Technical Doc. - Coated Steel Pipe Laying PDF

TECHNICAL SPECIFICATION FOR LAYING,
TESTING AND COMMISSIONING OF CGD –
STEEL PIPELINE NETWORK
Document No-TGPL/STEEL/18-19/001/R0-DEC-2018
Table of Contents
Sr. No Document Page No.

1. Vendor Evaluation Criteria 3
2. Scope of Work 4
3. Specification for Steel Pipeline Activity 66
4. Specification for Pipeline Welding 102
5. Specification for Field joint coating 147
6. Specification for Pipeline Crossing 160
7. Specification for Pipeline Hydro test 170
8. Specification for Swabbing & Drying 187
9. Specification for Casing Insulator & End seals 192
10. Specification for Pipeline Marker 198
11. Specification for Concrete Coating 203
12. Specification for Quality Assurance Plan
Annexure – I : Guidelines To Bidders for Coverage Of Documents 216
Annexure – II : Glossary of terms used in the specification
13. Specification for HDD 230
14. Specification for Cathodic Protection 246
15. HSE Specifications 261
16. Drawings 296
17. Datasheets 318
18. Technical Specifications - Fabrication and Erection Of Piping 322
19. Technical Specifications - Flanges 333
20. Technical specifications - Inspection, Flushing and Testing Of Piping Systems 339
21. Technical specifications – Painting 348
22. Technical specifications - Butt Welded, Socket Welded and Screwed Fittings 362
23. Technical specifications - Seamless Fittings 368
24. Technical specifications - Welding of Station Piping 375
25. Technical specifications - Studs - Bolts, Nuts & Gaskets 403
26. Technical specifications for Valve (size – below 4”) 408
27. Personnel Protective Equipment Matrix (PPE MATRIX) 419
28. Medical Fitness Requirements 420
Total no. of Pages: 420

Vendor Evaluation Criteria
Vendor Evaluation Criteria

The Bidder who intends to participate shall meet the following requirements
Sr. No Criteria Supporting Document

1. The bidder should have completed pipe line (including Approved Work Completion
testing and hand over to owner) laying of length 10 KM or Certificate and Copy of Work
higher for CGD Gas Line/hydro-carbon service for steel Order
Pipeline of Diameter 4” NB or higher and in last 2 years
from the Bid release date.
2. Execution of Temporary Cathodic Protection system for the Approved Work Completion
underground pipeline for the length of 03 KM Certificate and Copy of Work
Order
OR
Self-declaration on company
letterhead with Project details
with Work Order copy
3 List of competent and experience manpower List of employees and its

qualification and experience
certificates on letter head
4 List of Fit for use Equipment / Machinery and Measuring List of equipment / Instruments
Instruments available for inspection and Inspection Certificates issued
by competent authority
5. The bidder should have completed Station Piping/above Approved Work Completion
ground Piping works (including testing and hand over to Certificate
owner) for at least 2 station piping or 100 INCH DIA work OR
perform. Self-declaration on company
letterhead with Project details
with Work Order copy
6 HSE and Quality Policy Policy on company letterhead
7 Detail of HDD and NDT Sub contractor – If applicable Self-declaration on company
letterhead
TECHNICAL SPECIFICATION FOR LAYING, TESTING AND COMMISSIONING OF
CGD - STEEL PIPELINE NETWORK
Document No-TGPL/STEEL/18-19/001/R0-
Version: 1.0 DEC 2018
DEC-2018
SCOPE OF WORK
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Contractor Sign & Stamp
DEC-2018
TABLE OF CONTENTS
1. OVERVIEW
1.1 DESCRIPTION
1.2 DEFINITIONS
2. GENERAL TERMS & CONDITIONS
2.1 SCOPE
3. SPECIAL CONDITION OF CONTRACT
3.1 GENERAL
3.2 JOB SPECIFIC REQUIREMENT
3.2.1 Quality Assurance / Quality Control Program
3.2.2 Third Party Inspection
3.2.3 Work Execution
3.2.4 Emergency Response Plan
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1. OVERVIEW
1.1. DESCRIPTION
Torrent Gas Pvt. Ltd. (“Torrent Gas” or “TGPL”) is part of the Ahmedabad based
Torrent Group, one of the fastest growing industrial groups of the country with
diverse interests in Pharma, Power and Gas sectors.
Torrent Pharmaceuticals Limited, the flagship Company of Torrent Group, having a

turnover of Rs. 6,000 Crores is one of the leading pharma companies of the country
with 8 manufacturing plants and presence in 40+ countries.
Torrent Power Limited, having a turnover of Rs. 11,500 crores, is one of the leading
players in the Indian power sector with a strong presence in the entire value chain of
the power sector; generation, transmission and distribution including strong
presence in renewable segment. The company has a generation capacity of 3,661
MW and distributes 16,000 million units of power to more than 3.2 million
customers in six cities.
Torrent Gas is currently implementing the City Gas Distribution project in the Pune
District through its associate company (TGPL). Further, in 9th CGD bidding Torrent
Gas has been authorized by the Petroleum and Natural Gas Regulatory Board
(PNGRB) for establishing City Gas Distribution system in following districts across
India:
Sr. No. Geographical Area’s Name

T 1 Junagadh District, Gujarat
o 2 Patiala, SAS Nagar (Ex) & Sangrur Districts, Punjab
r 3 Jaipur & Alwar (Other than Bhiwadi) Districts, Rajasthan
r 4 Baran, Kota (ex) & Chittorgarh (Only Rawatbhata) Districts, Rajasthan
e 5 Chennai & Tiruvallur Districts, Tamilnadu
n 6 Medak, Siddipet & Sangareddy Districts, Telangana
t 7 Karaikal & Nagapattinam Districts, Tamilnadu
8 Auraiya, Kanpur Dehat & Etawah Districts, Uttar Pradesh
G 9 Gorakhpur, Santkabir Nagar & Kushinagar Districts, Uttar Pradesh
a 10 Moradabad (ex) District, Uttar Pradesh
Torrent Gas would be setting up an extensive network of steel and PE pipelines,
customer connections and CNG stations for city gas distribution in its authorised
areas.
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This document summarizes the Technical requirements and the specifications for
laying of steel pipeline, fabrication and installation of piping for extension and
reinforcement of gas network and associated civil work. The scope of this job
specification comprise of steel pipeline laying testing and commissioning, installation
of valve, above ground / underground pressure reduction station, construction of
valve chamber, station piping, fabrication and installation at CGS & CNG stations,
Cathodic protection system.
In addition to above, the scope of contract also includes end connection with
existing live gas network by shut down, Hot Tap support services.
All the operations of mentioned areas are performed from the City offices located in
Geographical area / City. The Pipeline used shall be API 5L, PSL-2, Grade X 52 / X 60,
Carbon Steel Pipe of 12 m approx. pipe length and of required Wall thickness.
This scope covers the combination of various activities required to execute

construction of Steel pipeline and associated facilities. The Work orders (WO) for
individual work shall be issued during the course of execution based on the
requirement arising out of business need. The quantum of the work defined in this
tender is tentative quantity and to be executed during the period as per the WO
issued for actual execution of work.
Under this scope CONTRACTOR shall be required to start the mobilize of resources
within 15 days from the kick off meeting.
1.2. DEFINITIONS
In the Bid / Contract (as hereinafter defined) the following words and expressions shall
have the meanings hereby assigned to them except where the context otherwise
requires.
i) "TGPL" or "COMPANY" or “OWNER” shall mean M/s. Torrent Gas Pvt. Ltd.
ii) The OWNER means M/s. Torrent Gas Pvt. Ltd.
iii) CONTRACT shall mean Purchase Order (PO) / Contract and all attached exhibits
and documents referred to therein and all terms and conditions thereof together
with any subsequent modifications thereto.
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iv) CONTRACT PRICE shall mean the price payable to the Contractor under the PO/
Contract for the full and proper performance of his contractual obligations.
v) COMPLETION DATE shall mean the date on which the goods are successfully
commissioned by the Contractor and handed over to the Owner.
vi) COMMERCIAL OPERATION shall mean the condition of the operation in which
the complete equipment covered under the Contract is officially declared by the
Owner to be available for continuous operation at different load up to and
including rated capacity.
vii) DRAWINGS shall mean and include Engineering drawings, sketches showing
plans, sections and elevations in relation to the PO/ Contract together with
modifications and/or revisions thereto.
viii) ENGINEER shall mean the Engineer or Executive-in-Charge of the Project SITE
nominated by OWNER at SITE.
ix) FINAL ACCEPTANCE shall mean the Owner’s written acceptance of the Works
performed under the PO / Contract after successful completion of performance
and guarantee tests.
x) GOODS shall mean articles materials, equipment, design and drawings, data and
other property to be supplied by Contractor to complete the contract.
xi) INSPECTOR shall mean any person or outside Agency nominated by OWNER to
inspect equipment, stage wise as well as final, before dispatch, at Contractor’s
works and on receipt at SITE as per terms of the PO / CONTRACT.
xii) INITIAL OPERATION shall mean the first integral operation of the complete
equipment covered under the Contract with sub-systems and supporting
equipment in service or available for service.
xiii) PERFORMANCE AND GUARANTEE TESTS shall mean all operational checks and
tests required to Determine and demonstrate capacity, efficiency and operating
characteristics as specified in the Contract Documents.
xiv) SELLER / BIDDER / CONTRACTOR shall mean the person, firm or company with
whom PURCHASE
ORDER/CONTRACT is placed / entered into by OWNER for supply of equipment,
materials and services. The term Contractor includes its successors and assigns.
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xv) SERVICE shall mean erection, installation and testing, commissioning, provision
of technical assistance, training and other such obligations of the Contractor
covered under the Contract.
xvi) SITE shall mean the Project or designated destination for which the Contract has
been issued and where the equipment / materials shall be erected.
xvii) SPECIFICATIONS shall mean and include schedules, details, description,

statement of technical data, performance characteristics, standards (Indian as
well as International) as applicable and specified in the Contract.
xviii) SUB-CONTRACT shall mean order placed by the Contractor, for any portion of
the contracted work, after necessary consent and approval of OWNER.
xix) SUB-CONTRACTOR shall mean the person named in the CONTRACT for any part
of the work or any person to whom any part of the CONTRACT has been sub-let
by the SELLER with the consent in writing of the OWNER and will include the
legal representatives, successors, and permitted assigns of such person.
xx) START-UP shall mean the time period required to bring the equipment covered
under the Contract from an inactive condition, when construction is essentially
complete to the state of readiness for trial operation. The start-up period shall
include preliminary inspection and check out of equipment and supporting
subsystems, initial operation of the complete equipment covered under the
Contract to obtain necessary pre-trial operation data, perform calibration and
corrective action, shutdown inspection and adjustment prior to the trial
operation period.
xxi) TESTS shall mean such process or processes to be carried out by the Contractor
as are prescribed in the Contract or considered necessary by Owner or his
representative in order to ascertain quality, workmanship, performance and
efficiency of equipment or part thereof. TESTS ON COMPLETION shall mean such
tests as prescribed in the Contract to be performed by the Contractor before the
Works are taken over by the Owner.
xxii) CONSULTANT shall mean outside agency other than OWNER as authorized by
the OWNER. The term includes successors, assigns of CONSULTANT.
xxiii) The "BID" shall mean the Bid submitted by the CONTRACTOR for acceptance by
the TGPL.
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xxiv) "TGPL's REPERSENTATIVE" shall mean the person designated as such by the
Torrent Gas Pvt. Limited and shall include his authorized nominee or agent,
provided however that the TGPL's representative to be so designated by TGPL
may be one person for certain aspects of this agreement and another person for
other aspects of work covered by this Bid / Contract.
xxv) “THIRD PARTY INSPECTION AGENCY” (TPIA) shall mean outside inspection
agency other than TGPL authorized by the Company.
xxvi) “STORES” shall mean the company stores located in GA.
xxvii) “PERMANENT WORKS” or “WORKS” shall mean and include all works to be
executed in accordance with the Contract or part thereof as the case may be and
shall include all extras, additional, altered or substituted works as required for
the purpose of contract.
xxviii) “TEMPORARY WORKS” shall mean all temporary works of every kind required in
or about the execution, completion or modification of the works, which are not
permanent.
xxix) “APPROVED” shall mean approved in writing including subsequent written

confirmation of previous verbal approval and Àpproval' means approved in
writing including as aforesaid.
xxx) “CONSTRUCTION EQUIPMENT” means all appliances / equipment and things of

whatsoever nature for the use in or for the execution, operation, or modification
of the work or temporary works but does not include materials or other things
intended to form or to be incorporated into the WORK, or camping facilities.
xxxi) "MOBILIZATION” shall mean establishment of sufficiently adequate

infrastructure by the CONTRACTOR at site comprising of construction equipment,
aids, tools tackles including setting of site offices & site camp with facilities such
as power, water, communication etc., establishing manpower organization
comprising of resident engineer, supervising personnel and an adequate strength
of skilled, semi-skilled and unskilled workers, who with the so established
infrastructure shall be in a position to commence execution of work at site (s), in
accordance with the agreed time schedule of completion of work.
MOBILIZATION shall be considered to have been achieved, if the CONTRACTOR is
able to establish infrastructure as indicated above to commence work at all site
(s)/ locations as per time schedule, where so warranted in accordance with
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agreed schedule of work implementation to the satisfaction of owner/ engineer

