Functional Familiarization Training Program

Functional Familiarization Training Program

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Contents
Introduction to the Project
Construction of Pipeline
Functional Familiarization Training Program
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Introduction to
the Project
 Functional Familiarization Training Program
INTRODUCTION OF PROJECT
PIPELINE ROUTE
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 INTRODUCTION OF PROJECT

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 TIME SCHEDULE:

Phase Period
1 Apr-2018 – Mar-2020 (24 months)

2 Apr-2020 – Sep-2021 (18 months)

3 Oct-2021 – Sep-2022 (12 months)

4 Oct-2022 – Sep-2023 (12 months)

 INTRODUCTION OF PROJECT

 In the first phase, the areas which will be covered by pipeline

will be Wagholi, Sanaswadi, Shikrapur, Ranjangaon, Khed
and Rajgurunagar (route is marked in Red Colour)
 In the second phase, the areas which will be covered by
pipeline will be Nhavare, Patas, Kurkumbh, Daund and
Baramati(route is marked in Blue Colour)
 In the third phase, the areas which will be covered by
pipeline will be Pirangut and Paud(route is marked in Pink
Colour)
 In the fourth phase, the areas which will be covered by
pipeline will be Lonavala (route is marked in Sky Blue
Colour)
SHPPL 24-09-2014
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PIPELINE
CONSTRUCTION
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STEEL PIPELINE CONSTRUCTION

CONSTRUCTION OF STEEL PIPELINE INVOLVES A

MULTITUDE OF ACTIVITIES WHICH CAN BE BROADLY
CLASSIFIED INTO THREE CATAGOREIS.
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PIPELINE
CONSTRUCTION

Pre-Construction Construction Post-Construction

Activities Activities Activities
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PRE-CONSTRUCTION ACTIVITIES

 Reconnaissance Survey
 Detailed Engineering Survey
 Permits and Clearance
 Cadestral Survey
 Acquisition of Right of Way (ROW)/Right of Use (ROU)
 Approval of QA/QC procedure
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CONSTRUCTION ACTIVITIES

Front End Activities Back End Activities

 Right of Use (ROU)  Tie-ins
 Surveys, Clearing and Grading  Crossings
 Handling, Hauling and stringing  Hydrotesting
 Trenching  Valves installation
 Lining Up, Welding & Radiography  Final cleanup and restoration
 Field Joint coating  Installation of pipeline
markers
 Lowering In
 Documentation
 Back filling
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POST-CONSTRUCTION ACTIVITIES

 Cathodic Protection
 Line preservation
 Commissioning
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 RIGHT OF USE (ROU):

 INSTALLATION OF BENCH MARKS, TURNING POINTS.

 MARKING OF CENTRELINE OF PIPELINE ROUTE WITH STONE PILLARS

BASED ON IP AND TP FIXED DURING DETAILED ROUTE SURVEY.

 PLACING OF STAKES OR PILLARS AT EVERY 100 MTR. INTERVAL IN

STRAIGHT SECTIONS AND 10 MTR. INTERVAL AT BENDS.

 EXISTING FOREIGN PIPELINE CENTRELINE HAS TO BE LOCATED BY

PIPELINE LOCATOR AND TRIAL PIT HAS TO BE EXCAVATED AT EVERY
250 MTR. INTERVAL.

 CARE SHOULD BE TAKEN IN RESTRICTED ROU, FLOODED AREA AND

DUST CONTROL AS PER EMS.
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 SURVEYS, CLEARING AND GRADING:

 COMPLETE ROU ROUTE SURVEY.
 ROU CLEANING AND GRADING FOR MAIN PIPELINE WORK.
 CLEANING AND REMOVING OF TREES, BRUSH, HEDGES AND
OBSTACLES WITHIN THE ROU THAT MAY HINDER THE
CONSTRUCTION ACTIVITIES.
 APPROVAL FROM CONCERNED AUTHORITIES BEFORE STARTING
CLEANING AND GRADING WORK.
 BANKS OF RIVER AND CANALS SHALL BE GRADED AFTER THE
PERMISSION FROM CONCERNED AUTHORITIES.
 ENTIRE CLEANING AND GRADING OPERATIONS SHALL COMPLY
WITH REQUIREMENTS OF ENVIRONMENTAL MANAGEMENT.
 GRADING IN STEEP AND ROCKY AREAS ON THE HILLSIDE OR IN
STEEP SLOPE AREAS, BARRIERS OR OTHER ARRANGEMENTS SHALL
BE PROVIDED.
 DISPOSAL OF DEBRIS
SURVEYS, CLEARING AND GRADING
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 HANDLING, HAULING AND STRINGING:

 CARE SHALL BE TAKEN WHILE LIFTING AND UNLOADING OF PIPE AND VISUAL
CHECK SHALL BE DONE AFTER EACH ACTIVITY.
 USE OF VACUUM LIFTING EQUIPMENT IS PREFERRED.
 LIFTING HOOKS MADE OF ALUMINIUM OR FORGED STEEL COVERED WITH RUBBER
OR TEFLON SHALL ALSO BE USED
 COATED PIPE MAY BE HANDLED BY MEANS OF SLINGS AND BELTS OF PROPER WIDTH
(MINIMUM 60 MM) MADE OF NON- METALLIC / NON-ABRASIVE MATERIALS
 ALL THE PIPE SHALL BE STRINGED WITH REFERENCE TO ALIGNMENT SHEETS AND
PROPER APPROVED DRAWINGS
 PIPE SHALL BE STRUNG AT MINIMUM HEIGHT OF 300 MM CLEAR OFF THE GROUND
SURFACE
 NO PIPE SHALL BE STRUNG WITHIN 50 M OF ANY AREA WHERE IT IS PROPOSED TO
BLAST.
 NO STRINGING SHALL BE CARRIED OUT ON SLOPES GREATER THAN 15% WITHOUT
PROPER AND ADEQUATE ANCHOURAGE.
 PIPES SHALL BE SUPPORTED AT MINIMUM TWO LOCATIONS.
 PIPE NUMBER, HEAT NUMBER, COAT NUMBER & LENGTH SHALL BE TRANSFERRED
AND RECORDED IN SERIAL ORDER .
 PIPE SHALL NOT STRUNG BEFORE TRENCHING IN ROCKY/HILLY AREAS.
 STRINGING OPERATION SHALL NOT BE IN ADVANCE OF WELDING / TRENCHING BY
MORE THAN 5 KM.
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 WELDING AND NDT:

 WELDING PROCEDURE SPECIFICATION (WPS) TO BE FOLLOWED FOR THE WELDING
IS QUALIFIED AND THE PROCEDURE QUALIFICATION RECORD (PQR) IS APPROVED
BEFORE START OFWELDING. APPROVED BRAND OF ELECTRODES ARE USED FOR
WELDING. PHYSICAL PROPERTIES OF THE WELDPRODUCED BY AN ELECTRODE
SHALL NOT BE LESS THAN MINIMUM VALUE OF BASE METAL. ELECTRODE
QUALIFICATION AND BATCH RECORD ARE MAINTAINED.
 EACH PIPE SHALL BE THOROUGHLY CHECKED INTERNALLY & EXTERNALLY FOR
VISUAL DEFECT/ DAMAGE AND CLEANED INTERNALLY BY COMPRESSED AIR
BLOWING.
 ALL FINISHED WELDS SHALL BE VISUALLY INSPECTED FOR PARALLEL AND AXIAL
ALIGNMENT OF THE WORK, EXCESSIVE REINFORCEMENT, CONCAVITY OF WELDS,
SHRINKAGE, CRACKS, UNDER-CUTS, CORRECTNESS OF DIMENSIONS, SURFACE
POROSITY AND OTHER SURFACE DEFECTS.
 DAMAGED END SHALL BE CUT AND RE-BEVELLED WITH BEVELING MACHINE. ALL
NEW BEVELS SHALL BE 100% DYE PENETRANT /MPI TESTED AND ULTRASONICALLY
TESTED FOR ANY LAMINATION.
 USE OF INTERNAL CLAMP IS MANDATORY FOR PIPE DIA.> 10”. EXCEPT TIE IN
JOINTS, FITTING ETC. IN SUCH CASE EXTERNAL CLAMPS ARE USED.
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 WELDING AND NDT:
• Cont…
 THE NUMBER OF WELDERS, AND WELDING SEQUENCE, SPEED ETC. SHOULD BE
SIMILAR TO THAT OF ADOPTED IN APPROVED WELDING PROCEDURE.

