinators and Inspectors will work in tandem with GAIL Officials to ensure and
assure quality standards laid down through the Quality Assurance Plan (QAP) for each category of
activity / job. The periodic observations will be communicated through different categories of
reports.

REPORTING
PMC Construction
In-charge

GAIL Coordinator at Site GAIL Engineer GAIL Coordinator at CO

for Pipe Laying In-charge Noida for Pipe
manufacturing

TPIA Project Manager RINA Project TPIA Project Manager

at RINA Delhi Office Coordinator at RINA at RINA Delhi Office
Delhi Office.

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 Report No.: 09
Monthly Report for Quality Surveillance Month:-
September 2019

Checklist for Quality Surveillance of Pipe Laying

Sr. No Activity

1. Right of way clearing & grading

2. Lowering, Post-Padding & Backfilling
3. Stringing
4. Trenching
5. Pre-padding
6. Welding
7. Welding procedure specifications
8. Procedure Qualification Tests related to pipeline construction in line with the
contract document for pipeline laying
9. Welder Performance Qualification/Evaluation
10. NDT, X-Ray, UT, Auto UT
11. Field Joint Coating
12. Concrete Coating
13. FC laying, Blowing, Splicing & Testing
14. Hydro-testing, Drying, Purging
15. All types of crossings Cased / Uncased like rail, road, river, canal, etc.
16. HDD / Open-cut / Boring
17. Restoration
18. Inspection of all bought-out items & free-issue material like valves, line materials,
electrical / instrumentation items etc.
19. Installation of markers and final clean up
20. All Pipeline station construction work at compressor station, SV’s, IP’s, TOP’s, Receipt /
Dispatch Stations etc. or related to various engineering disciplines namely Civil,
Mechanical, Electrical and instrumentation.

1 - Reference
Project : LAYING & CONSTRUCTION OF STEEL GAS PIPELINEALONG WITH ASSOCIATED
FACILITIES FOR DHAMRA ANGUL PIPELINE OF JAGDISHPUR-HALDIA -BOKARO-
DHAMRA PIPELINE PROJECT (JHBDPL) PH-II ,SEC-2A.

Project Spread : Dhamra-Angul-pipeline-Section -1&2

Plant Code : 3042
Name of GAIL I/C : Mr, Mathura Bari DGM (EIC) Mr. V S S Satyanarayan ,DGM(EIC)
Contractor : M/S PUNJLLYOD LIMITED.

Surveyors  Mr. Sanjay Kumar Bhola;

Initial Date of Deployment: - 19.09.2018; to Till Date.

2 - Documents
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 Report No.: 09
Monthly Report for Quality Surveillance Month:-
September 2019

(List of procedure / specification carried out at the time of inspection, Reference codes, standard
and specifications carried out at the time of inspection :)

 API 1104/ASME B31.4

 ASME B31.3, ASME Section- IX
 Welding Specification For Onshore Pipeline, MEC/S/05/21/01
 Standard specification For Pipeline Construction (Onshore), MEC/S/05/21/02
 Specification for Mainline construction(Onshore).MEC/S/05/21/01
 Typical Trench dimensions for Pipeline. MEC/TYP/05/21/01A/002
 WPS A18-058-PLN-02/WPS-01for 36”X15.9mm/19.1mm(SMAW)
 Specification for field joint coating(Onshore Pipeline) MEC/S/05/21/13
 Specification for Lowering & Backfilling
 Specification for warning mats-MEC/S/05/62/042
 Specification for pipeline crossing Roads, Rail roads, Minor water and other crossing-
MEC/S/05/21/05
 Typical Trench Dimensions For Pipeline, 7-71-0005 Rev. 4
 Standard Specification for Field Joint Coating (Onshore Pipeline), MEC/S/05/21/13
 Standard specification for repair of polyethylene coating, MEC/S/05/21/08
 Standard specification for major river / water crossings using directional drilling method,
MEC/S/05/21/75

3 - Quality highlights

 It was observed that during the month workers are using proper PPE whenever work is in progress.
Successfully mainline welding construction work started.

4 - Areas of concern:-

NIL

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 Report No.: 09
Monthly Report for Quality Surveillance Month:-
September 2019

5 -The availability of the machinery, unit or plant and reasons for fallback in availability.