– in-charge.
xxxii) “WORKING DAY” means any day, which is not declared to be holiday or rest day
by Owner.
xxxiii) “SPREAD” shall mean that combination of construction equipment including all
necessary tugs, supporting work, barges and personnel as defined in the Contract
and schedule of rates and prices, capable of performing specific portion of the
work.
xxxiv) “MECHANICAL COMPLETION” means completion of the pipeline laying and

installation work including clearing and grading the agricultural / Govt. land for
making ROW, Trenching, Stringing & Welding, Destructive and Non Destructive
testing, Field joint Coating, Lowering, crossing of other Under Ground Utilities,
Padding, Backfilling & Compacting, Final Clean-up etc. of all facilities including
pipeline work which may be included in scope of the work specification.
xxxv) “COMMISSIONING” shall mean placing into service of the system including the
plant(s), equipment(s), vessel(s), pipeline, machinery (ies), or any other section
or sub-section of installation(s) pertaining to the work of the CONTRACTOR after
successful testing and trial runs of the same.
xxxvi) “GUARNTEE” means the period and other conditions governing the warranty /
guarantee in respect of the work as detailed in section hereunder.
xxxvii) “CP” means Cathodic Protection system designed and installed for corrosion
control of Steel Pipelines.
xxxviii) “TCP” means Temporary Cathodic Protection system designed and installed for
corrosion control of Steel Pipelines during construction.
xxxix) “PCP” means Permanent Cathodic Protection system designed and installed for
corrosion control of Steel Pipelines after completion of construction activity.
xl) “HSE” means Health, Safety & Environment.
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2. GENERAL TERMS & CONDITIONS
2.1. SCOPE
2.1.1 This specification covers the minimum requirements for the various activities to be
carried out by CONTRACTOR for the Construction and Modification of the Steel
pipeline job.
The following is a broad description of activities, which shall be included as part of
this contract, as a minimum.
All the activities required for Pipeline Laying and Modification / Extension as per
the plan, including, but not limited to, the following:
o Issue & receipt of steel pipes and other free issue materials from TGPL
designated store or on site delivered directly from vendor as the case may
be.
o Supply of consumables such as Electrodes, coating sleeves, HDPE Warning
Mat (300 mm width + 5 mm X 300 micron thk.) etc. as per approved
vendor list of TGPL.
o Supply of Pipes and Valves of diameter less than 4” NB as per Approved
Vendor list of TGPL.
o Supply of all fittings such as Elbow, Tee, Flanges, Gaskets, Bolt & Nuts,
Plugs, Nipples, Socolets, Weldolets, Blinds etc., procured from approved
vendor list of TGPL is under scope of Contractor.
o Supply of O2 meter for working in confined areas, LEL meter for detecting
of any gas leakage prior to start of work. O2 meter and LEL meters shall
duly calibrated as per OEM schedule.
o Storage, Handling and Transportation of Pipes, Fittings, other project job
related material and equipment
o Stacking, Grading and Marker installation along the RoW
o Survey for utility identification.
o Procedure qualifications
o Pipe stringing and alignment along the RoW
o Excavation of trial pits / holes for utility identification and trenching.
Cable Locator for locating of any existing cable prior to start of
trenching. Local liasioning is in scope of contractor. TGPL will provide in
principal permission.
o Protection of trench using Shoring, Step cut and Shuttering
o Welding and NDT including Radiography
o Field Joint Coating
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o Pipeline laying through horizontal directional drilling (HDD) method

and restoration.
o Cleaning, gouging, Hydro test, Swabbing, Drying, Pre-commissioning
and Commissioning of Pipeline
o Restoration
o Spreading quarry spoil (If required)
o Supply and Installation of Paver Block
o RCC work for Road repairing
o Cold Field Bending / Induction Bending of Pipes
o Concrete Coating of Pipes
o Crossings by horizontal directional drilling (HDD)/ Thrust boring including
cased crossing
o Hook up of pipeline at the battery limits, as per the requirements.
o Prefabrication & testing of valve assembly / DRS
o Installation of Valves, Insulation Joints and other equipment in the Pipeline
o Transportation, shifting and Installation of DRS/CPRS
o Fabrication and Installation of Steel structures such as Supports, Cross
Over, ladders etc, as per site requirement
o Civil work for construction of valve chambers and DRS/CPRS
o Liaise with authorities and local people/bodies during the execution and
submit the NOC from the authorities after completion of work as per the
condition of permission.
o Obtain working RoW for pipeline construction wherever required
o Preparation of documents / reports for each activities
o Supply of Casing Pipe will be as per API / IS standard or Authorities having
jurisdiction.
o Installation of TCP including supply of all material and labour required for
carrying out the job, as per TGPL specification and requirement
o Implementation of COMPANY HSE policy, HSE Management System,
guideline in the project
o Establish Camp at location for equipment, Material, civil labour and staff.
o Supply of Manpower, Machineries, Equipment and Consumables “Fit for
Purpose”
o Certification of entire facilities and the resources (Machinery, tools and
tackles, & equipment) by COMPANY “Fit for Purpose”
o Man power deployed at the site, office, camp shall be medically fit and
medical fitness tests shall be conducted as per owner requirements.
o Man power deployed shall be trained in Basic safety, first aid and
firefighting as per training matrix and shall be assessed for its knowledge
and competency.
o Procure PPE’s as per the COMPANY approved specifications.
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o Provide Fabricated Caution Board and the Barricades as per the COMPANY
approved design.
o Preparation of detailed Risk register for Site Specific Risks along with
Mitigation plan for entire pipeline route.
o Conduct (Daily) site specific risk assessment with mitigation plan as per
COMPANY approved Formats.
o Entire mitigation plan shall be reviewed by TPI and approved by TGPL
o Site specific risk and Mitigation plan for entire pipeline route
o Preparation and approvals of HSE Plan
o Preparation and approvals of Project execution Plan as per time line
agreed while bidding
o Preparation and approval of resource deployment plan to complete the
project in time
o Preparation and get approval of HSE permit as per the COMPANY PTW
Matrix – Safe Working Practice.
o Conduct Tool Box talks with all involved man power at each location for
each activity and maintain record. `
o No Idle charges shall be payable to Contractor in any case.
The detail alignment, detailed route survey and soil investigation report for
proposed routes shall be provided to the CONTRACTOR by COMPANY for cross
country terrain or the pipeline in outskirts of city while for pipeline within the city
survey drawings will be made available. Also, the acquisition of Right of Use (RoW)
and statutory permission (in principal), shall be provided by Company.
The entire project shall be inspected and certified by a Third Party Inspection Agency
(TPIA), to be appointed by TGPL, from Material test certificates review, project
execution, commissioning to certification as per ASME B 31.8 “Gas Transmission and
Distribution Piping System” and PNGRB standards with any additional requirements
as demanded by the regulator for PNGRB during execution of work.
The total length of steel pipeline laying expected shall be as per the business plan
and size of the pipeline will vary from 4” NB to 16” NB depending upon the job
requirements.
2.1.2 This specification shall be read in conjunction with the conditions of all specifications
included in the BID.
2.1.3 CONTRACTOR shall, with due care and diligence, execute the work in compliance
with all laws, by-laws, ordinances, regulations, etc. and provide all services and
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labour inclusive of supervision thereof. All materials, equipment, appliances, or

other things (other than issued by TGPL) of whatsoever nature required in or about
the execution of the work, whether of a temporary or permanent nature shall be
provided by the CONTRACTOR.
2.1.4 CONTRACTOR shall take full responsibility for the stability and HSE of all operations
and methods involved in the work.
2.1.5 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 subsurface conditions, the extent and nature of work and
materials necessary for the completion of the work and the means of access to the
work area.
2.1.6 During the execution of work, CONTRACTOR should ensure that it should not
obstruct any or all other activities performed by other agencies.
2.1.7 CONTRACTOR shall be deemed to have obtained all necessary information on

subject as above mentioned as to risks, contingencies and all other circumstances,
which may influence the work.
2.1.8 CONTRACTOR shall, in connection with the work, provide and maintain at his own
cost, all lights, guards, fencing, watch, etc. when and where necessary or required by
OWNER or by any duly Constituted Authority for the protection of the work and
properties for the safety and convenience of the public and / or others.
2.1.9 Unless otherwise specified, all sections of this specification shall apply to all the
specification referred in this Contract.
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Torrent Gas Pvt. Ltd. TECHNICAL SPECIFICATION FOR LAYING, TESTING AND COMMISSIONING OF
DEC-2018
2.2 TECHNICAL REQUIREMENTS FOR PIPELINE CONSTRUCTION
2.2.1 PIPELINE CONSTRUCTION
2.2.1.1 Requirement of Right of Way (R.O.W.)

CONTRACTOR shall, before starting any clearing operations, familiarize himself with
all the requirements of the authorities having jurisdictions over the RoW for work
along the pipeline route in connection with the use of other lands and roads for
construction purpose.
CONTRACTOR shall notify TGPL and concern authority well in advance during work
progress for crossing road, railway, other pipeline, cable, canal, river and other
existing obstacles.
CONTRACTOR shall not commence work on such crossing before having obtained
approval from the Owner and necessary liaison with the concern authority. The
crossing shall be carried out to meet at all times the requirements & the conditions
of the permit issued by the authorities concerned. In absence of any specific
requirements by authorities, CONTRACTOR shall comply with TGPL/TPIA’s
instructions.
The right of ingress and egress to the RoW shall be limited to points where such right
of way intersects public roads. Arrangements for other access required by the
CONTRACTOR shall be made by him at his own cost and responsibility but for such
access the conditions of this specification shall also apply.
Where the work on RoW is along with of an existing line, utility or facility,
CONTRACTOR shall propose and provide methods to safe-guard the existing line or
facility. No work is allowed in such area without TGPL’s prior approval.
Any additional surveys or permissions required (for Working RoW / Space) and land /
RoW acquisition for Pipeline laying activity post issue of job order shall be carried
out by the CONTRACTOR at his own cost and submit NOC to TGPL.
The CONTRACTOR is required to perform his construction activities within the width
of Right-of-way set aside for construction of pipeline. Variation in this width caused
by local conditions or installation of associated pipeline facilities shall be identified in
the field.
For the laying of pipe line within city limit and industrial estate, no specific ROW will
be made available; CONTRACTOR shall use the roads available for general public for
the construction purpose.
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The Right-of-way boundary lines shall be staked by the CONTRACTOR so as to

prepare the strip for laying the pipeline. CONTRACTOR shall also establish all
required lines and grades necessary to complete the work and shall be responsible
for the accuracy of such lines and grading.
2.2.1.2 Restricted Right-of-Way

The route of Pipeline may run through various terrains with a restricted Right of Way
of through or along cultivated fields, orchids, gardens, lawns, ditches, public roads,
or obstacles distributaries canals. The CONTRACTOR shall only use such width as
made available plus extra land by private negotiation with landowners with his own
cost and no extra cost to TGPL and shall perform the work at such places in a manner
to compliance TGPL HSE requirements so as to avoid harm to people, assets and the
structures damage by the construction of the pipeline. After completion of the work,
CONTRACTOR has to restore RoW at his own cost to original condition.
2.2.1.3 RoW Markers