 EACH JOINT SHALL BEAR AN IDENTIFICATION NUMBER WHICH SHALL BE

FOLLOWED FOR NDT

 RADIOGRAPHY EXAMINATION OF 100 % GIRTH WELD IS CARRIED OUT. WELD

SHALL MEET THE REQUIREMENT OF API 1104. IN ADDITION 100% MANUAL
ULTRASONIC INSPECTION IS REQUIRED FOR CRITICAL WELD JOINTS i.e. TIE IN,
WELDING OF VALVES & GOLDEN TIE-INS.

 ALL FILLET AND GROOVE WELDS OTHER THAN THOSE RADIOGRAPHED SHALL
BE SUBJECTED TO DYE PENETRANT (DP)/ MAGNETIC PARTICLE (MP)
INSPECTION.
 REPAIR IS LIMITED TO MAXIMUM 30% OF THE WELD LENGTH. WELD CONTAINING
CRACKS SHALL BE CUT AND RE-BEVELLED TO MAKE A JOINT.

 DESTRUCTIVE TESTING OF WELD JOINTS ARE DONE FOR 0.1% OF THE TOTAL
NUMBERS OF WELDS COMPLETED.
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SHPPL 24-09-2014
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 FIELD JOINT COATING:
 THE CUT-BACK AREAS OF COATED PIPES WHERE WELD JOINTS ARE MADE ARE TO BE
COATED BY FIELD JOINT COATING.
 FIELD JOINT COATING MATERIAL IS HEAT SHRINKABLE WRAP AROUND SLEEVE USED AS
ANTICORROSION COATING OF BURIED ONSHORE PIPELINE.
 THE JOINT COATING SYSTEM SHALL CONSIST OF A SOLVENT FREE EPOXY PRIMER APPLIED
TO THE PIPE SURFACE PRIOR TO SLEEVE APPLICATION.
 THE SURFACE AREA IS BLAST CLEANED TO SA-2.5 (CHECKED BY PROFILE COMPARATOR )
FOLLOWED BY PRE-HEATING OF PIPE SURFACE, APPLICATION OF EPOXY PRIMER ( WET FILM
THICKNESS GAUGE APPROX. 100 MICRON) AND APPLICATION OF SLEEVE BY HEAT
SHRINKING.
 EACH SLEEVE JOINT IS INSPECTED BY MEANS OF A FULL CIRCLE HOLIDAY DETECTOR SET TO
DC VOLTAGE AT 25 KV (PIPE SURFACE TEMPERATURE BELOW 50 DEGREE CELSIUS) AND
THICKNESS OF SLEEVE CHECKED (AVERAGE ON WELD BEAD= 1.6 - 2.0 MM & BODY = 2 -
2.3 MM) BY THICKNESS GAUGE.
 ONE OUT OF 50 JOINTS COATING OR ONE COATING OUT OF EVERY DAY PRODUCTION (STRIP OF
25 X 200 SHALL BE CUT) SHALL BE TESTED TO ESTABLISH PEEL STRENGTH (0.5-3.5 N/MM).
 SURFACE ROUGHNESS BETWEEN 50 TO 70 MICRONS.
 RELATIVE HUMIDITY LESS THAN 85% & PIPE SURFACE TEMPERATURE SHALL BE MORE THAN
3°C ABOVE DEW POINT .
 OVERLAP BETWEEN SLEEVE AND CLOSURE PATCH IS MINIMUM 100 MM.
 WRAP AROUND SLEEVE WITH MINIMUM OVERLAP OF 50 MM ON BOTH SIDE OF YARD APPLIED
CORROSION COATING PIPE.
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 TRENCHING:
 THE PIPELINE SHALL BE LAID AT A DISTANCE OF 5 MTR. FROM ONE EDGE OF THE ROW IN
FLOW DIRECTION.
 STACKING OF TRENCH LINE.
 THE WIDTH OF EXCAVATION FOR TRENCH SHALL BE MINIMUM AS PER APPROVED
PROCEDURE (300 mm+DIA OF PIPE+200 mm)
 DEPTH OF COVER ABOVE PIPELINE SHALL BE AS SPECIFIED IN PROCEDURES (NORMAL= 1
M; ROAD= 1.2 M; RIVER= 1.5 M; RLY.= 1.7 M ETC)
 EXTRA WIDTH AND DEPTH SHALL BE PROVIDED IN ROCKY TERRAIN.
 STRIPPING OF THE TOP SOIL UPTO 30 CM OF THE TRENCH AND STORING SEPARATELY.
 SUITABLE CROSSING FOR PASSAGE OF MEN, EQUIPMENT, CATTLE ETC. SHALL BE
PROVIDED.
 PROTECTION OF UNDERGROUND UTILITIES.
 TRENCH BOTTOM AND SIDES SHALL BE FREE FROM ALL BRUSH KIDS, STAMPS, ROCKS
AND PROJECTING HARD OBJECTS
 IN CASE OF TRENCHING IN ROCKY AREAS, BLASTING IS PERFORMED WITH THE
GUIDELINES /SAFETY RULES OF CHIEF CONTROLLER OF EXPLOSIVES, NAGPUR.
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 LOWERING-IN:
 LOWERING SHALL COMMENCE AFTER INSPECTION OF TRENCH. TRENCH BOTTOM
SHALL BE FREE FROM PIPE SUPPORTS, STONES, ROOTS, DEBRIS, STAKES & RIGID
MATERIAL.