Sr.No. Equipment Detail Unit At Site Remarks

1 Pipe Bending Machine 36” Nos. 3

2 Excavator / Back Hoe- Ex 280/ 300 above/Equivalent Nos. 8
3 Flat Bed Trailers Nos. 18
4 Crane (20 MT)/F15/K10 Nos. 0
5 DG-Welding Machine (Singel Holder) Nos. 14
6 75 KV DG Nos. 0
7 Pay Welder Nos. 1
8 X-Ray M/C – External/Internal Nos. 5
9 Joint Coating Crew with Hopper Assembly Nos. 2
10 Air Compressor – (300 CFM)/450/600/850 CFM Nos. 10
11 Holiday Detector Unit Nos. 5
12 External line up Clamp (Mechanical) Nos. 12

13 JCB Nos. 2

14 Vehicle Nos. 4

15 Tractor Nos. 3
16 Welding Rectifiers Nos. 6
17 Boring machine (Auger Boring) Nos. 3
18 Hydra Nos. 6
19 Truck Nos. 0
20 Miller welding M/c Nos. 1
21 HDD Rig Nos. 0

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 Report No.: 09
Monthly Report for Quality Surveillance Month:-
September 2019

6 - Site-wise trends

Trends on main line welding & laying:

Achieved at site
Sr. No. Description Remarks
(%)
1 Repair Rate No any work is in progress due to
30.28%
financial crisis of M/S PLL
2 Rejection Rate 0% Nil
3 Recycling Rate 0% Nil
4 Plant availability
5 Laying Rate Slow progress due to shortage of
0.1248%
manpower of M/S PLL

7 - Trend-graphs
20.00%
18.00%
16.00%
14.00%
Progress in Percentage

12.00%
10.00%
18.89%
8.00%
6.00%
4.00%
2.00% 4.14%
2.12%
0.00% 0.00% 0.00% 0.00% 0.00% 0.00%

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 Report No.: 09
Monthly Report for Quality Surveillance Month:-
September 2019

Month-

8 - Status of inspection

Completed
Sr. Total Completed
Description Unit upto last Balance
No. scope this month
month
1 Handing Over of ROU Mtr 206595 166257 2761 37577
2 ROU Clearing & Grading Mtr 206595 56441 0 150154
3 Line Pipe Received at Site Mtr 206595 58114 0 148481
3.1 API 5L X70(PSL-2) 36ӯx 15.9mmWt Mtr 140241 40401 0 99840
,3LPE COATED.
3.2 API 5L X70(PSL-2) 36 ӯx19.1mmWt Mtr 63860 17713 0 46147
,3LPE COATED
3.3 API 5L X70(PSL-2) 36 ӯ x 23.1mmWt Mtr 2494 0 0 2494
3LPE COATED
4 Stringing Mtr 206595 45973 0 160622
5 Pipe Bending fabrication(Cold Field Nos 620 90 0 530
Bend)
Cold field bend Installation Nos 620 10 0 610
6 Mainline Welding, Nos 17147 3157 67 13923
Mtr 206595 38603.68 662.58 167328.74
7 Free Tie / Tie-in Welding Free Tie Nos 6 0
in

Tie-In Nos 4 0
Length Mtr
8 Total Welding Mtr 206595 37450.3 1153.38 167991.32
Nos 17147 3169 55 13923
9 Radiography Nos 17147
9.1 Taken Nos 17147 2951 112 14084
9.2 Reviewed Nos 17147 2772 258 14117
9.3 First Accepted Nos 17147 1848 63 15236
9.4 Repair Nos 248 18
9.5 Repair Accepted Nos 184 0
9.6 RT/RS/GRS Nos 493 5
9.7 Reshoot, Retake, DRS Accepted Nos 217 0
9.8 Repair Percentage % 13.41 28.57

9.9 Total Accepted Nos 17147 2247 65 14835

10 Field Joint Coating Nos 17147 1547 0 15600
11 Trenching Mtr 206595 15486 923 190186
12 Lowering (Including HDD Mtr 206595 14103 258 192234
installation)
13 HDPE Duct Laying Mtr 206595 14103 1701 190791
14 OFC Blowing Mtr 206595 0 0 0

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 Report No.: 09
Monthly Report for Quality Surveillance Month:-
September 2019

