SCOPE OF WORK-PIPELINE

CONTENTS

1. INTRODUCTION .......................................................................................................................................................

2. SCOPE .........................................................................................................................................................................

3. WORK TENDERED ..................................................................................................................................................

4. SCOPE OF WORK ...................................................................................................................................................

5. SCOPE OF SUPPLY .............................................................................................................................................

6. OTHER CONDITIONS OF BID ..........................................................................................................................

7. CONTRACTOR‟S RESPONSIBILITIES .........................................................................................................

8. AS BUILT DOCUMENT ........................................................................................................................................

9 DOCUMENTS, SPECIFICATION, STANDARDS & DRAWINGS ...........................................................

10 LIST OF ATTACHMENTS ..................................................................................................................................

1. INTRODUCTION
GAIL (India) Limited, is India's flagship Natural Gas company, integrating all aspects of
the Natural Gas value chain and its related services. In a rapidly changing scenario, GAIL
is spearheading the move to a new era of clean fuel industrialization, creating a
quadrilateral of green energy corridors that connect major consumption center in India
with major Gas Fields, LNG terminals and other cross border gas sourcing points. GAIL is
also expanding its business to become a player in the International Market. M/s. GAIL
(India) Limited envisages to strengthen local gas grid network in various parts of India
M/s GAIL (India) Ltd. proposes to cater to the demand of various small consumers in
Karnataka, Goa and Maharashtra sates.

2. SCOPE
The scope of work to cater to the demand of various small consumers in Karnataka, Goa
and Maharashtra sates has been indicated in following typical Drawings

 Typical Pipeline Schematics

 Typical Pipeline P&ID

 Typical Terminal GAD

 Typical Plot Plan

 The above drawings are indicative only and are furnished to the Bidder to
understand the nature of work involved. Issued for Construction (IFC) shall be
progressively furnished by the Company to the Contractor, at an appropriate time
during project execution stage.
The work southern region includes following States.
 Karnataka
 Goa
 Maharashtra

This document covers the details of work tendered, scope of work, and scope of
material supply pertaining to pipeline and associated facilities. All works and clauses of
this document shall be applicable unless specifically mentioned otherwise.

Scope of work pertaining to civil, structural, architectural, electrical, mechanical,

instrumentation and telecom works are covered elsewhere in the tender document.
 This document shall be read in conjunction with List of Attachments, Schedule of
Rates, specifications, standards, drawings and other documents forming a part of the
Tender Document.

3. WORK TENDERED
Work tendered in this bid package consists procurement (except free issue supply),
supply, installation, testing, pre-commissioning and commissioning of various Pipeline,
Sizes 4”, 8 and associated Terminal works from Tap-off to Consumer end under last mile
connectivity (LMC).
The work involves in connectivity as follows

 Laying of main pipeline of either of 4”, 8” Size between Tap off/ dispatch terminal
to Various Receipt Station/ Metering Station at Consumers End.

 Hook-up with existing Pipeline/ Piping through existing tap-off or by Hot tap

 All Piping works at tap off/ dispatch station including installation of Valves,
insulating joints, flow tees etc.

 All piping works of Consumer end/ receipt station including installation of insulating
joints, flow tees, valves, hook-up etc.

 Installation of metering units skid / filtration/ pressure reduction at consumer end

 Installation of Pig traps/Jib Crane whenever required.

 Crossings of road, utilities, forest, underground pipelines and water crossings by
Open cut, HDD and boring.

 Hot taping works, if required, for taking Tap off engaging approved agency for its
installation.

 Carrying out all topographical and geo-technical surveys, as required, preparation
of crossing drawing, procedures and submitting the same for Companys approval.
Installation works shall start only after getting Company approval of design
documents.

 All works related to hydro testing and pre-commissioning & Overall Commissioning
of the pipeline and terminal facility.

 Supply of Nitrogen for purging, if required / as advised by Engineer In charge
Contractor shall also provide all assistance to M/s GAIL during commissioning

 Works related to Optical fiber cable and Permanent/ temporary cathodic protection.

 All associated mechanical, civil, structural, architectural, electrical, instrumentation
work at all stations facilities.

  At any given time, the contractor will have to work at multiple fronts for minimum 2-
5 connectivity jobs. The contractor has to plan and mobilize the resources
accordingly.

 Any other work no mentioned but required for successful completion of work

 Work may allot to Contractor in multiple Front. Contractor shall be required to plan
and mobilize his resources accordingly to meet completion target Schedule of M/s
GAIL

3. SCOPE OF WORK
The scope of work detailed herein shall be read in conjunction with the other tender
documents i.e. specifications, standards and drawings etc. enclosed with the bid. The
detailed scope of work tendered includes residual engineering & procurement, installation,
testing and commissioning along with all associated works pertaining to complete pipeline
system and related facilities described here under.
The detailed scope of work in general but not limited to the works listed below and shall
be applicable, unless specifically mentioned otherwise.
A. Procurement

 Contractor shall procure and supply all materials other than Company supplied
materials, required for permanent installation of pipeline and piping system in sequence
and at appropriate time. All equipment, materials, components etc. shall be suitable for
the intended service.

 Approved vendor list has been enclosed with the bid package for various items. For
items which are not covered in the vendor list, Contractor shall obtain Company‟s prior
approval for the vendor. Equipment/ material offered shall be field proven. Equipment
require specialized maintenance or operation shall be avoided, as far as possible.

 Stores management including receipt, warehousing, preserving the material in good 

condition, issue of material to construction site, reconciling/ handing over surplus
material to Company for Company supplied items at Company‟s storage yard.

 Carryout proper documentation of inspection and quality assurance programmers for
bulk materials duly approved by Company. Contractor shall maintain an accurate and
traceable listing of procurement records for the location, quality and character of all
permanent materials in the Project.

 Contractor shall immediately report to the Company of all changes which will affect
material quality, and recommend any necessary corrective actions to be taken.

  Submit periodic manufacturing progress reports highlighting hold ups and slippages, if
any, to Company and take remedial measures.

 Interact with authorities such as Sales tax, Octroi, Excise, GST etc. as necessary and
arrange for dispatch of materials to site.

 All purchase requisitions including purchase orders shall be approved by Company.

 Compliance with vendors and suppliers instructions and recommendations for
transportation, handling, installation and commissioning.

 Contractor shall provide inspection of the items at vendor ‟s works by the reputed
inspection agency and shall submit inspection reports of OWNER‟s clearance. In case
of pressure containing materials, contractor has to provide 3.2 certificates (as per
EN10204) by the approved third party inspection agency without any extra cost to the
owner. In addition to the same, OWNER reserves the right to inspect any material
supplied by the contractor at any stage of manufacturing and delivery by themselves or
through their representative. Contractor scope includes providing the intimation to the
owner, for inspection at any stage. This intimation shall be given at least 10 days prior
to the inspection. Any extra payment will not be release to the contractor due to this
inspection. Contractor shall appoint anyone of the following TPIA for inspection
purpose.
i. Lloyds Register of Industrial Services.
ii. Technischer Uberwachungs Verein (TUV)
iii. Det Norske Veritas ( DNV)
iv. AIB – Vincotte
v. Bureau Veritas
vi. SGS
vii. American Bureau Services (ABS)
viii. Velosi Certification Services.

B. Construction

 All construction works shall be carried out as per “Approved for Construction”
drawings, procedures, specifications and applicable codes and standards. Any
changes at site shall also need prior approval from the Company and revision of
drawings.

 Company has obtained most of the clearances, No objection certificates (NOC) for
laying pipeline & for stations from concerned authorities. However, for some of the
permissions, if not available, Contractor shall do the follow up with the concerned
authorities to get the permissions to execute the job in time. In such cases, all
statutory payments required for such permissions shall be reimbursed by Company
at actuals. Contractor shall obtain permits/clearance from concerned authorities
before actual commencement of the job at site including preparation and
establishment of safety procedures for laying pipeline.

  Contractor shall also inform all local authorities in advance and obtain all necessary
approvals for crossing underground utilities/ pipelines wherever encountered along
the pipeline route. Contractor shall be required to carry out all the works as
mentioned in the work permit.

 Immediately after award of individual work, Contractor shall make a visit to the route
to establish the route and familiarize with the working conditions so as to plan for
deployment of man and machinery.

 Most of the areas the Pipeline shall be laid along the road and industrial area. The
ROU shall be restricted. Excavated trench & pits in area near heavy traffic and other
areas of movement, shall not be left open without barricading Contractor shall
consider all these eventualities while bidding.

 Contractor may plan to work in the Night shift to avoid traffic while crossing roads &
utilities. But Contractor has to plan and take approval from Engineer In charge/
Client and Concerned Authorities before start of construction. Contractor to arrange
all lighting and safety precaution for the same.

 In some areas where mechanized excavation is not possible, Contractor shall have
to do manual Excavation also. Contractor shall consider all these eventualities while
bidding.

 Providing schedules, progress reporting, organization chart at construction site,
quality assurance plan and developing quality control procedures, as per
requirements of the bid package.

 Contractor shall be responsible for claims if any arising out of damage/ obstruction
to public utilities like OFC lines of DOT, water pipelines etc. where the claims will
cover the restoration costs as well as loss of revenue due to down time.

 Providing all equipment ‟s, manpower, machinery, consumables, apparatus, tools
and tackles for fabrication, installation, inspection, testing, pre-commissioning and
commissioning complete as required including facilities for inspection and
interpretation of testing results by Company Representative personnel; providing all
types of safety tools, tackles, devices and apparatus, equipment etc.

 Obtaining all necessary approvals and work permits from Company/ Concerned
local authorities having jurisdiction including hot work permit as applicable for
performing the work in existing terminal facilities. Arranging of adequate firefighting
equipment viz. fire brigade, fire extinguisher, shielding from existing facilities,
oxygen mask etc. for carrying out the work safely in existing terminals to the
satisfaction of Company. 

 Coordination and supervising the work of sub-Contractors.

 Transportation of appropriate materials to worksite, intermediate storage points,
maintaining and operating an adequate material control procedure at worksite.
 
 Transportation from GAIL Stores, installation, hook-up testing and making the
complete metering system ready for commissioning. Skid comprising, cartige filter,
PCV/SDV/ Metering System etc.

 Fabrication of all piping, structural components as per approved drawings.

 All associated civil, structural, electrical, instrumentation; HDPE duct & OFC laying
and telecom works shall be performed in accordance with relevant specifications
and requirements enclosed elsewhere in the bid package.

 Contractor shall depute independent third party inspector for carrying out
radiographic inspection and interpretation of radiograph of welds. Third party
inspector shall be approved by Company.

 Provide, maintain and operate all temporary facilities required for the construction
related works and remove after completion of work.

 Hook up/tie-in of pipeline and piping system with terminal facilities.

 All works related to testing, dewatering, swabbing, pre-commissioning and

commissioning of the work tendered.

 Idle time preservation of pipeline, if required.


C. Pipeline Laying Works

 "Receiving and Taking-over" Company supplied free issue externally/ internally coated
line pipes from designated warehouse, loading, transportation, unloading, handling, and
stacking of pipes at Contractor’s worksite(s)/ workshop till the pipes are installed in
permanent installation. The pipeline laying contractor shall make his own arrangement of
crane for lifting of all free issue material.

 Carrying out inspection of Company supplied free-issue coated and bare line pipes at
the time of receiving and taking-over and recording of defects, etc. noticed in the
presence of Company’s representative. All defects to pipe and pipe coating noticed at
the time of taking over.

 Contractor shall carry out repairs (including supply of all materials) of line pipe and pipe
coating after receiving and taking over including repair of all defects/damages occurring
during transportation and/or handling.

 For pipes where cutting out involves more than 25mm from pipe ends, ultrasonic
inspection shall be carried out at pipe ends as per specification enclosed with the
tender. Contractor shall take prior approval from Company for the agency engaged for
carrying out ultrasonic inspection.

 Loading, transportation, unloading, handling, stacking, storing at workshop/work site of
all materials other than corrosion coated and bare line pipes that shall be used for the
construction of pipeline system supplied by Contractor.

 Carrying out all additional topographic, geo-technical survey and/or soil investigations
required for local detours, crossings and elsewhere during execution including preparing
plan and profile drawings as directed by Engineer-in-Charge.

 Mobilizing and providing all equipment, manpower (skilled and unskilled), consumables
and other resources etc. as required for the execution of complete work.

 Obtaining all necessary approvals from concerned local authorities having jurisdiction for
performing the work including shifting/ relocation and restoration of telephone/ electrical
poles and underground pipes and other crossings & utilities etc., as required by local
authorities and as directed by Company.

 Staking, clearing, grading, fencing of Right of Use as required, trenching to all depths in
all types of soils including soft/hard rock, by special techniques, chiseling or otherwise
cutting etc. to a width to also accommodate the OFC/ cable conduit as per relevant
standards, drawings, specifications etc., transportation of coated pipes to ROU along the
route, stringing, aligning, bending, welding, NDT including radiographic inspection, field
weld joint coating, sand padding including supply of sand/ soft soil, laying and lowering
of the pipeline, back filling including supply of select backfill wherever required, slope
breakers as required in slope areas where slope is more than 1 in 10, carrying out rail,
road, canal, drain, nala, utility and minor water course crossings by conventional/ HDD
method including installation of carrier pipe inside casing pipe at cased crossings
wherever required, clean-up, pigging, flushing, gauging, hydrostatic testing with the
quantity of inhibitor as required, dewatering with the addition of approved chemicals to
neutralize the effect of inhibitor added, at required dosage, swabbing, pre-
commissioning and all associated works for complete pipeline system as per relevant
specifications, standards and approved drawings.

 Thorough internal cleaning of all pipes to remove debris, shots, grit etc. to the
satisfaction of Engineer-in-Charge. However, adequate care shall be taken so as to
avoid damage to the internal coating.

 Installation of all in-line/ on-line instruments, valves, insulating joints, appurtenances, etc.

 Welding of all tie-in joints including tie-in joints and bends on either side of crossings/
with adjoining pipeline/ other facilities as required.

 Field weld joint coating shall be by heat shrink sleeve of approved make

 Supply and Installation of casing pipes (by open cut/jacking/ boring/ any other trenchless
technique) assembly, including supply of all materials, viz. casing pipe, casing insulators
and end seals, vents and drains etc. complete, at cased crossings.

 Supply and installation of all types of pipeline markers including their painting suitable for
and Normal corrosive environment as specified in Standard Specification and all
associated civil works. Location of markers shall be as per specification/ standards and
as directed by Engineer-in-Charge.

 Providing 300 micron epoxy on the external surface of all 6” CS conduits meant for OFC
and Casing Pipe

 Sand/ soft soil padding around pipe wherever required in areas where trenching has
been done in pebble/murom/ rock. The thickness of sand/soft soil padding at the bottom
of pipe shall be 150mm in these areas. The pipeline trench shall not be filled with gravel
& large stones or boulders. Extra digging of trench shall be carried out to comply with
above requirements & to provide minimum 1.0 M cover over pipeline.

 Installation of all inline/online instruments/valves/insulation joints/ appurtenances etc. as
per requirements of approved drawings.

 Crossings of Nala / streams/ canals/ drains or other minor water by Open Cut/ Boring/
Trenchless Technology method :

a. Pre-construction surveys, preparation of detailed construction method statement
and calculations for Company’s approval.
b. Geo-technical investigations, if required.
c. Site preparation, arranging required land for setting up of string fabrication yard
and obtaining necessary permissions from concerned authorities.

 HDD works shall be carried out in accordance with specification enclosed with bid
package. For directionally drilled crossing, following shall be performed:

a. Carrying out all surveys and collection of data, as may be required for the design
and construction of the crossings.
b. Carrying out all engineering, design calculations and preparing all construction
drawings for laying of pipeline and optical fiber cable inside steel pipe as per
requirements for installation of Road/ Canal/ nala/ minor river crossings by HDD
method.
c. All construction activities required for installation of the crossings viz. site
preparation, preparation of pipe string, field welding, radiography, pretest of
completed string, corrosion coating of field joints, drilling in all types of soil
including gravel, boulders and disintegrated and hard rock, installation of pipeline,
post installation hydro testing of the crossing section, capping, providing and
installing markers and temporary cathodic protection of pipeline section at
crossings.
d. Field joint coating shall be carried out by Dirax heat shrink sleeves or equivalent.
e. Supply of 6" NB, 6.4 mm W.T. API 5L Gr.B 300 micron epoxy coated steel
conduit, with interduct of flexible HDPE for laying of OFC cable.
f. Installation of pipeline and 6" NB steel conduit for OFC (together in a single drilled
hole or separately in two independent drilled holes).
g. Tie-in with main pipeline after successful installation of pipeline at river crossing.
 h. All associated pipeline work w.r.t. temporary and permanent cathodic protection.
i. Clean-up and restoration of ROU to original condition as per specification and
drawings to the entire satisfaction of Company and/or Authorities having
jurisdiction over the same, including disposal of surplus excavated soil and other
construction materials without causing any disturbance to environment and to the
entire satisfaction of Company. Contractor shall arrange necessary clearance
from the concerned authorities/ land owners to the effect that ROU/ ROW has
been restored back to original condition.

 Corrosion coating of long radius bends by heat shrink sleeve as per specification.
Contractor to use these bend judiciously. Contractor to fabricate and use cold field bend
in balance turning points of the route

 Carrying out Magnetic cleaning and Electronic Geometrical Pigging (EGP) including
supply of all types of pigs, pig locating and tracking device, spares, consumables,
manpower etc. as per specification enclosed with bid/ contract document.

 Carrying out repair of all defects found during Electronic Geometrical Pigging (EGP)
including locating, digging, cutting, welding, NDT etc.

 Carrying out cleaning, flushing, swabbing (as applicable), dewatering, testing and pre-
commissioning of pipeline and associated facilities at Receipt/Dispatch Station up to the
respective battery limits. Locating all major and minor leaks during hydro testing if any.

 Repair of any leaks/burst occurring during testing of main pipeline.

 Preparation of as built drawings, pipe books, documents, photographs, project records

as per specification and instructions of the Company including furnishing of all Test
Certificates/Inspection Reports for all materials used for permanent installation.

 All incidental and associated works and any other works not specifically listed herein but
are required to be carried out to complete entire work related to pipelines and the
associated facilities and making the entire pipeline system ready for operation..

 Installation of carrier pipe in canal/ road (NH/ Express highway)/ railway crossings by
boring/ HDD/ Trenchless method, as directed by Company. Whenever HDD/Trench- less
method is to be adopted for pipeline installation, the same shall be carried out as per
specification. Contractor to note that the minimum elastic bend radius to be adopted,
shall be as per pipeline engineering design basis enclosed with the tender..

 Carrying out temporary and permanent cathodic protection works as defined

 Loading, unloading, handing over and transportation of all surplus Company supplied
free issue linepipe after completion of works Company‟s designated warehouse as
directed by Engineer-in-Charge and stacking the same. Stacking of surplus pipe shall be
inclusive of supplying of sand bags etc. at Company store for proper stacking.


D. Terminal Works
a. Receiving and Taking-over" Company supplied free issue Filter, Metering and PRS skid
from designated warehouse, loading, transportation, unloading, at Contractor’s
worksite(s)/ workshop till the skid is installed in permanent installation. The contractor
shall make his own arrangement of crane for lifting of all free issue material.
b. Supply, fabrication and erection of pipe/ equipment supports (for all sizes/ thickness)
including shoes, pipes, cradles, turn buckles, T-posts for all types of guides, anchors, all
necessary equipment, consumables, labour etc. for completing all works including
supply of bolts, nuts, washers, U-clamps, wooden blocks etc. as required for supporting.
c. Hook-up of piping with skids, equipment’s & vessels, with the existing facilities, with the
pipeline and at the battery limit with the facilities installed by others by welding or by
flanged connection including cutting, fit-up, welding, NDT, radiography, interface/co-
ordination as required with other Contractor(s)/Agencies.
d. Painting of all equipment’s, structural steel elements for pipe supports, above ground
piping and all related miscellaneous items shall be provided suitable for mention
temperature application as per company specification enclosed with the bid document.
Application thickness shall be as per painting Specification of bid document.
e. Protective coating of 500 micron thick two component epoxy (achieved by application of
three coats) duly approved by Company for all underground piping, valves, fittings,
etc.as per specifications including supply of all materials.
f. Hydro testing, dewatering, flushing & pre-commissioning activities of piping system of all
sizes as per specifications enclosed including supply of all materials and manpower that
is required during pre-commissioning and all associated works. Identification of leaks
during hydro testing & repair of defects.
g. Final clean up and restoration of site, facilities etc. as per the requirement of
Company/Engineer-in-Charge.
h. Preparation of isometrics and/or fabrication drawings required for the purpose of
fabrication during execution of work.
i. Preparation of as-built drawings, documents and project records as per instructions of
Engineer-in-Charge.
j. Co-ordination as required with other Agencies/Sub-Contractor(s) till the time the
commissioning operations are complete.
k. Any other works not specifically listed herein but required for completion of the works in
all respects.


4. SCOPE OF SUPPLY

A. Materials to be supplied by Company as Free Issue

a. Company shall supply following materials as free issue:
- 3 Layer PE externally & epoxy internally coated line pipe for main line
- Metering Skid, pressure reduction skid, filtration skid
- Permanent Scraper Trap
- Insulating Joints
- Flow Tees
b. Free issue material shall be supplied from M/s GAIL designated stores in Vaghodia /
Vijaipur or other locations as instructed by Engineer In charge. Further, Contractor
shall also return any unused materials after completion of work to owners
designated store in Vaghodia/ Vijaipur or as directed by owner/ Engineer-in –
Charge at its own cost.
B. Materials to be supplied by Contractor
All materials (other than those mentioned in clause A above, consumables,
equipment required for completion and successful commissioning of entire pipeline
system shall be procured and supplied by the Contractor
As a minimum, the materials to be supplied by Contractor shall, but not limited by any
way, be as follows:
a. The procurement and supply, in sequence and at appropriate time, of all materials
and consumables required for completion of the Work as defined in this bid
document except the Company free issue material, shall be entirely the
Contractors responsibility and price quoted for the execution of the Work shall be
inclusive of supply of all these materials.
b. All materials supplied by the Contractor shall be strictly in accordance with the
requirements of relevant Company material specifications enclosed with the tender
document.
c. All equipment, materials, components etc. shall be new and specifically purchased
for this job. All material to be supplied by the Contractor shall be purchased from
the approved vendors of the Company, duly inspected by Third party inspection
agencies like Lloyds, Bureau Veritas etc. The list of approved vendor is enclosed
along with bid document.
d. All valves of all sizes and & ratings for mainline and at terminals, All Casing Pipes,
Assorted pipes for all sizes and thickness fittings, flanges, O‟lets (weldolets,
sockolets, nippolets, threadolets etc.), spectacle blinds, spacer & blinds required
for permanent installation in the system. Each item shall be inclusive of
commissioning spares. List of such spares shall be made part of the offer and the
 quoted unit/total price shall be inclusive of the spares. In case of exigency of work,
GAIL may procure valves, pipes as per SOR item list.
e. All stud bolts, nuts, all type of gaskets (metallic spiral wound / ring type) in required
quantities to be used for permanent installation into the system for all sizes and
ratings of flanges and flanged valves, equipment etc.
f. All consumable such as welding electrodes, oxygen, acetylene, inert gases, all
types of welding electrodes, filler wires, solder wires, brazing rods, flux etc. for
welding/cutting and soldering purposes.
g. All materials for all types of markers including paints Normal corrosive
environment, cement, sand, reinforcements, structural steel, etc.
h. All materials required for weld joint coating, corrosion coating of LR bends, and
repair of damaged corrosion coating of line pipe. Contractor shall confirm that
proposed field joint coating material is suitable for type of terrain encountered
along pipeline route. Contractor shall take prior approval from Company for field
joint coating material to be used.
i. Dirax or equivalent field joint coating material for HDD works.
j. All materials required for sand/soft soil padding around pipeline and optical fiber
cable, select backfill of approved quality, wherever required.
k. All materials including consumables required for hook-up with adjoining pipeline
section or wherever required.
l. All primer and paints for painting above ground piping shall be as per specification
enclosed with the bid document.
m. Corrosion monitoring system wherever specified as per specification.
n. Material for the maintenance of sand ridges and other materials for pipe stacking at
Contractors’ warehouse/storage yards/work site/ROU.
o. All materials for skin measurement instrument.
p. All temporary materials and consumables required for filling and pressurizing in
connection with hydrostatic testing, dewatering, swabbing and pre-commissioning
activities, etc. Including pipes, flanges, fittings, gaskets, bolts, nuts, etc. required
for fabrication of temporary pig traps and /or test headers.
q. All materials required for repair/restoration of pavements, roads, canals, temporary
water pipes, walls, other structures affected/damaged by Contractor‟s construction
activities.
r. Materials shall be equivalent/superior to those used for original construction of the
facility.
s. All pigs for cleaning, gauging, de-watering, swabbing, filling, pre commissioning
and commissioning of the pipeline.
t. Pumps and water to be used for hydrostatic testing/ flushing. All materials &
consumables such as Corrosion inhibitor, oxygen scavengers and bactericides,
required during hydro testing and idle time preservation, as required.
u. All casing pipes, casing insulators and end seals including materials for vent and
drain and strapping CS conduit with pipe and carbon steel pipes for optical fiber
cable (OFC) conduits in required quantities. Size of casing pipe for carrier pipe and
carbon steel conduit for OFC shall be as follows:

a) 219.1 mm, O.D. (8”), API 5 L Gr. B/ IS: 3589, for 4” carrier pipe
b) 355.6 mm O.D. (14”), API 5 L Gr. B/ IS: 3589, for 8” carrier pipe
c) 168 mm OD, Sch.40 API 5L Gr-B steel conduit with HDPE interduct for
laying of OFC at crossings.
The Minimum thickness of casing Pipe shall be as per API 1102. All CS casing
Pipe/ conduit shall have 300 micron external epoxy coating.
v. All consumables and equipment’s required for all types of tests and NDT such as
radiography, ultrasonic testing, magnetic particle, dye penetrant examination etc.
including radiography film etc.
w. All safety tools and tackles, devices, apparatus, equipment, personal safety
gazettes to be used as personal protective equipment (such as helmets, safety
belts, safety shoes, etc.) including ladders and scaffolding etc. complete as
recommended by Engineer-in-Charge as per relevant safety standards.
x. All structural steel material for all types of supports.

y. All materials and equipment for excavating trench or grading the Right-Of-Use
pipeline and pipe laying/installation and other works.
z. All steel materials such as structural steels, reinforcement steels and steel for all
types of supports, foundations, ladders, platforms etc. including Bolts, nuts,
washers, U bolts, clamps, clips, gaskets, Shims, wedges and packing plates
(Machined wherever required) and materials required for fabrication of low friction
sliding bearing supports.
aa. All fencing, gate and steel materials such as structural steels, reinforcement steels
and steel for all types of supports, foundations, ladders, platforms, etc.
bb. All materials, manpower, spares, tools & tackles and consumables for carrying out
pre-commissioning activities and during commissioning (including bi-directional
and foam pigs, Air compressor, nitrogen required for achieving the specified
criteria for pipeline inertisation/ purging prior to declaring pipeline fit for
commissioning) necessary piping and instrumentation connection for measuring
flow rate, pressure, temperature etc., temporary facilities for blowdown/ venting/
 flaring along with necessary piping, valves & instrumentation as well as
consumables and manpower required during pre-commissioning and
commissioning.