Prior to clearing operations CONTRACTOR shall carry out following if require or
instructed by TGPL,
• CONTRACTOR to take photograph of entire stretch to keep records of original
conditions.
• Install Benchmarks, Intersection Points and other required survey monuments.
• Stake markers in the centreline of the pipeline at distances of maximum 100
meters for straight-line sections.
• Stake two RoW markers at least at every 250 meters as per EIC approval.
Set out a reference line with respect to pipeline centreline at a convenient location
2.2.1.4 Protection of Underground and Overhead Structures

CONTRACTOR shall obtain plans and full details of all existing and planned
underground services, overhead lines from the TGPL / concerned authority having
jurisdiction and shall ensure it by GPR survey whenever instructed by TGPL or dig
verifications/trial pits & follow these plans closely at all time during the performance
of work.
CONTRACTOR will not be entitled to any other claims for any new obstacles
(underground utilities, pipes and cables) during the course of work execution.
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CONTRACTOR shall repair at his own cost any damages caused to existing facilities.
CONTRACTOR shall execute the work in such a manner that the said structures,
utilities, pipelines etc. are not disturbed / damaged.
Despite all precaution should damage to those utilities/ structure whether or not
shown in the drawing,
• CONTRACTOR must make repair or bear the cost of making good the same
without delay to the satisfaction of the Engineer or Executive-in-charge and
authority having jurisdiction.
• If CONTRACTOR fails to repair the damage in reasonable time (agreed by
authority / TGPL) TGPL reserve the right to have it repaired at the cost of
CONTRACTOR.
• Claims / Penalties notice received from authority shall be forwarded to
CONTRACTOR by TGPL for payment and receipt or NOC from authority shall be
submitted to TGPL
• CONTRACTOR shall be liable for any damage occurring to, or resulting from
damage to other pipelines, underground structures/utilities.
In case the drawings are not available, CONTRACTOR shall dig out trial pits at no
extra cost as per direction/instruction of TGPL/TPIA to locate underground utilities.
Where the pipeline crosses other underground utilities/structures, the CONTRACTOR
shall manually excavate to a depth in such a manner that utilities/structures are
located and extra care to be taken that utilities/structures are not damaged.
Temporary under pinning or any other type of support or other protective devices
necessary to keep the interfering structure intact shall be provided by the
CONTRACTOR at his own cost and shall be of such design as to ensure against their
possible failure.
2.2.1.5 Protection of Trench (Wherever Required)

CONTRACTOR shall keep the trench in safe condition until the pipe is laid and no
claim is to be made to the TGPL by reason of its cave in either before or after pipe is
laid. Protection of Trench shall be done in accordance with TGPL approved
Excavation procedure / guidelines using suitable methods like “V” shape, step cut or
shoring and shuttering. CONTRACTOR shall de-water, if necessary, using well point
system or other suitable systems, to excavate the trench and install the pipe, and
backfill the trench in accordance with the specifications.
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2.2.1.6 Protection of Working Site

CONTRACTOR shall protect the site by hard barricading at city area / public places or
soft barricading like cone / caution tape at out skirts. The method of protection of
work site shall be selected based on risk assessment and use of soft barricading shall
be allowed considering the risk profile submitted by CONTRACTOR. Final decision of
the type of barricading shall be decided by TGPL engineer in charge.
After completion of day time construction activities, an arrangement shall be done
for flickering lights / warning lights of suitable size at suitable locations right from
the first day of execution along the construction site in case of working at or near
traffic movement so as to prevent any accident. The cost of the same shall be borne
by the CONTRACTOR. Also the same arrangement shall be continued in case of low
light OR working during night time.
2.2.1.7 Identification of Pipe

CONTRACTOR shall state pipe identification number on the top of pipe as given
outside/ inside the pipe by pipe manufacturer for all pipes; CONTRACTOR shall also
measure their length and state it on the pipes. Pipes to be bent shall be measured
prior to bending. Identification (i.e. letter, number and length) shall be readable
(100mm font size and should be readable from 1mtr distance). All pipe identification
numbers shall be recorded in respective progress report and pipe logbook.
Before a pipe length, pipe end, etc. is cut, the painted serial number shall be
transferred by CONTRACTOR in the presence of TGPL/TPIA to either side of the joint
which is to be made by cutting, and the changes shall be recorded in the above
mentioned list stating the (new) length.
2.2.1.8 Night Caps

At the end of each day's work or every time when joining and welding operations are
interrupted, pipe lowered in trench the open ends on the welded strings of pipes
shall be capped with a securely closed metal / plastic cap or plug as approved by
TGPL/TPIA so as to prevent the entry of dirt, water or any foreign matter into the
pipeline. The cost of the cap shall be borne by the CONTRACTOR. These covers shall
not be removed until the work is to be resumed. The caps/plugs used shall be
mechanical type and shall not be attached to pipe by welding or by any other means,
which may dent, scratch or scar the pipe.
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2.2.1.9 Crossings
For all crossings CONTRACTOR shall seek and obtain prior approval from TGPL to
lay the pipeline and shall carry out the crossing as per the instructions of the
concern owner/authorities.
Highways, Main roads, Main Gates of various industries roads and their verges
and banks of water 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 TGPL.
CONTRACTOR is not allowed to close or divert roads or watercourses without

prior approval from TGPL. CONTRACTOR shall never unnecessarily hamper the
users of the roads, buried services and /or watercourses. The water flow shall
not be obstructed.
Owner reserves the right to demand from the CONTRACTOR for individual
crossings, a separate pre-test and /or a detailed report for approval, containing,
 Time Period
 Working method with equipment
 Test procedure
 Calculations of temporary works
The execution of the work may require working in deep trench requiring
extensive excavation ensuring all the required safety to maintain trench in
workable condition. The CONTRACTOR must plan, maintain minimum labour /
man power and necessary equipment as per the requirements of the job and
execute the pipeline construction according to prescribed schedule. No extra
costs shall be considered for such works. CONTRACTOR shall carry out
immediate restoration of crossing location and require to intimate concern
authority/owner for site visit.
2.2.1.10 Horizontal Directional Drilling

The laying of pipeline using Horizontal Directional Drilling (HDD) method shall
have two-stage process. The first stage will consist of drilling a small diameter
pilot hole along a designated directional path. The second stage involves enlarging
this pilot hole to a diameter that will accommodate the carrier pipe and pulling
carrier pipe back into the enlarged hole.
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The instrument shall be magnetic and accurate to survey the pilot hole during
drilling additionally, some deviation from the designed drilled path may be
experienced due to soil reaction. Therefore, anticipate a deviation in actual verses
designed pilot hole course of +/- 0.5% of the horizontal and vertical directions
drilled length. The error, when it is unacceptable, can be largely eliminated by re
drilling after "punch out" in the right of way limits. Best drilling standards shall be
followed to minimize the deflection as per the client’s requirements.
CONTRACTOR have to prepare and get approval of proposed bore profile
indicating depth, existing utility and pulling calculation prior to start HDD
operation.
On acceptance of drilling hole, a string on line pipe is pullback in the drilled hole
utilizing the cranes/side booms and pipe rollers to assure proper alignment and
entry angle into the hole. The entry angle is calculated and included as part of this
engineering and design package. Once the pipeline has been successfully pulled
into the drilled hole, the pull head is removed from the pipe string. The drill rig
will be demobilized and the job site secured. These activities are also a part of the
Quality Assurance responsibilities of the Driller.
Specification of HDD machine / equipment, manpower, equipment calibration as
well as HDD work is to be done as per the approved TGPL Guidelines
No extra costs shall be considered for such works.
2.2.1.11 Pipeline Markers

CONTRACTOR shall supply and install the pipeline markers as per the attached
drawing, along the route as per the directions of TGPL/TPIA. The markers shall be
fabricated and installed as per the approved job standards. Colour coding of
pipeline markers shall be as per approved job standards.
Pipeline Marker shall be installed as per the attached specification and same will
be paid as per SOR.
2.2.1.12 Installation of Fittings, Valves, Insulating Joints, Skid Assemblies

CONTRACTOR shall do all work necessary at each of the installations to provide
facilities, which are complete in all respects and ready for operations.
Without limiting the generality thereon, the work required to complete the
installations shall, where applicable, include all site surveys, site preparation,
filling, grading, fencing, foundations, installation of skid, civil work, painting,
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installation of all electrical equipment’s, and fixtures, piping, valves and fittings;
mount all instruments and make all piping and electronic connections, etc.
The CONTRACTOR at the locations as directed by the TGPL shall install fittings,
Valves and Insulating joints. CONTRACTOR shall obtain prior approval for
procedure of joints from the OWNER before installation.
Handling and installation of the insulating joints and valves shall be carried out
with all required precautions for avoiding damage and excessive stresses and that
the original pup length is not reduced.
The insulating joints and the welded joints shall be protected by external coating.
Insulating joints shall be electrically tested before welding into the pipeline. The
electrical conductance test shall be carried out using a Megger in presence of
TGPL/TPIA. The tests shall be repeated after installation and welding of the joint
into the pipeline to verify that the assembly is undamaged.
2.2.1.13 Pipeline Hydrostatic testing

Hydrostatic test shall commence only after mechanical completion, i.e., all welds
have been accepted and the pipeline has been laid and back filled according to
the specifications for entire pipeline. However, Pre /Post hydro testing shall be
carried out for all major crossings as per TGPL instruction.
Testing of any pipe section shall be commenced only after acceptance of Pipe
book by TPIA/TGPL. Before testing pipeline cleaning shall be done using cleaning
pig. Hydro test procedure to be approved by TGPL before commencing test.
2.2.1.14 Pneumatic Testing-as applicable, Drying and Commissioning

After acceptance of hydrostatic test by TGPL/TPIA, CONTRACTOR shall de-water,
clean, swab and dry the pipeline to standards of cleanliness and Pneumatic
testing as well as dryness to be done as per approved procedure and to the
satisfaction of TGPL/TPIA.
2.2.1.15 Valve Station & Hook-Up

After acceptance of hydro test and swabbing of pipeline, valves and valve stations
(including civil work) shall be installed to the satisfaction of the owner. Similarly
hook up shall also be carried out with prefabricated, NDT tested and hydro tested
sections. All this pre-fabricated section shall be certified by TPIA along with pipe
book. The golden joints for hooks shall be minimized. Only good performing
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qualified welder shall be used for golden joints. Golden joints shall be double NDT
tested (RT & UT) and other NDE as certified by TPIA. Golden joints shall be
identified / highlighted in pipe book. The CONTRACTOR shall propose the method
for installation / hook up of underground valves stations depending on the
methodology of carrier pipe installation (HDD or open cut methodology). The
same shall be approved by TGPL /TPIA prior to installation / hook up of
underground valves stations.
The work of prefabrication and testing shall be carried out at workshop or made
up site camp which is approved by Engineer or Executive in charge.
2.2.1.16 Domestic/Common Pressure Reduction Station & Hook-Up

The fabrication, installation and Civil work for hook-up to skid, shall be carried out
by CONTRACTOR as per the approved construction drawing to the satisfaction of
the TPI/TGPL. Similarly hook up shall also be carried out with pipeline. All this pre-
fabricated section shall be certified by TPIA.
The work of prefabrication shall be carried out at workshop or site camp which is
approved by engineer in charge /TPI.
2.2.1.17 Tar cutting and Soil handling/Shifting (Wherever Required)

CONTRACTOR shall cut the tar/RCC/PCC surface using power driven road cutter as
per direction of EIC or pneumatic/electrically operated breaker. The trench shall
be further excavated using machine or manual means and spoil will be
transported to a dump yard arranged by CONTRACTOR for the city laying or as per
the direction of engineer in charge at no extra cost to TGPL.
2.2.1.18 Soil Shortage (Wherever Required)

If due to unforeseen circumstances, during backfilling and compacting there is not
enough soil to fill the trench properly, or to install crown height as stipulated,
CONTRACTOR shall supply the necessary backfill material at CONTRACTOR's cost.
This soil brought from outside shall be backfilled before the top - soil cover is
replaced.
2.2.1.19 Rocky Terrain:

Rocky Terrain is defined as trench material with a single piece of rock, dimension
exceeding 1.0 m in any direction, and requires cutting by use of pneumatic chisel
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/ drill or sledge hammer and chisel or removal of the same by additional

excavation.
Additional applicable rates shall be payable for hard rock excavation as per line
item of SOR over and above the pipeline laying rates in case the cutting of rock is
more than 1.0 meter as per above. Approval of Engineer or Executive In-Charge is
required for any doubts / confirmation.
Excavation through soil mixed with small boulders that have been used for a road
base will not be considered as hard rock for the purpose of payment.
2.2.2 MATERIAL MANAGMENT

SCOPE OF SUPPLY MATERIALS TO BE SUPPLIED BY OWNER AS FREE ISSUE
 Carbon steel 3LPE coated 4”and above pipe of API 5L PSL2 Grade X52 /
X60.
 Steel pipeline Valves 4” and above.
 MDPE pipes
 PE Ball valves
 Insulating Joints 4”and above
 Skids.
TGPL may supply the line pipe directly to the yard of contractor, if deemed
suitable to TGPL.
MATERIALS TO BE SUPPLIED BY CONTRACTOR

The procurement and supply, in sequence and at the appropriate time, of all
materials (permanent and Temporary) and consumables required for completion
of the WORK as defined in the scope of work and tender, shall be entirely the
Contractor’s responsibility.
The materials to be supplied are, but not limited to the following:
i) CS/LTCS Pipes of Diameter less than 4” NB.
ii) Equal tee, reducing tee, valves and all fittings and materials other than
free issued carbon steel pipes required for completion of project shall be
supplied by contractor.
iii) All materials, equipment, trailers for transportation, loading, unloading,
stringing etc. for owner’s supplied material.
iv) All welding machines, lifting equipment, instruments, transporting
vehicles and consumables for welding such as oxygen, acetylene, inert
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gases and all types of electrodes, filler wire, solder wire, brazing rods, flux
etc. for welding/cutting and soldering purpose.
v) All materials, equipment and instruments required for all types of tests
such as radiography, Ultrasonic testing, magnetic particle and dye
penetrate examination and any other tests as per requirement of
Owner/Owner’s Representative.
vi) All materials, equipment, instruments and consumables including primer
calibrated pump required for external corrosion coating and concrete
coating (where required) of field weld Joints.
vii) All materials, equipment, instruments and consumables required for
repair of damaged Coating of line pipe.
viii) Casing pipes, insulators and end seals and materials for casing vents and
drains as per Drawings, if applicable.
ix) All materials, equipment, instruments and consumables required for
continuous concrete Coating / Concrete slabs for providing anti buoyancy
to the pipeline, wherever required.
x) All materials, equipment, instruments, temporary vehicles required for
sand/soft soil padding around pipeline, Warning MAT, select approved
quality backfill, bank stabilization of water crossings, etc.
xi) All materials, consumables and equipment related to blasting of rock for
excavating trench or grading the Right-of-Way.
xii) All equipment and material for excavation.
xiii) Corrosion inhibitor for water used for hydrostatic testing, including water
for testing.
xiv) All equipment, pumps, instruments, pipes, fittings and equipment,
metallic blinds, temporary gaskets as required for filling, pressurizing and
dewatering for hydrostatic testing, including pipe headers for air and
hydro testing.
xv) All pigs for cleaning, gauging, filling, dewatering and swabbing of the
pipeline.
xvi) All consumables, equipment (air compressors/air dryers of suitable
capacity), instruments for drying of pipeline includes pigs as required.
xvii) All primer and paints for painting above ground piping.
xviii) All materials, equipment, instruments for lowering and back filling
and tie-in of pipeline sections.
xix) All materials, equipment required for repair/restoration of pavements,
roads, bunds, other structures affected/damaged by Contractor’s
construction activities. Materials shall be equivalent/superior to those used
for original construction of the facility.
xx) Bolts, nuts, washers, U bolts, clamps, clips, and gaskets for supports.
xxi) Shims, wedges and packing plates (machined wherever required).
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xxii) All materials, equipment for civil and structural works, grouting etc.
xxiii) All safety tools/tackles/devices/apparatus/ equipment, etc. including
ladders and scaffolding as required.
xxiv) All materials for corrosion protection of buried piping, pipe-fittings,
valves, casing pipes, etc.
xxv) HDPE Warning mat & Protection of pipeline for HT Line crossing,
foreign pipeline crossing with PVC mat or RCC.
xxvi) All materials, equipment for all types of pipeline markers.
xxvii) Nitrogen gas if required, for filling in the pipeline system for
preservation.
xxviii) All other materials not specifically listed herein, but required for the
execution of the WORK.
2.2.2.1 Loading, Unloading, Handling, Hauling & Storing of Materials

The CONTRACTOR shall exercise utmost care in loading, unloading and handling line
pipe and other materials. CONTRACTOR shall be fully responsible for all materials
and their identification until such time that the pipes and other materials are
installed in permanent installation. CONTRACTOR shall be fully responsible for
arranging and paying for storage areas for the pipeline materials, however, method
of storage shall be approved by TGPL/TPIA.
CONTRACTOR shall check health of pipe and other free issue materials for coating
damage, thickness, Magnetization of pipes etc. prior to issue from TGPL stores. In
case of any deviation in technical requirements of material contractor is required to
inform engineer or executive in charge in writing and shall not accept the delivery
unless same is approved by Engineer in charge. CONTRACTOR shall check marking of
identification number and condition of material before receiving from TGPL store
and shall send Material Take Off report within two days after receiving of material.
CONTRACTOR shall reimburse the TGPL for the cost of replacement of all TGPL
supplied materials damaged / lost during the period in which such materials are in
the custody of the CONTRACTOR. It shall be CONTRACTOR’s responsibility to unpack
any packing for the materials supplied by TGPL.
2.2.2.2 Materials to Be Supplied by CONTRACTOR

The CONTRACTOR shall procure and provide whole of the materials required for the
construction including steels, cement and other building materials, tools, tackles,
construction plant and equipment for the completion and modification of the WORK
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except the materials which will be issued by the TGPL and shall take his own
arrangement for procuring such materials and transport thereof.
Completeness of the EQUIPMENT shall be the responsibility of the CONTRACTOR.
Any equipment, fittings and accessories which may not be specifically mentioned in
the specifications or drawings, but which are usual or necessary for the satisfactory
functioning of the equipment (successful operation and functioning of the
EQUIPMENT being CONTRACTOR’s responsibility) shall be provided by CONTRACTOR
without any extra cost.
The CONTRACTOR shall perform the necessary loading, unloading, hauling to points
designated by the owner and storing if necessary of the material furnished by
CONTRACTOR. The CONTRACTOR shall exercise care in handling, hauling, storing and
distribution of such materials in order to avoid damage or deterioration of these
materials.
Materials excluding line pipe shall be stored in the sheltered storage. Such materials
shall not be strung on the Right-of-way but shall be transported in conveyances for
use only at the time of installation.
CONTRACTOR shall ensure that all Pipes & valves and whenever applicable, other
materials are fitted with suitable end covers.
2.2.2.3 Material Reconciliation

CONTRACTOR shall submit account of material issued for job to be completed.
CONTRACTOR shall return all the balance material at OWNER's store along with the
necessary documents. Any discrepancies, if found in material account then cost of
the same shall be deducted from CONTRACTOR's final bill.
a) Contractor shall submit account of material issued for job to be completed.
• CONTRACTOR shall submit material consumption statement on Monthly
basis and on completion of each job order.
• CONTRACTOR shall maintain stock register for free issue materials on daily
basis.
• At the time of reconciliation CONTRACTOR shall return total balance
material for each of the projects being executed (even within the same
location) that is issued to him by company for execution of work at his cost.
• CONTRACTOR shall return all the balance material at TGPL designated store
along with the necessary documents. Any discrepancies, if found in material
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/ instruments, equipment (issued by TGPL) shortage / damage then cost of

the same shall be deducted from Contractor's final bill as per rate decided by
TGPL.
RECONCILIATION OF TGPL SUPPLIED MATERIALS
 Every month, the contractor shall submit an account for all materials
issued by TGPL in the Performa prescribed by the Engineer-in-Charge. On
Completion of the work, the contractor shall submit "Material
Appropriation Statement" for all materials issued by the TGPL in the
Performa prescribed by the Engineer-in-charge.
 The percentage allowance shall be accounted on the basis of final Pipe
book chainage for main pipeline and erected/approved fabrication
drawings for station piping as mentioned below:
A. For underground pipeline network
All coated line pipes as per line pipe specifications enclosed elsewhere in
the bidding document, shall be issued on linear measurement basis. Joints
etc. shall be issued on number basis. All other piping materials shall be
issued on number basis. All cut pieces of pipes measuring in length of
minimum 2 mtr, when returned to TGPL's designated storage points after
bevelling, shall be considered as serviceable material and TGPL reserves full
rights to re-issue the same to the contractors. All cut pieces of pipes
measuring less than 2 mtr will be treated as wastage/scrap.
For the purpose of accounting of coated line pipes following allowances shall be
permitted (maximum permissible limit).
 Unaccountable wastage 0.10%
 Scrap (all cut pieces of pipes measuring less than 2 mtr): 0.3%
(CONTRACTOR has to return scrap quantity to OWNER during
reconciliation of materials).
 Serviceable materials (all cut pieces of pipes measuring from 2 mtr up to
10 m): 0.5%
Unaccountable wastage/scrap/serviceable material shall be at actual as per
site assessment subject to maximum as stated above.
B. For above ground piping work
For the purpose of accounting of station piping, all cut pieces measuring in
length of 1 mtr and above when returned to TGPL's storage points after
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bevelling, shall be treated as serviceable materials. All cut pieces of pipe

measuring less than 1mtr will be treated as scrap.
For the purpose of station piping in case of free issued by TGPL, following
allowances shall be permitted (maximum permissible limit);
Unaccountable wastage 0.1%
Scrap (all cut pieces of pipes measuring less than 1m) 1.0%
Serviceable materials (all cut pieces of pipes measuring 1m and
above) 2.0%
Unaccountable wastage/scrap/serviceable material shall be at actual as per
site assessment subject to maximum as stated above.
C. All unused material / scrap material shall be the property of the TGPL and
shall be returned by the Contractor category-wise at his cost to the TGPL's
designated store. All the serviceable materials when returned to TGPL should
have details of Pipe No., Heat No., Coat No. (wherever applicable), Length
etc. on each of the steel pipe and pipe returned without the details pipe shall
not be considered as return quantity and liable for recovery. In case the
Contractor fails to do so/ or exceeds the limits of allowances specified above
for scrap/serviceable materials, then recovery for such quantities not
returned by the Contractor will be done at the penal rate i.e. 100 % of landed
cost at the time of final bill/closing of contract by Engineer-in-charge. The
recovery shall be affected from the Contractor's bill(s) or from any other
dues of the Contractor to the TGPL.
Upper limit for return of serviceable materials shall not be applicable for the
individual project having total steel laying length of 1.5 kms and below.
D. Contractor shall be responsible for the adjustment/ weighting
/measurement of the surplus materials to be returned to the store.
Contractor shall also be responsible for suitable segregation of returned
materials into separate stacks of serviceable and scrap materials.
E. Wherever certain material is covered under Contractor's scope of supply
whether part or in full or any item of work covered under wherever certain
material is covered under SOR, no allowance towards wastage/scrap etc.
shall be accounted for during execution stage.
2.2.3 WORK MANAGEMENT
2.2.3.1 Location of Site

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The location of work site shall be provided in detail job order issued from time to
time.
2.2.3.2 Scope of Work

The scope of work is defined in this bid document. The CONTRACTOR shall provide
all necessary materials, equipment, tools & tackles, labour etc. and get it approved
(Fit for Purpose) through TPIA / TGPL for execution and modification of the work till
completion.
CONTRACTOR shall, with due care and diligence, execute the work in compliance
with all laws, by-laws, ordinances, regulations, TGPL Business Principal etc. and
provide all services and labour inclusive of supervision thereof. All 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 shall be
provided by the CONTRACTOR.
CONTRACTOR shall, in connection with the work, provide and maintain at his own
cost, all lights, guards, fencing, watch, etc. when and where necessary or required by
TGPL/TPIA or by any duly Constituted Authority for the protection of the work and
properties for the safety and convenience of the public and / or others.
2.2.3.3 Sub- contracting of Works