 LOWERING SHALL COMMENCE AS SOON AS POSSIBLE AFTER COMPLETION OF JOINT

COATING OF PIPE STRING, AFTER THE TRENCH BOTTOM IS PREPARED AND LEVELS
TAKEN.

 BEFORE LOWERING IN, COMPLETE VISUAL CHECK AS WELL AS HOLIDAY DETECTION

(25KV) CHECK BY A FULL CIRCLE HOLIDAY DETECTOR FOR PIPE COATING AND FIELD
JOINT COATING IS CARRIED OUT FOR COMPLETE PIPE STRING (SPEED 300MM /SEC).

 ANY DAMAGE FOUND WHILE HOLIDAY TEST SHALL BE REPAIRED.

 SAND PADDING AND ROCK SHIELD ARE PROVIDED IN ROCKY AREAS BEFORE
LOWERING.

 THICKNESS OF COMPACTED PADDING (SOFT SOIL/SAND) SHALL NOT BE LESS THAN

300 MM AROUND PIPE SHALL BE PROVIDED IN ROCKY/ MURROM AREA & 700 MM IN
SEISMIC AREA.

 ENDS OF THE LOWERED PIPELINE SECTION SHALL BE CLOSED WITH NIGHT CAP TO
PREVENT INGRESS OF WATER, MUD ETC.
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 BACKFILLING:
 PRIOR TO START BACKFILLING WORK, LEVELS OF ORIGINAL GROUND BOTTOM OF THE
TRENCH, TOP COVER OF THE PIPELINE LAID AND GPS CO-ORDINATES TAKEN

 BACKFILLING SHALL BE CARRIED OUT IMMEDIATELY AFTER PIPELINE LOWERING IN

TRENCH AFTER INSPECTION, TO AVOID LONG EXPOSURE OF COATING TO HIGH
TEMPERATURE, DAMAGING ACTION OF ADVERSE WEATHER CONDITIONS, SLIDING DOWN OF
TRENCH SIDES AND PIPELINE MOVEMENT IN THE TRENCH.

 IF IMMEDIATE BACKFILL IS NOT POSSIBLE, A COVERING OF AT LEAST 200 MM OF EARTH,

FREE OF ROCK AND HARD LUMPS SHALL BE PLACED OVER AND AROUND THE PIPE AND
COATING, WITHIN 24 HOURS OF LOWERING-IN.