cc. All materials (100% solid epoxy coating 500micron thick) for corrosion protection of
buried piping (pipes, fittings, flanges, valves, etc.).
dd. Required quantities of Nitrogen for pre-commissioning & commissioning works.

ee. All spares for pre-commissioning and commissioning as required for all items
supplied by Contractor for the entire pipeline system.
ff. Any other material not specifically listed herein, but required for successful
completion of the Work.
C. Conditions for Company Supplied Material
a. The Contractor shall be responsible for taking over of the material and subsequent
handling, hauling, transportation to the actual work site(s)/fabrication yard(s) and
storage & safe keeping of the materials.
b. The Contractor shall inspect all Company supplied free issue materials at the time of
taking over from the Company and defects noticed, if any, shall be brought to the
notice of Company/Company representative and jointly recorded. Once the material
has been taken over by the Contractor, all the responsibility for safe keeping of the
materials and repair of damage/ defects to pipe & pipe coating shall rest with the
Contractor.
c. Rebuffing of dents in bevels less than 1 mm in depth shall be carried out by
Contractor ahead of welding in the field at no extra cost to Company.
d. On completion of the works Contractor shall submit a “Material Appropriation
Statement” for all materials supplied by the Company as free issue materials.
e. Every month the Contractor shall submit to the Company an account for the material
issued to the Contractor in the Performa prescribed by Engineer-in-Charge.
f. For the purpose of accounting of pipes all cut pieces in length of 2 m and above
when returned to the Company’s storage point shall be considered as serviceable
material. All pipes measuring less than 2 m shall be treated as scrap/wastage.
g. All unused pipes and serviceable/ scrap material shall be the property of the
Company and shall be returned by Contractor to Company at Company’s
designated storage point(s)
D. Storage of Materials:
a. All materials shall be preserved against deterioration and corrosion due to poor or
improper storage while under the custody of the Contractor.
 b. All materials shall be duly protected by the Contractor at his own cost with the
appropriate preservatives like primer, lacquer, coating, grease etc. and shall be
covered with suitable material to prevent them from direct exposure to sun, rain,
wind and dust.
c. Pipes shall be stacked according to the identification marks and stacks shall be
arranged on sleepers / sand bags at least 300 mm above ground.
d. The Contractor shall check that valves, fittings, specials etc. are not subjected to
corrosion from hydrostatic test water remaining in the piping. Any such condition
when detected should be brought to the notice of Engineer-in-Charge and remedial
measures taken as directed.
e. All machined surface shall be properly greased and should be maintained and
protected from damages.

f. Openings of equipment, machinery, valves etc. shall be kept blocked / covered with
blinds to prevent entry of foreign matter.
g. As far as possible materials shall be transported to the site of erection only just prior
to the actual erection and shall not be left around indefinitely on ground but kept on
packing/sleepers etc. to maintain the minimum distance from the ground as
specified and/or as per directions of Engineer-in-Charge.
6. OTHER CONDITIONS OF BID
A. Pipeline Survey
a. Contractor shall carry out topographic and geotechnical surveys required for entire
pipeline route during execution of the project shall be carried out any extra cost.
b. The surveyed pipeline alignment shall be staked on ground. It shall be the
responsibility of the Contractor to finalize the route and collect the survey data along
the route. Contractor shall maintain and preserve survey monuments (staked on
ground) such as bench marks and intersection points, till construction is completed.

c. Topographic surveys required to entire pipeline route & local detours during
execution of the project shall be carried out by the Contractor prior to execution of
job without any extra cost to the owner. However, laying and construction of entire
pipeline including detoured portion shall be within the scope of contractor and
governed by SOR of tender without any cost implication. Contractor shall be
deemed to have considered such eventualities while formulating his bid. Pipeline
route map/ alignment sheet showing the pipeline route shall be submitted to
Engineer-in-charge for approval prior to execution of the works.
d. Indicative plot plan drawing for terminal station (LMC consumer end) and tap-off is
provided for reference purpose. Indicative drawing for underground pipeline
construction is also included in the Bid package. These drawings are indicative only
 and are furnished to enable Bidder to estimate the quantum of work and to quote a
firm price for the work. Final drawings marked „Issued for Construction‟ (IFC) shall
be furnished by Owner to contractor at project execution stage. The IFC drawings
may vary to some extend from the drawings included in Bid package. Contractor
shall carry out all works in accordance with the IFC drawings.
e. Site visit
Bidders are advised to make site visits along the pipeline route prior to quoting to
familiarize themselves with all the salient features of terrain, availability of ROU and
infrastructure along the pipeline route. Contractor shall be deemed to have
considered all constraints and eventualities on account of site conditions along
pipeline route while formulating his bid. Contractor shall not be eligible for any
compensation in terms of cost and/or time, on account of site conditions along
pipeline route varying to any extent from whatever is described in the bid package
and the survey drawings/data furnished along with the bid package.
f. Soil Investigation
It shall be Bidder's responsibility to familiarize himself with sub-soil conditions along
the pipeline route, and workout the lengths of pipeline to be laid in different subsoil
conditions including the quantum of asphalt/ concrete road cutting excavation that
would be necessary. Price quoted by Bidder shall also be inclusive of all excavation.
No extra compensation shall be payable to Contractor later on.
B. Restricted R.O.U.
a. Most of the areas the Pipeline shall be laid along the road and Industrial area. The
ROU shall be restricted in pipeline Route. Contractor shall consider all these
eventualities while bidding. It shall be Contractor’s responsibility to make
arrangement for any additional land required for fabrication, construction, storage
and all other work areas. Contractor shall carry out construction work with in the
width as available to him. Damage to any obstruction, temporary/permanent
structure, boundary walls etc. shall be repaired and restored and shall be to
Contractor’s account.
b. The Contractor must ensure that during laying of the pipeline minimum damage
occurs to the land. The land has to be restored to original condition. All construction
activities shall be in accordance with the local Government regulations.
c. During pipeline construction, measures shall be adopted in order to minimize the
impact of pipeline construction activities on the environment.
d. In case contractor wishes to propose any detour from the acquired alignment due to
constructability problems or otherwise, he may be permitted to do so only after
explicit approval from the Company. All immediate measures for taking the land and
compensations to land owner(s) shall be to Contractor’s account. Company shall
proceed with regular notifications etc. in due course. All statutory fees shall be paid/
 reimbursed by Company. However, such activity shall not affect the construction
schedule and overall completion period.
C. Line pipe and Coating
a. Taking over of Pipes
Company shall supply bare and externally/ internally coated line pipes.
Contractor shall receive and take over the pipes progressively as per construction
requirements. At the time of taking-over from Coating Contractor, Contractor shall
perform inspection of pipes and pipe coating for all defects in the presence of
Company’s Representative. Contractor shall repair all defects occurring after taking
over including those during transportation and handling. Rebuffing for dents (in
bevels) less than 1 mm in depth shall be carried out by Contractor ahead of welding in
the field at no extra cost to Company. Contractor shall progressively takeover the
required quantity of bare & coated line pipe from the warehouse. Return of surplus
bare & coated line pipes at warehouse to Company’s designated storage yard is
installation Contractor’s scope including loading, transportation, unloading, handling,
stacking of pipes at company’s storage yard and getting the pipes inspected from
Company’s representative at storage yard.

b. Repair of Coating
Any repairs to 3-layer polyethylene coating shall be carried out by Contractor using
suitable material compatible with parent coating system and meeting the
requirements of coating system specified in specification attached with the Bid
Package. The coating repair material and procedure for application shall be
submitted to Company for approval prior to start of construction.
Repair of PE coated pipes in field shall be carried out as follows in accordance with
bid specification.
I. Damages caused to coating by handling such as scratches, cuts, dents, gouges,
not
picked up during holiday test, having a total reduced thickness on damaged
2
portion not less than 2.0 mm and an area not exceeding 20 cm shall be rebuild
by heat shrink patch only and without exposing to bare metal.
II. Defects of size exceeding above mentioned area or holidays of width less than
300 mm shall be repaired with heat shrink repair patch by exposing the bare
metal surface.
III. Defects exceeding the above and in number not exceeding 2 per pipe and linear
length not exceeding 500mm shall be repaired using heat shrinkable
D. Statutory Permissions
The Company shall obtain a general permission from most of the authorities having
jurisdiction over the area as necessary for construction of the pipeline. However, for
 some of the permissions, if not available, Contractor shall do the follow up with the
concerned authorities to get the permissions to execute the job in time. However, all
statutory payments required for such permissions shall be reimbursed by Company at
actuals. Contractor shall also obtain the necessary permits like work permit/
excavation permit/ trench opening permit etc. for all works from the authorities having
jurisdiction before the actual execution of various phases of the works and all
stipulations/ conditions/ recommendations of the said authorities shall be strictly
complied with no extra cost to Company. Contractor shall also obtain all necessary
permissions from the concerned authorities for installation of pipeline at railways,
roads and water / nala, drain crossings. Company may, however, assist Contractor in
obtaining such permissions, wherever required, by issuing recommendation letters
etc. In case of damage to other utilities/infrastructure, Contractor shall be responsible
and the required compensation, as per the directions of concerned authorities, shall
be paid by the Contractor. After completion of work, Contractor shall obtain a
certificate from the concerned authorities that the job has been completed as per their
requirement and the area/land has been restored to their satisfaction.
E. Burial Depth

The pipeline shall be buried normally at a depth of 1.0 meter below natural ground
level except rail/ road/ canal crossing where minimum cover shall be as per Design
Basis.
F. Crossings
For all Rails, Road, Canal, Drain & other water crossings, Contractor shall liaison with
relevant authorities and intimate them well in advance about the schedule and
methodology of crossing. It shall be obligatory on the part of the Contractor to ensure
that Authorized Representative of the authority under whose jurisdiction the crossing
falls should be made available at site by the Contractor at the time of making
crossing. After completion of works and complete restoration, Contractor shall provide
NOC from the relevant official pertaining to complete restoration to their satisfaction.
For all crossing including above mentioned shall be crossed by heaviest wall
thickness carrier pipe among available pipes at site or as per approved drawings/ as
decided by Engineer-in-charge. All crossing drawing including HDD profile shall be
prepared by contractor and approval on the same shall be obtained from Engineer-In-
Charge before execution.
G. Water Crossings

 Crossings of Minor water crossings/ streams/canals/ Drains/ Nalas by

conventional methods

I. No damage should be caused to any irrigation sources, while laying the
pipeline through canal crossings
 II. The flood banks of the River/canal should be brought to the original condition,
if they are damaged by the laying of pipeline. Stabilization of banks shall be
carried out as per requirements of concerned authorities.
III. In general the top of the pipeline shall be taken at least 1.5 meter below the
scour level other river crossing. If scour level is not known minimum 3.5 m
cover should be kept unless specified otherwise.
IV. The top of the pipeline shall be at least 1.5m to 2m below the drain/ canal bed
unless specified otherwise.
V. Pre-construction survey, preparation of the detailed construction methodology/
plan and time etc. shall have to be finalized by contractor in consultation with
concerned authorities having jurisdiction over canals/ rivers. Company shall
provide the required permission.
VI. Pre-construction surveys, preparation of detailed construction method
statement and calculation for owner’s approval.
VII. Geo-technical investigation, if required.
VIII. Obtaining necessary permissions from concerned authorities for site
preparation and arranging required land for setting up of string fabrication yard
shall be owner responsibility.
IX. Preparation of pipeline Launch-way, continuous concrete coating of pipes,
repair of damages to corrosion and concrete coating, string preparation, field
welding, NDT including radiography, pre-test of completed strings, corrosion
and concrete coating of field joints, Trenching, laying at approved depth,
stabilization of bank, post installation of hydro-test, capping , providing and
installation of markers. etc.
X. The major canals with lining/ perennial canals need to be crossed by HDD/
boring method only.

 Crossings of Road/ Canals/ Drains/ Other crossings by Trenchless

Technology method

a. Carrying out all surveys and collection of data, as may be required for the design
and construction of the crossings.
b. Carrying out all engineering, design calculations and preparing all construction
drawings for laying of pipeline and optical fiber cable inside steel pipe as per
requirements for installation of river crossings by HDD method.
c. All construction activities required for installation of the crossings viz. site
preparation, preparation of pipe string, repair of damages to corrosion coating,
field welding, NDT including radiography, pretest of completed string, corrosion
coating of field joints, holiday testing of complete pipe string, drilling in all types of
soil including gravel, boulders and disintegrated and hard rock, installation of
 pipeline, post installation hydro testing of the crossing section, capping, providing
and installing markers and temporary cathodic protection of pipeline section at
crossings.
d. Field joint coating shall be carried out by Direx heat shrink sleeves of Approved
make by Raychem or equivalent.
e. Supply of 6" NB, 6.4mm W.T. API 5L Gr.B 300 micron epoxy coated steel
conduit, with interduct of flexible HDPE/plastic corrugated tubing for laying of
OFC cable, preparation of steel conduit string and corrosion coating of weld
joints.
f. Installation of pipeline and 6" NB steel conduit for OFC (together in a single
drilled hole or separately in two independent drilled holes).
g. Tie-in with main pipeline after successful installation of pipeline at river crossing.
h. Testing and jointing of OFC at either ends with OFC in main pipeline trench.
i. All associated pipeline work w.r.t. temporary and permanent cathodic protection.
j. Clean-up and restoration of ROU and other conveniences like road, rail, canals,
cultivable land, water facilities, irrigation facilities, boundary wall/fence etc. to
original condition as per specification and drawings to the entire satisfaction of
Company and/or Authorities having jurisdiction over the same, including disposal
of surplus excavated soil and other construction materials to a location identified
by Contractor approved by local authority without causing any disturbance to
environment and to the entire satisfaction of Company. Contractor shall arrange
necessary clearance from the concerned authorities/ land owners to the effect
that ROU/ ROW has been restored back to original condition. Contractor shall
carry out joint survey with representative of Competent Authority (CA) and will
obtain clearance in writing from CA that ROU has been restored to original
condition.

Necessary clearance from statutory authority / NOC for restoring the ROU to
original condition shall be in Contractor’s scope.
H. Railway Crossings
The general arrangement drawings for Railway Crossings shall be approved by Indian
Railways and construction shall be carried out accordingly. It should be noted that the
extent of casing pipe generally specified by Railways, is 14.0 m beyond centerline of
the outermost tracks on either side or 0.6 meter beyond the ROU limits of Railways
on either side, whichever is more. All railway crossings shall be cased crossings and
installed by boring method only. The railway crossing shall comply with the
requirements of API 1102 and Indian Railways regulations. The crossing angle shall
be as close to 90° as possible. Cover of casing pipe for railway crossings shall be
minimum 1.7 m wherever railway track is on embankment. Care shall be taken to
 isolate the pipeline crossing installation from aerial electrical wires and shall be
suitably insulated from underground conduits carrying electrical wires. The casing
pipe shall be provided with minimum 50 mm diameter vent pipe. Casing vent pipe
shall be at least 1.2 m away vertically from aerial electrical wires and shall be suitable
insulated from underground conduits carrying electrical wires on railway land. Casing
pipe should be so placed and oriented so as to prevent leakage inside railway
boundary except through the vent pipes. The casing pipes shall be installed with even
bearing throughout the length.
I. Road Crossings

a. The method of crossing of roads such as open cut / boring/ trenchless

technology shall be firmed up by Contractor in consultation with concerned
authorities and Company. The Contractor shall also take due care to identify and
take due precautions so as not to disturb or damage the utilities like cables,
water lines and other structures.
b. After laying the pipeline in a road crossing by open cut method, the Contractor
shall completely restore the road to its original condition.
c. While laying the pipeline in road crossings by open cut method the Contractor
should ensure that the traffic is not stopped during the execution of work. This
may be done by cutting half of the road at a time so as to enable the traffic to
pass on the remaining half of the road. Alternatively, the Contractor can provide
diversion roads to maintain the flow of traffic.
d. The Contractor shall provide proper caution boards during day time and danger
lights during night time when the cutting operation of the road is going on.
e. For cased crossings, the pipeline should be taken through the casing pipeline,
the top of which should be at least 1.2 meters below the road top as specified or
as per the requirements of the local authorities, whichever is higher. All National
Highway shall have to be cased crossing.

J. Installation of Conduits for Optical Fiber Cable at Crossings

At all crossing locations (viz., rail, road, canal and minor water course crossings) the
optical fiber cable shall be installed inside a cable conduit to be installed by the
Contractor.
At all such crossings where the carrier pipe is installed by open-cut of the facility
crossed, HDPE conduit shall be installed along with the pipeline for installation of the
Optical Fiber Cable. At crossings of water bodies, HDPE conduit will be strapped to
the mainline at 5m interval using high strength PE straps. For all crossings by HDD,
CS conduit shall be strapped with carrier pipe for bundle pulling or a separate drilling
shall be performed for CS conduit. Required HDPE conduit shall be installed inside
CS conduit.
 At all such crossings where the carrier pipe is installed by jacking/boring of carrier
pipe directly, 168 mm OD, Sch.40 API 5L Gr-B steel conduit with HDPE interduct
shall be installed by jacking/boring separately. Each casing end seal shall have a
moulded opening suitable for HDPE conduit. The center to center distance between
pipeline and CS cable conduit shall be 4.0 m based on as installed dimensions.
K. Cathodic Protection Works
Temporary and Permanent Cathodic Protection works shall be carried out by
contractor as per the requirements stipulated elsewhere in the bid document.
L. Typical Drawings
Typical drawings for stations on the pipeline route are included in the bid package.
These drawings are indicative only and are furnished for Bidder’s information.
M. Hydrostatic Testing, Dewatering, Swabbing and Commissioning
I. Pipeline
Hydrostatic testing of Pipeline shall exclude valves at tap off stations, and
terminals and facilities that are to be installed as a part of the stations. Temporary
test headers shall be provided and the pipeline shall be hydrostatically tested
between the temporary test headers only. The pipeline shall be hydrostatically
tested at least 1.5 times of Design pressure. But the maximum hydro test
pressure shall not exceed 90 % SMYS of the pipe material at any location and at
any point of time of the lowest wall thickness of that section. The highest point of
the test section shall be subjected to the minimum test pressure as specified
above. Hydro test shall be for 24 hours duration.
Hydro test shall be done with corrosion inhibitor and dosage of corrosion inhibitor
shall be suitable for 3 months.
Subsequent to separate hydro testing of pipeline and associated facilities, tie-
in/hook up shall be carried out by the Contractor. Pipes/prefabricated assembly
used for such tie-in shall be pretested to a test pressure specified for the pipeline.
All materials required for the fabrication of the test headers shall be provided by
the Contractor at no extra cost to Company. After successful completion of
hydrostatic testing, the Contractor shall de water the pipeline as per the directions
of Engineer-in-charge.
II. Terminal Facilities
Piping facilities between the insulating joint and hook up point/battery limit and all
above ground facilities installed by Contractor shall be hydrostatically tested to a
test pressure equivalent to 1.5 times design pressure in accordance with
“Standard specification for Inspection, Flushing and Testing of Piping System”
enclosed with the Contract document. Duration of testing shall be minimum 6
 hours. All valves in the piping network being hydro tested shall be kept in the
crack open position.
III. Dewatering and Swabbing
It is envisaged that dewatering and swabbing operations shall be carried out as a
part of pre-commissioning activities. Dewatering of pipeline after hydrostatic
testing shall be taken up by Contractor only when Contractor is ready for
swabbing operations.
The dewatering shall be consist of at least two runs of bidirectional HD foam Pigs
for 4 and 8“Pipeline. Dewatering operation considered complete when volume of
water received after dewatering is less than of 2 meter pipe length.
Once dewatering completed, a train of foam pigs consist of High, Medium and
Low density foam pigs for swabbing operation shall be launched. Swabbing
operation shall be continued till the weight of the last foam pig does not increased
by more than 50% or 6 such runs of foam pigging completed, whichever is earlier
However, Till Contractor is ready to start pre-commissioning activities; the
pipeline/section of pipeline after hydrostatic testing shall be left filled with inhibited
water. In case, dewatering of any test section is proposed by Contractor for any
reason depending upon site conditions (e.g. using test water for adjoining section
due to non-availability of water), the Contractor shall swab such sections as per
applicable requirements of Contract and fill the section with nitrogen at a
pressure of 0.5 bar (g) with residual content of oxygen less than 1% v/v at no
extra cost to the Company in case overall commissioning of the pipeline system
is expected to be taken up later than three months from such dewatering.
Decision of Company/ Engineer-in charge shall be final in such cases.
In no case shall the pipeline section be kept empty i.e. without nitrogen filling.
IV. Leak Detection
Contractor shall submit a detailed procedure for leak detection during hydro test.
Such method of detection shall consume minimum possible time to complete the
hydro test activity within contractual completion schedules. This procedure needs
approval of the Engineer-in-charge.
All works for locating and repair of major leak/burst attributable to Company
(occurred during hydrostatic testing) including necessary repairing/replacing/
cutting and removing out defective pipe length as defined in the specification and
shall be payable as per relevant items of schedule of rates.
All works for locating and repair of minor leak attributable to Company (occurred
during hydrostatic testing) which require sectionalizing of pipeline shall be
payable as per relevant items of schedule of rates.
 Contractor shall carry out repairing / replacing of defective pipe length including
cutting and removing of defective pipes, pre testing of replacement pipe for 24
hours and welding into main line, NDT of the welds, coating of the weld joints,
clean up, re testing of pipeline including providing all equipment’s, manpower &
consumables.

N. Magnetic Cleaning, Caliper Pigging and Commissioning

Contractor shall carry out magnetic cleaning and Caliper pigging (EGP) of the
pipeline system as per requirements stipulated elsewhere in the bid document.
Rectification of defects observed during pig run, shall be carried out by individual
Contractor including digging, cutting, replacement, repair, welding, NDT etc.

O. Overall Commissioning
Overall commissioning activities including drying, nitrogen purging etc. for entire
pipeline and terminals shall be performed the Contractor.
Contractor shall mobilize all equipment, consumables, nitrogen and manpower for
carrying out pigging, drying, inertization and commissioning activities.

7. CONTRACTOR’S RESPONSIBILITIES
Contractors responsibilities, besides the scope of work to be performed by him
defined earlier shall also include the following:

a. Appraisal and taking cognizance of site-conditions, pipeline route, Central

Government, Maharashtra State Government rules and regulations/ bye-laws,
applicable Indian Standards and Codes, authorities having jurisdiction over the
work site(s), environmental and pollution concerns including conditions/
stipulations laid down by the concerned authorities etc. The Contractor is deemed
to have recognized any restrictive features and constraints of the site(s), pipeline
route and /or specific requirements of the work and made due allowance for it in
the work to be performed by him.
b. Company has provided the available information and survey data along pipeline
route and crossings. Company gives no guarantee or warranty as to the accuracy
or completeness of the information provided. It is the Contractor’s sole
responsibility to obtain sufficient information / data along pipeline route and
crossings to allow safe and sound design and installation of the proposed
pipeline.
c. Interpretation and verification of data/information furnished by Company in
respect of pipeline route surveys, crossing details, contained in the bid package.
Any additional information/data/surveys etc. required by Contractor for detailed
 engineering and execution of the works shall be obtained by him. Company may
assist him in obtaining such information/ data by issuing recommendatory letters.
d. Entire design and detailed engineering including drawings and installation
procedures, engineering for procurement & fabrication, engineering for
installation including drawings, QA/QC procedures, etc performed by the
Contractor for complete pipeline system shall be reviewed and approved by
Company. Contractor shall submit six sets of design/detailed engineering
documents, drawings, procedures Company’s review and approval. All works
shall be executed based on approved documents only.

e. Provide office and office support services/facilities for Company’s Personnel at

Contractor’s design office for design review and approval of documents as per
the requirement of the bid package.
f. Review and approval of Contractor’s entire work(s) by Company shall in no way
relieve the Contractor of his sole responsibility for safe and efficient design,
engineering, installation and subsequent operation of pipeline system.
g. Furnishing and mobilizing at site(s) of all construction equipment, manpower, tools
and tackles, construction spreads, fully equipped and fully manned with other
required support facilities etc. commensurate for spreads needed for successful
execution of the works.
h. Contractor shall depute independent third party inspector for carrying out
radiographic inspection/ UT and interpretation of radiograph/ UT of welds. Third
party inspector shall be approved by Company.
i. Pre-commissioning/ commissioning of entire pipeline/piping system.
j. Preparing and furnishing calculation books, pipe books, material/ purchase
requisitions, final purchase orders including specifications, Vendor's data books
(including Guarantees), fabrication and construction drawings, all survey reports,
inspection and testing reports, as-built records for all phases of work.
k. The Contractor is cautioned to exercise extreme care and take necessary
precautions to prevent damage to the existing pipeline(s), facilities, electrical and
other cables during execution of the entire works. Restoration/reconstruction of
all structures/ facilities affected during pipeline construction shall be carried out
by Contractor.
l. Wherever Contractor comes across water lines/open channels/drains in the fields
used for cultivation, suitable arrangements similar to or higher specs. Than the
existing type shall be made by the Contractor for ensuring water supplies across
the fields and maintain the same till construction is completed in that stretch. Any
claims arising out of noncompliance to the above requirements, as granted by
competent authorities shall be to Contractor’s account.
 m. Contractor shall carry out all testing and inspection of materials, equipment etc.
in independent testing institutions, laboratories, if so desired by Company.
n. Disposal and treatment of treated hydro-testing water, excavated materials, and
surplus materials etc. as per local authority’s requirements.
o. Any other work not specifically listed but required for successful completion of
entire pipeline system.
8. AS BUILT DOCUMENT
On successful completion of hydrostatic testing, the Contractor shall prepare As Built
drawings / reports for entire pipeline/piping system as specified in scope of work. All
“As Built” drawings / reports shall be submitted as below.
a. Main Pipeline

 As laid alignment sheets and crossing drawings/details.

 As built HDD crossing details, as applicable.
 All Inspection, Testing and NDT records. Radiographs/ UT of all weld joints
packed kilometer wise in separate card board boxes in one set.
 Pipe and calculation books/records.
 All WPS and WQT
 All NOC from authority
 All inspection & testing documents.
 All purchase specification & procurement documents.

b. Dispatch and Receiving Stations
 All piping GA drawings and supports at terminals.
 All P&ID, layout, Isometric drawings
 Installation and testing reports.
 All Test reports, IRN‟s for procured materials
 All purchase specification and procurement documents.

9 DOCUMENTS, SPECIFICATION, STANDARDS & DRAWINGS

Owner shall furnish piping and Instrumentation diagrams (P&ID), preliminary plot plan
for the construction of Terminal along with the tender. Owner shall also supply design
and engineering drawings including general arrangement drawing for piping,
electrical, mechanical & instrumentation system and other related/ required systems,
at appropriate times and as requisitioned by contractor in his time schedule.