No part of CONTRACT / WORK shall, in any manner of degree be transferred,
assigned or submitted by the CONTRACTOR directly or indirectly to any person, firm
or corporation whosoever, without prior written approval from TGPL.
CONTRACTOR shall submit to the TGPL the details of SUB-CONTRACTOR for the
activity of NDT and CP including experience and skill of their manpower along with
the bid to declare their intent for execution of work. After evaluation of the SUB-
CONTRACTOR, TGPL may give written consent to SUB-CONTRACTOR for the
execution of any part of the work at site, being entered in to by CONTRACTOR.
Consent for sub-contracting is not required for supply of manpower for civil,
excavation and related works.
The CONTRACTOR shall be and shall remain solely responsible for the quality, proper
and expeditious execution of the work and the performance of all the condition of
the contract in all respect as if such subletting of sub-contracting had not taken
place, and as if such work had been done directly by the CONTRACTOR.
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If any SUB-CONTRACTOR work which in opinion of the TGPL/TPIA is not in

accordance with the contract documents, the TGPL may issue written notice to the
CONTRACTOR, and the CONTRACTOR upon the receipt of such notice, shall
terminate such subcontract. Contractor may propose additional list of Sub contract
for CP and NDT; TGPL reserves right to approve or disqualify the same.
2.2.3.4 Construction Equipment and Site Organization

Construction Equipment
The CONTRACTOR shall without prejudice to his overall responsibility to execute and
complete the work as per specifications, time agreed in Job order, progressively
deploy at site adequate equipment, tools and tackles and augment the same as
decided by the TGPL/TPIA depending on the exigencies of work so as to suit the
construction schedule. All equipment shall be “FIT FOR USE”. Audit / Inspection of all
equipment shall be carried out by TGPL/TPIA at CONTRACTOR place / site prior to
mobilize equipment for TGPL.
Site Organization
Subject to the provisions in the Bid Document and without prejudice to

CONTRACTOR’s liabilities and responsibilities to provide adequate qualified and
skilled personnel on the work, CONTRACTOR shall deploy site organization and
augment the same as decided by the Engineer-in-charge depending on the
exigencies of work.
Recruitment of Personnel by CONTRACTOR
The CONTRACTOR shall not recruit personnel of any category from among those who
are already employed by other agencies working at the various sites of TGPL.
However, CONTRACTOR shall give priority and make maximum use of local workers
available. If in any case CONTRACTOR wants to recruit personal of any category from
among those who are already employed by other agencies working at the various
sites of TGPL than CONTRACTOR have to get No Objection Certificate from other
agencies.
2.2.3.5 Water Supply

CONTRACTOR will have to make his own arrangements for supply of drinking water
to his labour camps and for works.
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2.2.3.6 Power Supply

It shall be the responsibility of the CONTRACTOR to provide electrical power supply
to its equipment’s at site. All the cabling, equipment, installations etc. shall comply
in all respects with the latest statutory requirements and safety rules etc.
2.2.3.7 Land for CONTRACTOR’s Field Office, Godown, Store, Camp and Workshop
The CONTRACTOR shall at his own cost hire the facilities or provide land to construct
all these temporary facilities including camp site for technical staff and for
excavation workers, line pipe stockyard and provide suitable water supply and
sanitary arrangements. TGPL as a part of mobilization would audit the facilities with
respect to HSE requirements.
a) Camp Site / Land for
• Suitable water supply and sanitary arrangements
• Health and Hygienic conditions
• First Aid facilities
• Fence and security
b) Pipe yard / Godown with
• Secured Boundaries
• Elevated or prevented against logging of water
• Stable ground for stocking of line pipes and the vehicular movements
• Stable approach for Movements of pipe loaded tailor
• Support to avoid rolling over of pipe from pipe stack
• Covering protection against Rain
• Covering of end of pipe by night cap
• Free from passing over head electrical wire
• First Aid facilities
The contractors need to clearly separate out the camp yard and pipe yard for risk
reduction purpose.
2.2.3.8 Information – Verification & Responsibility

The CONTRACTOR in fixing his rate shall be, for all-purpose, whatsoever reason may
be, deemed to have himself independently obtained all necessary information for
the purpose of preparing his BID as accepted and shall be deemed to have taken into
account all contingencies as may arise due to such information or lack of same.
Although, every endeavour has been made to provide correct and full information
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the correctness of the details given in the Bid Document to help the CONTRACTOR to
take up the Bid is not guaranteed.
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 subsurface conditions, the extent and nature of work and
materials necessary for the completion of the work and the means of access to the
work area.
CONTRACTOR shall be deemed to have obtained all necessary information on subject
as mentioned above as to risks, contingencies and all other circumstances, which
may influence the work.
2.2.3.9 Work in Monsoon and De-Watering

The execution of the WORK may entail working in the monsoon and areas requiring
extensive dewatering with ensuring all the required safety measures are taken to
maintain site in workable condition. The CONTRACTOR must maintain a minimum
labour force and necessary dewatering pump as may be required to Make the site
safe for the job and plan and execute the construction and erection according to the
prescribed schedule. No extra rate will be considered for such Work during Monsoon
period is subject to prior approval from TGPL and availability of permission from the
authority.
Risk profile for work during monsoon shall be prepared, and get it approved from
TGPL prior to start of the work during monsoon. All the mitigation actions suggested
in Risk profile shall be ensured by CONTRACTOR. No extra cost will be paid for such
risk mitigation.
2.2.3.10 Mechanization of Construction Activities
The CONTRACTOR shall without prejudice to his responsibility to execute and
complete the work strictly as per the specifications, HSE Compliances and within the
stipulated TIME PERIOD, mechanize the construction activities to the maximum
extent by deploying all necessary construction equipment / machinery in adequate
numbers and capacities and commensurate with the extent of enhanced
mechanization required to suit the construction schedule / progress reviewed from
time to time as per recommendation of the TGPL/TPIA.
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2.2.3.11 Work Responsibility

From the commencement to completion of the WORK, the CONTRACTOR shall take
full responsibility for the all works including all temporary works and in case any
damages, loss or injury to employees / TPI shall happen to the WORK or to any part
thereof or to any temporary works from any cause whatsoever, CONTRACTOR shall
at his own cost repair and make in good order and in conformity in every respects
with the requirement of the CONTRACT and the TGPL/TPIA’s instruction.
CONTRACTOR shall have public liability and property damage insurance.
2.2.4 INSPECTION and DOCUMENTATION
2.2.4.1 Action Where No Specification Is Issued

In case of any class of WORK for which there is no SPECIFICATION supplied by the
TGPL as mentioned in the Bid Documents such work shall be carried out in
accordance with ASME Standards, API standards & PNGRB Regulations / Guidelines
and as per the standard Engineering Practice subject to the approval of the
TGPL/TPIA.
2.2.4.2 Tests and Inspection

 The CONTRACTOR shall carry out the various tests as enumerated in the
technical specifications of this bid document and the technical documents
that will be furnished to him during the performance of the work and no
separate payment shall be made unless otherwise stipulated.
 All the tests either on the field or at outside laboratories, concerning the
execution of the work and supply of materials by the CONTRACTOR shall be
carried out by CONTRACTOR at his own cost.
 The work is subjected to inspection at all times by TPIA. The CONTRACTOR
shall carry out all instructions given during inspection and shall ensure that
the work is being carried out according to the technical specifications of this
bid, the technical documents and the relevant codes of practice furnished to
him during the performance of the work.
2.2.4.3 Erection and Installation

The CONTRACTOR shall carry out required supervision and inspection as per Quality
Assurance plans and furnish all assistance required by the TGPL/TPIA in carrying out
inspection work during this phase. The TGPL will have engineers; inspectors or other
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authorized representatives present who have free access to the work at all time. If
TGPL/TPIA’s representative notifies the CONTRACTOR’s authorized representative
not lower than a foreman of any deficiency, or recommends action regarding
compliance with the specifications, and the HSE, the CONTRACTOR shall make every
effort to carry out such instructions to complete the work conforming to the
specifications. HSE requirements and approved drawings in the fullest degree
consistent with best engineering practice.
2.2.4.4 Line Drawings and Pipe Book:

CONTRACTOR shall prepare Line Drawings of pipeline section showing as laid
pipeline Reference measurement with respect to permanent structure, Direction
change i.e. Horizontals and the Verticals, and chainage and submit it to TGPL/TPIA
daily.
Further CONTRACTOR shall prepare a pipe book as per approved format and weld
book along with the line diagram indicating pipe number, joint numbers and submit
it to TGPL after completion of each spread / section before hydrostatic testing.
2.2.4.5 Documentation
“AS BUILT” DRAWINGS”
Notwithstanding the provisions contained in standard specifications, upon
completion of WORK, the CONTRACTOR shall complete all of the related drawings to
the “AS BUILT” stage (including all vendor / sub vendor drawings for bought out
items) and provide the owner, the following.
 Two complete set of full size (Alignment Sheets) reproducible drawings (Soft
Copies - Digital format, in latest available version / informed by TGPL of
AutoCAD, in CDs – 3 sets)
 One complete set of original size prints (Hard Prints) and Two Xerox copy of
the same.
 Soft copies / scan copies of all project documents in CDs or USB – 3 Sets
“Hand Over Take Over Document”
CONTRACTOR shall prepare and submit Hand over Take over Documents (3 Set)
along with as built drawing one day before the commissioning as part of
documentation.
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2.2.4.6 Completion Document

The CONTRACTOR as a part of completion documents shall submit during and
immediately after the construction in original, in hard binder as well as 3 set of CD as
a minimum but not limited to the following;
Pipeline activities
 SOP generated from specifications for each activity approved by TGPL / TPIA.
 Progress Report of Various activity (Daily/Weekly and Monthly)
 Inspection and Test reports of Various activity
 Testing, Flushing and Clearing Reports.
 Welding Procedure Qualification Report.
 Welder Qualification Report.
 Electrode Qualification Test Report.
 Radiographic Procedure Qualification.
 Pipe Book
 As built up drawings and alignment sheets.
 Certified Copy of material test certificates and consumables for Pipeline
supplied by CONTRACTOR
 All the document mentioned in the Technical Specification
 Calibration Reports of all Testing Equipment’s.
 Pre-commissioning report
 Commissioning checklist.
 Final closeout report
HSE activities
 OHSAS:18001 & ISO:14001 Compliance documents
 Training / HSE briefing records
 HSE Plan and Review Documents
 Records of SSRA & Tool Box talk
 Records of Closing of Non Conformities
 Site photos
 Final Closeout report
 Waste Disposal records
This shall as a minimum include but not limited to the following: -
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Daily:
a) Progress Report
 Machinery deployed Report

 ROW Clearing Grading Report
 Stringing Report
 Trenching Report
 Line up & Welding Report
 Radiography Report
 Field joint Coating Report
 Lowering Report
 Tie in Report
 Backfilling Report
 Restoration Report
 Marker Installation Report
 Material take off report
 Welder Performance report
 Cold Field Bending Report
 Cased Crossing
 HDD Crossing
 Concrete Coating and Repair
 Weld Repair
 Dye Penetration Report
 Ultrasonic Testing
 Tie in Joints
 Painting report
b) Inspection Report of critical activity.
 Material take off Report

 Welder Performance Report
 Welding Parameter Conformance Report
 Field joint Coating / Damage Report
c) Summarized Progress Report.
Weekly:
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a) HSE Reports (Hazards, near miss, Accident, Training etc.)

b) Progress on procurement activity (including material requisition status report)
c) Progress Review Report
d) Planning for the next week
e) Activity completed (Major Milestones)
f) Resource Deployed Man – Machine
g) Material Balance Report.
Monthly:
a) Planned v/s Actual percentage progress / progress curves

b) Area of Concern / problem / hold ups, impact and recovery action plan
c) Status against HSE Plan / Monthly HSE performance Report
d) Summary of Major events/activity
e) Construction Photographs
Testing, Flushing and Clearing reports:
a) All the reports of Hydrostatic Testing;
 Pigging and Cleaning report.

