> VIJAYPUR AURAIYA PIPELINE PROJECT & @KSs pA JOB PROCEDURE FOR CASED CROSSING Doc. No. KSS-VAPL-PLC-022 PROJECT : Vijaypur Auraiya Pipeline Project CLIENT : GAIL India Limited CONSULTANT =: Engineers india Ltd. CONTRACTOR JSC “OGCC KazstroyService" 0 | 05.2018 | Fortiont review and approval Rev [Date Purpose of Issue ——___Procedure For Cased Crossing Dec. No. KSS:VAPL-PLC-022 Rev: ‘TABLE OF CONTENTS 1.0 PURPOSE 2.0 SCOPE 3.0 REFERENCES 4.0 RESPONSIBILITIES 5.0 METHODOLOGY 6.0 HEALTH, SAFETY & ENVIRONMENT 7.0 INSPECTION, TESTING& DOCUMENTATIONProcedure For Cased Crossi Qxss ot <= Doc. No. : KSS-VAPL-PLC-022 Rev: 0 1.0 PURPOSE The purpose of this procedure is to guide the job performers viz technicians, supervisers, inspectors, engineers etc. during execution of cased crossings and tocontrol the quality of work for and Vijaypur Auraiya Pipeline Project. SCOPE The scope of this procedure covers the installation of pipeline by boring across roads, rails roads etc. by using Augur Boring Machine. REFERENCES Following documents in totality or in part shall form the reference documents . EIL spec 6-71-0052 for Standard specification for pipe line crossings. EIL spec 6-71-0051 for pipeline construction. . EIL spec 6-71-0035 for Casing Insulators and End Seals. . Route maps, alignment sheets &crossing drawings. . Job standard — 6922-7-71-001 6,6922-7-71-0020,692: ROLES & RESPONSIBILITIES Boring Engineer Shall report to the Resident Construction Manager and shall be responsible for + Preparation of boring schedules addressing specific issues and characteristics of each spread. Overall contro! and safety management and for the implementation of procedure and supervises the activity. Execution of the boring implementing this procedure, Generation of reports during the activity. Supervising all other persons involved in boring of the detailed operations to be done during the activity. QC Engineer » Reports to site QAQC in-charge * Checks and verifies the activity at the stages & to the extent indicated in ITP. * Coordinates with inspectors of owner for inspection & verification as per ITP. HSE Officers ‘Shall reports to Resident Construction Manager/Project Manager administratively and to HO for technical matters and shall be responsible for + Implementation of all safety requirements during survey operations ser (loe KSS Procedure For Cased Crossing Doe. No. :KSS-VAPL-PLC22 Rev: Ensuring that the communication system is working properly and that emergency system is in order. METHODOLOGY The work to be carried out for road and rail road crossing shall meet the minimum requirements of API RP 1102 latest edition. Prior approval from the statutory authorities shall be obtained to lay the pipeline across the Highway/road/railways. KSS shall submit the following documents to EIL for perusal and approval, prior to the commencement of the works. ‘* Time Schedule for the Crossings to be executed + List of equipments deployed. List of manpower deployed. Soil/Survey Investigation Report, and construction drawing. Working method Calculation of temporary works. Part-A Boring and Casing Pipe Before starting the boring activities necessary approvals from statuary authorities shall be obtained by KSS. After taking the levels in the ROW, bottom of the trench or pits at the launch and receiving end shall be graded for atleast 12 mirs. and back filled with clean sand and compacted to 95% proctor density to an elevation that will provide sufficient and continuous support to the pipe line so that the pipe line remains correctly aligned at the casing ends during and after backfilling. Boring lino shall be marked as per Alignment Sheel. Boring Pit and Receiving Pit shall be prepared and trenching of the same shall be done as per required depth and width. (ElL)shall ensure that pit does not collapse. Temporary fencing warming sign shall be provided. ~ ‘°< Before starting of the boring KSS shall execute a soil investigation and determine the ground water table. Based on these investigations KSS shall prepare a construction drawing and submit to EIL for approval including time schedule and soil investigation report. After leveling, the machine shall be lowered in the pit and alignment shall be done. The machine shall be traversed on the rails to and fro several times and alignment shall be checked and rectified, if required, Visual checks