Contractor shall prepare isometric drawing & bill of materials and submit the same
from Owner/ consultant ‟s approval/ record. Contractor shall prepare drawing for
utilities line as required as per SOR and submit the same for Owner/ Consultant’s
approval /record.
 No construction small or big shall be carried out without proper construction drawings
duly approved by Owner’s Engineers at Delhi or site office or Owner’s representative
duly authorized to do so. For Mainline route survey alignment sheets and crossing
survey details shall be furnished along with bid by owner. However, detail crossing
drawings with crossing methodology shall be submitted by Contractor for prior
approval. Any additional survey and data required to complete above shall be done
by contractor without any extra cost

After completion of construction & commissioning of Terminal, contractor shall

incorporate all the correction in drawings, prepare and issue the drawings “As-built
drawings “as listed below the owner as final submission of drawings. For Mainline
pipeline alignment sheet, all crossing details, all CP drawings, pipe book etc. and for
Terminal P&ID, layout drawing, piping GAD, Isometric, all electrical and
instrumentation drawing, all civil drawings. For final submission only 4 sets of
document plus the original transparencies shall be handed over by the contractor.
Any construction done by the contractor without duly approved by the drawings shall
be wholly at risk and cost Contractor shall also submit soft copy of pipe book in excel
along with hard copy. Soft copy of all as-built drawings shall be also submitted in
AutoCAD. Videography/ photograph of all major activities/ milestone achieved shall
also be arranged and submitted by the contractor. For details of documentation to be
submitted for mainline and terminal refer “Specification for pipeline construction”
enclosed elsewhere with tender

10 LIST OF ATTACHMENTS
All works shall be carried out by Contractor strictly in accordance with the drawings
/documents/ specifications indicated in the list of attachment document.
A. LIST OF ATTACHMENT FOR PIPELINE 1.0

SCHEMATIC

S NO Doc Number Description

1 PL-SM-001 SCHEMATIC DIAGRAM

2.0 SPECIFICATION

Sr. No Specification Number Description

STANDARD SPECIFICATION FOR MAJOR WATER
1 SS-PL-001 CROSSINGS (CONVENTIONAL TRENCHING)
STANDARD SPECIFICATION FOR 3 LAYER
2 SS-PL-002 POLYTHYLENE COATING OF LINEPIPES
STANDARD SPECIFICATIONFOR CONSTRUCTION OF
PIPELINECROSSING ROADS, RAIL, ROADS &MINOR
4 SS-PL-003 WATER CROSSINGS STANDARD
SPECIFICATION FOR DETAILED PIPELINE ROUTE
5 SS-PL-004 SURVEY
STANDARD SPECIFICATION FOR FIELD JOINT
6 SS-PL-005 COATING
STANDARD SPECIFICATION FOR HORIZONTAL
7 SS-PL-006 DIRECTIONAL DRILLED CROSSINGS
STANDARD SPECIFICATION FOR HYDROSTATIC
8 SS-PL-007 TESTING OF ONSHORE PIPELINES
STANDARD SPECIFICATION FOR INSPECTION,
9 SS-PL-008 FLUSHING AND TESTING OF PIPING SYSTEM
STANDARD SPECIFICATION FOR PIPELINE
10 SS-PL-009 CONSTRUCTION (ONSHORE)
STANDARD SPECIFICATION FOR PIPELINE
11 SS-PL-010 MARKERS
STANDARD SPECIFICATION FOR PIPELINE PLUG
12 SS-PL-011 VALVES ONSHORE

STANDARD SPECIFICATION FOR PIPELINE BALL

13 SS-PL-012 VALVES ONSHORE
SUBMERGED ARC WELDED LONGITUDINAL SEAM
14 SS-PL-013 (SAWL) LINE PIPE
STANDARD SPECIFICATION FOR CASING
15 SS-PL-014 INSULATORS AND END SEALS
16 SS-PL-015 STANDARD SPECIFICATION FOR CHECK VALVES
17 SS-PL-016 STANDARD SPECIFICATION FOR FLOW TEES
18 SS-PL-017 STANDARD SPECIFICATION FOR INSULATING JOINTS

STANDARD SPECIFICATION FOR SEAMLESS FITTINGS

21 SS-PL-018 AND FLANGES {SIZE UPTO DN 400MM(16”)}
STANDARD SPECIFICATION FOR QOEC (BLOW DOWN
22 SS-PL-019 LINES)

24 SS-PL-020 QUALITY MANAGEMENT SYSTEM

STANDARD SPECIFICATION FOR PIPELINE GLOBE
25 SS-PL-021 VALVES ONSHORE

3.0 STANDARD DRAWINGS

Standard Drawings
Sr. No Description
Number

1 SD-PL-001 PIPELINE SYMBOLS

2 SD-PL-002 TOPOGRAPHICAL SYMBOLS
3 SD-PL-003 OVER HEAD POWER LINE CROSSING
4 SD-PL-004 TYPICAL HDD WITH CASING PIPE FOR HDPE
5 SD-PL-005 TYPICAL TRANCH DIMENSION FOR PIPE LINE
 Standard Drawings
Sr. No Number Description
6 SD-PL-006 RAIN CAP

7 SD-PL-007 CASED CROSSING PIPE LINE - ROAD/ HIGHWAY

8 SD-PL-008 PARALLEL PIPE LINE IN SAME TRENCH
9 SD-PL-009 ROU FOR FOREST AREA
10 SD-PL-010 PIPE LINE WARNING SIGN
11 SD-PL-011 DIRECTION MARKER
12 SD-PL-012 TYPICAL RIGHT OF USE FOR PIPELINE
13 SD-PL-013 TYPICAL K.M. POST MARKER
14 SD-PL-014 TEST STATION WITH FOUNDATION DETAILS
15 SD-PL-015 AERIAL MARKER
16 SD-PL-016 NAVIGABLE WATERWAY WARNING SIGN
17 SD-PL-017 TYPICAL ROW BOUNDARY MARKER
18 SD-PL-018 DETAIL OF CASING VENT AND DRAIN
19 SD-PL-019 TYPICAL STREAM CROSSING
20 SD-PL-020 CASED CROSSING PIPLE LINE CANAL
21 SD-PL-021 TYPICAL SLOPE BREAKER DETAILS
22 SD-PL-022 BANK PROTECTION DETAILS FOR WATER CROSSING
23 SD-PL-023 TYPICAL DETAILS OF RAILWAY CROSSING
TRENCH DIMENSIONS AND COHESIONLESS SELECT BACKFILL
24 SD-PL-024 FOR PIPELINE IN SEISMIC ZONE
25 SD-PL-025 SELECT BACKFILL FOR STATION APPROACH
26 SD-PL-026 SLOPE STABLISATION IN GHAT/ HILL AREAS
27 SD-PL-027 TYPICAL CROSS SECTION FOR ROU PREPARATION IN HILL AREAS
28 SD-PL-028 EXISTING UNDERGROUND PIPE CROSSING
29 SD-PL-029 UNDER GROUND CABLE CROSSING
30 SD-PL-030 TYPICAL LINED CANAL CROSSING (UNCASED)
31 SD-PL-031 CASING PIPE DETAILS

B. LIST OF ATTACHMENT FOR PIPING

Sr. No. Document Number Document Title

PIPING MATERIAL SPECIFICATION

1.0 PL-PMS-001 PIPING MATERIAL SPECIFICATION (PMS)
GENERAL ARRANGEMENT DRAWINGS
1.0 PL-SCH-001 TYPICAL SCHAMATICS
2.0 PL-P&ID-001 TYPICAL P&ID
3.0 PL-PP-001 TYPICAL PLOT PLAN
DATA SHEETS
DATA SHEET – BALL VALVES (0.75 TO 1.5 INCH – SOCKET
1.0 DS-BV-001 WELDED ENDS)
DATA SHEET – PLUG VALVES (0.75 TO 1.5 INCH – SOCKET
2.0 DS-PV-001 WELDED ENDS)
DATA SHEET – GLOBE VALVES (0.75 TO 1.5 INCH – SOCKET
3.0 DS-GV-001 WELDED ENDS)
4.0 DS-GOA-001 DATA SHEET – ACTUATOR OF GOOV
 INSPECTION AND TEST PLAN

S No Document Number Description

INSPECTION AND TEST PLAN – FLANGES SPECTACLE
1 PL-ITP-001
BLINDS & DRIP RINGS
INSPECTION AND TEST PLAN – LR BENDS FOR ONSHORE
2 PL-ITP-002
PIPELINES
INSPECTION AND TEST PLAN – FORGED, SEAMLESS &
3 PL-ITP-003
WELDED FITTINGS

4 PL-ITP-004 INSPECTION AND TEST PLAN-BALL VALVE

5 PL-ITP-005 INSPECTION AND TEST PLAN-GLOBE VALVE

6 PL-ITP-006 INSPECTION AND TEST PLAN-PLUG VALVE

C. LIST OF ATTACHMENT FOR MECHANICAL

Sr. No. Document Number Document Title

1 SS-MC-001 STANDARD SPECIFICATION – CO2 TYPE EXTINGUISHER

STANDARD SPECIFICATION-PORTABLE DRY POWDER TYPE
2 SS-MC-002 EXTINGUISHER

D. LIST OF ATTACHMENT FOR TECHNICAL SPECIFICATION

Sr. No. Document Number Document Title

1 SS-PI-001 TECHNICAL SPECIFICATION – ASSORTED PIPES

2 SS-PI-002 TECHNICAL SPECIFICATION – ASSORTED VALVES
SS-PI-003 TECHNICAL SPECIFICATION – SEAMLESS FITTINGS &
3 FLANGES
4 SS-PI-004 TECHNICAL SPECIFICATION – FASTENERS
SS-PI-005 TECHNICAL SPECIFICATION – FABRICATION AND ERECTION
5 OF PIPING
SS-PI-006 TECHNICAL SPECIFICATION – HYDROSTATIC TESTING OF
6 PIPING SYSTEMS
SS-PI-007 TECHNICAL SPECIFICATION – INSPECTION, FLUSHING AND
7 TESTING OF PIPING SYSTEMS
8 SS-PI-008 TECHNICAL SPECIFICATION – PAINTING
SS-PI-009 TECHNICAL SPECIFICATION ERECTION OF EQUIPMENT AND
9 MACHINERY
PIPELINE DESIGN BASIS
TABLE OF CONTENTS

1.0 INTRODUCTION

2.0 SCOPE

3.0 DESIGN CODES AND STANDARDS

4.0 DESCRIPTION OF FACILITIES

5.0 PIPELINE ROUTE

6.0 DESIGN DATA

7.0 PIPELINE AND ASSOCIATED FACILITIES DESIGN

8.0 OTHER TECHNICAL REQUIREMENTS

ANNEXURE-A LIST OF CODES AND STANDARDS

ENCLOSURES:

1. Typical Pipeline Schematics (3 sheets)

1.0 INTRODUCTION

GAIL (India) Limited, is India's flagship Natural Gas company, integrating all aspects of the
Natural Gas value chain and its related services. In a rapidly changing scenario, GAIL is
spearheading the move to a new era of clean fuel industrialization, creating a quadrilateral of
green energy corridors that connect major consumption center in India with major Gas
Fields, LNG terminals and other cross border gas sourcing points. GAIL is also expanding its
business to become a player in the International Market. M/s. GAIL (India) Limited envisages
to strengthen local gas grid network in various parts of India
M/s GAIL (India) Ltd. proposes to cater to the demand of various small consumers in
Karnataka and Goa

2.0 SCOPE

This document establishes minimum design parameters and basis for design and detailed
engineering of the Pipeline and Associated facilities covered under this project as defined
briefly herein below.

3.0 DESIGN CODES AND STANDARDS

Pipelines and terminal facilities envisaged shall be designed and engineered primarily in
accordance with the provisions of the latest edition of Code ASME B 31.8: Gas Transmission
and Distribution Piping Systems and OISD 226: Natural Gas Transmission Pipelines and City
Gas Distribution Networks and PNGRB guidelines. In addition, requirements, as applicable to
gas service of following codes/standards shall be complied with.
OISD Std. 138 Inspection of Cross Country Pipelines-Onshore

ASME B 31.3 Chemical Plant & Petroleum Refinery Piping

API Std. 1102 Steel Pipeline Crossing Railways & Highways

API Std. 1104 Standard for Welding Pipelines and Related Facilities

ISO 13623 Petroleum & natural gas industries – Pipeline transportation systems
PNGRB Petroleum & Natural Gas Regulatory Board

In addition to above, codes and standards listed in Annexure-A shall also be referred.
In case of conflict between the requirements of ASME B31.8/OISD 226 and other
codes/Standards referred above, requirement of ASME B 31.8/OISD 226 shall govern.
In case of conflict between requirements of B31.8/OISD 226 and this document,
requirements of this document shall govern.
4.0 DESCRIPTION OF FACILITIES

Details of facilities shall be as per P&ID’s, process design basis, data sheets, line schedule
etc. covered in the process package.

The typical pipeline facilities envisaged as a part Work of LMC are shown below.

,
1

! .."' ............ '

j' , • ",
I
i (-
i 1=
!
!
--
4.1 Dispatch Station
Facilities at Dispatch Station are Pig launcher complete with associated piping with Blow
down Facility for Depressurizing the Pipeline.
4.2 Main Pipeline

Pipeline facilities are schematically indicated in Schematic attached with tender.

4.3 Receiving Station

Facilities at Receiving Station for the Pipeline shall consist of Pig Receiver complete with
associated piping, Filtering, PRS in and Metering Skid, Blow down Facility for Depressurizing.
4.5 Other Intermediate Installations

5.0 PIPELINE ROUTE

5.1 Pipeline Route & Terrain Details

Most of the areas the Pipeline shall be laid along the road and residential area. The ROU
shall be restricted in all along the pipeline Route. Most route comes under either in Class III or
Class IV.
6.0 DESIGN DATA
6.1 pipeline shall be designed for conditions as follows:

Pipeline Design Parameters

Description Value

Main line 4”/8”

Products Gas
2
Design Pressure (kg/cm g) 98/52/20
(600/300/150)#
2
Operating Pressure (kg/cm g) 92/ 30/19
(600/300/150)#
 Max. Design Temperature, 0 C
-29 to 65.0
i. Above ground section
ii. Underground section -29 to 60.0
Operating temperature, °C 7 to 35

Economic Design Life, years 35

Corrosion Allowance, mm 0

All terminal facilities (equipment and associated piping) shall be designed for design and
operating conditions given in the process package.
7.0 PIPELINE AND ASSOCIATED FACILITIES DESIGN

7.1 General
Pipeline and pipeline stations to be installed as a part of this project shall be designed and
engineered in accordance with the standards/codes referred in section 3.0 of this document.
7.2 Pipeline

7.2.1 Pipeline shall be designed in accordance with requirements of ASME B 31.8 and OISD 226
& PNGRB guidelines. The pipeline shall withstand all installation, testing and operating
condition/ loads. All necessary calculations shall be carried out to verify structural integrity and
stability of the pipeline for the combined effect of pressure, temperature, bending (elastic),
soil/pipe interaction, external loads and other environmental parameters as applicable during all
phases of work from installation to operation. Allowable stress limit shall be as per ASME B 31.8.
Such calculations shall include, but are not limited to following:

- Buoyancy control and stability analysis for pipeline section to be installed in areas
subjected to flooding/submergence. Unless specified, specific gravity of installation in
such area shall be at least 1.2.
- Stress analysis at crossing of rail and highway etc.
- Crossing analysis of rivers by HDD as applicable.
- Pipeline expansion and its effect on station piping (above ground/below ground).
7.2.2 Pipeline shall also be checked for adequacy against anticipated earthquake loading and any
special measures such as increase in wall thickness/ grade/ select backfill etc. as required to
ensure safety and integrity of the pipeline system shall be implemented.
7.2.3 Mainline shall be provided with pigging facilities (wherever specified )suitable for handling all
types of pigs including intelligent pigs.
7.2.4 Pipeline and its associated facilities shall be designed using the applicable design code and
as modified below.
The pipeline shall be designed to meet the Location Class as defined in ASME B31.8,
except as modified below.
 Location Type of Facility Design
Class Factor

All Station Piping 0.5

River/Stream Crossings

 Drilled/ Bored/ Inaccessible/ open cut 0.6

 Others 0.72

Class 1  HDD 0.5

Cased/Uncased Crossings or Parallel
Encroachments on ROW of Hard Surfaced
0.6
Roads, Public Streets and Highways
Rail Crossings 0.5
River/Stream Crossings

 Drilled/ Bored/ Inaccessible/ open cut 0.5

 Others 0.6

 HDD 0.5
Class 2
Cased/Uncased Crossings or Parallel
Encroachments on ROW of Hard Surfaced
0.5
Roads, Public Streets and Highways

Rail Crossings 0.5

Class 3 All 0.5
Class 4 All 0.4

7.3 Station Piping

7.3.1 Station piping to be provided at all stations shall be designed in accordance with OISD
226/ASME B 31.8 and utility piping (if required) to be provided at these locations shall be
designed in accordance with the provisions of ASME B 31.3.
7.3.2 All piping shall be designed for combined effects of pressure, weight and temperature during
operating conditions without over stressing the piping, valves or equipment. All piping shall
be adequately supported, guided or anchored so as to prevent undue vibration, deflection or
loads on connected equipment such as filters, meters etc.
7.4 Materials
Pipeline and its appurtenances shall be provided with carbon steel materials suitable for the
intended service, as detailed in subsequent paragraphs
7.4.1 Line pipe for main line
Line pipe shall conform to API 5L and Company specifications. Type of line pipe to be used
shall be EW/ HFW/ Seamless/ LSAW/ HSAW. Line pipe size, material grade shall be as per
wall thickness calculation for that particular class and Zone.
7.4.2 Other Materials
All other materials and equipment’s including scraper traps (if required), flow tees, insulating
joints, ball valves, plug valves, globe valves, check valves, pig signaler’s, flanges and fittings
shall be carbon steel suitable for the service conditions and shall be compatible with the line
pipe material.
7.5 External/ Internal corrosion coating
7.5.1 Pipeline to be installed below ground shall be protected against external corrosion by a
combination of high integrity externally applied coatings and permanent impressed Cathodic
protection system. Externally applied coating shall be three layer side extruded polyethylene
coating.
7.5.2 In addition, pipeline shall be provided with minimum 40 micron thick liquid epoxy internal
coating conforming to ISO 15741/API RP 5L2.
7.5.3 All above ground piping and structures shall be painted to prevent atmospheric corrosion.
Painting of above ground piping and structures shall be as per SSPC-SP-10, P- 6 and F-6
shall be provided suitable for mention temperature application as per company specification
enclosed with the bid document. Application thickness shall be as per painting Specification
SS-PI-008. Painting shall be suitable for normal corrosive environment/corrosive
environment, as applicable, as defined in Painting Specification for all stations and
terminals.
7.6 Insulating joints

Insulating joints shall be provided to electrically isolate the buried pipeline from above
ground pipeline. Insulating joints shall be monolithic type and shall allow smooth passage of
pigs. Insulating joints shall be installed in above ground portion of the pipeline, immediately
after the buried/aboveground transition at the scraper stations.
Wherever pressure/ temperature transmitters are used on cathodically protective pipeline
the same shall be electrically isolated by providing insulating joints/ flanges.
7.7 Pipeline Burial

The pipeline shall be buried normally at a depth of 1.0 meter below natural ground level
except river/ rail/ road/ canal/waterways crossing where minimum cover shall be as given
below or as per the requirements of statutory/local authorities whichever is more stringent.
Increased cover shall be provided at critical locations and crossings.

Sl. Minimum Cover (m)

Location
No. (refer note 1)

1.0 Industrial, commercial and residential area 1.0

 Sl. Minimum Cover (m)
Location
No. (refer note 1)

2.0 Flat terrain 1.0

Minor water crossing/ canal/ drain/ nala/
3.0 1.5
waterways
4.0 HDD crossing of canals (below bed) 2.5
River crossings for which scour depth is
5.0 1.5
defined (below scour)
2.5 (For normal soil)
6.0 Other River/ water crossings (Below Bed)
1.5 (For rocky strata)
7.0 Cased/uncased road crossing 1.2
8.0 Cased railway crossing 1.7
Drainage, ditches at roads/railway
9.0 1.2
crossings
10.0 Marshy land/Creek area 2.5

Note:1
Additional soil cover other than specified above shall be provided at locations indicated by
statutory/ local authorities or in areas likely to have an increased risk of impact damage or
third party interference as per agreements between COMPANY and authorities. In case, any
private dwelling, industrial building or place of public assembly falls within 15m of pipeline,
additional cover of minimum 300mm shall be provided over and above the cover indicated in
the above table.
7.8 Marshy Areas / Areas Prone to Flooding

Wherever marshy areas/areas prone to flooding are encountered along the pipeline route,
pipeline shall be provided with anti-buoyancy measures viz. continuous concrete coating/
Geotextile gravel filled bags. Unless specified otherwise in AFC drawings, specific gravity of
installation in such areas shall be at least 1.2.
7.9 Pipeline in common ROW
The location of new underground pipeline, when running parallel to an existing underground
pipeline in same ROU/ROW shall be laid at minimum clear distance of 5.0 m from the
existing underground pipeline. This distance may be reduced to 3.0 m after assessment of
construction methodology which do not result in unsafe conditions during construction.
7.10 Backfilling

In normal cross-country areas, the pipeline trench shall be backfilled with excavated soil.
Select rockfill/ slope breakers shall be provided in the trench in steep areas (slope generally
10% and more) to prevent erosion. In case of rivers/water bodies prone to scour and
 erosion, the safety cover shall be provided below the predicted scour level. In addition to the
cover, anti-buoyancy measures (concrete coating) shall be provided at river crossings.
Contractor shall keep top 150 mm of excavated top soft soil (free of gravels) aside, which shall
be back filled in the end as top layer.
Select backfill shall be provided at approaches to terminal up to transition point (below
ground/above ground) inside terminal.
Select back fill shall also be provided as applicable for areas prone to seismic activity.
In rocky/pebbles, marram areas, the trench bottom shall have sand/soft soil padding of 150
mm. After laying of pipeline, sand/soft soil padding shall be placed around and on top of the
pipe so that thickness of compacted padding on top of pipe corrosion coating shall be at least
150 mm.
Disposal of debris and surplus material to designated disposal areas or designated place(s), as
the case may be and as directed by Engineer-in-charge shall be carried out.
8.0 OTHER TECHNICAL REQUIREMENTS

8.1 Scraper Stations (whenever required)

Scraper traps shall be provided at the Dispatch & Receiving terminals. The scraper traps
shall be capable of handling intelligent pigs and other cleaning pigs. The launching and
receiving barrels shall be designed in accordance with the requirements of ASME B 31.8
and its end closure shall be designed and fabricated according to ASME Section VIII, Div.1.
Adequate arrangements for launching, retraction, handling and lifting of cleaning and
instrumented pigs shall be provided at the scraper stations. Traps shall be accessible by
walkway/road for movement of equipment, pigs etc. These stations shall be provided with
access road from the nearest metaled road.
Corrosion resistant coating shall be provided on the pipeline up to a minimum length of 500
mm after it comes aboveground / before it gets buried underground at terminals and scraper
stations.
The diameter of barrel of the launcher cum receiver shall be three nominal sizes larger than
the pipeline nominal size. Center line elevation of scraper trap shall be at suitable height
from grade level. Suitable arrangements shall be provided for handling & lifting of pigs.
The piping system at the terminals and intermediate stations shall be designed to have
sufficient flexibility to prevent pressure and thermal expansion or contraction from causing
excessive stresses on the connected equipment. The piping shall be designed /fabricated
as defined in clause 8.3.
As far as possible, pipeline expansion shall be absorbed by allowing the scraper traps to
move on supports. Installation of anchor block in the underground pipeline is not permitted.
If required adequate length of trench in approaches to stations shall be provided with a
select backfill to ensure flexibility.
8.2 Piping

8.2.1 General
This section describes the design requirements of piping applicable for Despatch station,
intermediate pigging stations, sectionalizing valve stations and receiving station.
All piping and equipment shall be designed as per ASME B 31.8. All piping materials shall
be as per Piping Material Specification (PMS).
Utility piping (if required) to be provided shall be designed in accordance with the provisions
of ASME B 31.3.
Design shall provide consideration for all loadings like weight, temperature etc., significantly
affecting the pipe material stresses in addition to fluid pressure.
8.2.2 Piping flexibility/stress analysis
All piping shall be designed for thermal expansion under start up, operating and shut down
conditions without over stressing the piping, valves or equipment. Provisions for expansion
shall normally be made with bends and offsets.
All piping shall be adequately supported, guided or anchored so as to prevent undue
vibration, deflection or loads on connected equipments. Equipment’s/ valves requiring
periodical maintenance shall be supported in such a way that the valves and equipment can
be removed with minimum temporary pipe supports.
8.2.3 Piping layout
- Piping will be located above-ground wherever possible within the terminals.
- Piping shall be designed considering skin temperature of piping material under empty
conditions as 65ºC or design temperature of pipeline whichever is higher.
- Piping stress analysis shall be carried out to determine allowable pipe movement and
support requirements wherever felt necessary.
- Buried piping inside the terminal area will have a minimum depth of cover of 1.2 m.
- Where buried pipes come out of the ground, the underground coating on the pipe will
continue for a distance of 500 mm above ground.
- Platforms, crossovers shall be provided for ease of operation and maintenance.
- Painting above ground piping and structures shall be as per specifications
8.3 Welding
Welding shall be carried out in accordance with API 1104, specification for welding. Butt
welds shall be 100 % radio graphed / for all pipelines.
8.4 Hydrostatic Testing

After installation, the entire pipeline system shall be hydrotested with inhibited water. The
water shall tested, as applicable prior to using for hydrotesting. The minimum hydrostatic
pressure in any section shall be as per ASME B 31.8 for gaseous hydrocarbon pipelines.
The maximum hydrostatic test pressure at any location of the pipeline shall not exceed the
pressure required to produce a hoop stress equal to 90% of SMYS of the pipe material
based on minimum wall thickness in the test section. The test duration shall be minimum 24
 hours. Hydrostatic testing of terminals shall be carried out separately. Terminals as well as
other intermediate facilities shall be tested at 1.5 times the design pressure. The test
duration shall be 6 hours. Mainline valves shall be installed after successful completion of
hydrotesting.
8.5 Dewatering and swabbing

Dewatering, swabbing and pre-commissioning operations shall be carried out after

hydrotesting and prior to commissioning of the pipeline as per Project specifications.
Swabbing shall be carried out prior to installation of Sectionalizing valves. After swabbing
operation the pipeline sections shall be dried.
8.6 Crossings
8.6.1 Water Crossings
All water crossing shall be installed by open cut or may be crossed by Horizontal Directional
Drilling (HDD)/Micro Tunneling method. The requirement shall be finalized at site based on
permission available and as advised by Engineer In-Charge.
8.6.2 Rail Crossing
Pipeline at rail crossings shall be provided with casing pipe. The casing pipe shall be three
nominal pipe sizes larger than carrier pipe (unless advised otherwise by concerned
authorities) and shall be installed by boring/ jacking. The rail crossing shall comply with the
requirements of API 1102 and Indian Railway Authorities. The crossing angle shall be as
close to 90º as possible. It should be noted that the extent of casing pipe generally specified
by Railways is 14.0 m beyond centerline of the outermost tracks on either side or 0.6 meter
beyond the ROU limits of Railways on either side, whichever is more. Carrier pipe shall be
electrically insulated from the casing pipe and casing ends shall be sealed using durable,
electrically non-conducting materials. The crossing drawing shall be subject to approval of
concerned Railway Authorities prior to implementation.
8.6.3 Road Crossing
Road crossings shall comply with the requirements of API 1102 and the requirements of the
concerned road authorities. Unless otherwise required by concerned Authorities, casing
pipe shall not be used. However at national highway road crossings pipeline shall be
provided with casing pipe, which shall extend min. 600 mm beyond Road ROW on either
side. The casing pipe shall be installed by trenchless method like ramming/ boring/ jacking/
Micro Tunelling. Provision of casing at locations other than national highways shall be
decided based on type of road crossing and as per requirements of local authorities if
necessary. The casing pipe shall be three nominal pipe sizes larger than carrier pipe. The
crossing angle shall be as close to 90º as possible. Casing insulators and end seals shall be
provided to ensure electrical isolation of carrier pipe and casing pipe.