 BACKFILL MATERIAL SHALL NOT CONTAIN ANY EXTRANEOUS MATERIAL OR HARD LUMPS OF
SOIL WHICH CAN DAMAGE PIPELINE OR COATING OR LEAVE THE VOIDS IN BACKFILLED
TRENCH.

 AFTER PLACING OF INITIAL BACKFILL, PROPER COMPACTION SHALL BE DONE. THE SURPLUS
MATERIAL SHALL BE CROWNED (300 MM) DIRECTLY OVER TRENCH AND ADJACENT
EXCAVATED AREA ON BOTH SIDE OF TRENCH.

 INSTALLATION OF PVC TAPE OF APPROXIMATELY 150 MM WIDTH MARKER TAPE AT

LOCATIONS INDICATED IN APPROVED DRAWINGS (600-700 MM ABOVE PIPE).

 SLOPE BREAKERS SHALL BE PROVIDED IN STEEP GRADIENTS TO AVOID WASH OUT OF THE
TRENCH.
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 TIEING-IN:
 THE UNCONNECTED SECTIONS OF THE PIPELINE AT VARIOUS
LOCATIONS HAVE TO BE TIED-IN, AFTER THE SECTIONS ARE
COATED, LOWERED AND BACKFILLED TO MAKE THE SECTIONS
READY FOR POST INSTALLATION HYDRO TEST.

 THE MINIMUM LENGTH OF PUP PIECE SHALL BE ADDED IS 1.0 M

AND TWO OR MORE SUCH PUPS SHALL NOT BE WELDED
TOGETHER.

 WELDING AND NDT OF TIE WELDS SHALL BE DONE AS PER

APPROVED WPS, PQR, CODES AND SPECIFICATIONS.

 PUP PIECE USED FOR GOLDEN TIE IN JOINTS SHALL BE PRE

HYDROTESTED.
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 CROSSING AND SPECIAL INSTALLATION:

 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, AND THE LIKE
AND THE VERGES AND/OR BANKS THEREOF AND THE BURIED
SERVICES WITH APPROPRIATE PROVISIONS.

 INSTALLATION OF THE CROSSING SHALL BE BY THE METHOD (I.E.,

BORING/OPEN-CUT) APPROVED BY AUTHORITIES HAVING
JURISDICTION.

 CASED & UN-CASED CROSSINGS FOR ROADS & RAILWAYS

 OPEN CUT & HORIZONTAL DIRECTIONAL DRILLING (HDD) FOR

MINOR & MAJOR RIVER CROSSING
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 HORIZONTAL DIRECTIONAL DRILLING:

 HDD IS TRENCHLESS DRILLING METHOD WITH ONLY ONE START
AND EXIT POINTS, OF INSTALLING UNDERGROUND PIPES,
CONDUITS AND CABLES IN A SHALLOW ARC ALONG A PRESCRIBED
BORE PATH BY USING A SURFACE-LAUNCHED DRILLING RIG, WITH
MINIMAL IMPACT ON THE SURROUNDING AREA.
 HDD (DIRECTIONAL BORING) IS USED WHEN TRENCHING OR
EXCAVATING IS NOT PRACTICAL.
 HDD IS SUITABLE FOR A VARIETY OF SOIL CONDITIONS AND JOBS
INCLUDING ROAD, LANDSCAPE AND RIVER CROSSINGS.
 NO DISRUPTION TO ROAD, RIVER OR RAIL TRAFFIC AND NO
SCARRING OF THE LANDSCAPE
 PIPES CAN BE INSTALLED EITHER STRAIGHT OR CURVED TO
STEER CLEAR OF OBSTACLES.
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 HORIZONTAL DIRECTIONAL DRILLING:

Cont…

IN HDD METHOD, PIPELINES ARE LAID IN THREE STAGES :-

 FIRST, A PILOT DRILL IS CARRIED OUT FROM THE ENTRY POINT.