of the casing pipe will be made in order to check out of roundness and that no dents are present. If such dents are present pipe shall be either rejected or the Portion containing dent shall be cut and removed. Insertion of casing pipe and Augur Boring shall be carried out simultaneously. Boring shall be carried out at low speed initially and after inspecting the soil that is cut by Augur, the speed shall be increased or decreased. Levels shall be checked at both end of the casing pipe to confirm the slopes as per approved drawing. The diameter of the hole bored shall be as close as practicable to the outer dia of the casing pipe. During the execution of the boring and ground water table over the length of boring shall be lowered up to at least 0.5 meters below bottom of pipeline. This water table is to beProcedure For Cased Crossing Doc. No. : KSS-VAPL-PLC-022 Rev 0 regularly inspected and maintained and reported to ElL. To safeguard the stability the stability of the bore pit, KSS shall, if netcessary in ElL’s opinion, use a closed sheet piling which shall extend atleast over 50% of the length in undisturbed soil. In approaches to the crossing, KSS shall eliminate unnecessary bending of pipe by confirming to the counter of the ground by gradually deepening the Ditch at such approaches in consultation with ElL. Separate boring heads shall be used for cutting rocky terrain. The casing pipe and boring shall be extended a minimum of 0.6 m on either side of crossings. Soil cut by the Boring Heads shall be inspected from time to time and in case, the soil strata change the entire length of Boring Augurs shall be retrieved and the boring head shall be replaced with the suitable one. Care shall be taken that the leading Augur remains in the front, which facilitates easy insertion of casing pipe. P Casing pipes shall be welded in the pit itself after insertion of the first pipe. During welding and fit-up any internal high low is not allowed. The passage of the carrier pipe should be unhindered so as to protect insulaters applied on it. The methodology of bevel preparation and welding shall be as per approved tie-in welding procedure. Filler motal used shall be as per approved tie-in welding procedure. A welder shall be deputed for welding and Visual inspection shall be done on completion of weld joint. After completion of boring augurs will be retrieved and the casing pipe will be cleaned from inside by swabbing and capped from both ends. The OFC shall be laid in HDPE pipe put in a separate carbon steel-casing pipe, which shall be installed separately. After the finish of the casing pipe vent and drainpipes shall be welded at both the ends. Nightcaps / casing end seals shalll be provided to the casing so as to restrict the ingress of water and any other foreign matter. Part-B Insertion of Carrier Pipes String of carrier pipe shall be prepared as per conventional norms and kept ready for insertion. Before insertion of the carrier pipe the complete casing shall be carefully inspected and internal cleaning shall be done to remove the foreign material. The string of carrier pipe required for crossing shall be made ready and shall be pretested as per approved procedure prior to joint coating. The test pressure shall be the resulting in the hoop stress corresponding to 90% SMYS of the pipe material. The test pressure shall be retained in the pipeline for a minimum period of 4 hours and the weld joint shall be checked for leakage. ‘After completion of Pre-testing string joint shall be blast cleaned and Coating done. i mee Dryle The crossing section shall be holiday tested.Procedure For Cased Crossing Doc. No. = KSS-VAPL-PLO-022 Rev.: 0 * After completion of pretesting and holiday, insulators shall be installed by means of rings/fasteners, as per ElL Specification. Insulators shall be placed at an interval as shown in drawing. The carrier pipe string is then lifted by side boom and centered in the casing and insertion is done smoothly without causing any damage to the carrier pipe, its coating or the insulators etc. After installation of the carrier and casing pipes, an electrical test shall be conducted to determine the resistance between the casing and carrier pipe or the carrier pipe and the soil. The tests shall show at least a resistance of 100,000 ohm m2. Casing end seals shall be provided as per manufacturer recommendations at both ends of the casing for sealing the annular space between carrier and casing pipe to prevent water injection, soil ingress etc. Boring pit shall be backfilled after completion of the respective tie-in. © In overall, work shall be executed as per job standards. 