8.6.4 Existing Pipeline Crossing/ Other utility Crossing

The specific requirements of Owner/operator of existing pipeline shall generally be followed.
The minimum clearance between the lines shall be 500 mm unless specified otherwise. A
Concrete slab shall be provided 300mm above the new Pipeline or below in case new
Pipeline is laid above existing utilities. In both the cases, the cover over Pipeline shall not
anyway less the requirements
8.7 Valves

8.7.1 Application of various types of valves shall be as follows:

Valve type Typical application

Globe Throttling
Ball On/off, Isolation (on main line)
Plug On/off, Isolation (in the terminals)
Check Uni-directional flow
All pipeline valves shall comply with the requirements of API 6D/ relevant PMS. In order to
minimize potential leak sources, valves used in mainline shall be with butt-weld ends. Valve
installed within the terminal to isolate the mainline/ pipeline shall also be provided with butt
welding ends. However terminal valves shall be flanged ends. Flanges may be used where
frequent access or removal of equipment is required.
Wherever underground valves are provided, valves shall be provided with a stem extension
in such a way that the centerline of the rim of the hand wheel on a horizontal shaft or centre
of power actuator as approximately 1.0 m above the finished ground level.
Minimum size of any tapping from the underground pipeline shall be 2" NB and shall be
provided with an isolation ball valve located at a minimum distance from the pipeline.
8.8 Branch Connections

All branch connections or side tap on the piggable lines wherever the branch line diameter
is approx. 40% or more of the main line size, shall be provided with flow tees to enable
smooth passage of all types of pigs. Flow tees for this purpose shall have an internal pipe
housed in a tee.
8.9 Pipeline Bends
In order to accommodate changes in vertical and horizontal alignment in piggable section of
pipeline, elastic bends/cold field bends/hot formed long radius bends shall be used. Miter
bends shall not be used for change in direction. Minimum bend radius shall be as follows:

Minimum Bend Radius

Pipeline Cold Field Bend LR Bend Remarks

Radius Radius

4” R=30D R=6D For Non

pigable Lines
8” R=30D R=6D 3D LR bend
may be used
12” R=30D R=6D

8.10 Pig Signaler’s ( Whenever Required)

8.10.1 Pig signalers shall be installed as a minimum at the following locations:

Downstream of Pig launcher, & upstream of Pig Receiver & One location on the line.
8.10.2 Pig signaler shall be with trigger mechanism, suitable for maintenance with pipeline under
operating pressure.
8.11 Specifications

All procurement of materials shall be as per Piping Material Specification (PMS) and
specifications indicated in PMS.
ANNEXURE - A
LIST OF CODES AND STANDARDS
In addition to the codes/standards mentioned in Para 3.0, the latest edition of the below listed
equivalent codes and standards shall also be used for design of proposed pipeline. The listing includes,
but is not limited to, the following:
1. Line Pipes
API 5L Specification for Line pipe
API 5L1 Recommended Practice for Railroad Transportation of Line pipe
API 5LW Recommended Practice for Transportation of Line pipe on
Barges & Marine Vessels
2. Valves
API 6D Specification for pipeline valves (Steel Gate, Plug, Ball and
Check Valves)
API 602 Compact Steel Gate Valves-Flanged, Threaded, Welding &
Extended Body ends.
ASTM A694 Forgings, Carbon & Alloy steel for Pipe Flanges, Fittings, Valves
& parts for High Pressure Transmission Service.
MSS-SP-6 Finishes for Contact Faces of connecting End Flanges of Ferrous
Valves and Fittings.
MSS-SP-25 Standard Marking System for Valves, Fittings & Unions
BS 5351 Steel Ball Valves for the Petroleum, Petrochemical and Allied
Industries
3. Flanges & Fittings
MSS-SP-44 Steel Pipeline Flanges
ANSI B16.5 Pipe Flanges and Flanged Fittings
ANSI 16.20 Ring-joint Gaskets & Grooves for Steel Pipe Flanges

ASTM A105 Forgings, Carbon Steel for Piping Components

ASTM A193 Carbon & Alloy Steel Bolts & Studs for High Temperature Service
API 601 Standards for Metallic Gaskets for Raised-Face Pipe Flanges &
Flanged Connections
ANSI B16.9 Factory Made Wrought Steel Butt Welding Fittings
ANSI B16.11 Forged Fittings, Socket Welded & Threaded

ANSI B16.26 Butt Welding Ends

ASTM A234 Piping Fittings of Wrought Carbon Steel and Alloy Steel for
Moderate and Elevated Temperatures
 ASTM A694 Forgings, Carbon & Alloy Steel for Pipe Flanges, Fittings, Valves
& Parts for High Pressure Transmission Service.
MSS-SP-75 Specification for High Test Wrought Butt Welding Fittings
MSS-SP-97 Integrally Reinforced Forced Branch Outlet Fittings – Socket
Welding, Threaded and Butt Welding Ends.
PFI-ES-24 Pipe Bending Methods, Tolerances, Processes & Material
Requirements
4. Testing & Welding
ANSI/AWS D1.1 Structural Steel Welding

API 1104 Standard for Welding Pipelines and Related Facilities

AWS A3.0 Welding Terms and Definitions
AWS A5.1 Welding Electrodes
AWS A5.5 Specification for Low Alloy Steel Covered Arc Welding Electrodes
ASTM E165 Liquid Dye Penetrant Inspection of Pipeline Welds
ASTM A370 Standard Methods and Definitions for Mechanical Testing of
Steel Products.
ASTM E18 Standard Hardness Test for Metals
ASTM E23 Standard for Impact Test for Metals
ASTM E84 Standard Test Method for Micro-hardness of Metals

ASTM E92 Standard Test Method for Vickers Hardness of Metallic Materials
ASTM E110 Standard Test Method Indentation Hardness for Metallic
Materials by Portable Hardness Testers
ASTM E709 Standard Guides for Magnetic Particle Examination
MSS-SP-53 Quality Standard for Steel Casting & Forging-Magnetic Particle
Method
MSS-SP-54 Quality Standard for Steel Casting & Forging-Radiographic
Examination
MSS-SP-55 Quality Standard for Steel Castings & Forgings-Visual Method.
5. Surface Preparation, Painting and Coating
SIS-05-59 Pictorial Surface Preparation Standards for Painting Steel
Surfaces
SSPC-SP-01 Solvent Cleaning

SSPC-SP-03 Power Tool Cleaning

SSPC-SP-05 Joint Surface Preparation Standard: White Metal Blast Cleaning

 SSPC-SP10 Structural Steel Painting Council – Joint Surface
NACE No.2 Preparation Standard - Near-White Metal Blast
Cleaning
SSPC-PA-02 Measurement of Dry Paint Thickness and Magnetic Gauges

ASTM E12 Measurement of Pipeline Dry Film Coating Thickness

ASTM-G6 Abrasion Resistance of Pipeline Coating

ASTM G8 Cathodic Disbonding of Pipeline Coatings

NACE-RP-0274 High Voltage Electrical Inspection of Pipeline Coatings Prior
to
Installation
IEC 454 – 2 Specification for Pressure-Sensitive Adhesive Tapes for
Electrical Purposes
CSA Z245.20-02 External Fusion Bond Epoxy Coating for Steel
Pipe
6. Safety Systems
IP Model Code of Safe Practice in the Petroleum Industry parts 3, 6 and 9.
 STANDARD SPECIFICATION
FOR
MAJOR WATER CROSSINGS
(CONVENTIONAL TRENCHING)
ABBREVIATIONS:

ASME American Society of Mechanical Engineers

ASTM American Society of Testing of Materials

API American Petroleum Institute

OISD Oil Industry Safety Directorate

 CONTENTS

1.0 SCOPE......................................................................................................................................................................

2.0 REFERENCE CODES, STANDARDS AND SPECIFICATIONS .......................................................

3.0 GENERAL REQUIREMENT ...........................................................................................................................

4.0 TRENCHING .........................................................................................................................................................

5.0 POLLUTION CONTROL MEASURES .......................................................................................................

6.0 CONTINUOUS CONCRETE COATING ....................................................................................................

7.0 HYDROSTATIC PRE-TESTING ...................................................................................................................

8.0 INSTALLATION ..................................................................................................................................................

9.0 INSTALLATION OF PARALLEL PIPELINES ........................................................................................

10.0 BACKFILLING AND BANK PROTECTION ............................................................................................

11.0 POST-INSTALLATION HYDROSTATIC TEST ..................................................................................

12.0 POST-CONSTRUCTION SURVEY ...........................................................................................................

13.0 FINAL CLEAN-UP ...........................................................................................................................................

14.0 DOCUMENTATION........................................................................................................................................
1.0 SCOPE

This specification covers the minimum requirements for the various activities to be performed by
Contractor for the construction of pipeline major water crossings by conventional trenching method.
Provisions of this specification are applicable only for "Major Water Crossing" specifically named as
such in the contract.

This specification shall be read in conjunction with the condition of all specifications and documents
include in the contract between company and contractor.

2.0 REFERENCE CODES, STANDARDS AND SPECIFICATIONS

The latest edition of following Codes and Standards are referenced in this specification and all
provisions of these reference codes and standards shall be applicable.

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

B31.4 : Pipeline Transportation system for liquid

Hydrocarbon & other liquids.
B 31.8 : Gas Transmission and Distribution Piping
Systems.

AMERICAN PETROLEUM INSTITUTE (API)

1102 : Steel Pipeline Crossing Railroads and Highways

1109 : Marking Liquid Petroleum Pipeline Facilities

1104 : Welding of Pipelines and Related Facilities

OIL INDUSTRY SAFETY DIRECTORATE (OISD)

STD-141 : Design and Construction Requirements for

Cross Country Hydrocarbon Pipelines.
STD-226 : Natural gas Transmission Pipelines and city gas
distribution network.

US DOT PIPE LINE SAFETY STANDARD

Part 192, Title 49 : Transportation of Natural and other Gases by Pipe

Line
Part 195 : Transportation of Liquid by Pipe Line

COMPANY STANDARD SPECIFICATIONS

Following Company specifications shall form integral part of this specification and shall be complied
with when applicable to the works covered in the contract.

SS-PL-015 Standard Specification for Pipeline Construction

SS-PL-005 Standard Specification for Pipeline Concrete Weight Coating of
Onshore Pipelines
SS-PL-012 Standard Specification for Hydrostatic Testing of Onshore Pipelines
SS-PL-016 Standard Specification for Pipeline Markers

In case of conflict between various requirements of this specification and reference standards mentioned
above, more stringent requirement shall apply unless otherwise agreed by Company
3.0 GENERAL REQUIREMENT

a. If specified, Contractor shall carry out all geotechnical and hydrological investigation as per
relevant specification. Contractor shall also carry out scour calculation based on the above
and submit all reports and calculation to company for review and approval.

b. Contractor shall comply with all the conditions and requirements issued by Authorities having
jurisdiction in the area where the work is to be performed. Contractor shall, at his own
responsibility, obtain necessary permits from the Authorities having jurisdiction, for
performing its work.

c. Contractor shall take full responsibility for the suitability, stability and safety of all operations
and methods involved in the work.

d. Contractor shall be deemed to have inspected and examined the work area and its
surroundings and to have satisfied himself so far as practicable as to the form and nature
thereof, including sub-surface conditions, hydrological and climatic conditions, the extent
and nature of the work and materials necessary for the completion of the work, and the
means of access to the work area.

e. Prior to start of any work, Contractor shall carry out a pre-construction survey of the major
water crossings and. acquaint himself with site conditions and to collect any data regarding
the water velocity and the tidal variation in the flow pattern and shall verify the suitability of
his equipment and the method of construction.

f. Contractor shall, with due care and diligence, execute the work in compliance with all laws,
by-laws, ordinances, regulation etc., and provide all services and labor, inclusive of
supervision thereof, all materials, excluding the materials indicated as "Company Supplied
Materials", equipment appliances or other things of whatsoever nature required in or about
the execution of the work, whether of a temporary or permanent nature.

g. Contractor shall be deemed to have obtained all necessary information subject as above
mentioned as to risks, contingencies and all other circumstances, which may influence the
work.

h. Contractor shall, in connection with the work, provide and maintain at his own-costs all lights,
guards, fencing, watching etc., when and where necessary or required by Company or by
any duly constituted Authority for the protection of the work and properties or for the safety
and the convenience of public and/or others.

i. If no public roads exist, Contractor shall arrange at his own for access to work areas at no
extra time and cost to Company.

j. Before start of the field construction work, Contractor shall submit the following for approval
of each major water crossing
 Installation method.

 Proposed time schedule indicating start and finish dates with detailed break-up
showing critical activities.

  Layout, location and other drawings / sketch of work area.

 Details of equipment (including number and capacity of equipment deployed)
 Proposed sub-contractors and / or vendors (if any) along with their scope of work.

The description of the installation method as a minimum shall include the following:

a. Preparation of fabrication yard and launching area along with proposed Layouts.
b. Pipeline construction details (including hauling, stringing, welding, NDT, concrete coating,
etc.).
c. Study of water currents in relation to the method of launching (on bottom and on surface)
d. Calculations For stability of pipeline during launching and final test.
e. Buoyancy Studies.
f. Pre-test procedure.
g. Pulling or other installation method and related calculations / analysis including rope test,
checking of winch/crane pulling capacity etc.
h. Pulling arrangement including launch way and anchoring and braking device.
i. Trench correction before launching / lowering.
j. Method of positioning and sinking / lowering of pipeline.
k. Method of rectification of damages to the pipeline / coating, during launching.
l. Method of backfilling and bank protection.
m. Final test procedure after backfilling. .
n. Safety system adopted
o. Communication system adopted during construction/testing/survey.
p. Abandonment and recovery procedures.
q. Dredging, anchoring requirements spoil deposit and trench survey method and Contractor's
proposed methodology for execution of these activities.

Approval by Company of the methods used by Contractor shall in no way relieve Contractor from the
sole responsibility for safe and satisfactory installation of the crossing.

4.0 TRENCHING

4.1 EXCAVATION

Contractor shall dredge or excavate the trench for the water crossing in conformity with the
approved drawings. Dredging of the trench shall be executed as accurately as possible.

The trench shall be excavated to such depth as, required to provide the minimum cover and the
pipeline configuration as specified. The pipeline profile of the crossing shall be followed as
accurately as possible. Before laying, the trench shall be cleaned and leveled. The trench shall be
subject to inspection by Company prior to installation of the pipe.

Navigational traffic shall not be obstructed, unless permission has been given thereto. Contractor
shall issue all necessary, publication according to the local requisitions. Instructions given by
Authorities shall be followed accurately and immediately, so that traffic encounters no hindrance.

Contractor will not be entitled for any compensation in terms of time and cost, if his work is
hampered or delayed due to weather conditions, any obstacles / or any traffic on the spot, where
work is executed.
Contractor is fully responsible for the execution of the blasting (wherever permitted), the dredging
and excavation work, hopping of the spoil; transportation, dumping on land or in water, all to be
executed in agreement with Authorities, land owners and Company.
 Contractor maybe obliged to dredge or excavate a trench deeper or wider than indicated in the
drawings. in order to-properly lay the pipeline in unstable (underwater) areas, or near and adjacent
to the banks of water-courses. It shall be understood that Contractor is aware of such problems at
the time of his Bid and that when such additional excavation is required, it shall be done by
Contractor as part of the work and that he will install the necessary provisions and/or temporary
works such as sheet-piling, special filling materials, etc. at no extra cost to Company.

During the execution of dredging work by Contractor, bearings, measurements and levels shall be
taken by or on behalf of Company. Contractor shall render assistance for this purpose and make
available for Company appropriate survey boats, fully manned and equipped, before the trench
excavation work of the water crossing can be started- Contractor, if so desired by Company, shall
make cross profiles at intervals of not more than 10.0 m of the bottom of the watercourse along the
surveyed centerline of the water crossing. In such a case, horizontal measurements shall be taken
by triangulation or tapping between known points and shall be made with such accuracy that the
location of each vertical measurements is known with 1.0 m. Vertical measurements shall be taken
with a sonic recording device, or with line and rod, as directed by Company and shall be taken with
such an accuracy that each depth is known within 0.2 m. Vertical measurements shall be taken at
points averaging not more than 5.0 m apart and no two measurements shall be more than 7.0 m
apart. The cross profiles shall extend at least 10 m on both sides of the top of the trench.

All measurements shall be recorded by Contractor. Company may witness such measurements.
The resulting profile, corrected to the elevation of the undisturbed watercourse, shall then be the
reference profile. Said profile shall be plotted on a 1:200 vertical and horizontal scale.

Contractor shall keep the trench in good condition until the pipe is laid, and no claim is to be made
to the Company by reason of its caving either before or after the pipe is laid. Contractor shall do
whatever is required to excavate the trench, install the pipe in it and backfill the trench in
accordance with the specifications at no extra cost to Company.
Immediately before installation of the water crossing in the excavated trench, Contractor shall
prepare a profile of the trench bottom along the surveyed center line of the water crossing for
comparison with the reference profile. Contractor shall also make cross sections of the trench at
intervals of not more than 50 m. All profiles and cross section measurements shall be taken as
specified and, if required, shall be witnessed by Company. These data shall be submitted to
Company for approval.

Contractor shall grade the trench in such a manner as to give the maximum amount of uniform
support to the pipeline when it is lowered or pulled into place. The maximum unsupported span
shall not exceed 10.0 m.
In submerged sections, where rock or gravel is encountered in the bottom of the trench, padding is
required. The thickness of the padding under the concrete coated pipe shall at least be 0.5 m and
after installation at least 0.5 m around the pipe. Blasting, if any, and padding shall be included in
the Contractor's work.

4.2 DIKES, DAMS AND WEIRS

Contractor shall install temporary provision in the existing dikes, dams, etc. to prevent flooding of
low areas.
Therefore in general, in existing dikes, dams, etc. a double substituting weir must be installed
before start of excavation in the existing dike or dam. Such a double substituting weir can be a
closed wall of sheet piling, supported by soil. The provisions shall be such that the underwater
profile of the dredged trench, the water flow and water movement caused by boats/ ships etc.
cause no slides / cave-ins of the dike or dam.
5.0 POLLUTION CONTROL MEASURES

Contractor shall take all necessary precautions not to pollute river water and banks during entire
construction operation. Equipment deployed and, construction methodology adopted shall be-such,
that minimum damage is caused to the existing environmental conditions. Union and State
Government requirements concerning pollution control and environmental protection 'shall be fully
complied with.

6.0 CONTINUOUS CONCRETE COATING

Contractor shall provide concrete coating over the pipeline including the bends in accordance with
the specification issued for the purpose and approved procedure. Contractor shall coat the weld
joints in order to arrive at the continuously concrete coated pipeline. However the concrete coating
shall be applied after the hydrostatic pretest.

7.0 HYDROSTATIC PRE-TESTING

Contractor shall hydrostatically pre-test the pipe string of each water crossing before installation as
per approved procedure.
Joint coating of the welds shall be done after this pre-test.
The section of the pipeline corresponding to the crossing shall, before installation, be subjected to
a minimum hydrostatic test pressure equal to 1.4 times design pressure for gas pipeline and 1.25
times design pressure for liquid pipeline. The combined equivalent stress in the pipeline due to
bending and test pressure shall not exceed 95% of the SMYS of the pipe material.
After the temperature has been stabilized, the pressure shall be maintained in the pipeline for at
least six hours and recorded by man thermograph. During test, the Contractor shall check all welds
for leakage. Failure, if any, during the test shall be rectified by the Contractor. If the same is due to
failure on account of any cause other than defect in materials supplied by Company, the repairs
shall be done free of cost, to the satisfaction of Company.

8.0 INSTALLATION

Contractor shall submit a detailed scheme for the method, proposes to adopt for installing the
pipeline to Company for approval. Contractor shall calculate all stresses in the pipeline while laying
and check whether the stresses remain within permissible limits. A set of all calculations shall be
submitted to Company for approval.

Contractor shall perform all work required to install the water crossings, including the possible
appurtenances indicated in the drawings. The water crossings shall be installed in such a manner
as to comply with the requirements and conditions stated by the Relevant Authorities issuing the
permits. Contractor shall pay special attention to minimize any damage to embankments and dikes
in the vicinity of water crossings.

The equipment for launching shall be arranged in such a way that the pipeline is laid without impact
or jerking and is not subjected to stresses of any type other than those which are allowable.
Minimum allowed radius of curvature shall be followed, particularly at the end of the launching way
towards the water in the freely suspended section.

After the water-crossing section has been installed in place, Contractor shall fill this pipeline section
including the pertaining land pipeline sections with water for the final testing. Contractor shall check
if the position and depth of the water crossing are in accordance with the approved drawing, by
means of a profile of the pipeline, before and after the water crossing section is filled with water.

Prior to backfill the pipeline shall, when laid in the trench, conform to the bottom contour of the
trench grade, so that it will be firmly, uniformly and continuously supported within the permissible
limits of unsupported spans as specified in Para 4.1.
 If the pipe does not properly fit the trench or does not rest at sufficient depth to satisfy the minimum
requirements of cover as specified in approved drawings, the Contractor shall make necessary
corrections to trench so that the pipe, when finally in position in the trench, shall fully meet the
specification, failing which Contractor may be asked to remove the pipeline. This shall be done at
no extra time and cost to the Company.

9.0 INSTALLATION OF PARALLEL PIPELINES

When parallel pipelines are required to be installed across major water crossing, Contractor shall
further comply with the following requirements.

Depending on the diameter of the parallel pipelines, the characteristics of the crossing and the
limitation of Contractor's equipment, Contractor may propose installation of the parallel pipelines
either together in a combined operation or separately in a common trench.

If the pipelines are installed together, the minimum clear distance between the parallel pipelines
(measured from the outside diameters of the concrete coated pipes) shall be 300 MM. Contractor
shall provide spacers (at sufficient intervals along the length of the pipe sections), securely fixed to
the pipes, or shall propose other suitable alternative methods, so as to ensure that the stipulated
minimum clear distance is maintained. The buoyancy of the combined installation (pipes+spacers),
shall be checked before installation. The spacers may be removed before the trench is backfilled.

Contractor shall furnish detailed drawings/calculations for the pipe assembly, showing the details
of spacers/other arrangements for Company's approval before start of construction.
If the parallel pipelines are installed separately in a common trench, the minimum clear distance
between the parallel pipelines in the trench shall be 5000 mm. Contractor shall ensure that this
minimum spacing is maintained till the time the trench is backfilled.
Construction Equipment
All critical construction equipment deployed shall have a factor of safety of 2 (minimum) over the
calculated loads/capacities.

10.0 BACKFILLING AND BANK PROTECTION

10.1 BACKFILLING

Backfilling of the water-crossing section shall be performed as described in the following clauses.

The bottom of the water way shall be reinstated to its original level by backfilling the trench in a
manner and with suitable material and as prescribed and approved by the Authorities and
Company. In case material other than the original spoil is required, this shall be supplied by
Contractor.

Wherever boulders, rock; gravel and other hard objects are encountered, they shall not be placed
directly on the pipe.
Sufficient soft earth, sand or selected and approved back fill material shall be backfilled initially
around and over the pipe to provide a protective padding or cushion extending to a minimum
thickness of 0.5 m around the pipe before backfilling remainder of the trench with excavated or
other material.

Wherever required by Company, Contractor shall cover the nearly backfilled trench with a layer of
rock boulders to be approved by Company over a width equal to the width of excavated trench with
an extra of 5m on either side at no extra cost to Company.

Backfilling progress of the trench shall be checked continuously and a daily progress report shall
be made in three-fold and handed over to Company.
 All embankments and/or dikes, bed and banks shall be reinstated to their original state and levels,
unless otherwise prescribed in the drawings or by the competent Authorities or Company.

All remaining spoil-deposits shall be cleaned by Contractor to the satisfaction of Company.

10.2 BANK PROTECTION

a. Trenches in banks of major water crossing shall be backfilled with soil approved by Company.
The fill at the banks shall be compacted firmly and reinforced with sacked earth, rip-rap, or by
other means as directed by Company to the satisfaction of Authorities having jurisdiction
thereof. In areas where the backfilled soil is expected to be of loose type, which is prone to
flow, the trench shall be backfilled with crushed rock of size approved by Company and pipe
shall be provided with adequate padding of soil of a quantity approved by Company. Slope
breakers if required shall be provided in both the banks. After the trench has been backfilled
and during the cleanup works, the water crossing shall be cleaned across the whole width of
RoU.

b. Unless stipulated otherwise by the Authority or by Company, Contractor shall protect the
banks of the major water crossings by using gravel and boulders filled embankment
mattresses of galvanized iron wire to be laid over the backfilled, compacted and graded
banks. In case slope of the banks is 1:1 or more, bank protection shall be carried out using
gabions. Bank protection works shall be carried out by Contractor in accordance with the
relevant drawings. All materials required for such works shall be supplied by Contractor and
all works carried out in accordance with specifications, approved drawings, instructions of
Company and to the complete satisfaction of Authorities having jurisdiction at no extra cost to
Company.

c. The width of the above protection shall be equal to the width of trench excavated and damage
and further extending 3 m on either side. The width of the restoration on the slope shall be
determined by the levels.

d. Length of Bank protection shall be as per standard no VCS-PL-PL-STD-042.

e. Before post installation hydrostatic testing, Contractor shall "prove" the Diameter of the
pipeline by passing a gauging pig 95% of ID through the pipeline. The gauging pig shall be
capable of locating and detecting defects permitted by governing code. Contractor shall
supply and install all temporary test headers and other equipment, piping materials and other
consumables for the purpose.

11 POST-INSTALLATION HYDROSTATIC TEST

The test pressure shall be same as adopted during pre-testing. The combined equivalent stress in
the pipeline due to bending, static head and test pressure shall not exceed 95% of the SMYS of the
pipe material. After temperature stabilization, pressure shall be retained in the pipeline for a
minimum 24 hours and recorded by manothermograph. The hydrostatic testing shall be carried out
in accordance with approved procedures.
12 POST-CONSTRUCTION SURVEY

After laying of the pipeline, Contractor shall carry out a post-construction survey jointly with
Company. Any defects brought to the notice of Contractor shall be promptly corrected by
Contractor at his own expense to the complete satisfaction of Company.

13 FINAL CLEAN-UP
After completion of construction, Contractor shall clear the site of all balance material and debris.
All balance pipe lengths, in case supplied by company, shall be returned to Company's designated
stock yard(s). Site shall be cleared to the complete satisfaction of Company and Authorities having
jurisdiction. All such works shall be done at no extra cost to Company.