 IN THE SECOND STAGE, REAMING THE PILOT DRILL, THE

DRILLING DIAMETER IS SUCCESSIVELY ENLARGED

 FINALLY, THE PREFABRICATED PRETESTED PIPELINE OR PIPE

BUNDLE IS PULLED BACK FROM THE EXIT POINT INTO THE
ENLARGED AND CLEANED BORE HOLE.
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 HORIZONTAL DIRECTIONAL DRILLING:

Cont…
Stage – 01

 A PILOT DRILL IS CARRIED OUT FROM THE ENTRY POINT.

 IN THIS PROCESS STEP, A COMPUTER-CONTROLLED SURVEYING

SYSTEM LOCATED BEHIND THE DRILLING BIT STEERS THE DRILL
STRING ALONG THE PLANNED ROUTE TO THE EXIT POINT ON THE
OTHER SIDE OF THE OBSTACLE TO BE CROSSED.
 THE SURVEYING SYSTEM, THE STEERING AND THE DRILLING TOOLS
CAN BE ADAPTED TO ANY SOIL CONDITIONS, THUS ENSURES THE
SUCCESS OF A PROJECT.
 HDD CROSSING

STAGE-01

DRILLING PILOT HOLE

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 HORIZONTAL DIRECTIONAL DRILLING:

Cont…
Stage – 02
 IN THE SECOND STAGE, REAMING THE PILOT DRILL, THE DRILLING DIAMETER IS
SUCCESSIVELY ENLARGED.
 TO ACHIEVE THIS, THE DRILL BIT IS REPLACED BY A REAMER. THE REAMER IS
EQUIPPED WITH JETS AND CUTTING TOOLS, ENABLING IT TO REMOVE THE SOIL
BOTH HYDRAULICALLY AND MECHANICALLY.
 DEPENDING ON THE SOIL CONDITIONS, A MIXTURE OF WATER AND BENTONITE
OR OTHER ADDITIVES CAN BE USED FOR HYDRAULIC EXCAVATION.
 THIS BOTH SUPPORTS THE BORE HOLE AND REDUCES FRICTIONAL FORCES, WHILE
ALLOWING THE EXCAVATED MATERIAL TO BE TRANSPORTED TO A SEPARATION
PLANT ON THE SURFACE.
 HDD CROSSING

STAGE-02

REAMING
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 HORIZONTAL DIRECTIONAL DRILLING:

Cont…
Stage – 03

 FINALLY, THE PREFABRICATED PRE-HYDROSTATIC TESTED PIPELINE OR

PIPE BUNDLE IS PULLED-BACK FROM THE EXIT POINT INTO THE
ENLARGED AND CLEANED BORE HOLE.
 TO DO THIS, THE PIPELINE IS CONNECTED TO THE PIPE STRING AND
PULLED BACK TO THE ENTRY POINT.
 WHEN THE PIPELINE APPEARS AT THE ENTRY POINT, IT HAS REACHED
ITS FINAL AND SAFE POSITION AND THE PIPELINE INSTALLATION IS
COMPLETE.
 POST HYDROSTATIC TEST SHALL BE PERFORMED
 HDD CROSSING

STAGE-03

PULL BACK
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 FLUSHING AND HYDROTESTING:

 HYDROSTATIC TEST IS PERFORMED ON ENTIRE LENGTH TO CHECK THE INTEGRITY
OF THE PIPELINE.
 THE MAXIMUM PERMITTED LENGTH OF HYDRO TESTING SECTION IS 50 KMS.
 HYDROSTATIC TEST DIAGRAMS INDICATING NUMBER OF TEST SECTIONS AND
MINIMUM AND MAXIMUM TEST PRESSURE IN EACH TEST SECTION ARE PREPARED
BEFORE PERFORMING HYDROSTATIC TEST.
 HYDROSTATIC TEST COMMENCE ONLY AFTER COMPLETION OF ALL WELDING
WORKS SO AS TO AVOID/ MINIMIZE UNTESTED HYDRO-TEST JOINTS/ GOLDEN
JOINTS.
 HYDRO TEST INCLUDES ALL THOSE SECTIONS WHICH ARE TESTED EARLIER FOR
ROAD, RAIL ROAD CROSSINGS, MAJOR WATER CROSSINGS ETC.
 DURATION OF HYDROSTATIC TEST IS MINIMUM 24 HOURS AFTER THERMAL
STABILIZATION.
 BEFORE WATER FILLING, PIPELINE SHALL BE CLEANED WITH AIR DRIVEN PIGS TO
REMOVE ALL MILL SCALE, RUST, SAND ETC. FROM THE INTERNAL PIPE SECTION
 WHILE WATER FILLING INHIBITOR SHALL BE ADDED BY DOSING PUMP AS PER THE
MANUFACTURERS RECOMMENDATION TO MAINTAIN THE PH VALUE OF FILLING
WATER BETWEEN 6.5 TO 7.5.
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 FLUSHING AND HYDROTESTING:

Cont….
 AFTER CLEANING OPERATION, UN-INHABITED WATER IS PUMPED
INTO THE SECTION.
 AFTER WATER FILLING OPERATION, THERMAL EQUILIBRIUM
BETWEEN PIPELINE AND ENVIRONMENT SHALL BE CHECKED WITH
THERMOCOUPLES INSTALLED ON THE PIPELINE.
 AFTER THERMAL STABILIZATION PRESSURIZATION IS CARRIED OUT
IN CYCLES OF 50% TEST PRESSURE & 75% TEST PRESSURE AND HELD
FOR 1 HOUR AT EACH TEST PRESSURE AND DEPRESSURIZED TO ZERO
PRESSURE AND THEN PRESSURIZED TO FINAL TEST PRESSURE.
DURING EACH TEST PRESSURE, TWO TEST SHALL BE CARRIED OUT
FOR CALCULATION OF AIR VOLUME IN THE PIPELINE UNDER TEST
AND ON ACCEPTANCE OF AIR VOLUME TEST THE SECTION IS HELD
FOR 24 HOURS AT FINAL TEST PRESSURE AND PRESSURE AND
TEMPERATURE RECORDED ON CHART
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 FLUSHING AND HYDROTESTING:

Cont….
 ENTIRE PIPELINE SHALL BE HYDROSTATICALLY TESTED ATTEST
PRESSURE.
 THE HYDROSTATIC TEST SHALL BE CONSIDERED POSITIVE IF PRESSURE
HAS KEPT A CONSTANT VALUE THROUGHOUT THE TEST DURATION,
EXCEPT FOR CHANGE DUE TO TEMPERATURE EFFECTS. THE PRESSURE
VALUE THUS ADDED SHALL BE COMPARED WITH INITIAL VALUE AND
THE TEST SHALL BE CONSIDERED AS ACCEPTABLE IF THE DIFFERENCE
IS LESS THAN OR EQUAL TO 0.3 BAR.
 AFTER POSITIVE TEST RESULTS, TEST SHALL BE TERMINATED . THE
PIPELINE SHALL BE DEPRESSURIZED AT CONSTANT RATE. DEWATERING
SHALL BE CARRIED OUT BY USING FOAM PIGS DRIVEN BY COMPRESSED
AIR.
 FOAM PIGS SHALL BE PASSED TO COMPLETE THE DEWATERING.
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 FINAL CLEAN UP, RESTORATION AND MARKER INSTALLATION:

 AS SOON AS BACKFILLING IS COMPLETE, THE ROU SHALL BE CLEANED UP BY

REMOVING SURPLUS MATERIAL, RESTORING SERVICES TO THEIR ORIGINAL
CONDITION, DISPOSING OF REFUSE, SMOOTHING DISTURBED EARTH, REMOVING
TEMPORARY FILLS, CULVERTS AND BRIDGES, AND PERFORMING SUCH WORK AS
MAY BE NECESSARY TO LEAVE THE ROU AS NEARLY LIKE ITS ORIGINAL CONDITION
AS POSSIBLE.
 ALL TEMPORARY STRUCTURES SUCH AS BRIDGES, CULVERTS, SHEET PILING,
POSTS, SIGNS, ETC., WHICH WERE ERECTED OR INSTALLED BY THE CONTRACTOR
AS TEMPORARY MEASURE, SHALL BE REMOVED.
 DAMAGES TO ROADS, BRIDGES, AND PRIVATE PROPERTY SHALL BE REPAIRED.
 ALL FENCES AND OTHER STRUCTURES WHICH ARE DAMAGED DURING THE
CONSTRUCTION SHALL BE RESTORED TO ORIGINAL CONDITION.
 THE ROU AND THE BACKFILLED TRENCH IN PARTICULAR SHALL BE FINISHED IN
SUCH A WAY THAT AFTER SETTLEMENT OF THE SOIL, THE FIELDS ARE AT THEIR
ORIGINAL LEVEL.
 PIPELINE MARKERS SUCH AS KILOMETER POST, TURNING POINTS/ DIRECTION
MARKERS, WARNING SIGNS AND BOUNDARY PILLARS ARE PROVIDED.
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MAINLINE ISOLATION/TAP-OFF VALVE

INSTALLATION:
 BLOCK VALVES ARE EITHER HAND OPERATED OR MOTOR
OPERATED.
 MAINLINE ISOLATION VALVES ARE PROVIDED AT AN
APPROX. INTERVAL OF 3 KM.
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 CATHODIC PROTECTION WORK:

 TEMPORARY CATHODIC PROTECTION (TCP) : DC CURRENT
SHALL BE PROVIDED BY USING ACTIVE METAL ANODES SUCH
AS MG, ZN, AL ETC.

 PERMANENT CATHODIC PROTECTION (PCP ) : EXTERNAL DC

POWER SOURCE USED FOR PCP

 TEMPORARY CATHODIC PROTECTION (TCP) TO THE PIPELINE

SHALL BE PROVIDED DURING CONSTRUCTION PHASE USING
SACRIFICIAL ANODE SYSTEM AND SUBSEQUENTLY PIPELINE
SHALL BE PROTECTED BY PERMANENT CATHODIC PROTECTION
(PCP) USING IMPRESSED CURRENT CATHODIC PROTECTION
(ICCP) SYSTEM.
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 PRESERVATION:

 CONSTRUCTED PIPELINE IS PRESERVED WHEN THERE IS A SUBSTANTIAL LAG

BETWEEN MECHANICAL COMPLETION AND ACTUAL COMMISSIONING.

• PRESERVATION IS CARRIED OUT BY NITROGEN FILLING AT 1 BAR.

 COMMISSIONING:
AFTER MECHANICAL COMPLETION OF THE PIPELINE , THE LINE IS
COMMISSIONED AFTER COMPLETION OF THE FOLLOWING ACTIVITIES.
 COMMISSIONING AND MAKING READY OF THE
PUMPING AND DELIVERY STATIONS.
 OBTAINING VARIOUS PERMITS AND CLEARANCES.
 ARRANGING PRODUCTS.
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 DOCUMENTATION:

 DAILY LOG BOOK

 SEPARATE REGISTER FOR EACH ACTIVITY
 PIPE BOOK
 WELDING INSPECTION REPORT
 RADIOGRAPHIC INSPECTION REPORT
 TIE-IN CHARTS
 PIPE DAMAGE REGISTER
 DEVIATION/ NCR REGISTER
 EQUIPMENT & MANPOWER MOBILIZATION REPORT
 HYDROSTATIC TESTING REGISTER
 CLAIMS REGISTER
 Due to deviations
 Due to change in work plan
 Damage to pipes etc
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Code No. Description

API – 5L : Specification for line pipes
API – 1102 : Steel pipeline crossings (Rail roads and Highways)
API – 1104 : Welding of pipeline and related facilities
ASME B31.8 : Gas Transmission and Distribution Piping Systems
API 1110 : Pressure testing of liquid petroleum pipelines
OISD 141 : Design and construction requirements for cross
country hydrocarbon pipelines

PNGRB : Regulations - Technical Standards and Specification

including Safety Standards for Natural Gas (T4S for
natural gas)

OISD 226 : Natural Gas Transmission Pipelines and City Gas

Distribution Networks
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