 Water filling.
 Air volume calculation.
 Thermal stabilization data report.
 Pressurization Report.
 Pressure Holding Data Report.
 Dewatering Report.
 Material Reconciliation Statement
b) Swabbing and Drying Reports
c) Pneumatic Testing.
d) Nitrogen Purging Report
e) Commissioning Report
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2.2.5 Health, Safety and Environment
2.2.5.1 General Safety Regulation

a) CONTRACTOR shall comply with all HSE related statutory requirements including
labour laws relevant to the activities. Legal compliance matrix shall be prepared
by CONTRACTOR.
b) In respect of all labour, directly or indirectly employed in the WORK for the
performance of CONTRACTOR’s part of this agreement, the CONTRACTOR shall
at his own expense arrange for all the safety provisions as per safety codes of
Indian Standards Institution, The Electricity Act, the Mines Act and such other
acts as applicable.
c) CONTRACTOR shall maintain first aid facilities for its employees and those of its
SUB-CONTRACTOR.
d) CONTRACTOR shall adhere to safe construction practice and guard against
hazards and unsafe working conditions and shall comply with TGPL/TPIA’s safety
HSE standards.
e) All critical incidents shall be reported promptly to TGPL.
f) CONTRACTOR shall carry out HSE Management. CONTRACTOR shall prepare the
job Specific Risk Assessment after detail site survey and Mitigation Action Plan
according to “OHSAS Risk register”. It will be approved by TGPL Project in charge.
The same will be displayed on site and will be discussed in daily tool box as
projects progress.
g) CONTRACTOR shall also develop Project Specific HSE Plan based on the “HSE
CONTRACT” signed for the period and shall be strictly adhere to it.
h) CONTRACTOR shall depute qualified and experienced HSE engineer to undertake
HSE related activities of job.
i) “CONTRACTOR” shall ensure that all the near misses occurred during execution
of the contract are reported time to time to TGPL. Any hazard spotted while on
job shall be reported to TGPL for further mitigation. “CONTRACTOR” shall
Report-Nos. of Near miss and Hazard Report as per HSE annual Plan. Any
Incident/Accident shall be reported to TGPL as per incident reporting matrix.
j) The “CONTRACTOR” shall ensure that all the HSE requirements are properly
discussed for any subcontracted activities with the staff employed to do the sub-
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contracted activity. No such activity shall be performed without clearance from

TGPL Work In-Charge.
k) “CONTRACTOR” shall strictly abide by the work permit system / Permit to Work
wherever applicable and explained by the TGPL work in-charge.
l) All personnel working in the project shall be trained & educated for Basic Safety
awareness. He / She shall be well aware of risk and mitigation action/s for the
activities undertaken.
2.2.5.2 Health Safety & Environment (General)
1. The “CONTRACTOR” shall act as an independent “CONTRACTOR”.
2. Before initiating activities against the order, “CONTRACTOR” and OWNER
representative should ensure following:
a. The employee only belongs to the CONTRACTOR are allowed for the work at
site
b. All the employee of CONTRACTOR is checked for “Medically fit”.
c. All personal working at TGPL work site shall be trained and assessed.
d. CONTRACTOR shall comply with all TGPL HS&SE requirements.
e. Deployed equipment, Machinery, tools & Tackles are inspected for “Fit for
Use” before it sent to the site for performing the activities. Equipment “fit
for use” shall be available with equipment at site and same shall be
reviewed timely as per approved HSE guideline.
f. CONTRACTOR to Procure Cordoning / Barricades material as per
specifications submitted by TGPL.
g. Material Camp establishments, Material storage, Offices, and

accommodation facilities are audited by the TGPL representative and the
HSE while finalization of temporary land, office, Camp establishments, Pipe
Yard etc.
h. CONTRACTOR to Signed HSE Contract with TGPL and prepared HSE Plan for
executions of activities. The same shall be approved by TGPL
i. Site Specific Risk Assessment is done on daily basis and in case of change in
site conditions
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j. Risk Mitigation plan for each risk is decided as per the OSHAS Risk register
communicated by TGPL.
k. First aid facilities are maintained at each site, office, store, vehicles with
trained first aid provider
l. A Toolbox talk is conducted at each site / activities with all the involved to
updates them on each risk with required Mitigation action.
3. CONTRACTOR shall erect and maintain barricade required in connection with
this operation to guard the work site as directed by TGPL (Specification of
Barricade provided TGPL).
4. “CONTRACTOR” shall ensure proper disposal of solid / liquid waste and shall
ensure to follow the legal requirements associated with waste handling and
shall maintain waste disposal record. If found appropriate, these requirements
shall form part of the HSE orientation discussions held before commencement
of the job.
5. “CONTRACTOR” must ensure that tools, appliances, machines, vehicles or other
equipment which are going to be used for the job are periodically inspected and
maintained. The “CONTRACTOR” shall maintain records of these inspections and
modification activities. TGPL reserves the rights to verify these records and
prohibit use of items not found fit for use.
6. “CONTRACTOR”'s personnel shall not smoke or resort to misuse of drugs,
medicines or alcohol while on duty. “CONTRACTOR” shall also ensure that in no
case the ability of his employees to carry out their assigned duty is impaired by
use of the substances mentioned herein.
7. “CONTRACTOR” shall comply with all applicable statutory requirements.
8. No child labour below 18 years of age shall be employed by the “CONTRACTOR”
during the execution of job.
9. Qualified employee, if behave unsafely at site shall be disqualified for working at
site
10. The safe working practice Guideline for specific pipeline construction related
activities is implemented during execution of projects.
11. CONTRACTOR shall ensure that as a minimum, but not limited to, these
guidelines shall be followed and ensured by its personnel / sub-CONTRACTOR at
work site / office at all the times.
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2.2.5.3 Safe Systems of Work

Safe Systems of Work provide the foundations for safety in all of our activities, it is
one of the most important and critical for our business. It covers almost all
operations and affects everyone at TGPL.
a. It is everyone’s duty to stop work which they believe unsafe.
b. No work is to proceed unless a risk assessment has been carried out.
c. All persons must be trained and competent to carry out the intended task.
d. Before starting work, an appropriate emergency plan must be established and
tested.
e. Daily site plan shall be communicated to TGPL in one day advance at least.
f. Before starting work, check if permit to Work (PTW) is required.
g. The PTW must have a detail scope of work, clearly identifying hazard and
associated risk and control measures.
h. The PTW must be issued by a competent authority.
i. All relevant information should be communicated to all involved in the work
through Tool Box talk before start of the work / activities.
j. PPE’s must be as per risk assessment and as per any additional minimum site
requirements
k. Before working on isolated facilities, check that all electrical, process and
mechanical isolations have been completed by the appropriate authorized
person.
l. Change to plant and equipment or procedures must place via an approved
management of change procedure.
m. If not sure about the task or ability to perform safely, stop the job and discuss it
with Engineer in charge.
n. Ensure adequate control in handover to normal operations.
2.2.5.4 Safe Working Practice - Guidelines

Some of the safe working practice guidelines for specific pipeline construction
related activities are given in the following sections. CONTRACTOR shall ensure that
as a minimum, but not limited to, these guidelines shall be followed and ensured by
its personnel / sub-CONTRACTOR at work site / office at all the times.
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2.2.5.5 Working Hours

The working hours at site are the period of day lights
Work will be carried out in the day light with Lunch timings.
Work timings based on the criticality and the site conditions can be extended further
if required and approved as per the project requirement. Workings on public
holidays and on weekly off are permitted subject to prior approval from TGPL and
shall be allowed by TGPL on case to case bases.
2.2.5.6 Lighting
Proper lighting shall be arranged at work site in case the day lighting is insufficient.
Recommended illumination level shall be as follows
 General work area: 50 Lux

 Fine working area: 300 Lux
As use of power tool, welding
 Hand lamp shall be used with protective cover/guard and double insulated
wire
2.2.5.7 Equipment
All the equipment present on the site, regardless of its purpose, must be kept in
faultless condition and be suited to the work (Fit for Purpose) to be carried out.
Activity wise critical equipment shall be identified and list will be prepared. Identified
equipment will be checked through government approved and recorded.
The equipment must be regularly checked by an authorized person and any defect in
the equipment must immediately be repaired and action taken report is filled Safety
devices which were originally part of the equipment must never be removed or
adapted without the express approval of the owner and/or the engineer and after
the submission of a clear written justification for the adjustment concerned.
The instruction for use and safety and health instruction must be made available
upon simple request by the owner.
2.2.5.8 Working at Height

The work to be carried out at Height is evaluated shall be considered as working at
height i.e. above 6 feet or 2-meter height or in depth. The same shall have proper
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fall prevention systems viz. Scaffoldings, platforms etc. apart from the above all
personnel shall be provided with safety harnesses as line of defence.
All scaffolds and ladders shall be inspected by Designated Competent person
before allowing personnel to work at heights.
It is ensured that the persons trained in working with safety belt, fall arrestor,
scaffolding are allowed to work at height.
A warning tape just below the work at height is provided and warning boards are
displayed to restrict entry into that protected area. This is ensured to protect the
injury to the person due to fall of object or person from height.
2.2.5.9 Electrical Safety on Site
Inspection
every electrical installation at site, including generators, distribution cabinets, etc
will be inspected on site by a Recognized inspection agency before it is brought in
to service; any defect must be reported immediately.
Cables and connections
Distribution panels must remain closed at all times during use. The connection to
distribution panels may only be made using approved and waterproof plugs.
The electrical cables for connection to the various users of site electricity shall be in
impeccable condition and shall be protected in a sufficient manner. In places where
traffic must run over the connecting cables, they must be buried with a protective
sleeve. The same rules are applicable for the connections of the cables.
Furthermore, they must be watertight.
All connections must be at least suitable for use in humid conditions.

Earthing
Both the central electrical site installation and any stand-alone generators will be
fitted with proper earthing for which the earthing resistance will be checked before
use.
Metal site shed and material containers will each be properly earthed to rule out
the possibility of the structure becoming live.
The central electrical site installation will be equipped with a suitable earth switch
with circuit-breaker.
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Electrical tools
Electrical hand-tools must confirm to the stipulations of the regulations of the
Country concerned, be in impeccable condition and be suitable for the work to be
carried out. They must be properly earthed or double-insulated.
Welding transformer and generators must be equipped with a power limiter that
will guarantee the prescribed safety current.
In closed area, tunnels, deep construction pit and damp crawling spaces, only tools
with safety current may be use.
2.2.5.10 Working in confined space

As far as possible it is checked whether work can be carried out from outside, to
avoid the entry in confined space.
If at all work is to be carried out in confined space, prior to start of the job, the
hazards shall be identified, risk assessment shall be carried out, necessary control
measures / safety precautions specific to work site are finalized and methodology is
worked out for safe completion of the job.
The precautions for work in confined space are mentioned in the permit which
includes protection of trench, storage of execrated soil defined permit space,
authorized entrants, the hazards of the permit space, elimination or control of
hazards before entry to permit space, environment test, rescue and emergency
arrangements, communication system, etc.
When testing for atmospheric hazards, test first for oxygen, then for Combustible
gases and vapours, and then for toxic gases and vapours if applicable. Parameters
for non-hazardous atmospheres are:
 Oxygen between 19.5 and 23.5 percent;

It is ensured that work at confined spaces is carried out by deputing adequate
manpower; working at confined space alone is prohibited.
If gas fumes, vapours can enter the space physical isolation of the valves of gas
pipelines is ensured and in all cases check is made to ensure that isolation is
perfect.
It is ensured that entrance to confined space is big enough so that the persons
entering can enter / climb in or out with equipment put on like self-breathing
apparatus etc at ease and entrance provide easy access & egress in an emergency.
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If required, mechanical ventilation shall be arranged to ensure that fresh air is

available inside.
2.2.5.11 Road Safety and Driving Management

a. All vehicles used for transportation within TGPL sites / premises shall comply
with the current RTO rules.
b. Seat belts shall be used by all passengers travelling by four wheelers and crash
helmets shall be used by both rider and pinion for travelling by two wheelers.
2.2.5.12 Loading & Unloading of line Pipe