14 DOCUMENTATION

In addition to the documents specified elsewhere in this specification, Contractor shall submit to the
Company six copies of leach of the following documents/records.

i. Pipe book of the crossing.

ii. Copies of the permits obtained from Authorities having jurisdiction for the various
works.
iii. Clearance certificates from the land owners and Authorities having jurisdiction
regarding satisfactory clean-up and restoration of pipeline ROU and work areas.
iv. Pre and post installation Hydrotest Report.
v. True profile of the bed and banks of water crossing along the pipeline after backfilling
vi. True profile of the pipeline as installed and depth of cover at top of pipe at 10 m
interval.
vii. Location and angle of sag bends and over bends.
viii. Cross section along the pipeline indicating nature and extent of backfill materials,
thickness of concrete coating to pipe etc.
ix. Method and extent of bank protection.
 STANDARD SPECIFICATION
FOR
3 LAYER POLYTHYLENE COATING OF LINEPIPES
ABBREVIATIONS:

ASME American Society of Mechanical Engineers

ASTM American Society of Testing of Materials

API American Petroleum Institute

OISD Oil Industry Safety Directorate

 CONTENTS

1.0 SCOPE ........................................................................................................................................................

2.0 REFERENCE DOCUMENTS ...........................................................................................................

3.0 MATERIAL REQUIREMENTS .........................................................................................................

4.0 COATING APPLICATION ..................................................................................................................

5.0 INSPECTION AND TESTING ..........................................................................................................

6.0 HANDLING, TRANSPORTATION AND STORAGE .............................................................

7.0 REPAIR OF COATING AND FINAL ACCEPTANCE ............................................................

8.0 MARKING AND PIPE IDENTIFICATION ...................................................................................

9.0 PRODUCTION REPORT ...................................................................................................................

10.0 QUALITY ASSURANCE ...................................................................................................................

1.0 SCOPE

This Specification covers the minimum requirements for supply/arrangement of all materials, plant,
equipment, plant sites, consumables, utilities and application including all labor, supervision,
inspection and tests etc. for application of external anti-corrosion coating of pipes by using Three
Layer Side Extruded Polyethylene coating conforming to DIN-30670, 1991,'Polyethylene Coating for
Steel Pipes and Fittings' and the requirements of this specification.

2.0 REFERENCE DOCUMENTS

2.1. CODES AND STANDARD

Reference has also been made to the latest edition (edition enforce at the time of issue of enquiry
unless otherwise specify) of the following Standards, Codes and Specifications. The edition enforce at
the time of floating the enquiry shall be termed as latest edition.
AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)
ASTM D-149 Standard Test Methods of Dielectric Breakdown Voltage and Dielectric
Strength of Solid Electrical Insulating Material at commercial frequencies.

ASTM D-257 Standard Test Methods for D-C Resistance or Conductance of Insulating
Materials
ASTM D-543 Standard Method of Test for Resistance of Plastics to Chemical Reagents

ASTM D-570 Standard Method of Test for Water Absorption of Plastics

ASTM D-638 Standard Method of Test for Tensile Properties of Plastics
ASTM D-792 Standard Test Method for Density and Specific Gravity (Relative Density) of
Plastics by Displacement
ASTM D-1238 Test Method for Flow Rates of Thermoplastics by Extrusion

ASTM D-1525 Test Method for Vicat Softening Temperature of Plastics

ASTM D-1603 Test Method for Carbon Black in Olefin Plastics

ASTM D-1693 Test Method for Environmental Stress Cracking of Ethylene Plastics

ASTM D-2240 Test Method for Rubber Property - Durometer Hardness

STM D-3895 Test Method for Oxidative-Induction Time of Polyolefin by Differential
Scanning Calorimetry
ASTM G-42 Tentative Methods for Cathodic Disbonding of Pipeline coatings Subjected to
Elevated or Cyclic Temperatures

AMERICAN PETROLEUM INSTITUTE (API)

API 5L Specification for Line Pipe
API RP 5L 1 Recommended Practice for Railroad Transportation of Line pipe

API RP 5LW Transportation of Line Pipe on Barges and Marine Vessels

 DEUTSCHES INSTITUT FUR NORMUNG (DIN)

DIN EN 10204 Metallic Products - Types of Inspection Documents

DIN 53735 Testing of Plastics: Determination of Melt Index of Thermoplastics

DIN 30670 Polyethylene Coating for Steel Pipes and Fittings

INTERNATIONAL STANDARD (IS)

ISO 8502 - 3 Preparation of Steel Substrates before Application of Paints and Related
Products part 3 - Assessment of Dust on Steel Surfaces Prepared for
Painting (Pressure Sensitive Tape Method)

ISO 11124 Preparation of Steel Substrates Before Application of Paints and Related
Products

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B31.8 Gas Transmission and Distribution Piping Systems. Liquid

ASME B31.4 Transportation Systems for Hydrocarbons, Liquid, Petroleum Gas,

Anhydrous Ammonia, and Alcohols

CANADIAN STANDARD ASSOCIATION (CSA)

CSA Z245.20-2 External Fusion Bond Epoxy Coating for Steel Pipe

1.0 MATERIAL REQUIREMENTS

3.1 FUNCTIONAL REQUIREMENT
The three layer coating system shall comprise of a powder epoxy primer, polymeric adhesive and a
polyethylene topcoat. Coating materials shall be suitable for the service conditions and the pipe sizes
involved. The coating materials i.e. epoxy powder; adhesive and polyethylene compound shall
have proven compatibility. The coating system and materials shall be pre –qualified and approved by
Company in accordance with provisions of Annexure I of this specification Contractor shall obtain
prior approval from Company for the coating system and coating materials

3.1.1 OPERATING TEMPERATURE

The coating must be able to withstand minimum and maximum continuous in-service operating
temperatures of 0°C and (+) 65°C respectively and still comply with the performance requirements of
this specification

EXPOSURE TO ENVIRONMENT
The coating materials shall withstand exposure to ultraviolet radiation (i.e. sunlight) and heat due to
o
exposure to sunlight with a daytime coating temperature of at least 80 C without impairing its
serviceability and properties specified

3.2. PROPERTIES

3.2.1 GENERAL

The 3 Layer Polyethylene coating shall conform to DIN 30670, Type „S‟ and the requirements of this
specification.
3.2.2 FUSION BONDED EPOXY (FBE) POWDER

Epoxy powder shall comply Canadian Standard Association (CSA) Standard Z245.20-02. The color of
epoxy powder shall be either green or dark red or any other color approved by Company except grey.

3.2.3 ADHESIVE

Co-polymer adhesive used shall be grafted type and the adhesive shall have the following properties:

Sr.
Properties Unit Requirement Test Method
No.

a Melt Flow Rate (190°C / 2.16 kg) g/10 minutes 1.0 min. ASTM D 1238

b Vicat Softening Point °C 100 min. ASTM D 1525

c Specific Gravity - 0.926 min ASTM D 792

Sr.
Properties Unit Requirement Test Method
No.

2
a Tensile Strength @ + 25 °C N/mm 17 min. ASTM D 638

ASTM D 1238 or
b Melt Flow Rate (190 °C / 2.16 kg) g/10 minutes 0.25 min.
DIN 53735
0.926
Specific Gravity @ + 25 °C min.(MDPE)
c -- ASTM D 792
0.941 min.
(HDPE)
Hardness @ + 25 °C
d Shore D 50 min ASTM D 2240

Water Absorption, 24 hours,

e @+ 25 °C % 0.05 max ASTM D 570

15
f. Volume Resistivity @ + 25°C Ohm-cm 10 min. ASTM D 257

Dielectric withstand, 1000 Volt/sec

g Volts/mm 30,000 min. ASTM D 149
rise @ + 25 ° C

Vicat Softening Point

h °C 110 min. ASTM D 1525

Elongation
i % 600 min ASTM D 638
 Oxidative Induction Time in
j Oxygen at 220°C, Aluminum pan, Minutes 10 ASTM D3895
no screen
Environmental Stress Crack
Resistance (ESCR) (for F50) 300
k. Hours ASTM D1693
■ Medium Density [Condition "C"]
■ High Density [Condition "B"] 300
Carbon Black Content
l % 2 min. ASTM D 1603

3.2.5 COATING SYSTEM PROPERTIES

Sr. Properties Unit Requirement Test

No. Method
Bond Strength (using Type 2 Test
Assembly i.e. Dynamometer
8.0 min
a Kg/cm DIN 30670
5.0 min
@ 20+/-5 ° C
 @ 65+/-5°C

Impact Strength
Joules per mm
(Min. of 30 impacts on body
b of coating 7 min DIN 30670
along the length. No breakdown
thickness
allowed when tested at 25 KV)

Indentation Hardness
0.2 max
c  @ 23 +/- 2°C mm DIN 30670
0.3 max
 @ 70 +/- 2°C

Elongation at Failure
d % 300 min. DIN 30670

2 8
e Coating Resistivity (*) Ohm - m 10 min. DIN 30670

Melt Flow Rate

Heat Ageing (*) shall not deviate
f. _ DIN 30670
by more than 35% of
original value
Melt Flow Rate
shall not deviate
g Light Ageing (*) _ DIN 30670
by more than 35% of
original value
Cathodic Disbondment mm radius of
 @ +65 °C after 30 days disbondment 15 max. ASTM G42
h
 @ +65 °C after 48 hrs (**) 7 max.

Degree of Cure of Epoxy CSA Z

 Percentage Cure,ΔH 245.20-98
i 95
% +3/-2 (***)
 ΔTg °C
NOTES
(*) Test carried out in an independent laboratory of national/international recognition on PE topcoat
is also acceptable.
(**) Disbandment shall be equivalent circle radius of total unsealed area as per ASTM G42.
(***) Temperature to which the test specimens are to be heated during cyclic heating shall however
be as per the recommendations of epoxy powder manufacturer

3.2.6 The acceptable combinations of coating material shall be as per Annexure-I

3.3. REPAIR MATERIAL

Repair material shall be such that is capable of complying with the functional requirements stated for
3LPE coating under Para 3.1 above and shall be compatible with the 3LPE coating.

3.4. MATERIAL APPROVAL

The coating materials shall be pre-qualified and approved by the Company. Contractor shall submit
data sheets of proposed material combinations to Company for prior approval. The data sheets shall
cover all aspects required by this specification. The materials brands offered by Contractor for coating
(i.e. Epoxy powder, co-polymer adhesive and the polyethylene compound) shall have proven
compatibility. The contractor shall submit compatibility certificates from manufacturers in this regard.
Only Company approved materials/combination of materials shall be used for coating of pipes

3.5. MATERIAL CERTIFICATES

For each batch of all materials, the Contractor shall obtain from the manufacturer(s) relevant
certificates of material conformity and test results as per DIN 10204, 3.1 b. These certificates shall be
submitted to Company for approval prior to the use of material for coating application.

3.6. In addition to Manufacturer's certificate, the Contractor shall draw samples from each batch of epoxy,
adhesive and polyethylene in the presence of Company Representative and test for the following
properties at the coating yard at least one week prior to its use, to establish compliance with the
Manufacturer's test certificates.

3.7. MATERIAL IDENTIFICATION

All materials to be used shall be packed in damage free containers suitably marked with the following
minimum information for identification:
a. Name of the manufacturer.
b. Type of material and product designation.
c. Batch Number.
d. Date and place of Manufacture
e. Shelf Life / Expiry Date
f. Storage Conditions
g. Quantity

Any materials found without above identification markings shall be deemed suspect and rejected by
Company. Rejected materials shall be promptly removed and replaced by the Contractor. Coating
materials shall be segregated by batch number during shipment, storage and handling.

3.8. INFORMATION FOR FBE MATERIAL

Contractor shall obtain Infrared scan of each batch of epoxy powder to assure that powder used in
manufacturing is same as powder used in qualification.

3.9. MATERIALS STORAGE

Coating materials shall be stored, handled and transported in accordance with the Manufacturers
recommendations. Storage time of materials shall not exceed the shelf life recommended by the
 Coating Manufacturer. The contractor shall be required to use all material on a date received
rotation basis i.e. first in first used basis.

3.10. MATERIAL SUBSTITUTION

Contractor shall not substitute Company approved materials with alternative materials, even if
alternative materials comply with the requirements of this specification, without written approval
from Company.

3.11. ABRASIVE MATERIALS

Abrasives used for blast cleaning shall be clean, free of oil or contaminants and dry. The
particle size shall be capable of producing the specified surface profile and roughness. Abrasive
materials shall meet the requirements of ISO 11124-1.

4.0 COATING APPLICATION

4.1. COATING APPLICATION PROCEDURE SPECIFICATION

Prior to the commencement of any coating application activities, the Contractor shall submit a
project specific Coating Application Procedure Specification, giving full details of the proposed
coating process for Company‟s approval. The Coating Application Procedure Specification shall
include, but not be limited to, the following information and proposals:
a. Inspection of bare pipes and removal of surface defects and surface contaminants.
b. Steel surface preparation, including preheating, removal of steel defects, method of
pipe cleaning, dust removal, abrasive blast cleaning and surface profile; methods of
measurements and consumables.
c. Pipe heating, temperatures and control prior to epoxy application.
d. Complete details of raw materials including current data sheets showing values for all
the properties specified together with quality control and application procedure
recommendations from manufacturer(s).
e. Application of FBE powder, adhesive and polyethylene, including characteristics,
temperature, line speed, application window, curing time, etc.
f. Quenching and cooling, including time and temperature.
g. Quality Assurance System, Quality Plan, Inspection and Test Plan and reporting
formats, including instrument and equipment types, makes and uses, etc
h. Detailed method of repair of coating defects duly classified depending upon nature and
magnitude of defects and repair thereof including coating stripping technique.
i. Details of instrument and equipment calibration methods and frequency of calibration
including relevant standards and examples of calibration certificates.
j. Complete details and inventory of laboratory and equipment for procedure qualification
and regular production.
k. Pipe handling and stock piling procedures.
l. Sample of recording and reporting formats, including laboratory reports, certificates and
requirement.
m. Complete details of test certificates for raw materials including test methods and
standards used.
n. Test certificates from PE compound manufacturer for tests for thermal aging, coating
resistivity and aging under exposure to light. These test certificates shall not be older
than three years.
o. Storage details of coating materials and chemicals.
p. Continuous temperature monitoring at various stages of coating
q. Health, Safety and Environmental (HSE) plans for the storage of raw materials
and coating application.
r. Procedure for transferring of bare pipe identification numbers and applying coated pipe
identification marking.
 Coating application shall proceed only after written approval from Company has been obtained
on the Coating Application Procedure Specification.
Contractor shall submit the detailed Inspection and Testing Plan (ITP) mentioned for the entire
coating application to Company for review and approval. The Company will advise the
Contractor of the specific inspection review, witness and HOLD points required by the Company
or its Representatives by marking up the ITP.
After approval of the Coating Application Procedure Specification and ITP by the Company no
changes shall be in the procedure specification or ITP shall be permitted. Unavoidable changes,
if any, shall be brought to the notice of Company and specific written approval obtained before
implementing the same.

4.2. COATING APPLICATION PROCEDURE QUALIFICATION

4.2.1. GENERAL

Prior to start of production, the Contractor shall, at his expense, carry out a coating PQT for
each pipe diameter on max. wall thickness, for each type of pipe, for each coating material
combination, and for each plant, to prove that his plant, materials, and coating procedures result
in a quality of end product conforming to the properties stated in clause 3.2, relevant standards,
specifications and material manufacturer's recommendations. Contractor shall give seven (7)
working days‟ notice to witness all procedures and tests.
A batch representing a normal production run, typically 15 pipes, shall be coated in accordance
with the approved coating procedure and the coating operations witnessed by Company
Representative. Out of these pipes, at least one pipe shall be coated partly with epoxy and
partly with both epoxy and adhesive layers.
At least 5 (five) test pipes shall be selected by Company Representative for coating procedure
approval tests and shall be subjected to procedure qualification testing as described hereinafter.
Company Representative shall witness all tests. Out of 5 (five) test pipes, 1 (one) pipe partly
coated with epoxy and partly coated with both epoxy and adhesive layers shall be included.
Remaining 4 (four) test pipes shall have all three layers.
During PQT, the Contractor shall qualify various procedures forming a part of coating
operations as detailed subsequently.

4.2.2. PIPE PRE-HEATING

Temperature variation due to in-coming pipe temperature, line speed variation, pipe wall
thickness variation, emissivity, interruptions, etc. shall be established and documented during
PQT stage .Proper functioning of pipe temperature monitoring and recording system including
audible alarm shall be demonstrated.

4.2.3. SURFACE PREPARATION

The procedure to clean and prepare the pipe surface shall be in accordance with the
requirements of this specification. The ratio of shot to grit shall be established during procedure
qualification testing, such that the resultant surface profile is not dished and rounded. The
qualification shall be performed through a visual inspection, measurement of roughness and
check of the presence of dust on the abrasive blast cleaned pipe surface.

4.2.4. PIPE HEATING AND EPOXY POWDER APPLICATION

Parameters affecting pipe heating such as rating and frequency of induction heater or number
of burners in case of gas heating vis-à-vis pipe thickness and line speed and epoxy application
such as air pressure in the spray guns, dew point of air, pipe surface temperature, etc. shall be
established and documented so that specified minimum epoxy thickness and other coating
quality requirements are met with. In addition quality and quantity of epoxy that can be recycled
shall be established. For this purpose, samples of reclaimed epoxy powder shall be drawn and
subjected to visual examination, thermal analysis and moisture content testing. Only if the
properties of reclaimed epoxy are established to be within manufacturer specified range,
reclaimed epoxy shall be allowed to be recycled. Contractor shall also establish maximum
quantity of reclaimed epoxy that can be mixed with fresh epoxy without affecting quality of
coating.
4.2.5. ADHESIVE AND PE APPLICATION

Parameters affecting application of co-polymer adhesive and polyethylene layers such as line
speed, fusion bonded epoxy curing time and temperature of co-polymer adhesive and
polyethylene, quenching time and temperature, etc. shall be established and documented so
that specified minimum coating thickness and other quality requirements specified are met with.

4.2.6. TESTING

At least five (5) test pipes, including one (1) pipe partly coated with epoxy and one (1) pipe
partly coated with both epoxy and adhesive layers, shall be randomly selected by Company
Representative for carrying out PQT as per Table 5.3.1. The procedure shall be considered
qualified only when all tests as per Table 5.3.1 meet specified requirements. In case any of the
tests fails to comply specified requirement, coating application procedure shall be re-qualified
after necessary modifications. Company representative shall witness all tests.
All pipes coated during coating application procedure qualification shall be subjected to same
visual and other inspection as required during production coating. Acceptance criteria shall be
as specified under Section 5.4 of this specification.
Company reserves the right to conduct any or all the tests required for Coating Application
Procedure Qualification through an independent laboratory or agency, at the cost of the
Contractor, when in Companys opinion, the test results are deemed suspect. Company decision
in this regard shall be final.

4.2.7. PQT REPORT

Upon completion of the testing, the Contractor shall prepare and submit to the Company a
detailed report covering operating and controlling parameters, inspection and test reports and
material test certificates for Company approval. Only upon written approval from Company, the
Contractor shall commence production coating.

4.2.8. DISPOSAL OF TEST PIPES

On completion of coating application procedure qualification, the Contractor shall completely

remove the coating on all remaining intact pipes coated for the purpose of procedure
qualification and recycle them for production coating.

4.2.9. PROCEDURE RE-QUALIFICATION

The coating application procedure shall be re-qualified in the event of, but not limited to, the
following:
- Every time there is a change in the previously qualified procedure
- Every time there is a change in the epoxy/adhesive/polyethylene manufacturer and
change in formulation of any of the material.
- Every time the coating yard is shifted from one location to another location/ critical
equipment viz. induction heater, epoxy spray system, extruder etc. are changed.
- Any time when, in Companys opinion, the properties are deemed to be suspect
during regular production tests.

4.3. PIPE SURFACE PREPARATION

4.3.1. PRE-INSPECTION

Prior to cleaning operation, Contractor shall visually examine the pipes and shall ensure that all
defects, flats and other damages have been repaired or removed. The Contractor shall also
remove marking stickers, if any, present within the pipe. Record shall be kept of such marking
on the stickers to ensure traceability of pipe after coating

4.3.2. REMOVAL OF SURFACE CONTAMINANTS

Any oil, grease, salt or other contaminants detrimental to the formation of a good coating bond
or coating quality shall be removed prior to coating application. Contaminants may be removed
by the use of non-oily solvents. Gasoline or kerosene shall not be used for this purpose. Visible
oil and grease spots shall be removed by solvent wiping. Solvent cleaning shall be in
accordance with SSPC-SP1. Steel surface shall be allowed to dry before abrasive cleaning.
4.3.3. PRE-HEATING
o
The pipe shall be preheated prior to blast cleaning to a temperature at least 5 C above the dew
point to remove moisture and to raise slivers and other similar surface defects.

4.3.4. BLAST CLEANING

Prior to blasting operation, pipe ends shall be closed to prevent any abrasives and/or foreign
material from entering the pipe‟s interior during blasting. Alternatively the Contractor may link
the pipes suitably together to prevent the entry of any short/grit into the pipe. Pipe shall be
handled in a manner so as to prevent any damage to bevels.
The external surface of the pipe shall be cleaned by dry abrasive blast cleaning unit(s). The
abrasive blast cleaning unit(s) shall have an effective dust collection system to ensure total
removal of dust generated during blast cleaning from the pipe surface. Traps, separators and
filters shall be checked for condensed water and oil at the start of each shift and emptied and
cleaned regularly. Metallic abrasives shall be continuously sieved to remove “fines” and
“contaminants” and the quality checked at every four hours.
At no time shall the blast cleaning be performed when the relative humidity exceeds 85% or
when the steel temperature is less than 5°C higher than the dew point, unless the pipes are
preheated to a temperature of 65°C to 85°C.
The ratio of shots and grits in abrasives used for blast cleaning shall be such that the resulting
surface profile does not appear dished and rounded when viewed under 30X magnification and
specified anchor pattern is achieved.
Any abrasive and/or foreign material in the pipe shall be removed before further coating
operations. Immediately after the blast cleaning operation, all dust and grit shall be removed
from inside of the pipe by a combination of air blast, brushing and vacuum cleaning.

4.3.5. REPAIR OF SURFACE IMPERFECTIONS

All surface defects visible on blast cleaned pipes such as slivers, scab, burns, laminations, weld
spatters, gouges, scores, indentations, slugs or any other defect considered injurious to the
coating integrity shall be removed by filing or grinding in consultation with Company
Representative.
The method employed to remove surface defects shall not burnish or destroy the anchor pattern
or contaminate the surface with oil or water. Pipe repairs by grinding resulting in ground areas
more than 50 mm in diameter shall be re-blasted.
After any grinding or mechanical repairs, the remaining wall thickness shall be checked and any
pipe having wall thickness less than 95% of specified wall thickness shall be kept aside and
disposed off as per the instructions of Company Representative.

4.3.6. ACCEPTANCE OF SURFACE PREPARATION

Upon Completion of the blasting operations, the Contractors quality control supervisor shall
inspect the pipes for their compliance to requirements specified below:
 The surface finish after blast cleaning shall conform to near white metal finish i.e.
Sa 2 ½ of Swedish Standard SIS 055900.

 Anchor pattern/roughness profile shall be between 50 to 70 microns.
 Dust contamination shall be rating max. 2 as per ISO 8502-3.

 Salt content shall be less than 2 µg/cm2.

Pipes complying above requirements shall be accepted. Pipes that don‟t comply with above
requirements shall be returned for re-blasting.
In order to ensure that pipes with improper surface preparation or unacceptable defects are not
processed further, provisions shall be available to lift the pipes from inspection stand.

4.3.7. ELAPSED TIME FOR COATING APPLICATION

Maximum allowable elapsed time between completion of the blasting operations and
commencement of pipe heating for coating application shall be as given below:

Relative Humidity % Maximum Allowable Elapsed Time

>80 2 hours
70 to 80 3 hours
<70 4 hours
 Pipes that have exceeded the allowable elapsed time shall be returned for complete re-blasting.
Any pipe showing flash rusting shall be re-blasted even if the above conditions have not been
exceeded.
Pipe handling between abrasive blasting and pipe coating shall not damage the surface profile
achieved during blasting. Any pipe having damage to the surface exceeding 200mm² shall be
sent for re-blasting.

4.4. COATING APPLICATION

The external surface of the cleaned pipe conforming to clause 4.3 of this specification shall be
immediately coated with 3-layer extruded polyethylene coating in accordance with the
procedures approved by Company, relevant standards and this specification. In general the
procedure shall be as follows:

4.4.1. PIPE HEATING

a. Immediately prior to heating of pipe, all dust and grit shall be removed from inside of the pipe
by combination of air blast, brushing and vacuum cleaning. Suitable arrangement shall be
made to protect the bevel ends from getting damaged during the coating operation
b. Induction heater or gas fired heating shall be used for heating the pipe. The method shall be
capable of maintaining uniform temperature along the total length of the pipe, and shall be
such that it shall not contaminate the surface to be coated. In case of induction heating,
appropriate frequency shall be used to ensure `deep heating' and intense skin heating is
avoided. Gas fired heating system shall be well adjusted so that no combustion products are
deposited on the steel surface. This shall be demonstrated on bare pipes prior to start of
PQT. Oxidation of the cleaned pipe surfaces prior to coating (in the form of blueing or other
apparent oxide formation) is not acceptable.
c. External surface of the pipe shall be heated to about 190 °C or within a temperature range
(min. to max.) as recommended by the powder manufacturer. Required pipe temperature
shall be maintained as it enters the coating chamber.
d. Temperature of the pipe surface shall be continuously monitored & recorded by using
suitable instruments such as infrared sensors, contact thermometers, thermocouples etc.
The recording method shall allow correlating each line pipe. The monitoring instrument shall
be able to raise an alarm/activate audio system (hooter) in the event of tripping of induction
heater/ gas fired heater or in the event of pipe temperature being outside the range
recommended by the manufacturer. Any deviation from the application temperature range
recommended by manufacturer shall be rectified. If immediate rectification is not feasible,
the production shall be stopped until cause of deviation has been removed. Any pipe coated
during the duration of temperature deviation shall be identified by marking and rejected.
Such rejected pipes shall be stripped, re-cleaned and recoated.
e. Temperature measuring & monitoring equipment shall be calibrated twice every shift and/or
as per Company Representative's instruction.
f. Contractor shall ensure that pipe surface emissivity variations are minimized during pipe
heating. To avoid significant variance, more than once blasted joints should be coated at the
same time and not mixed with joints blasted only once
4.2. APPLICATION OF EPOXY, ADHESIVE AND POLYETHYLENE

The heated pipe surface shall be applied with following coating layers:

Minimum Coating Thickness In mm

Specified Pipe OD, Inches (mm) [3, 4]
Total
[1] [2]
FBE Adhesive PE [2, 3] Normal Reinforced
Type (v)
Type (n)

Up to 4½ (114.3) 0.15 0.2 1.45 1.8 2.5

Over 4½ (114.3) Up to 10¾ 2.7

0.15 0.2 1.65 2.0
(273.1)

Over 10¾ (273.1) to below 0.15 0.2 1.85 2.2 2.9

20 (508.0)

From 20 (508.0) to below 32

0.15 0.2 2.15 2.5 3.2
(813.0)

From 32 (813.0) and above 0.15 0.2 2.65 3.0 3.7

Notes:
1. Epoxy shall be applied by electrostatic spray method the maximum thickness shall not
exceed the epoxy thickness specified by epoxy powder manufacturer.
2. Grafted co-polymer adhesive and polyethylene layers shall be applied by extrusion.
3. In case HDPE is used as top coat, 10% reduction in PE top coat thickness is permissible
4. Unless indicated otherwise in Purchase Order, total thickness corresponding to Normal Type
(n) coating shall be applicable.