Completed
Sr. Total Completed
Description Unit upto last Balance
No. scope this month
month
15 Cased Crossings (NH ,SH) Nos 26 2 0 24
16 Asphalted Roads / RCC / Metaled Nos 52 2 0 50
Road
17 Unlined / Left main / distributary / Nos 120 0 0 0
Minor lined / Field Canal Crossing
18 HDD Crossing Nos 23 3 0 20
Pre/Post Hydrostatic Testing Nos 0 0 0 0
19 Pipeline Crossing Nos 0
20 Backfilling Mtr 206595 13265 450 192880
21 Cleaning & Gauging Mtr 206595 0 0 0
22 Hydro testing Mtr 206595 0 0 0
23 CP Work
23.1 Soil Resistivity Mtr 206595 0 0 0
23.2 Mg. Anode-2.5 Kg Installation Nos 0 0 0
23.3 Mg. Anode-10 Kg Installation Nos 0 0 0
23.4 Zn. Anode-20 Kg Installation Nos 0 0 0
23.5 Thermite Welding Nos 0 0 0
23.6 TLP Installation Nos 0 0 0
23.7 TCP Commissioning Mtr 206595 0 0 0
24 Marker Installation
24.1 Direction Marker Nos 580 0 0 0
24.2 Pipeline Warning Signs Nos 160 0 0 0
24.3 Kilo Meter Posts Nos 207 0 0 0
24.4 Aerial Marker Nos 42 0 0 0
24.5 Navigable Waterway Marker Nos 10 0 0 0
24.6 ROU Boundary Marker Nos 1650 0 0 0
24.7 OFC Distance Markers Nos 0 0 0
25 Clean up &Restoration Mtr 206595 0 0 206595
26 Nitrogen (N2) Pursing Mtr. 206595 0 0 206595
27 Pre-Commissioning & Mtr. 206595 0 0 206595
Commissioning
28 Cathodic Protection Mtr. 206595 0 0 206595
29 ANY OTHER ACTIVITY

9 - Bottlenecks of Project:

 Infra-Structure short Fall (Insufficient Infrastructure)



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 Report No.: 09
Monthly Report for Quality Surveillance Month:-
September 2019

10 - Quality Index

Location of Site Jajpur

1. Approved QAP & other QA/QC Documents Actual Weightage 20%

followed by the contractor. Weightage Achieved 20%
2. Equipment& Measuring Instrument Actual Weightage 20%
Calibrations Records Availability at Site Weightage Achieved 10%
3. Observation / Repetitive Observation from Actual Weightage 20%
the contractor Weightage Achieved 10%
Actual Weightage 10%
4. Any Alertness Found
Weightage Achieved 10%
Actual Weightage 10%
5. Any Imperfection Found
Weightage Achieved 10%
Actual Weightage 10%
6. Any NCR Raised
Weightage Achieved 10%
Actual Weightage 10%
7. Response Time for Rectification
Weightage Achieved 7%

Total Weightage Achieved by Contractor out of 100% 77%

11 - Quality Observations/ Non Conformity

1. Safe Working atmosphere observed while work is under progress.

2. Workers were observed wearing PPE While working.

11.1 Non Conformity:

NC. Description Open/closed

No.
01 NIL

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 Report No.: 09
Monthly Report for Quality Surveillance Month:-
September 2019

11.2Observations:

Obs. Description Open/closed

No.
1 Observation, Date: 01.03.19:
Contractor Name: :- M/S PUNJLLYOD LIMITED.
It has been observed that 405 joints (Repair/others) balance for Repair & RT Taken OPEN
balance.
2 Observation, Date: 01.03.19:
Contractor Name: M/S PUNJLLYOD LIMITED.
It has been observed that 766 joints balance for field joint coating due to
unviability of coating team & manpower. OPEN

3 Observation, Date: 31.07.19:

Contractor Name: -M/S PUNJLLYOD LIMITED. OPEN
It has been observed that 218 joints balance for RT taken.
4 Observation, Date: 01.03.19:
Contractor Name:-. -M/S PUNJLLYOD LIMITED. OPEN
It has been observed that HDD crossing section Cleaning, Gauging & post hydro
test balance since long.
5 Observation, Date: 01-03.19..
Backfilling and barricading not done at various locations where tie in OPEN
pockets/trench is open condition which in turn could be caused of accident.
6 Observation, Date: 10.02.19.
Contractor Name:-. -M/S PUNJLLYOD LIMITED.
TCP balance of lowered section 141361 mtrs. approx. OPEN
7 Observation, Date: 31.07.19.
Contractor Name:-. -M/S PUNJLLYOD LIMITED. OPEN
It has been observed that Cased crossing section Hydro test & Carrier pipe
insertion balance since long.

11.2 Non Conformity:

NC. Description Open/closed

No.
01 NIL

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 Report No.: 09
Monthly Report for Quality Surveillance Month:-
September 2019

12 - Photographs

Mainline Welding work Trenching work

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 Report No.: 09
Monthly Report for Quality Surveillance Month:-
September 2019

Backfilling Work Lowering work

SV Station work Lowering Section

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 Report No.: 09
Monthly Report for Quality Surveillance Month:-
September 2019

REPORT REVIEWED BY
Name: SharalSasidharan
Signature:
Date:

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