All lifting equipment and tackles shall not be loaded beyond the 80 % of maximum
safe working load.
Supervisor in charge should ensure that no one remains in a position of danger in
the course of loading/unloading operation.
All lifting equipment / gears shall be inspected and tested by competent personal
as per statutory requirement and test certificate shall be available at work site. All
critical safety aspects of equipment shall be checked by site supervisor before
taking in use.
In no case transportation of material shall be allowed using Cranes except the
shifting within site if approved by the engineer in charge. The shifting within site is
only permitted on approval of mitigation actions based on site specific risk
assessment approved by contract holder.
The crane operator shall be skilled and experienced. He must know and comply
with the standard lifting hand signals and should have approved lifting plan at Site.
Ensure compliance with TGPL requirements.
a. Cranes or lifting equipment should be placed at safe location and jacks shall be
properly secured / balanced, ensuring that it does not obstruct any traffic or
emergency exits.
b. Appropriate warning signs /boards must be placed at both sides of equipment
danger zones, on the road to warn the traffic to avoid collision/accident.
c. The stingers/riggers are responsible for properly attaching the load to the
crane and must be properly trained/ skilled in stringing & rigging with
knowledge of standard lifting hand signals.
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d. All persons engaged in loading/unloading operation must wear appropriate

personal protective equipment like, safety shoes, hand gloves etc.
e. When mobile cranes are working or moving, ensure that they do not interfere
with any pipeline, structures and overhead electric lines. Proper protection like
Goal post shall be provided.
f. Crane, lifting tackles like chain slings, rope slings, hooks, shackles should
conform to the standard specifications and must be in good condition.
Defective equipment/tackles must not be used.
g. When the weight of an object is in doubt, lifting tackles of higher safe working
capacity should be used.
h. Riding on loads being lifted or lifting of personnel up or lowering them on crane
ropes is strictly forbidden.
i. Standing/working under suspended load is prohibited.
j. Only a qualified/ authorized stinger/ rigger shall give the standard signals to the
crane operator, but the crane operator must obey an emergency STOP signal
given by any one.
k. Ensure that the hook is directly above the load to be raised, to avoid additional
strain on the crane and swinging of the load.
l. Crane should not be used for pushing, dragging or sliding the load or any
object.
m. Placing of crane should be in such a way that while lifting or swinging load, the
crane does not get imbalanced / collapse.
n. Unauthorized persons should not be allowed in boom swinging area/restricted
zone.
o. Appropriate supports should be provided at the bottom of pipes while
unloading/stacking.
p. Teflon coated lifting hooks/brackets should be used to lift the pipe from both
ends to avoid damage of bevel edge of the pipe ends.
q. Loads should be raised and lowered smoothly avoiding jerks due to sudden
starts or stops.
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r. While lifting/lowering pipes by crane, one end of pipe should be tied with a
rope with other end of the rope (Tag Line) held by competent rigger to avoid
dancing of hanged pipes.
s. Adequate lighting arrangement and warning signals to be provided while under
taking operations in night.
t. Ensure that the operator must properly secure the crane and boom in safe way
before going off duty or when operations are shut down.
u. During manually handling of pipe or material, care should be taken that

pipe/object does not fall on leg/hand. Clear understanding required amongst
the persons while handling materials.
2.2.5.13 Stacking in tailor and transportation of line pipes

a. Driver should be trained and qualified for driving.
b. Pipe tailor should be inspected and made “Fit for use” by issuing Equipment
c. Pipes should be firmly supported from bottom and sides, and so secured that
during trailer movement on rough road, pipe does not roll off.
d. Pipe should be protected from sides on the tailor by providing vertical supports
and tied up with the Belts or chain with adequate protection / Soft packing
against the damage of coated line pipes.
e. Red light / red flag signal shall be fitted at the outer most end of pipe stack to
warn off the road traffic.
f. Care should be taken at turning, crossings, bridge etc.
g. While parking the trailer, traffic should not be affected.
2.2.5.14 Storing / Stacking of line pipes at Yard / Site

a. Pipes should be so firmly supported so that they do not roll off, and provide
easy / safe access for inserting slings for lifting. Open ends of pipes shall be
capped with a securely closed metal / plastic cap or plug as approved by
TGPL/TPIA
b. U grooved type wooden support with PE/Rubber sheet shall be used for pipe
stacking.
c. Sandbags or wooden chip bags should be provided as supports to avoid
damage on the wrapping/coating of pipe.
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d. Pipes should not be stored on the road affecting traffic.

e. The stored pipes shall be fully covered with full barricading all along the sites to
avoid unauthorized entry of any one.
f. Pipe size and crane lifting capacity to be kept in mind for lifting number of
pipes in one operation.
g. During lifting of pipes, no one should be allowed to stand under the hanging
load.
Pipes should be so firmly covered during monsoon to avoid corrosion of Pipes
2.2.5.15 Excavation and Backfilling of trench

a. Underground utilities should be referred before starting excavation and trial pit
should be excavated first.
b. It is to wear safety shoes /gumboots during manually excavation.
c. Appropriate warning signboards to be displayed at work place (“road closed-
work in progress” or “go slow-work in progress” boards).
d. Bypass road should be available before closing the road.
e. Trench shall be protected using shuttering / shoring or any other appropriate
protection method to prevent collapsing for the depth beyond 1.25 meter.
f. Soil shall be kept at least 2 ft away from edge of trench to prevent load on
edge.
g. Any cable/wire found during excavation should be considered as live and care
to be taken accordingly.
h. Extra care should be taken for underground gas pipelines.
i. Care should be taken for unsafe electric/telephone poles. Unsafe poles must be
tied properly by ropes to protect them from falling, as electric pole can cause
serious accident.
j. Trench should be excavated equally wide, i.e. from top to bottom. Never allow
to make it broad from bottom side as cavity, which may collapse any time.
k. While using excavator, care should be taken for traffic on the road.
l. Temporary arrangement should be done at some locations on the trench for
crossing/walking facility with hand rails for public.
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m. Trench should not be kept open/ exposed.

n. After laying the pipeline, trench should be backfilled properly.
o. Follow TGPL excavation procedure / guidelines.
2.2.5.16 Laying / Lowering of pipeline section in bore hole and trench:

Please refer all precautions mentioned in Loading and Unloading of the pipes.
a. Lifting equipment like crane, hydra and moving parts etc. should not project
towards the road, so as to endanger the traffic.
b. Appropriate warning signboards must be placed on both side of the equipment

on the road to warn the traffic to avoid accident-collision.
c. Lifting equipment must be placed securely before lifting pipe section.
d. While using two or more lifting equipment to lift/lower the pipe section,
proper balancing is must. Approved lifting plan shall be available at site.
e. Signals to the operators shall be given by only one authorized person to avoid
any confusion. However, STOP signal given by any one will be obeyed for
emergency.
f. Overhead electric lines, poles, trees etc. must be watched during operation.
g. Unsafe poles in the trench must be tied with ropes before lifting pipe section.
h. No one shall stand or move under suspended load.
i. Unauthorized persons will not be allowed in restricted area.
j. Care shall be taken for moving parts of cranes.
k. Load should be lifted within the safe working load capacity of lifting equipment
and tackles.
l. Instead of shifting lifted load by cranes, load should be lowered and change the
suitable location of the cranes accordingly.
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m. Lifting and lowering operation should be done slowly, without sudden jerks.
n. Entire operation shall be done under responsible person-in charge.
2.2.5.17 NDT Testing
2.2.5.17.1 Dye Penetration test:

a. D.P. cleaning solvents, powder and dye chemicals are harmful to the health.
Safety measures written by the manufacturer on the containers / as per MSDS
must be strictly followed.
b. Keep away from flame, fire and hot objects. Do not throw empty can in fire. Do
not take internally and avoid smoking during use.
c. Safety goggles/face shields, masks should be used for protection.
d. Appropriate warning signboards to be displayed at work place
2.2.5.17.2 Radiography (X-Ray) Test:

a. Since indiscriminate exposure to ionizing can produce biological damage to
human body, strict control on human exposure to radiography is essential.
b. Radiography should be carried out during night to avoid public being
unknowingly exposed to radiation. Affected area to be cordoned off and
necessary warning signboards displayed.
c. No unauthorized personal movement to be permitted in this area.
d. Engineer of the section/network and local people must be informed in advance
about the work, to enable them to inform their persons to stay away.
e. Qualified operator and assistant must be equipped with survey/ dosimeter to
measure radiation. Use of alcohol/drug is strictly prohibited at work site.
f. Use the exact source of radiation. Do not use more powerful source.
g. When not in use the radiation source must be kept away from human presence
and keep in safe place. Appropriate warning signboards to be displayed at
work place.
2.2.5.18 Holiday detection test:

Sever electric shock is main hazard in the operation of holiday detection test.
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a. Persons engaged in this operation must be trained and experienced. Defective

instrument shall not be allowed. Appropriate hand gloves and safety shoes
must be worn.
b. Test shall not be carried out in wet location and in rain.
c. No one should be allowed to sit on, cross or touch the pipe section during test.
d. The person holding instrument must be alert and watch the situation, to switch
off the instrument in the case of emergency.
e. Specified insulated handle to push/move the ring must be used.
f. Earthing of the equipment shall be ensured.
2.2.5.19 Pressure testing

a. Standard fittings, instruments, hose, equipment shall be used and test
certificates shall be available.
b. Calibrated pressure gauges to be used with appropriate range and gauges must
be provided at all required safe locations before starting pressurizing.
Appropriate warning signboards to be placed at work place.
c. All required valve keys must be available at work places.
d. During depressurizing and flushing care must be taken for overhead electric
lines. Keep away as stones/particles may cause injury.
e. During flushing, connected hose must be tied/ protected properly from
whipping action due to pressure.
f. Communication system shall be established during flushing operation.
g. Permit to work shall be obtained as per TGPL PTW matrix.
Appropriate warning signboards to be displayed at work place
2.2.5.20 Electric Welding and Gas cutting

Welding and gas cutting operation requires special skills and experience. It is
always associated with fire & explosion hazards besides several injuries to
personnel if proper care and safety procedures are not followed.
A. Electric Welding:
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a. Welding on gas pipeline shall be done only by qualified welder approved by

TGPL/TPIA.
b. Appropriate warning signs boards must be kept on suitable locations on the
road to warn the traffic, in case of welding work on/near road.
c. All persons engaged in welding and cutting operation shall wear appropriate
dresses. The clothes should not be oily, greasy or damp. Avoid wearing pure
terelene, nylon and other synthetic fibre clothing’s. All persons engaged in
welding/cutting operation must wear appropriate safety appliances like
welding hoods or shields, goggles, leather hand gloves, leather or apron, leg
guard, safety shoes etc.
d. All combustible materials near and around the place within the reach of flying
sparks to be removed, if not possible to be covered by asbestos free fire
blanket or sheets. Fire extinguishers must be kept nearby, if hazard exists.
e. Ensure that the place where such job of welding/cutting is to be done is safe
and there is no danger of anything falling from the top as well as risk from
traffic movement.
f. Use scaffoldings, full body safety harness shall be used as per TGPL “Working at
Height” Procedure.
g. Metal frames of electric welding machines shall be effectively earthed. All
cables and connections must be in sound condition and safe from shock
hazards.
h. Welding earth/ground return circuit shall be provided direct on job end and
never be used on steel bars, or pipe line containing flammable gas/liquid or
conduits carrying electrical conductors, which may generate sparks at loose
contact surfaces.
i. Canvas screen / hard barricading should be used wherever it is practicable
while arc welding is to be done, for protection of fellow workers & general
public from radiation hazards.
j. In case of generating set, refuelling in running condition is not allowed. Switch
off the set and then refuel. Avoid smoking.
k. Portable welding units must not be moved unless the power is shut off.
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l. Electrode holder when not in use shall be placed on insulated hook. Live
electrode shall not be left on welding shield, gloves or cables and should not be
left unattended.
m. Arc weld rod size and amperage of the machine shall be left to the desecration
of experienced, qualified welder and shall be within the limits of a required
procedure.
n. The welding operation shall be adequately sheltered from wind. Work should
be avoided on wet location/rain.
o. After a welding job completed, the material/work piece should be chalk
marked ‘HOT’ to warn other workers.
p. Whenever welding is discontinued, machine shall be isolated by operating both
switches on the machine and on the power supply line.
q. Ensure adequate fire extinguishers are available at site with trained personals
in fire-fighting.
B. GAS CUTTING & HEATING OPERATION
a. Gas cutting/heating work shall be done by skilled/experienced person.
b. Before starting work, all hoses, blow pipe, torch, pressure regulators, gauges
and all connections shall be checked thoroughly for any defects, leakage, by
experienced person. Greasy or oil soaked hoses shall not be used.
c. No cutting/heating job shall be carried out unless suitable regulator and
pressure gauges are provided.
d. Only standard keys or spanners shall be used to open or close cylinder valves.
During work leave key in position on the cylinders for use in emergency.
e. Oxygen cylinder valves and fittings shall never be handled with oily or greasy
hands. Acetylene cylinder and accessories, hoses, torches etc. shall never be
fitted with parts of copper or copper alloys to avoid forming of explosive
compounds.
f. Hoses should be examined before use. Defective hoses shall never be used and
replaced immediately.
g. Oxygen and fuel gas hoses shall not be interchanged. (Black or green hose for
oxygen, while red or maroon hose for fuel gas).
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h. Hoses should not rout over the shoulder or between the legs of persons
engaged in works. Hoses shall be protected from falling sparks, flames or slag
and damaging by sharp objects.
i. Hoses in use should be replaced when a flash back occurs as it may sustain
unseen internal damage. While lighting torch, care shall be taken that flame
should not affect any part of the body of self or fellow workers. Torch shall not
be dropped during operation.
j. During work breaks torches must be extinguished and lighted torch shall never
be left unattended.
k. In case of leakage developing in cylinder, same shall be removed immediately
from the work to open & safe space.
l. Cylinders should never be allowed to come in contact with live electric wires
and shall be protected from sparks, flames, arc or slag falling from welding and
cutting operations.
m. After completion of job, cylinder valve should be tightly closed, re-place the cap
and store at the proper place.
n. Ensure flame arrestors / NRVs on Oxygen & Acetylene cylinders.
o. Ensure adequate fire extinguishers are available at site with trained personals
in fire-fighting.
2.2.5.21 Portable Power Tools