4.4.3 EPOXY APPLICATION

Epoxy powder shall be sprayed on to heated pipe using electrostatic spray technique.
Only dry air, free of oil and moisture shall be used in the coating chamber and epoxy spraying
system. Dew point of air supplied to epoxy spray/recycling system shall be at least - 40°C.
Air pressure in the epoxy spray guns shall be controlled, continuously monitored and recorded
at least four times per working shift (maximum 12 hours). The air pressure shall be controlled
within the limits established during coating application procedure qualification. The monitoring
system shall be able capable of raising an alarm / activate audio system (hooter) in the event of
change in air pressure beyond the set limits. All pipes coated during the duration of air pressure
deviation beyond set limits shall be stripped and recoated.
The recycled epoxy powder mixing with fresh epoxy powder shall be permitted subject to
following conditions:
 Quality of recycled epoxy powder has been established to be acceptable during
coating application procedure qualification.

 Proportion of the recycled epoxy powder in the working mix does not exceed
that established during coating application procedure qualification or 20% at a
time, whichever is less.

 Quality of the recycled powder is checked minimum once per working shift
(maximum 12 hours) by visual examination, thermal analysis & moisture
content testing and properties of recycled epoxy are established to be within
manufacturer specified range.
4.4.4 ADHESIVE AND POLYETHYLENE LAYER APPLICATION

Extruded adhesive layer shall be applied before gel time of the epoxy coating has elapsed and
within the window recommended by the manufacturer. The Contractor shall establish, to the
satisfaction of the Company Representative, that the adhesive is applied within the gel time
window of epoxy and at the temperature recommended by the adhesive manufacturer. The
Contractor shall state the minimum and maximum time interval between epoxy and adhesive
application at the proposed pre-heat temperature and line speed.

Extruded polyethylene layer shall be applied over the adhesive layer within the time limit
established during PQT stage and within the time/temperature range recommended by the
manufacturer. The extrusion temperatures of the adhesive and polyethylene shall be
continuously recorded. The monitoring instruments shall be independent of the temperature
control equipment. The instruments shall be calibrated prior to start of each shift.

The extrusion temperatures of the adhesive and polyethylene shall be continuously monitored
and recorded at least four times per working shift (maximum 12 hours). The monitoring
instruments shall be independent of the temperature control equipment. The instruments shall
be calibrated prior to start of each shift.

Contractor shall ensure that there is no entrapment of air or void formation along the seam weld
(where applicable) during application of coating.

Resultant coating shall have a uniform gloss and appearance and shall be free from air
bubbles, wrinkles, irregularities, discontinuities, separation between layers of polyethylene &
adhesive, etc.

The coated pipe shall be subsequently quenched and cooled in water for a period that shall
sufficiently lower the temperature of pipe coating to allow handling and inspection.

4.4.5. COATING CUT BACK

Coating and/or adhesive shall terminate 120 mm +20 / -0 mm from pipe ends. Contractor shall
adopt mechanical brushing for termination of the coating at pipe ends. Edge of the coating shall
be shaped to form a bevel angle of 30º to 45º.

4.4.6. REJECTION OF COATING

Failure of the Contractor to comply with above coating application requirements including
approved coating application procedure shall result in rejection of the coating applied and the
Contractor shall remove the coating from such coated pipes and recycle the pipes through
entire coating process

5.0 INSPECTION AND TESTING

5.1. GENERAL

The Contractor shall establish and maintain such quality assurance system as are necessary to
ensure that goods or services supplied comply in all respects with the requirements of this
specification. The minimum inspection and testing to be performed shall be as indicated
subsequently herein. Pipes with unacceptable coating shall be stripped and recycled.

5.2. TESTING OF MATERIALS

One week prior to use, Contractor shall carry out following tests on samples randomly drawn by
Company Representative from each batch of raw materials proposed to be used for coating
application in the next week’s production to establish compliance with coating material
manufacturers test certificates.
 Table 5.2 : Coating Material Testing

Test method and acceptance

Material Test
criteria
Gel Time, Cure Time,
Epoxy Powder Moisture Analysis and Thermal As per CSA standard Z245.20.02
Characteristics (Tg1,Tg2 ,∆H)
Specific Gravity, Melt Flow Rate(Condition As per Section 3.2.3 (b) of this
Adhesive 190/2.16), Vicat Softening Point specification

Melt Flow Rate(Condition 190/2.16)

Specific Gravity, As per Section 3.2.4 (a) of this

Polyethylene specification
Vicat Softening Point,

Moisture Content,

Oxidative Induction time

In case of failure of any of the above tests, batch of material from which samples are drawn
shall be tested for all properties specified under section3.2.1, 3.2.2 and 3.2.3 (except ESCR) of
this specification. If all tests results comply with required properties, the batch shall be accepted
for coating. If any of the tests fail to comply with required properties, batch of material that fails
to comply shall be rejected

5.3. TESTING OF COATING

Testing requirements and frequency of testing during PQT and production coating shall be as
per Table 5.3.1 and Table 5.3.2 respectively. The method of testing, acceptance criteria and re-
testing shall be as described hereinafter.

Table 5.3.1 : Testing Requirement for Coating Procedure Qualification

Sl. Test Testing Test Method and Remarks

No. Frequency acceptance
Criteria
a Degree of Cure Two Test Pipe Section 5.3.1 Note 1
b Adhesion Tests One Test Pipe Section 5.3.2 Note 2
c 2.5° Flexibility Test One Test Pipe Section 5.3.3 Note 2
d Cross Section and Interface One Test Pipe Section 5.3.4 Note 2
Porosity Test
e Bond Strength Three Test Pipes Section 5.3.5 Note 3
f Impact Strength Three Test Pipes Section 5.3.6 Note 4
g Indentation Hardness All Test Pipes Section 5.3.7 Note 4
h Percentage Elongation at All Test Pipes Section 5.3.8 Note 4
Failure
i Air Entrapment Test All Test Pipes Section 5.3.10 Note 4
Thickness Measurements
j Epoxy Layer Adhesive Layer One Test Pipe Section 5.3.11 Note 2
Total Coating Thickness
k Holiday Inspection All Coated Pipes Section 5.3.12 Note 5
Cathodic Disbandment Test
i 30 days test at (+) 65° C One Test Pipe Section 5.3.9 Note 3, 6
48 hour test at (+)65° C
Notes:
1. Test shall be carried out on one partly coated test pipe one test pipe coated with all three
layers.
2. Test shall be carried out on test pipe partly coated pipe
3. Test shall be carried out on test pipes coated with all three layers.
4. Test shall be carried out on all test pipes coated with all three layers
5. Test shall be carried out on all pipes coated with all three layers.
6. Both 30 days and 48 hour tests shall be carried out for a particular material combination and
pipe diameter. In case results for 30 days test are satisfactory, subsequent coating
application procedure qualification for different pipe size with same coating material
combination, 48 hours test shall be acceptable

 Working shift shall be maximum 12 hours.

 In case the test fails to comply the specified requirement, preceding and
succeeding coated pipes shall be tested. If both pipes pass the test, then the
remainder of the coated pipes in the lot shall be accepted. If tests on any one of the
two pipes fail to meet the specified requirements then either all pipes shall be
individually tested or entire lot rejected at the option of the Contractor. All rejected
coated pipes shall be stripped and re-coated.
 In case of failure of test, the test shall be repeated using two additional samples
taken from same end of pipe. In case both test pass, the pipes shall be accepted. If
one or both tests fail all pipes coated after the previous acceptable test and prior to
next acceptable test shall be reject. All rejected coated pipes shall be stripped and
re-coated.
 Pipes not meeting the specified requirements shall be rejected. All rejected coated
pipes shall be stripped and re-coated

5.3.1. DEGREE OF CURE

The samples for epoxy testing shall be taken from cut back area, separated from
adhesive and polyethylene layer by silicon coated sulphite paper, in case of fully coated
pipe and from epoxy coated section of pipe partly coated pipe during application
procedure qualification.

Epoxy samples (minimum 4 no.) shall be removed from the coated pipe using hammer
and cold chisel and the samples shall be taken for cure test using DSC procedure. Care
shall be taken to remove the samples of full film thickness avoiding inclusion of steel
debris. Glass transition temperature differential (∆Tg) and % cure (∆H) shall comply
with the requirements of Section 3.2.5 (i).

5.3.2. ADHESION TESTS

For Pre Qualification Testing (PQT)

Adhesive test (24 hrs or 48 hrs) shall be carried out on epoxy coated pipe. Test method,
no. of test specimen and acceptance criteria shall comply CSA Z.245.20-02, Table 4.
 For PQT and Regular Production Testing

Adhesion of epoxy layer shall be determined at ambient temperature by the “St Andrews
Cross” method i.e. by cutting two straight lines through the epoxy layer with a sharp knife at
the cut -back portion of the pipe from which the Degree of Cure test has been carried out. The
incisions shall intersect at an angle of 30°/150°. The epoxy coating shall resist disbondment
from the steel when attempts are made to flick/lift the coating from the 30° angle with a sharp
knife.

5.3.3. 2.5° FLEXIBILITY TEST

Samples for 2.5° Flexibility test shall be taken as indicated under Section 5.3.1. 2.5° Flexibility test shall
be carried out at a test temperature of 0°C. Test method, number of test specimen and acceptance
criteria shall comply CSA Z.245.20-02, Table 4.

5.3.4. CROSS-SECTION & INTERFACE POROSITY TEST

Samples for cross section porosity and interface porosity test shall be taken as indicated under Section
5.3.1. Cross section porosity and interface porosity test method, number of test specimen and
acceptance criteria shall comply CSA Z.245.20-02, Table 4.

5.3.5. BOND STRENGTH TEST

One test shall be performed at cut back portion at each end and one in the middle of test pipe for each
specified temperature (i.e. total 6 tests per pipe).
Test method and acceptance criteria shall be as per Section 3.2.5, Sl. No. (a) Of this specification. The
coating system shall disbond/ separate cohesively either in adhesive layer or in polyethylene layer.
Majority of the peeled off area on the pipe shall show presence of adhesive. Disbondment/separation at
epoxy to steel interface or epoxy / adhesive interface or adhesive / polyethylene interface shall not be
permitted. The failure mode shall also be recorded for each test.

5.3.6. IMPACT STRENGTH TEST

Test method and acceptance criteria shall be as per Section 3.2.5, Sl. No. (b) of this specification.
A minimum of 30 impacts, located equidistant along the length of test pipe, shall be performed.
Immediately after testing, the test area shall be subjected to holiday detection. The pipe shall be
rejected if any holiday is noted in the test area.

5.3.7. INDENTATION HARDNESS

Test method and acceptance criteria shall be as per Section 3.2.5, Sl. No. (c) of this specification.
One test shall be performed at cut back portion at each of test pipe for each specified temperature (i.e.
total 4 tests per pipe).

5.3.8. PERCENTAGE ELONGATION AT FAILURE

Six samples from each test pipe shall be tested in accordance with Section 3.2.5, Sl. No. (d) of this
Specification. Only one sample per pipe may fail.

5.3.9. CATHODIC DISBONDMENT TEST

Test shall be carried out on pipe having all three layers as per Section 3.2.5, Sl. No. (h) of
this Specification.

5.3.10. AIR ENTRAPMENT TEST

Air entrapment test shall be carried out by examining strips of coating removed from coated pipe under
30X magnification hand held microscope for presence of voids.

Strips shall be obtained from the cut back area of pipe. Additional strips shall be taken from weld area
when applicable. Alternatively strips from bond strength tests may be used.

Bond strength strip shall be viewed from the side and at the failure interface. Utility knife shall be used
to cut the edge of the coating to a 45° angle at pipe and cut surface viewed under microscope. Similar
 examination shall be done in the coating strip obtained from cut back area.

The polyethylene and adhesive layers shall have no more than 10% of the observed area taken up with
air entrapment (porosity or bubbles). Air entrapment shall not occupy more than 10% of the thickness in
each case. Bubbles shall not link together to provide a moisture path to the epoxy layer.

5.3.11. THICKNESS MEASUREMENTS

EPOXY AND ADHESIVE LAYER

Epoxy and adhesive layer thickness shall be checked at one meter spacing at 3, 6, 9 and 12 o’clock
positions. All readings must meet the minimum thickness specified under section 4.4.3. Epoxy and
adhesive layer thickness shall be measured on pipe partly coated with epoxy and partly coated with
epoxy and adhesive.

TOTAL COATING THICKNESS

The coating thickness shall be determined by taking at least 10 measurements at locations uniformly
distributed over the length and periphery of each pipe. In case of welded pipes, five of the above
readings shall be made at the apex of the weld seam, uniformly distributed over the length of the coated
pipe

5.3.12. HOLIDAY DETECTION

Each coated pipe length shall be checked over 100% of coated surface by means of a “holiday
detector” of a type approved by Company for detecting holidays in the finished coating.
The holiday detector shall be a low pulse D.C. full circle electronic detector with audible alarm and
precise voltage control complying with DIN VDE 0433 Part 2.

Holiday detector shall be calibrated at least once every 4 hours of production. Contractor shall have
necessary instruments or devices for calibrating the holiday detector.

Travel speed during holiday inspection shall be as recommended by the manufacturer of holiday
detector.

The holiday detector set voltage and acceptance criteria shall be as follows:

ONLY EPOXY / EPOXY AND ADHESIVE COATED PIPES

Only epoxy coated section shall be subject to holiday inspection at a test voltage set to exceed 5V /
micron of epoxy thickness. Section of pipe coated with both epoxy and adhesive shall be tested at a
voltage of 25kV. No holidays are permitted.

PIPE COATED WITH ALL THREE LAYERS

The coated pipe shall be inspected with the holiday detector set at minimum 25kV.

Coated pipe shall be rejected if more than one (1) holiday & area more than 100 cm² in size are
detected in its length attributable to coating process.
2
Coated pipe with a single holiday of an area equal or less than 100cm shall be accepted after repair.

In case more than 10% of coated pipes per shift production are rejected on account of holidays, the
Contractor shall stop production and make a detailed investigation and submit a report to the Company
representative on the probable cause(s) for the holidays. Production shall restart only after such a
cause has been rectified.

5.4 REPAIR OF COATING DAMAGES DUE TO TESTING

Damages occurring to pipe coating during the above tests shall be repaired in accordance with the
Section 7 of this specification
5.5 VISUAL INSPECTION

Pipes shall be visually inspected throughout the coating process from incoming bare pipe to finished
coated pipes as described herein below:

5.5.1. INSPECTION OF INCOMING PIPES

All incoming pipes, before any coating application process starts, shall be examined visually for any
surface defects such as split seams, dents, gouges, slivers or other imperfections that would make the
pipe unsuitable for use. Pipes with such defects shall be repaired in accordance with approved
procedure before they are released for further processing.

5.5.2. INSPECTION OF BLAST CLEANED PIPES

Surface of pipes after blast cleaning shall be examined for any defects injurious to coating application.
Surface profile shall be examined by using suitable instrument such as surface profile depth gauge for
compliance to anchor pattern requirements. In addition the pipe surface shall be checked for the degree
of cleanliness (Sa 2½), degree of dust and shape of profile.
In addition, inside surface of the pipe shall also be visually examined for presence of any foreign
material or shots and grit (free or embedded/sticking to pipe inside surface). Any foreign material or
shots/grit present in the pipe shall be completely removed by suitable means (mechanical brush, high
pressure air jets, by tilting of pipe etc.).
The blast-cleaned surface shall not be contaminated with dirt, dust, metal particles, oil, water or any
other foreign material, nor shall the surface or its anchor pattern be scarred or burnished.

5.5.3. INSPECTION OF COATED PIPES

Each coated pipe shall be visually checked for imperfections and irregularities of the coating.
The resultant coating shall have a uniform appearance with natural colour & gloss and shall be free
from air bubbles, blisters, wrinkles, scratches, engravings, cuts, swellings, disbonded zones, tears,
voids, irregularities, discontinuities and separation between layers of FBE/adhesive/PE. Special
attention shall be paid to the areas adjacent to the weld seam (if applicable). Coating surface shall not
be physically damaged or contaminated with any foreign material such as dirt, metal particles, coating
debris during application, curing, and handling process.

5.6 SOLUBLE SALT MEASUREMENTS

Chlorides and ferrous salts present on pipe surface that can affect the coating performance shall be
monitored prior to application of coating.
After blast cleaning, all pipes shall be tested for salt contamination. One test shall be carried out at each
end of each pipe using salt meter (SCM 400 or approved equivalent). The acceptance criteria shall be 2
2 2
µg/cm . Any pipe having salt contamination exceeding 2 µg/cm shall be treated by phosphoric acid
wash followed by de-ionized water wash in accordance with the recommendations of the manufacturer.
The Contractor shall submit a detailed procedure for phosphoric acid wash for Company approval.

6.0 HANDLING, TRANSPORTATION AND STORAGE

6.1. The Contractor shall be fully responsible for the pipe and for the pipe identification marking from the
time of "taking over" of bare pipe from Company until such time that the coated line pipes are 'handed
over' and/or installed in the permanent installation as the case may be according to the provisions of the
CONTRACT.

At the time of "taking over" of bare pipes Contractor shall inspect and record all the relevant details
referred above including pipe defects in the presence of Company. All pipes shall be checked for bevel
damages, weld seam height, dents, gouges, corrosion and other damages. Company Representative
shall decide whether pipe defects / damages are suitable for repair. Damage to the pipes that occur
after the Contractor has taken delivery such as dents, flats, or damage to the weld ends shall be cut off
or removed and pipes re-bevelled and repaired again as necessary. The cost of this work, as well as
that of the pipe lost in cutting and repair shall be to the Contractor's account. All such works shall be
carried out after written approval of the Company. Any reduction in length shall be indicated in the
Contractor's pipe tracking system.
6.2. The Contractor shall unload, load, stockpile and transport the bare pipes within the coating plant(s)
using suitable means and in a manner to avoid damage to pipes.

The Contractor shall stockpile the bare pipes at the storage area of the coating plant. The Contractor
shall prepare and furnish to Company a procedure/calculation generally in compliance with API RP-5L1
for stacking of pipes of individual sizes, which shall be approved by Company prior to commencement.

6.3. The Contractor shall load, unload, transport and stockpile the coated pipes within the coating plant
using approved suitable means and in a manner to avoid damage to the pipe and coating. The
Company shall approve such procedure prior to commencement of work.

6.4. Coated pipes maybe handled by means of slings and belts of proper width (minimum 60 mm) made of
non- abrasive/non-metallic materials. In this case, pipes to be stacked shall be separated row by row to
avoid damages by rubbing the coated surface in the process of taking off the slings. Use of round
sectional slings is prohibited. Forklifts may be used provided that the arms of the forklift are covered
with suitable pads, preferably rubber.

6.5. Bare/coated pipes at all times shall be stacked completely clear from the ground, at least 300 mm, so
that the bottom rows of pipes remain free from any surface water. The pipes shall be stacked at a slope
so that driving rain does not collect inside the pipe. Bare/coated pipes may be stacked by placing them
on ridges of sand free from stones and covered with a plastic film or on wooden supports provided with
suitable cover. This cover can be of dry, germ free straw covered with plastic film, otherwise foam
rubber may be used. The supports shall be spaced in such a manner as to avoid permanent bending of
the pipes.

Stacks shall consist of limited number of layers such that the pressure exercised by the pipe's own
weight does not cause damages to the coating. Contractor shall submit calculations for Company
approval in this regard. Each pipe section shall be separated by means of spacers suitably spaced for
this purpose. Stacks shall be suitably secured against falling down and shall consist of pipe sections
having the same diameter and wall thickness. The weld seam of pipes shall be positioned always in a
manner so as not to touch the adjacent pipes.
The ends of the pipes during handling and stacking shall always be protected with bevel protectors.

6.6. The lorries used for transportation shall be equipped with adequate pipe supports having as many
round hollow beds as there are pipes to be placed on the bottom of the lorry bed. Total width of the
supports shall be at least 5% of the pipe length and min. 2 no. support shall be provided. These
supports shall be lined with a rubber protection and shall be spaced in a manner as to support equal
load from the pipes the rubber protection must be free from all nails and staples where pipes are in
contact. The second layer and all following layers shall be separated from the other with adequate
number of separating layers of protective material such as straw in plastic covers or mineral wool strips
or equivalent, to avoid direct touch between the coated pipes.

All stanchions of Lorries used for transportation shall be covered by non-abrasive material like rubber
belts or equivalent. Care shall be exercised to properly cover the top of the stanchions and other
positions such as reinforcement of the truck body, rivets, etc. to prevent damage to the coated surface.
Slings or non-metallic straps shall be used for securing loads during transportation. They shall be
suitably padded at the contact points with the pipe

6.7. Materials other than pipes and which are susceptible of deteriorating or suffering from damages
especially due to humidity, exposure to high thermal excursions or other adverse weather conditions,
shall be suitably stored and protected. Deteriorated materials shall not be used and shall be replaced
at Contractor's expenses. These materials shall always be handled during loading, unloading and
storage in a manner so as to prevent any damage, alteration and dispersion. When supplied in
containers and envelopes, they shall not be dropped or thrown, or removed by means of hooks, both
during the handling operations till their complete use. During unloading, transport and utilization, any
contact with water, earth, crushed stone and any other foreign material shall be carefully avoided.
 Contractor shall strictly follow Manufacturer's instructions regarding storage temperature and methods
for volatile materials that are susceptible to change in properties and characteristics due to unsuitable
storage. If necessary the Contractor shall provide for a proper conditioning.

6.8. In case of any marine transportation of bare/coated line pipes involved, the same shall be carried out
in compliance with API RP 5LW. Contractor shall furnish all details pertaining to marine transportation
including drawings of cargo barges, storing/stacking, sea fastening of pipes on the barges/marine
vessels to the company for approval prior to undertaking such transportation works. In addition
contractor shall also carry out requisite analyses considering the proposed transportation scheme and
establish the same is safe and stable. On-deck overseas shipment shall not be allowed.

7.0 REPAIR OF COATING AND FINAL ACCEPTANCE

7.1. COATING REPAIR

Contractor shall submit and qualify a comprehensive repair procedure for carrying out repairs of
defects. The procedure shall be subject to approval of Company. The repair procedure shall cover
application over bare as well as over coated pipe surfaces.
Testing of repairs shall be in the same form as testing production coating. All repairs shall result in a
coating thickness no less than the parent coating thickness. Defects, repairs and acceptability criteria
shall be as follows:
 Pipes showing porosities or very small damage not detected during holiday test and having a
2
surface area less than 0.5cm or linear damage (cut) of less than 3 cm, and does not expose
bare steel, shall be repaired by stick using material of same quality as coating. 

 Damage to coating caused during handling such as scratches, cuts, dents, gouges, not
detected during holiday test, having a total reduced thickness on the damaged portion of not
less than 2.0 mm and an area not exceeding 20 cm2 shall be repaired by applying a heat
shrink patch without exposing bare metal surface.

 Defects exceeding the sizes as indicated above or any holidays of size less than 300 mm
shall be repaired using heat shrink patch. The defect area shall be exposed up to bare metal
prior to application of heat shrink patch

 Defects exceeding the above and in number not exceeding 2 per pipe and linear length not
exceeding 500 mm shall be repaired using heat shrinkable sleeves of HTLP 80 or equivalent. 

 Pipes with bigger damage shall be stripped and recoated. 

 In case of coating defect close to coating cut back, Contractor shall remove the coating throughout
the entire circumference of the pipe down to the steel surface and increase the coating cut back
length. Now if the coating cut back exceeds 140 mm of linear length of pipe then the coating shall
be repaired by the use of heat shrink sleeves thereby making up the coating cut back length of 120
mm.

Notwithstanding the above, if any defect exceeds 70 mm from the original coating cut back
length, the entire coating shall be removed and the pipe shall be recycled through the entire
 coating procedure.
Irrespective of type of repair, the maximum numbers of repair of coating shall be as follows: 
2
 Holiday repair of size ≤ 100 cm attributable to process of coating application shall be
maximum one number per pipe.

 In addition to the above, defects to be repaired by heat shrink patch/sleeve shall be maximum
2 (two) per pipe.
Defects exceeding the above limits shall cause pipe coating rejection, stripping and recoating. The
above is exclusive of the repairs warranted due to testing as per this specification.
All repairs carried out to coating for whatever reason shall be to the account of Contractor.
Cosmetic damages occurring in the polyethylene layer only need not be repaired by exposing up to
steel surface, as deemed fit by the Company Representative. In any case the Contractor shall
establish his material, methods and procedure of repair that result in an acceptable quality of product
by testing and shall receive approval from Company prior to use.
 Testing of repairs shall be in the same form as testing coating. All repairs shall result in a coating
thickness no less than the parent coating thickness. Contractor shall test repairs to coating as and
when required by Company.

8.0 MARKING AND PIPE IDENTIFICATION

The Contractor shall preserve pipe identity by maintaining the identity of each joint of pipe. Final
markings shall be applied on the outside wall of the pipe at a maximum distance of 500 mm from the
end. The marking shall indicate, but not be limited to, the following information:
i. Pipe number, Heat number.
ii. Coated pipe number.
iii. Colour band.
iv. Diameter, wall thickness, weight and length.
v. Re attach barcode labels from inside of pipe, or replace labels.
vi. Any other information considered relevant by Purchaser.
Vii. Pipe manufacturer‟s name
Viii. Inspection Marks /Punch
Contractor shall obtain prior approval from Company for the marking procedure to be adopted.

9.0 PRODUCTION REPORT

Contractor shall prepare and maintain a detailed production reporting system, which shall provide a
detailed history of each pipe length. The Company shall provide pipe manufacturing data files (in MS
Excel format) to the Contractor. The pipe manufacturer data files shall, as a minimum, the contain the
following data:-
 Pipe number
 Heat number
 Pipe grade
 Diameter
 Length
 Wall thickness
 Pipe weight

Prior to acceptance of the pipe at the wharf, the Contractor in the presence of the Company
Representative shall identify and record any minor defects, such as dents, flats or damaged bevels,
found during the acceptance inspection. The Contractor shall be responsible for any subsequent
damage to the pipe.
The Contractor shall update the pipe data files received from pipe manufacturer by adding coating
data.
As a minimum, following data shall be added.
 Details of defect repairs, if any, carried out on the bare pipes received
 Coating material batch numbers
 Pre-qualification tests for raw materials
 Coating procedure qualification tests
 Coating material balance
 Coated pipe sampling details
 Coated pipe test results
 Coated pipe weight
 Coating defects
 Coating repairs
 Hold points
 Rejected pipe

10.0 QUALITY ASSURANCE

10.1. The Contractor shall have established within his organization and, shall operate for the contract, a
documented Quality System that ensures that the requirements of this specification are met in all
aspects. The Quality System shall be based upon ISO 9001/2 or equivalent.
10.2. The Contractor shall have established a Quality Assurance Group within its organization that shall be
responsible for reviewing the Quality System and ensuring that it is implemented.