6.0 HEALTH, SAFETY & ENVIRONMENT 1. Machine operator involved shall be an experienced & qualified person. 2. It's to be noted that the special care like wearing of full length gum boots, hand. gloves etc. to be adopted against snake / insects bite. 3. PPE such as full length gum boots, hand gloves, helmet, shield, goggle etc. shall be used in this activity. Proper nose cover shall be used in dusty atmosphere. 4. Only trained rigging personnel to be deployed for this activity. 5. Personnel around the machine (if any) should be cautious about overhead falling objects. Use of hard helmet shall be ensured. 6. During the movement of earth moving equipment the operator should blow horn to caution the people around. All equipments shall be provided with back horn. 7. Alllifting devices & Tolls used shall be certified for use by proper authority. 8. Boring pit shall be properly fenced and safety sign board shall be displayed in local language & English. 7.0 INSPECTION, TESTING & DOCUMENTATION ite FORMATS NOTE: In case of any conflict between the above procedure and EIL Specification the later shall govern, witht Rejaidice a ion oF A“PHT eipyy suseul6u3 he ea ie peaady wim =e oe eis 38H asa [or wl om saueadacoy Ie souendany 12st ZOE UYASS od iy ano19 dep [st wl souendasoy ens souendenoy [ens ZOD WYASS 29 Buse auyodid veamsea iy 9019 [vt I wal anueidasoy lens soundeoy ens zoos raynssy seve pug jo vorejewu [et | BuyepPeR pu U wl _m | ecome-ravassy souendonoy ens | zeo me Tavis | ou esoq ones oye syooyo anvers'se f2432013 | EE wl om aouendasoy ens | souydasoy ers 220714 TYAS 39d sae) so uonuasu [TT whom sBuyweia penoidey suoginsuyjo uoaejexu [or wa] swvwwos zoe tavi'ssy |_uorses sxque up jo au Aepyoy Buco sor Pl | *6 w| im SLOAN aged se did sowse3 o s00 upheld | 8 wu aunpasoig pavesdey SPaMIOLNY | ¥ uone=jpeds way Tadigaynep jo voneouaes "9 wu oO TTE TYNES aiaearidy se vont s W aouendy [sin sBumeig Sus0r) aged se 3d Ba09 0 vo ” wil woreypads wad stumesq Susso19 | __sosemnpeuns / Sue vononiasues jo von € wl # a = Tajuossiuzeg | Honan Weis 0 ApOWANe paureDu09 wou eNeuddy | 2 vl 8 EOE TAVA SY woneaypeds we LOANS _sveuoog panoicy 40 Auiereny |“ ww | $4 ‘sBumeia / woneaypeds wonbadsuljo wang | wownog BuIA ea souerdenoy ‘wvausn20q 2242/9;09 wondu2sea Aunay | “W'S "TES TEGINSY 'ZOTT dUId¥ 3a 81g "sunpasoug ‘uorreayrneds quaiia~(uoneay!zeds °g sepoo) od se uonzedsul 3591 /Buymeia pancadde sad se Suy0@/ino ado Suiss019 pase - wwoHduDseq o:waneu "Ta aueynueD sox soei009 ws awa 220-aLIavA~SSH ‘ON 200 ava wafoid ona SNISSOUD G3SV9 HOS NVTd 1531 8 NOLLIZdSNI Sig)CASED CROSSING BY BORING 7: VIJAYPUR AURAIYA PIPE LINE PROJEGT(VAPL) Format No, P22 + Mls GAIL (INDIA) LIMITED. Page Lot 2 Jconsuctanr + M/s ENGINEERS INDIA LTD. JCONTRACTOR §——: JSC “OGCC KarstroyService” Spread: JbocuMENT No: =: KSS-VAPL-FW-022 Report No: Date ‘Alignment Sheet No. Pipe Dia Chainage Length (Opencut) Length (Borin) Total Casing Longth(Mte) [eengih —[loint No. [weld visual Painting Remarks osing Pipe Casing Pipe internal ort | CathaPine 5) CASING VENT AND DRAIN SKETCH: ze & Length of Vent Pipe size & Length of Oran Pipe Pipe Grade [coating/ Painting of Vent & Drain AVG urs [C10FC ste! Conduit Detaits DPE Duct & Seating Details Size Rating End Seal DetailsBoring Operation start Date & Time Icompleted Date & Time REMARKS: KS: CASED CROSSING BY BORING pRovect {VMIAYPUR AURAIVA PIPE LINE PROJEGTIVAPL) Format No.1 P22 cunt = Mis GAIL (INDIA) LIMITED Page 2of 2 CONSULTANT: Wis ENGINEERS INDIALTD Spread: CONTRACTOR: JSC “OGCC KazstroyService” DOCUMENT NO _: KSS-VAPL-FM.022 PEDETALS lao omy Js.o cinta, findng Jwelcng Fer neport ta, |UTREPOt Joretyro est Report Na, [coating [checking — = [Report No, |Reprot Checked Other Details Le Bottom Level of casing Pipe nstallation o nslotors & Numbers installation of End Seas Electrical Continuity Resstance Check ( Before Backfilling and Tie-in) ecrical Continuity Ressance Check After Backing and Tein Carrier Pipe installation Start Date & Time Completed Date & Time STG [si@N NAME oATE Engineers India Ltd. pur Aural fa Pipeline Project