10.3. The Contractor shall submit the procedures that comprise the Quality System to the Company for
agreement.

10.4. The Contractor's Quality System shall pay particular attention to the control of Suppliers and Sub-
contractors and shall ensure that the requirements of this specification are satisfied by the Suppliers
and Sub-contractors operating Quality system in their organization.

10.5. The Contractor shall, prior to the commencement of work, prepare and issue a Quality Plan for all of
the activities required satisfying the requirements of this specification. The plan shall include any sub-
contracted work, for which the sub-contractors Quality Plans shall be submitted. The plan shall be
sufficiently detailed to indicate sequentially for each discipline the requisite quality control, inspection,
testing and certification activities with reference to the relevant procedures and the acceptance
standards.

10.6. The Contractor's Quality system and associated procedures may, with due notice, be subject to formal
audits. The application of quality control by the Contractor will be monitored by the Company
Representatives who will witness and accept the inspection, testing and associated work required by
this specification.
ANNEXURE-I

LIST OF ACCEPTABLE COMBINATIONS OF COATING MATERIALS

The following combinations of coating materials are considered acceptable. In case any of the
combinations listed below are offered, details regarding properties of the offered materials need not
be furnished with bid. However, In the event of award of contract, Contractor shall furnish the
combination(s) proposed and re-confirmation of compatibility of the proposed combination (s) from
the raw materials Manufacturers.

Epoxy Powder Adhesive PE Compound

(Manufacturer) (Manufacturer) (Manufacturer)

CORRO-COAT EP-F 2001 FUSABOND 158D SCLAIR 35 BP HDPE

(JOTUN) (DUPONT) (NOVACOR)

PE 50-8190/8191
(BASF)
LUCALEN G3510H LUPOLEN 3652 D SW 00413
CORRO-COAT EP-F 2001 (BASF) (BASF)
(JOTUN)

PE 50-6109
(BASF)
ME 0420
CORRO-COAT EP-F 2001 HE 3450
(BOREALIS)
(JOTUN) (BOREALIS)

SCOTCHKOTE 226N
(3M)
ET 509 B
CORRO-COAT EP-F 2001 LE - 149 V
(S K CORPORATION)
(JOTUN) (S K CORPORATION)

Although the above combinations would be acceptable to Company, the responsibility of suitability
for application, performance and compliance to the coating system requirements shall
unconditionally lie with the Contractor
 STANDARD SPECIFICATION
FOR
CONSTRUCTION OF PIPELINE CROSSING ROADS, RAIL ROADS &
MINOR WATER CROSSINGS
ABBREVIATIONS:

ASME American Society of Mechanical Engineers

ASTM American Society of Testing of Materials

API American Petroleum Institute

OISD Oil Industry Safety Directorate

CONTENTS

1.0 SCOPE........................................................................................................................................................

2.0 REFERENCE CODES, STANDARDS AND SPECIFICATIONS ...................................

3.0 GENERAL .................................................................................................................................................

4.0 ROAD AND RAILROAD CROSSINGS ......................................................................................

5.0 MINOR WATER COURSE CROSSINGS ..................................................................................

6.0 CROSSING OF BURIED SERVICES ..........................................................................................

1.0 SCOPE
This specification covers the minimum requirements for the various activities to be carried
out by the Contractor for or about installation of pipelines crossing roads, railroads, minor
water courses and other services.

The provision of this specification are not applicable for pipelines crossing water courses,
which are specifically designated as “Major water Courses” in the CONTRACT.

This provision are formulated to protect the facilities crossed by the pipeline as well as to
provide adequate design for installation and operation of pipeline.

Requirements related to installation of pipeline crossing including, but not limited to site
preparation, supply of materials, string fabrication, joint coating application, boring /
jacking, testing, tie-in, clean-up, restoration and as-built drawing are addressed in this
specification.

2.0 REFERENCE CODES, STANDARDS AND SPECIFICATIONS

Reference has been made in this specification to the latest edition (edition enforce at the
time of floating the enquiry) of the following codes, standards and specifications.

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

B31.4 : Pipeline Transportation system for liquid
Hydrocarbon & other liquids.
B31.8 : Gas Transmission and Distribution Piping
Systems.
AMERICAN PETROLEUM INSTITUTE (API)
API RP 1102 : Recommended practice for liquid Petroleum
Pipeline Crossing Railroads and Highway
OIL INDUSTRY SAFETY DIRECTORATE (OISD)
STD 226 : Natural Gas Transmission Pipelines and City
Gas Distribution Networks
STD 141 : Design and Construction Requirements for
Cross Country Hydrocarbon Pipelines.
Part 192. Title 49 : Transportation of Natural and other Gases by
pipeline (US DOT-Pipeline safety standards).
Part 195 : Transportation of liquids by pipeline
(US-DOT-Pipeline safety stands)
SPECIFICATIONS
SS-PL-015 : Standards Specification for pipeline
construction (onshore)
SS-PL-012 : Specification for Hydrostatic Testing of Onshore
Pipeline.

2.1 In case of conflict between the requirements of above mentioned codes, standards,
specifications and practices, the most stringent requirement shall govern. In case of conflict
 between the requirements of this specification and that of the above referred codes,
standards, specification and practices, the requirements of this specification shall govern.

2.2 For the purpose of this specification the following definitions shall hold:

 Words „Shall‟ and „Must‟ where used indicate that a provision is mandatory.
 Words „Should' and `Will' where used indicate that a provision is not mandatory
but is recommended as good practice.

3.0 GENERAL
3.1 Crossing of roads, railroads, buried services, canals and minor water courses with
equipment and/ or personnel is allowed only after acquiring approval from the authorities
having jurisdiction and after making arrangements for safeguarding the roads, etc. and the
verges and/ or banks thereof and the buried services with appropriate provisions.

The carrier pipe shall be firmly supported on both sides of the crossing. The bottom of
trench and pit for at least 12 m length at approaches to crossing shall be graded and filled
with soil compacted up to 95% Proctor density to an elevation that will provide sufficient
continuous support to the carrier pipe. Earth or sand filled bags may be used to firmly
support the carrier pipe adjacent to the crossing. In case of cased crossing, carrier pipe
shall be supported in such a manner that it remains correctly aligned at the casing ends
during and after backfilling.

Highways, Main-Roads and Railroads and their verges and banks of water crossings are
not allowed to be used for loading, unloading or stacking of materials and/ or equipment.
For secondary roads, such loading/ unloading is permitted only after prior approval from
the concerned authorities. Contractor is not allowed to close or divert roads or
watercourses without prior approval from the company and the concerned authorities.
Contractor shall never unnecessarily hamper the users of the roads, railroads, buried
services and/ or watercourses. The water flow shall not be obstructed in any way.

3.2 Contractor shall submit the followings before start of any crossing works:

 Approval letter from concerned authorities

 Time Schedule
 Execution methodology with details of equipment
 Test procedure
 Manpower deployment
 Description of temporary works
 Design calculations for crossing (if any)
 Soil investigations etc.
 Construction drawings
Such works shall be without any extra cost to company.
3.3 SURVEYS AND INVESTIGATIONS

The Company may carry out surveys and soil investigations along pipeline route including
crossing locations. The details of the surveys, soil investigations and other data collected
by the Company shall be presented in the drawings and documents enclosed with the
Contract for the information of the Contractor.

The Contractor shall be deemed to have reviewed and satisfied himself with regard to the
details provided in the Contract. It shall be the responsibility of the Contractor to assess
requirement of any additional surveys and/ or soil investigations or any other data
collection that may be deemed necessary for proper execution of the works in accordance
with the drawings, specifications, other requirements of the Contract including
requirements of concerned Authorities.

The Contractor shall be responsible for carrying out survey, soil investigation and data
collection, as deemed necessary by the Contractor, for proper execution of the works. The
Company shall not provide any additional details in this regard.

Whenever specified in the contract, contractor shall carryout all geotechnical investigation
and Hydrological, scour calculate in case of water

3.4 PROTECTION OF UNDERGROUND UTILITIES

Contractor shall ensure that the crossing is not interfering with any of the existing
underground utilities. Should any damage to any utility/ structure occur, the Owner/
Authority concerned shall be contacted by the Contractor and repair shall be carried out
by the Contractor to entire satisfaction of the Owner/ Authority. All costs for reinstatement
or incidental to reinstatement shall be settled and paid by the Contractor.

3.5 MINIMUM COVER REQUIREMENT

Within the limits of bored crossings, unless noted otherwise on the Contract drawings,
minimum requirements of cover indicated in Table-1 shall be satisfied.

Table 1 – Minimum Cover Requirements for Crossings

Utility Crossed Minimum Cover
National Highways and Expressways 1.2 m from top of road to top of pipe
State Highways 1.2 m from top of road to top of pipe
Railroads 1.7 m from base of rail to top of pipe
Canal (Lined / Unlined) 1.5 m below the canal bed level
2.5 m (below scour depth/ Lowest bed level)
River
1.5 m in case of rocky strata

In case any additional cover over and above the above minimum cover is stipulated by the
Authorities, the Contractor shall ensure compliance with the requirements of the
Authorities.
3.6 HYDROSTATIC TESTING

Pipeline crossings for road, railroad, canals and rivers etc., shall be hydrostatically
pretested ex situ, prior to joint coating, whenever,

 Crossing is executed by boring of carrier pipe

 Casing pipe used in crossing installation
 River Crossing pipes which are to be continuously concrete weight coated (to be
tested prior to concrete coating).
 Whenever, in company's opinion, the repair of pipeline at crossing, in case of a
leak during final hydrostatic testing, would require inordinate amount of efforts
and/ or time
 Whenever pretesting is insisted upon by the Authorities having jurisdiction over
the utility crossed.
After installation, the pipeline shall be hydrostatically tested to a minimum test pressure
equal to 1.4 times the design pressure for gas pipeline and 1.25 times the design
pressure for liquid pipeline. The combined equivalent stress in the pipeline due to bending
and test pressure shall not exceed 95% of the SMYS of pipe material. Test pressure shall
be retained in the pipeline for minimum period of 2 hours. Test section shall be visually
examined for leaks/ defects, etc.

4.0 ROAD AND RAILROAD CROSSINGS

4.1 The work under crossings shall include necessary clearing, grading and trenching to
required depths and widths, welding of casing and carrier pipes, lowering-in, back filling,
clean-up, restoration to the original condition and further strengthening and protective
works, testing, installation of assemblies, insulators and seals, and temporary works such
as sheet piling, bridges etc.

The work shall be carried out in accordance with the approved drawings and job
standards, as directed by Company and to the satisfaction of Company and the
authorities having jurisdiction over the facility crossed. The work carried out for road and
railroad crossings shall meet the minimum requirements of API RP 1102.

Prior approval from the statutory authorities shall be obtained to lay the pipeline across
the highway/ road either by boring or by open-cut- method. Installation of the crossing
shall be by the method (i.e. boring/ open-cut) approved by Authorities having jurisdiction.
Railroad crossings shall always be bored/ jacked.

Before the installation work of crossings is started, the Contractor shall provide suitable
barricades, temporary bridge/ bypass work (especially where roads are open cut) with
railing, if required by Company for safety of traffic. Adequate traffic warning signals and/
or traffic lights and suitable diversions shall be provided as directed by Company/
Authority having jurisdiction over these areas. Such diversions shall not cross the pipeline
where it has already been installed, unless proper safeguarding at Company opinion is
ensured.
4.2 Boring/ jacking of carrier pipes for crossings is allowed only if the pipes for boring/ jacking
are provided with a suitable corrosion coating and Contractor remains liable for the
suitability of the pipe and weld coating of carrier pipes to be bored and type of coating and
method of application are anyhow to be authorized by Company without prejudice to
Contractor's liability. In all other cases the carrier pipes shall be cased. Before start of the
boring/ jacking, Contractor shall execute a soil investigation and determine the ground
water table. Based on these investigations Contractor shall prepare a construction
drawing and submit to Company for approval including time schedule and soil
investigation report.

During the execution of the boring, the ground water table over the length of the boring
shall be lowered up to at least 0.50 M below bottom of the pipeline. This water table is to
be regularly inspected and maintained by Contractor and reported to Company to
safeguard the stability of the bore pit. Contractor shall, if necessary in Company opinion,
use a closed sheet piling, which shall extend at least over 50% of the length in
undisturbed soil. The length of the boring shall be in accordance with the width of the
ROU of the crossing (road, railroad, etc.) with minimum 0.6 M extra on either side. In
approaches to the crossing, Contractor shall eliminate unnecessary bending of pipe by
conforming to the contour of the ground by gradually deepening the ditch at such
approaches as directed by the Company.

4.3 The diameter of the hole for a bored section shall have a hole diameter as close as
practicable to the outside diameter of the carrier or casing pipe. If excessive void or too
large hole results, or if it is necessary, in the opinion of Company, to abandon the bored
hole, prompt remedial measures such as filling the hole with suitable material shall be
taken to the entire satisfaction of the Company and Authorities having jurisdiction thereof
at no extra cost to Company. Equipment used for installation of casing pipe shall be of the
type approved by Company.

An installation consisting of hydraulic jacks shall be provided with easily readable

pressure gauge (in bar) and sealable pressure limits. Their proper operation shall be
demonstrated before the work is started. Company can request that the maximum
pressing force be limited.

At the front of the pipe there may be a cutting ring which may be 12 MM larger than the
outside diameter of the pipe or casing. A lubricating pipe can also be used in jacking, the
nipples of which shall not protrude from the cutting ring. Said lubricating pipe shall not be
fixed to the pipe or casing. When jacking, only biologically degradable lubricants shall be
used.

The progress in the work, the readings of the gauge pipes, the jacking pressures
observed, etc., shall be recorded in a log book, to be shown to Company upon request. All
information shall be supplied to Company on completion of the work.
 In case of jacking failure e.g. resulting in pipe buckling or the equipment being unable to
push the pipe further, the pipe shall be left in the hole, filled with sand and plugged at both
ends. Cost of pipe lost due to such failure shall be borne by the Contractor.

Company reserves the right to inspect certain lengths of pipes to assess damages, if any,
to the corrosion coating of the carrier pipe used for boring. Contractor shall weld additional
lengths of pipe and pull the required extra lengths for Company's inspection. If during
inspection any defects are noticed, Contractor, in consultation with Company, shall carry
out the remedial measures required.
4.4 After completion of the pipe laying, the trench shall be properly compacted by mechanical
compactors to the satisfaction of the Authorities and restored back to the original.

While welding of the casing and vent/ drain pipes, internal high or low is not allowed.
Welding of casing and vent/ drain pipes need not be radiographed, however, only normal
visual checks shall be carried out. Before welding, the single length of pipe shall be
inspected in order to check that there is no out of roundness and dents. When such
defects are noticed, these must be completely removed before joining the pipes. If these
defects cannot be repaired, the defective section shall be cut out.

4.5 In the case of crossings where excavation has been authorized, the welding for the casing
pipe and for a continuous section of the pipeline corresponding to the expected length
shall be carried out in the proximity of the crossing. Casing must be laid immediately after
the trenching. Casing pipe must be laid with a single gradient in order to allow for an easy
insertion.

4.6 The assembly of vent pipe units as approved by Company shall be carried out by direct
insertion and welding to the ends of the casing pipe before introducing the carrier pipe to
avoid damage to insulators from welding heat. The operation of assembling and extending
the vent pipe shall be carried out in such a way that there is no contact with the carrier
pipe. The painting/ coating of the vent pipes shall be applied before backfilling as per
relevant specifications.

4.7 Before installation of carrier pipe, the casing pipe shall be thoroughly cleaned to remove
soil, mud, stones and other foreign material. A nose-piece having a diameter equal to that
of the pipe shall be welded to the front end of the carrier pipe to facilitate correct
installation of the carrier pipe in the casing. Pushing or pulling force is evenly and
constantly applied to avoid damage to the insulators.

4.8 Insulators, as per specification as approved by Company, shall be securely fastened to

the pipe with all bolts and fixtures firmly tightened. The number of insulators and spacing
shall-be as shown in Standard drawing No VCS-STD-2009 or 2.5 meters centre
(whichever is more stringent). At the end of both sides of the casing, a double set of
insulators shall be installed.
4.9 Care must be taken in pushing or pulling carrier pipe into the casing so that the pipe is
aligned correctly in the casing and that the pushing or pulling force is evenly and
constantly applied to avoid damages to the insulators. A nose piece having a diameter
equal to that of the pipe shall be welded on the front and back end of the carrier pipe to
facilitate installation of the carrier pipe properly in the casing and to keep it dry and clean.

4.10 In the event of failure, the pipe/ section removed from the installed pipeline shall be kept
aside and preserved for further investigation of the reasons for failure.

After successful testing the ends of the pipeline section shall be capped and buried unless
immediate tie-in is carried out. The location of the ends shall be marked on ground by
installing markers.

4.11 After installation of the carrier pipe section, the casing and the appurtenances, but prior to
making tie-in welds and backfilling, an electrical test shall be conducted by the Contractor
in the presence of the Company, to determine the resistance between the casing and the
carrier pipe or the carrier pipe and the soil. These tests shall show at least a resistance of
2
100,000 ohm M . After backfilling and compaction, additional tests shall be conducted to
determine if the casing is electrically shorted to the pipe. If the installation is found to be
shorted, Contractor shall make the necessary corrections and repairs at his cost, unless a
test to the satisfaction of the Company is obtained.

In case of failure of test, the Contractor shall assess the reasons for lower resistance and
if it is established that casing and carrier pipe are electrically short circuited, the
Contractor shall make the necessary repairs and verify that short circuiting has been
successfully removed.

5.0 MINOR WATER COURSE CROSSINGS

5.1 Minor water crossings are crossings of (future) ditches, canals, water courses, rivers,
streams etc. whether the bed(s) contain(s) water or not, and not being specified as "Major
Water Crossings" in the CONTRACT.

5.2 For minor water crossings a standard drawing or a separate detailed approved drawing
for individual crossing shall be applicable, and all further specifications are applicable.

5.3 Whenever minor water crossings in the ROU are to be crossed, Contractor shall install
bridges and further comply with the provisions as laid down in this specification.

5.4 In crossings of water courses with either moderate flow rate or of torrential nature with
marked and unpredictable flooding, an adequate survey shall be carried out before
starting the work with the object of determining what precautions are necessary and the
most favorable period for executing the work.

5.5 In case of crossings of water courses for which no special methods of laying are required,
a pipe section of a size as per the approved drawings shall be assembled and
subsequently laid. Bends shall be of cold field type.
 The depth of the existing bottom of a minor water course crossing shall be determined in
relation to the adjacent ground level by taking the average of four measurements.
Measurements shall be taken with a gauge rod having a flat bottom. The minimum force
to be exerted shall be 360N (36kgf).

Contractor shall take special care to check with the responsible authorities for special
conditions applying to working on, over, under or thorough minor water crossings and
Contractor shall comply with any such conditions. Written arrangements with authorities
shall be drawn up in cooperation with Company.

5.6 Whenever required by Company, Contractor shall, before start of construction, execute a
geo-technical and hydrological investigation. Based on these investigations Contractor
shall also calculate scour level and prepare construction drawings, Contractor shall submit
all reports, calculations and drawings for approval by Company.

5.7 The minimum cover over the pipe shall be as specified in the relevant approved drawings
and job standard.

5.8 For crossing beneath the bed of water courses, the pipe section shall be made in such a
way that it conforms to the existing or future bed as indicated in the approved drawings. In
crossings for which an individual drawing has not been prepared, the minimum cover of
the pipeline shall not be less than that indicated in- the standard drawings for a similar
type. of crossing.

5.9 Whenever the crossing requires a straight section of pipe between the lower bends
coinciding with the river bed, this section shall be laid at a single horizontal level.

5.10 For crossing of ditches, canals, banked channels, etc. by boring, the pipe section shall be
prepared, laid and tested in accordance with the applicable clauses of Section 4.0 of this
specification.

5.11 The Contractor shall arrange temporary installation of diversions as may be necessary, to
ensure the effective functioning of these watercourses crossed, to the entire satisfaction
of the concerned local Authorities as well as the Company.

5.12 Banks and trenches of minor water crossings shall be backfilled with soil which is to be
approved by Company and shall be thoroughly compacted to prevent soil and bank
erosion as per the drawings and standards to the satisfaction of authorities having
jurisdiction thereof and the Company. Whenever boulders, rock, gravel and other hard
objects are encountered, they shall not be placed directly on the pipe. Sufficient earth,
sand or selected and approved backfill material shall be backfilled initially around and
over the pipe to provide a protective padding or cushion extending to a minimum
thickness of 30 centimeters around the pipe before backfilling remainder of the trench with
excavated or other material as per approved drawings and standards.

After the trench has been backfilled and during the clean up works, the minor water
crossing shall be cleaned at least across the whole width of the ROU.
 When specified in the CONTRACT, Contractor shall repair the ditch bank with materials to
be supplied by himself as follows:

The excavation shall be backfilled with well compacted solid soil, followed by a minimum
0.25 M thick layer of properly shaped boulders (75-150 MM) encased in a net of
galvanized iron wire of dia 3 MM spaced at a maximum distance of 50 MM to be laid over
the backfilled, compacted and graded banks.

The width of the above protection shall be equal to the bank excavated and damage and
extending 3 M on either side. The length of this protection on the slope shall be
determined by the following:

 2 M plus the highest water level.

 Up to the bottom of the crossing or 20 M below the highest water level whichever
is smaller.
5.13 After completion of crossing, any temporary arrangements made for diversion flowing
water shall be restored back to the original.

Where possible a gradual slope to the pipe shall be given on both sides to avoid use of
sag bend at the crossing. Otherwise, single pipe sag bend suitable for each nala / stream
shall be prepared by field cold bending and installed at the crossing.

5.14 The crossing of any embankments shall be carried out strictly in accordance with
approved drawings.

No drilling work on embankments shall be permitted without prior written approval from the
competent Authorities.

6.0 CROSSING OF BURIED SERVICES

6.1 The pipeline under construction may pass above or below the existing buried facilities
such as pipelines, cables, etc. Type of crossing shall be such that a minimum depth of
cover as required in the drawings and specifications are guaranteed. The minimum
clearance required between pipeline and the existing facility shall be 500 MM as per job
standard.

6.2 Whenever buried services in the ROU are to be crossed by Contractor, Contractor shall
safeguard the buried facilities and the required protecting precaution shall be executed as
approved by Company of the buried services and by Company.
 STANDARD SPECIFICATION
FOR
DETAILED PIPELINE ROUTE SURVEY
ABBREVIATIONS:

ASME American Society of Mechanical Engineers

ASTM American Society of Testing of Materials

API American Petroleum Institute

OISD Oil Industry Safety Directorate

CONTENTS

1.0 SCOPE ........................................................................................................................................................................

2.0 REFERENCE CODES, STANDARDS AND SPECIFICATIONS ..............................................................
3.0 REQUIREMENTS ....................................................................................................................................................
4.0 SURVEY NOTES, OBSERVATIONS AND COMPUTATIONS .................................................................
5.0 DOCUMENTATION .................................................................................................................................................

APPENDIX-A PIPELINE ROUTE CENTRELINE SURVEY

APPENDIX-B DETAILED ROUTE SURVEY

APPENDIX-C SOIL INVESTIGATION SURVEY

APPENDIX-D POPULATION DENSITY SURVEY

APPENDIX-E CADASTRAL SURVEY

ANNEXURE-I PIPELINE ROUTE SURVEY DATA SHEET

ANNEXURE-II SAMPLE FORMATS

1.0 SCOPE

This specification covers the minimum requirements for various type of surveys required to
be carried out for an onshore pipeline. The requirements for surveys and investigations
related to locating pipeline route centreline, dumpsites and intermediate station/ terminal
facilities on ground, obtaining topographic features, ground profile and soil data along the
pipeline route; collection of revenue maps/ data and preparation of cadastral maps for ROU/
Land acquisition purposes; collection of population density data along the pipeline route are
specified in this specification.

The specification also covers requirements related to construction of survey monuments,

field measurements and presentation of survey data including preparation of maps,
drawings, documents and reports.

2.0 REFERENCE CODES, STANDARDS AND SPECIFICATIONS

Reference has been made in this specification to the latest edition (edition enforce at the
time of floating the enquiry) of the following codes.

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

B31.4 : Pipeline Transportation system for liquid

Hydrocarbon & other liquids.

B31.8 : Gas Transmission and Distribution Piping

Systems.

OISD 226 : Natural gas Transmission Pipelines and city gas

distribution network.

OISD 141 : Design and Construction requirements for cross country

hydrocarbon pipelines

3.0 REQUIREMENTS

3.1 All survey works shall be performed by and/ or under the direct supervision of a qualified
land Surveyor.

All survey work shall be carried out using modern and well-maintained survey equipments/
instruments such as DGPS, GPS, EDM, Total Station, Theodolite, Inclinometers and any other
equipments/ instruments deemed necessary for completion of works as per this specification.

3.2 Following type of surveys are covered under this specification:

i) Pipeline route centerline survey as per Appendix-A

ii) Detailed pipeline route survey as per Appendix-B
iii) Soil investigation surveys as per Appendix-C
iv) Population density survey as per Appendix-D
v) Cadastral survey as per Appendix-E

Specific requirements of surveys for a particular Project shall be as indicated in Contract.

3.3 Normally detailed route survey shall be carried out after centerline survey has been completed
and the pipeline route established on ground has been accepted by the Company. In case the
pipeline route has already been identified by the Company and/ or the centerline survey is not
required to be carried out by the survey contractor, the Surveyor shall make himself fully aware
of the general conditions of the terrain along the pipeline route prior to start of survey work.

3.4 In case, the pipeline for which the route survey is proposed to be carried out is to be used
for transportation of hydrocarbons in gaseous phase, the population density survey shall be
carried out as per Appendix-D of this specification.

3.5 All major crossings and routing in critical areas shall be finalized by Surveyor in consultation
with Company Representative. Company may depute its representative during the survey
work to assist the contractor in finalizing such location at its sole discretion.

3.6 The Surveyor shall avoid major deviations from identified/ established route during detailed
survey. Any such major deviation must be approved by Company representative.

Surveyor shall clearly specify reasons for such deviations while submitting his proposal for
change in route.

3.7 When so specified in contract document the Surveyor shall locate dump site(s), for storage
of line pipe and other pipeline materials, along pipeline route.

Unless specified otherwise in data sheet/ contract document the dumpsite(s) shall be
located at 75-100 km interval and shall have an area of 5 - 10 hectares.

Following aspects shall be taken into account while selecting dumpsite location(s):

a. Dumpsite should preferably be a barren land free from water logging/ low lying
areas.
b. The site shall be located in close proximity of identified/ established route.
c. It should be in the vicinity of National/ State Highway.
d. The site should be nearly flat with minimum undulation that might require earth
work (fill-up and earth-cutting).
e. Site should not be under overhead power lines.
f. Site should preferably be on government land.

4.0 SURVEY NOTES, OBSERVATIONS AND COMPUTATIONS

4.1 The procedures followed both for field and office calculations shall be such that the results
obtained shall be maintained by surveyor.

4.2 All up-to-date notes and observations related to the basis for determination of boundary
lines and corners shall be maintained by surveyors.

4.3 Survey records must contain schematic diagrams of all horizontal controls pertinent to the
project showing all existing and established control points, bench marks, any triangulation
station and boundary lines.

4.4 Geo-graphical and UTM co-ordinates of all Turning Points and starting/ end points of the
pipeline shall be computed and furnished to the Company Representative.
5.0 DOCUMENTATION

5.1 MAPS & DRAWINGS

All maps and drawings shall be made using standard formats enclosed with this
specification. The Surveyor shall perform all mapping and drawing work so as to contain all
relevant data consistent with the survey notes and observations according to Cl. No. 3.0.
The drawings shall also contain details of roads, streets, highways, structures, all types of
crossings, terrain, surface vegetation and all other details which will be required for the
purpose of engineering design. The type of drawings and maps to be prepared shall be as
per requirements specified under Appendix-A to Appendix-E.

5.2 REPORTS

The reports to be prepared by Surveyor shall be exhaustive and shall contain all relevant
information. The report shall describe in brief the survey methodology adopted, equipment used
and tests (if required) conducted for obtaining the details/ data presented in the report. The final
results/ conclusion shall be based on sound practices and detailed analysis of the data
collected. The report must include recommendations as applicable for the Company's
consideration.

5.3 DRAWING/ DOCUMENT SUBMISSION

All drawings and document shall be prepared using computers. Hard copies and soft copies
of all required drawings and documents shall be submitted to Company for review/ approval.
The Company shall review and comment, if any, shall be passed on to the Surveyor. The
Surveyor shall incorporate all comments, including carrying out fresh field works/ laboratory
testing (when required) and revise the drawing/ document to entire satisfaction of Company.
Number/ sets of hard copies and soft copies of each drawing and document (submitted for
review/ comments by Company) shall be as indicated in Contract.

Once the drawings/ documents have been reviewed by the Company and updated by surveyor
to entire satisfaction of Company, the Surveyor shall submit entire documentation (drawings,
maps, reports etc.) both in hard copy as well as soft copies for Company's records (number of
copies as specified in Contract). All hard copies shall be signed and stamped by Surveyor. All
drawings/ reports/ formats etc. submitted to the Company shall be prepared on electronic media.
All drawings/ sketches shall be prepared using Auto CAD release 2006 or above. All reports and
write-ups shall be in Microsoft Office software. All photographs shall be in JPG/ TIF format.
Whenever data base is used for presentation of data (population density, ground profile etc.),
the same shall be prepared in Access Data Base Software using Microsoft Office release 2006
or above. Final approved survey data/ documents shall be submitted to Company on CD
ROMs.
APPENDIX-A

PIPELINE ROUTE CENTRELINE SURVEY

1.0 OBJECTIVE
The objective of the centerline survey work is

i) Physical verification of the identified route and confirm its suitability for pipeline
construction.
ii) Identify restrictive areas and suggest modifications/ detours to the identified route.
iii) Establish the route on ground.
iv) Collection of development plans along the proposed pipeline route from various
agencies having jurisdiction thereof.
v) Collecting information required for obtaining clearances from various authorities
including environmental clearances.

2.0 REQUIREMENTS
2.1 GENERAL

2.1.1 The Company shall provide the Surveyor identified pipeline route details.

2.1.2 The Surveyor shall transfer the Company identified route onto Survey of India (SOI)
topographic maps (in scale 1:250,000, 1:50,000 or less in case identified route passes
through hilly areas) for use during field verification and preparation of route maps. The maps
for this purpose shall be arranged by Surveyor unless specified otherwise in contract. For
section of the identified pipeline route covered in maps identified/ declared by SOI as
"Restricted" maps, Company may arrange such maps and make them available to the
Surveyor during field verification. Surveyor may also use satellite imagery for updating of
SOI maps, if required, as per provisions of Contract document.

2.1.3 Surveyor shall carryout reconnaissance survey as necessary to orient the most practical
alignment along identified route using best judgment and experience of the Surveyor to
interpret the needs of pipeline construction. The Surveyor shall use Global Positioning
System (GPS) and other survey equipment such as magnetic compass, inclinometer,
theodolite etc. as required during the reconnaissance survey.

2.1.4 The Surveyor shall locate and identify all existing features and obstructions along the route,
identified by Company, and within a corridor of 5 km on either side of centerline that are not
shown in the available maps and update the SOI maps to reflect such changes. Surveyor
shall collect all development plans from the concerned authorities.

2.1.5 Surveyor shall establish stakes/ mark flag control points on ground along the centerline of route.
Flag control points shall be clearly identified on the route maps. The flag control points shall also
be established at all major road, rail, canal, pipeline, river crossings and terminal locations.

2.2 PIPELINE ROUTE DEVIATION

2.2.1 Surveyor in general shall avoid any major deviation from the route identified by Company.
Deviation from route, if considered essential by the Contractor, shall be brought to the
notice of the Company representative for Company's approval.

2.2.2 Contractor shall avoid obvious man made or natural obstructions such as culverts, bridges,
utility poles, buildings/ structures, gorges, plantations, archaeological sites, reserve forest,
environmental sensitive areas, mining sites, future built-up areas etc.
2.2.3 Surveyor shall take into account following criteria while selecting pipeline route alignment in
hilly areas/ ghat regions etc.
a. A longitudinal slope along pipeline route shall not exceed 1:5
b. A transverse slope across pipeline route shall not exceed 1:1
c. As far as possible ridges/ spurs should be used to climb up/ come down from hill.
Side slopes of hills requiring excessive side hilling should be avoided.

Hand held inclinometer shall be used for estimation of slopes

2.2.4 Centerline alignment thus established shall be shown prominently on the route maps. In
addition chainage in km, major turning points, intermediate facilities, planned developments,
existing features/ obstructions, flag control points etc. shall also be marked on route maps.

2.3 FIELD MARKING

2.3.1 The entire length of the surveyed route shall be staked on ground along the proposed
centerline. Stakes shall be 8 mm dia. painted twisted rods. Sketches/ photographs to
facilitate location of stakes in field shall be furnished giving reference of existing features
wherever major directional change takes place.

2.3.2 Stakes shall be installed at flag control points, major crossings, major turning points and at
an approximate 1.5 to 2.0 km interval as dictated by field conditions.

2.3.3 Consideration shall be given to land use in placing the stakes e.g. stakes placed and left in
cultivated land may not be acceptable to the land owner. Stakes in such areas shall be
placed at boundaries between cultivated areas where necessary.

3.0 PRESENTATION OF SURVEY DATA

Centerline survey data shall be presented in the form of following drawings/ documents:.

a. Pipeline route map showing route on SOI Topo sheets of scale 1:50,000 or 1:25,000
for unrestricted areas. (SOI topo sheets shall be updated for distance of 5 km on
either side of pipeline centerline).
b. Pipeline route maps showing route on maps developed from SOI topo sheets or
satellite imageries of 1:50,000 or 1:25,000 scale for areas covered in "Restricted" SOI
maps.
c. Overall pipeline route map in 1:5000,000 scale.
d. Ground profile drawing and ground elevation v/s pipeline chainages in Microsoft
Access software (ground elevations to be furnished on an average at every km
interval or at locations where major change in ground elevation occurs).

e. Route report consisting of but not limited to following:

i) Route Description
ii) Topographic features
iii) Major Crossing details
iv) Extent of reserve forest
v) Land use pattern and soil strata along route.
vi) Developments plans
vii) Estimates for land cost for ROU acquisition.
viii) General metrological details
ix) Site photographs. (Photographs shall be sufficient in numbers to represent the
entire terrain features).
x) Dump site locations suitable for pipe storage (when specified)
xi) Ground Profile along the route
xii)Comparison of alternative routes considered
APPENDIX-B

DETAILED ROUTE SURVEY

1.0 OBJECTIVE

Objectives of detailed pipeline route survey are as follows:

a. To fix the pipeline alignment on ground.

b. To determine exact pipeline route length.
c. Finalize crossing locations and crossing angles.
d. Establish survey monuments on ground along pipeline route.
e. To obtain detailed topographic features within 30 m on either side of centreline.
f. To obtain ground levels and/ or contours.
g. To obtain cross-section details and topographic features at all crossings.
h. To gather details of land use pattern and soil characteristics

2.0 REQUIREMENT
2.1 Pipeline route and turning points (TPs) along the pipeline route shall be located by the Surveyor
in consultation with Company Representative considering the following:

a. To avoid obstructions along the line, by ranging on ground and shifting the Turning
Points if need be.
b. Terrain gradient to be checked by using hand held inclinometer.
c. Ensure proper angle of crossing by keeping as nearly right angle (to road/ canals/ rail/
rivers/ streams, etc.) as possible. The right angle may be laid on ground by using a
chain or string lengths in ratio of 3, 4 and 5.
d. To check from construction point of view and avoid objects like power, telephone and
telegraph poles, walls, tube wells or such other structures falling in the strip of land,
30m on either side of pipeline alignment.
e. To maintain minimum distance of 100m between two consecutive turning points.
f. “R.C.C. Pillars shall be provided with reinforcement of 4 nos. - 6mm dia bars with 4
equally spaced rings of 6mm dia. All pre-cast R.C.C. pillars should also be engraved
with Company name on one shorter vertical face.”
g. Surveyor shall locate and identify the existing features or obstructions along the route
that are not shown in available maps or drawings.
h. Archeological sites, reserved forests, environmentally sensitive areas, mining sites and
built-up areas shall be avoided.
i. Where it becomes apparent that a better route could be followed, the Surveyor shall
consult the Company Representative for authorization to make a change.

2.2 STAKING OF PIPELINE ROUTE

2.2.1 The pipeline defining trench centre line shall be staked by placing suitably painted marker
stakes at Turning Points (TPs) and at Intermediate Points (IPs) between consecutive TPs. All
Turning Points (TPs) and Intermediate Points (IPs) are referred as Intersection Points.

The pipeline centre line shall be staked on the ground as follows:

First, the Turning Points (TPs) shall be staked on the ground. After locating and marking the
TPs, the intermediate points shall be staked while measuring slack distance. The staking shall
normally be done at intervals of 500 m along the centre line of the pipeline
2.2.2 The Intersection Points shall be serially numbered form the starting point. The serial number of
each Intersection Point shall be boldly inscribed on the marker stake. In addition, the Turning
Point (TP) marker stake shall identify the Turning Point reference number from the starting
point.

2.2.3 For Intermediate Points (IPs) letter "P" shall precede the serial number of the intersection point
marker. For Turning Points, the letters "TP" shall precede the Turning Point reference number,
and the letter "P" shall precede the serial number of the Intersection Point.

2.2.4 The marker stakes at Turning Points (TPs) shall be referred with three reference stakes around
the TP. The reference stakes shall carry the Turning Point reference number and their
respective distance from the TP marker stake.

2.2.5 Change in direction of line shall be marked on the TP marker stakes. In addition, direction
markers near TPs and other locations shall be placed wherever necessary.

2.3 STAKES AND MARKERS

2.3.1 All marker stakes shall be pre-cast reinforced concrete blocks having dimensions 150 x 200 x
800 mm, and shall be buried to a depth of 500 mm. Stone pillars of similar dimensions can be
used in place of concrete blocks.

The exposed surface of the blocks shall have a smooth finish and shall be painted with 'Post
Office' red paint. All letters and figures shall be paint marked on the surface of the blocks in
white.

2.3.2 On the top surface of the marker stake, a cross inside a circle shall be engraved at the centre or
a nail shall be put centrally inside an engraved circle, to indicate the exact position of the
Intersection Point. The circle shall be of approximately 50 mm diameter.

2.3.3 Surveyor can, however, propose to the Company Representative other types of stakes/ markers
which are better suited to site conditions.

2.4 BENCH MARKS

2.4.1 Permanent Bench Marks (BM) approx. every 5 km or permanent structures on or off the Right-
of-Use (ROU) shall be established and described. Bench marks shall be located in such a
manner that they will not be destroyed when the ROU is cleared for construction.

2.4.2 Additional permanent bench marks shall be established near the major pipeline crossing sites.
2.4.3 Location of Bench Marks shall be established in the field by using reinforced concrete/ stone
blocks similar to pipeline marker stakes described in clause 2.3.1 of this specification. Exact
position of BM shall be marked by a cross inside a circle or a nail put centrally inside an
engraved circle on the top surface of the concrete block. The reduced level of the BM shall be
paint marked on the concrete block. Letters "BM" shall precede the reduced level of bench
mark recorded to the second place of decimal.

2.4.4 Accuracy of the reduced levels of the Bench Marks shall be verified wherever possible by
checking levels with the nearest permanent Bench Mark established by Survey of India.
2.5 CROSSINGS

2.5.1 GENERAL
As far as possible, crossings shall be made at right angles. The Surveyor shall record the angles of
crossing for all fences, property lines, utilities, roads, railways, canals, streams, etc. that are
crossed. In addition, the true bearings of the centerline of the road, railway, canal, as well as that of
the pipe centre-line shall be recorded. Turning Points (TPs) provided on either side of crossings
shall be located, minimum 50m from the crossing's boundaries, in stable and firm ground.

2.5.2 RAILWAY CROSSINGS

The angles for all railway crossings shall be as close to 90 degrees as possible, but in no case
be less than 85 degrees to the centre-line of the railway.

2.5.3 PRIMARY ROAD CROSSINGS

Primary roads are the National & State Highways, all-weather roads (paved/ unpaved) and
roads providing access to major installations. The angle of crossings shall be as close to 90
degrees as possible, but in no case be less than 80 degrees to the centre line of the road.

2.5.4 SECONDARY ROAD CROSSINGS

The angles of crossing for secondary roads shall be as close to 90 degrees as possible, but in
no case less than 45 degrees to the centre-line of the roads. All seasonal roads, unpaved
village roads, cart-tracks, etc. come under this category.

2.5.5 RIVER CROSSINGS

These crossings shall be established as close as possible to the locations shown on the route
map. Crossings shall be located in a comparatively straight reach of the river where the banks
are stable and there is sufficient area for construction. Angle of crossing shall be as close to
90 degrees as possible.

2.5.6 CANALS/ DRAINAGE/ STREAM/ NALA/ DITCH CROSSINGS

The angle of crossing shall be as close to 90 degrees as possible but in no case be less than
60 degrees to the centre-line of the canal/ drainage/ stream/ nala/ ditch. Crossings shall be
located where there is no evidence of slumping or erosion of banks, or bed.

2.5.7 UTILITY CROSSINGS

Utilities crossed shall be located at their centerlines with stakes containing station numbers in
the survey. The angle of crossings shall be measured and locations established relative to
their above ground facilities. The names and sizes of all utility lines shall be included in the
survey notes. In cases of overhead power and telephone lines, the distance to the poles and
towers on each side of the survey line shall be measured, and the numbers of poles or towers
noted. Line voltage shall also be recorded. Where possible, the survey shall be established so
that there is a minimum distance of 50 metres from the survey line to the nearest High
Tension (11KV and above) pole or tower.

Underground utilities shall be located as far as possible and staked for a minimum distance of
30 meters on each side of the survey line.

2.6 BUILT-UP AREAS

2.6.1 MONUMENTS AND PROPERTIES

The pipeline alignment shall run clear of the existing monuments, properties and structures
etc., as indicated in Pipeline Route Survey Data Sheet (Refer Annexure-I for sample).
 For congested areas, closer distance may be adopted; however, location shall be approved by
Company Representative.

2.6.2 PARALLEL ALIGNMENT

The pipeline alignment wherever runs parallel to an existing or planned under/ over ground
facility will be treated as parallel alignment. For underground facilities Surveyor shall identify
and locate them with suitable pipe locator/ cable locator. The following clearances shall be
observed in case of parallel alignment defined above unless specified otherwise:

a. Between existing/ planned electrical power cables/ lines and the proposed pipeline -
50.0 meters
b. Between existing/ planned communication cables/ lines and the proposed pipeline -
25.0 meters
c. Between existing/ planned pipeline and the proposed pipeline - 50.0 meters
2.6.3 PARALLEL ENCROACHMENT
Unless otherwise stated, when the pipeline alignment runs generally parallel to a road or railway
it shall be kept sufficiently clear of the Right of Way limits of the facility.

2.7 ACCURACIES IN MEASUREMENT

2.7.1 Surveyor shall incorporate corrections to the linear ground measurement due to standard errors
(and variations from standard temperature and/ or pull in case of chain survey, wherever
specifically approved by Company).

2.7.2 The error for angular closure for the work shall not exceed one minute per station and for linear
measurements it shall be read to the nearest 0.001 m.

2.7.3 The error on closure for measurements on vertical distance to establish bench marks shall not
be more that 24√K millimeters (where 'K' is the linear distance in km). The observations for
measurement of vertical distances on bench marks shall be read to accuracy to the nearest 5
mm and for Intersection Points and other points along the pipeline route and at crossings to the
nearest 10 mm. The error of misclosure in vertical distance shall be distributed linearly.

2.7.4 Azimuth control shall be maintained by observations of the Sun or Polaris at intervals of 15-20
km by closing the traverse on existing control points. These observations of bearings together
with deflection angles shall be recorded in survey notes.

Azimuth misclosure based on bearings with observed angles at Turning Points shall be equally
distributed over the number of stations observed in between. Accuracy of azimuth observations
shall be acceptable if the three deductions agree within one minute when Sun is used for
Azimuth observation. In case of stars/ polaris observation, computed values should agree within
10 to 15 secs.

This check is not mandatory when using DGPS system for establishing location/ co-ordinates.

2.8 CHAINAGE

2.8.1 Distance measurement shall be made by Electronic Distance Measurement (EDM) equipment
(or by using 50 m steel tape or 30 m chain if specifically approved by the Company). However,
in case of abrupt slope change the tape/ chain shall be used and it shall be straightened parallel
to the probable grading.
2.8.2 Distance between Intersection Points staked along the pipeline route should be measured and
recorded. In addition, distance between level points shall also be measured and recorded.

2.8.3 Chaining, wherever permitted, shall be continuous in the direction of survey.

2.8.4 The true bearing of all straights shall be observed and recorded.

2.8.5 Data on nature of terrain, viz. sandy, stony, vegetation, etc. and type of ground will also be
recorded along with chainages of change points.

2.8.6 Check on distance measurements shall be by Stadia method at the time of leveling.

2.8.7 Standard survey formats shall be used for record keeping.

2.9 MEASUREMENT OF HORIZONTAL ANGLES

2.9.1 Horizontal angles are measured to indicate the change in direction of alignment and specify the
horizontal bend at the Turning Points.

2.9.2 Theodolite, reading direct to 10 seconds or better, shall preferably be used. Angles shall be
measured clockwise from back station to fore-station. Mean of two readings-one on face left
and other on face right shall be taken as the horizontal angle.

2.9.3 The line at both ends shall be tied to the grid control system being used for end facilities. True
bearing at the beginning, end and at every 15-20 km shall be observed to keep a check on
errors in angular measurements.

2.10 PROFILE
2.10.1 Continuous profile of the proposed pipeline route shall be established from the reduced levels
taken.
i) at the starting point,
ii) at all Turning Points (TPs),
iii) at all Intermediate Points staked on the ground,
iv) at all points on the pipeline route where there is a change in slope.

2.10.2 When the terrain is flat, reduced level shall be additionally recorded along the pipeline route at
100 m interval.

2.10.3 When the terrain is undulating, observation of reduced level shall be made at a sufficient
number of points so as to give an accurate plotting of the ground profile along the route.

2.10.4 For road and railway crossings, the reduced levels shall be recorded at interval of 5 m along
the pipeline alignment and at closure intervals wherever there is a change in slope within the
entire width of the Right-of-Use of the road/ railway.

2.10.5 For river/ stream/ nala/ canal crossings, levels shall be taken at intervals of 5 m up to 30 m
beyond the highest banks on both sides. Levels shall be taken at closer intervals, if there is a
change in slope.

2.10.6 In right-of-use having slope acrokss the pipeline alignment, as encountered in hilly areas, Ghat
regions, ravines and other similar areas as directed by Company, cross-sections at 50 m interval
and for a length of 30 m on either side of the pipeline alignment shall be observed and recorded.

2.10.7 For major water crossing sites, cross section as above shall be observed at both banks.

2.10.8 Method of RISE and FALL shall be used to compute reduced levels of various points. Check
on computation shall be made by using the following formula:
Back site - Fore Site = ∑Rise - ∑Fall = First R.L. - Last R.L.
2.10.9 Maximum misclosure shall not exceed 24√K mm where 'K' is the distance in km. Maximum
length of line of sight shall not exceed 100 m.

2.10.10 All levels shall be with respect to Mean Sea Level (MSL).

2.11 CO-ORDINATES AND GRID

2.11.1 Differential Global Positioning System (DGPS) shall be used to determine co-ordinates of all
intersection points and facilities along pipeline route. Accuracy of co-ordinates shall be within
0.5 metre. Non-differential or autonomous GPS are not acceptable.

The following information shall be submitted for DGPS proposed by Surveyor for Company
approval:
 GPS Receiver Model used:
 Differential Receiver Type:
 Guaranteed accuracy in meters:
Surveyor shall submit a procedure for setting up & use of DGPS. All co-ordinates shall be
indicated in UTM grid as well as geographic grid. In case more than one survey party is
deployed, each party shall use same reference grid and DGPS system.

2.12 LEVELS AND CONTOURS

2.12.1 In addition to the elevation along centre line of route, the Surveyor shall obtain, using Total
Station, levels within 30 m wide corridor on either side of route alignment. Co-ordinates (in
UTM grid) of each level point shall also be recorded.

2.12.2 All such level points shall be plotted in the planimetry portion of the alignment sheets. The
levels shall be taken in such a manner that contour can be drawn with a contour interval of 5
in. Surveyor shall draw the contours from the data collected.

2.12.3 Electronic data shall be made available in a format compatible with commercially available
Digital Terrain Modeling (DTM) software

3.0 PRESENTATION OF SURVEY DATA

The data collected during survey shall be presented in the form of drawing and document
listed below:

3.1 DRAWINGS
3.1.1 As a minimum following drawings shall be prepared and submitted:

S. No. Description Scale

a. Detailed Route Map 1:50,000 on SOI
Topographical Maps
b. Additional Route Map 1:15,000

c. Alignment sheets covering

1:2500 along the line
 Right-of-Use Planimetry in UTM grid
1:2500 across the line
 Ground Profile
1:2500 Horizontal
d. Crossing Details 1:100 Horizontal
(Road/ Railway/ Stream/ Nala/ Canal/ Crossings)
1:100 Vertical
 S. No. Description Scale
e. Crossing details (River Crossings)
1:200 Horizontal
 Up to 250 m width
1:200 Vertical
 250 to 500 m width
1:500 Horizontal
 Greater than 500 m width
1:500 Vertical

f. Cross Section for sloping Right-of-Use 1:100 Horizontal

Note: Crossing drawings shall be prepared using same horizontal and vertical scales as
indicated above. In case one crossing cannot be accommodated in single sheet
additional sheets may be used. Not to scale (NTS) drawings shall be rejected.

3.1.2 Pipeline route map shall show all features including, but not limited to roads and railroads,
canals, streams, lakes, rivers, villages, towns, and cities that are located within a distance of
5 km from the pipeline centre-line on either side of it. For the entire region, contours shall be
plotted on the route map at 20 m contour interval. Additional information like cultivated areas,
barren land, areas prone to flooding, rocky areas and forests including access paths/ roads
to Right-of-Use shall also be shown on the route maps.

Additionally for areas which are undulating such as hilly areas, Ghat regions, ravines, and
other areas as directed by Company, Pipeline route map to a scale 1:15,000 shall be drawn
over a distance of 1.0 km from the pipeline centre-line on either side of it. For such areas,
contours shall be plotted at 10 m contour interval.

3.1.3 Right-of-Use Planimetry drawings shall show all objects within 30 meters on either side of
the Pipeline in Plan and shall show spot level & contours at 5m interval.

3.1.4 For all rail, road, river, stream, canal and utility crossings, the angle of crossing shall be
mentioned.

3.1.5 For rail, road, river, stream and canal crossings wider than 10 m, the distances at the start
and at the end of the crossing from the nearest IP shall also be mentioned. For crossings
less than 10 m, the distance of the centre line of crossing from the nearest IP shall be given.

3.1.6 For all river, stream and nala crossings, the level of water at the time of survey, High flood
level recorded in last 100 years and the approximate surface velocity of the flowing stream
(observed & recorded during survey) shall be reported in the survey drawings. Also, the
general nature of the surface soil (soft/ hard, normal soil or rock/ boulders) at the bed and
banks of the river/ stream/ nala shall be observed and mentioned in the drawings.

Ground profile (chainage v/s ground elevation) for the entire pipeline route shall be prepared
and presented in a tabular format using Microsoft Access Database format.
 3.2 DOCUMENTS
In addition to the drawings listed above, the Surveyor shall submit a report giving,
  Details of survey methodology followed
  Details of equipments used
  Brief Route Description
  Salient features of the route such as
- Total length of pipeline
- State wise distribution of pipeline route
- Terrain details and land use pattern summary
- No. of crossings (state wise & chainage wise)
- Details of River crossings
- State wise extent of forest/ reserve forest/ environmentally sensitive area
- Significant elevation changes along the pipeline route with chainages
- Nature of soil (sandy, clay, rocky, marshy, etc.)

  Print out of information required to be submitted as data base including

- Level & contour information for DTM
- Pipeline Profile data
- TP detail
APPENDIX-C

SOIL INVESTIGATION SURVEY ALONG PIPELINE

1.0 Objective

The objective of soil investigation survey is to obtain visual engineering classification of soil
and geotechnical properties of soil for design & engineering of various facilities required along
the pipeline route.

2.0 Requirements
2.1 General
2.1.1 The soil investigation includes boring, collection of disturbed samples from bare holes and
visual engineering classification of soil along the pipeline route, carrying out Standard
Penetration Test (SPT) at specified locations and getting the soil sample collected, from
such bore holes, tested at laboratory for specified engineering properties and submission of
detailed report to Company.

2.1.2 Visual classification of soil shall be in accordance with IS-1498; "IS Classification and
Identification of Soils for General Engineering Purposes". Geotechnical investigation of soil
shall be carried out as per relevant clauses of IS 1892 and other applicable IS standards.

2.2 Location of Bore Holes

2.2.1 Boreholes shall be made at an interval of 250 m along the pipeline route, at all intermediate
points where there is apparently a change in the type of soil and at other places as given
below by Company/Engineer-in-charge.

2.2.2 For canal, stream and river crossings, boreholes shall be made one on either bank and one
on the bed of water crossing. For railroads, state highways and national highways, at least
one bore hole shall be made at each crossing location.

2.2.3 Boring shall be carried out in accordance with the provision of IS : 1892. Minimum diameter
of boring shall be 150mm. Auger boring shall be resorted to above water table, whereas
below water table the boreholes shall be advanced by rotary drilling with mud circulation
through all kinds of soil other then rock. While boring above water table, no water shall be
introduced in boreholes. Casing shall be used to support the sides of boreholes in soft to
firm soil.

2.2.4 Except for crossing location as defined under clause 2.2.5, the boring shall be either
terminated at a depth of 3 m below NGL or on top of bed rock if rock is encountered at a
depth of less than 3 m.

2.2.5 In case of boring at Highways (National/ State), River and Railways crossings, the boring
shall either be terminated at a depth of 5 m below NGL or on top of bed rock, if rock is
encountered at a depth less than 5 m.

2.2.6 Additionally, bore holes shall be made at all SV stations, IP stations and at all terminal
locations.