Electric shock and severe cut injuries are the main hazards associated in operation
of portable power tools like grinding machine, drilling machines etc. Careless
handling and poor modification of electric power tools contributes to accidents.
Following minimum safety precautions to be taken while using electric power tools
a. Only trained person should use it.
b. Always fit or disconnect accessories after removing the electric cord from
power supply. Ensure that trigger/on-off switch on the machine operates
properly and it does not operate accidentally.
c. Defective power tool shall not be used.
d. Machine should not be used with direct power supply, without operating
switch. Machine should have Three Pin Plug connection facility.
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e. The user should wear appropriate dress & safety equipment like, safety
goggles, face shields, safety shoes etc., for protection against flying metal chips.
f. Earthing / grounding must be provided for electric tools.
g. Never start machine when its rotating component is in contact with work piece
or any object. Ensure that the moving parts have come to a complete stop,
before placing it on the floor.
h. Excess force during its use may break the disc /tool resulting in accident.
i. Special care must be taken while using it in overhead position.
j. Power supply should be disconnected after completion of the job and tool
should be stored in proper safe place.
k. Use double insulated portable power tools.
l. Use of grinding disc with correct speed rating. Never use disc whose validity is
expired.
2.2.5.22 Hand Tools

Accidents by hand tools may cause effects like sprain in muscles or fracture of
bones, puncture wounds & infection, falls, sever cut injuries, abrasions, loss of eye
and other injuries, due to following main causes
a. Using wrong tools.
b. Using defective tools.
c. Using tools incorrectly.
d. Unsafe keeping/carrying of tools.
e. Failing to use proper dress/personal protective equipment.
f. Improper modification& inspection.
All concerned supervisors / personal of CONTRACTOR should take care about above
causes of accidents.
2.2.5.23 Site cleaning / Restoration

The CONTRACTOR shall take care for cleaning the work site from time to time for
easy access to work site and also from safety point of view.
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Work site should be always kept clean to the entire satisfactions of the TGPL/TPIA.
Before handing over any work to TGPL, the CONTRACTOR in addition to other
formalities to be observed as detailed in the document shall clear the site to the
entire satisfaction of TGPL/TPIA.
The CONTRACTOR shall carryout restoration as per permission authority
requirements mentioned in Permit and also as per the satisfaction of the
nominated person of the authority at no extra cost to TGPL.
3. SPECIAL CONDITION OF CONTRACT - Technical

3.1 GENERAL
a) Special Conditions of Contract (SCC) shall be read in conjunction with the

Schedule of Rates, General Terms and Conditions of Contract, Material
Specifications, Specifications of Work, Drawing and any other document forming
part of this contract wherever the context so requires.
b) Wherever it is stated anywhere in this Bid document that such a supply is to be
effected or such and such a work is to be carried out, it shall be understood that
the same shall be effected / carried out by the CONTRACTOR at his own cost,
unless a different intention is specifically and expressly stated herein or
otherwise explicit from the context.
c) The materials, design and workmanship shall satisfy the relevant Standards /
Codes, the job specifications contained herein and codes referred to. Where the
job specifications stipulate requirements in addition to those contained in the
standard codes and specifications, these additional requirements shall also be
satisfied. In the absence of any Standard / Specifications / Codes of practice for
detailed specifications covering any part of the work covered in this Bid
document, the instructions / directions of TGPL / TPIA will be binding on the
CONTRACTORCONTRACTOR.
d) The CONTRACTOR shall acquaint himself with the access to the site, availability
of local facilities such as railway sidings, transport facilities, material and labour
and shall provide suitable allowance in his quotation. The CONTRACTOR quoted
price shall take into account all expenses likely to arise in this regard.
e) The intending bidders shall be deemed to have visited the site and familiarized
themselves thoroughly with the site conditions before submitting their bid. Non
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familiarity with the site conditions will not be considered a reason either for
extra claims or for not carrying out work in strict conformity with drawings and
specifications and TGPL HSE requirements.
f) In case of contradiction between referred Standard, General Conditions of
Contract, Special Conditions of Contract, Specifications, Drawings, Schedule of
Rates, the following shall prevail in order of precedence.
 Letter of Acceptance along with Statement of Agreed Variations

 Schedule of Rates as enclosures to Letter of Acceptance
 Fax of Intent / Letter of Intent
 Job / Material Specifications with reference to SOR
 AFC drawings
 Technical Specifications
 Special Conditions of Contract
 General Conditions of Contract
 Indian Standards
 Other applicable Standards
3.2 JOB SPECIFIC REQUIREMENT
3.2.1 Quality Assurance / Quality Control Program
CONTRACTOR shall strictly adhere to the Quality Assurance Plan agreed with the
TGPL.
3.2.2 Third Party Inspection
During the execution of work, entire / part activity shall be carried out under the
"Third Party Inspection". The brief scope of TPIA shall be as follows:
SR.
ACTIVITY DESCRIPTION PROPOSED SCOPE FREQUENCY
NO.
[A] – Pipeline
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1 Review of Documents;
1.1 Material Test certificate (CONTRACTOR bought Review
out material)
1.2 Material Test certificate for consumables Review
1.3 Instrument calibration Review / Witness
1.4 Instrument Test certificate Review
1.5 WPS / PQR, Drawings: Alignment sheet & cross Witness & Review
sections
1.6 Verification of Measurement Sheet for Bill Review
2 Pipeline Construction;
2.1 Trenching & Backfilling Random Inspection Daily
2.2 Welding & Laying Random Inspection Daily
2.3 Stringing & Hauling Random Inspection Daily
2.4 Field Joint Coating & Coating repair Random Inspection Daily
2.5 Lowering Witness Daily
2.6 Review of construction reports Random Inspection Daily
2.7 Canal crossings Witness, Check, Review Daily
SR. ACTIVITY DESCRIPTION PROPOSED SCOPE FREQUENCY

NO.
3 Destructive and NDT;
Witness Daily
3.1 DP Test
Witness100% of total weld Daily
3.2 Ultrasonic Test
Inspection Daily
3.3 Radiographic examination
Witness
3.4 All Destructive testing
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4 Testing;
4.1 Approval of Pipe book Review
4.2 Hydro testing including pigging, final cleaning & Witness
drying
4.3 Pneumatic Testing Witness
5 Pre-commissioning Witness
6 Commissioning Witness
7 HSE Compliances
7.1 Site Specific Risk Assessment and Witness Daily
ensuring risk mitigation plan in place
7.2 Tool Box Talk Participation / Briefing Daily
7.3 Lesson Learnt Sharing Briefing As when
required
7.4 Un Safe actions Interventions Daily
7.5 HSE Documentation / Data Verifications Daily
[B] – Cathodic Protection
1 Approval of Documents;
1.1 TCP design basis document and detail design Approval
document
1.2 Material and Equipment Specification and Data Approval
sheet
1.3 Detail Bill of Material Approval
1.4 QA/QC Plan Approval
SR.
ACTIVITY DESCRIPTION PROPOSED SCOPE FREQUENCY
NO.
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2 Review of Documents;
2.1 Material Test certificate (CONTRACTOR issue Review
material)
2.2 Material Test certificate for consumables and Review
Instrument calibration
2.3 Instrument Test certificate Review / Witness
2.4 Drawings Review

2.5 Verification of Measurement Sheet for billing Witness
2.6 Bill Review
3 Installation
3.1 TLP Unit Random Inspection Daily
4 Testing and Commissioning of TCP System Witness
5 Final Document Handover Review and Handover
However, above scope should be referred with approved QAP.
During the execution of work, entire / part activity shall be carried out under the
"Third Party Inspection". The brief scope of TPIA shall be as follows:
“Review” means checking, identifying & certification of the documents for

conformance of standards & specifications.
“Witness” means physical inspection & certification of activities for conformance of

standards & specifications
“Approved” shall mean approved in writing including subsequent written

confirmation of previous verbal approval and Àpproval' means approved in writing
including as aforesaid.
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“Prepared” shall means collect information and documents, and reporting to the
concern persons.
“Perform” shall means deliver / execute actions to deliver the required level of
performance
“Certification” shall mean ensures and confirm the quality parameter confirming to
code, standards and the specifications
CONTRACTOR shall submit QA/QC procedure along with equipment / instruments to

be used for various activities e.g. Welding, Laying, Hydro Testing, Pigging, and
Commissioning before starting of work and it shall be certified by TPIA before
commencement of job.
Cutting/Welding of pipeline shall not be allowed after Hydro Testing /Pigging

operation. CONTRACTOR shall carry out additional work as and when asked by the
TGPL/TPIA.
3.2.3 Work Execution
The work referred in this bid is for laying of gas pipeline ranging from 4” dia to 16”
dia underground and above ground installations.
The work requires a special skill and attention as majority work will be on gas
network. The contractor is required to understand the full scope of work detailed in
the bid. The contractor is also required to keep sufficient equipment, skilled
manpower to act on an emergency work that may arise while executing the hook up
on live pipeline without any additional cost to TGPL.
CONTRACTOR shall be prepared to work simultaneously in number of spreads with

different crews for the activity of construction and modification to expedite the work
for timely completion, without any additional cost to TGPL.
CONTRACTOR has the option to demonstrate alternate method of mobilization at

the Bidding stage itself so as to complete the work safely as per schedule. In either
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case, CONTRACTOR shall submit relevant “Job Execution Statement” along with
resource allocation and planning before starting the contract. The same shall be
properly supported with proposed manpower and equipment deployment chart.
3.2.4 Emergency Response Plan
In case of any injury or an accident at the site, the CONTRACTOR shall immediately
inform the TGPL Engineer of the incident and further take immediate steps to take
the injured person(s) to any of the TGPL nominated hospitals.
3.3 PENALTY CLAUSE
3.3.1 Service Level, Penalty & Reward
The following critical parameter describes the system performance and service level
expectations and requirements during the Implementation phase of contract. The
service level includes target performance measures, unacceptable measures and the
related penalties for not meeting required service levels.
Sr. No Parameter Service Level Penalty

1 Agreement
Non-Compliance with Standards and Technical Specification
Following actions to be initiated
against observation of non-
compliance at site.
 First Instance Rs. 5000/-
observation.
 Second Instance Rs. 10000/-
Standards and observation within 2 months of
100 % Quality
1.1 TGPL Technical first instance.
Compliances
Specification  Third Instance within 1 months of
second instance Warning letter
will be issued and meeting will be
held with Top management of
Contractor.
• If still no improvement observed
Contract will be Terminated.
-----X X X-----
Page 60 of 60
TECHNICAL SPECIFICATION FOR LAYNG, TESTING AND COMMISSIONING OF CGD-
DEC-2018
(Technical specification)
PIPELINES
Page 1 of 123
CONTRACTOR Sign & Stamp
DEC-2018
Index
1. Specification for Steel Pipeline Activity

2. Specification for Pipeline Welding and Testing
3. Specification for Field Joint Coating
4. Specification for Pipeline Crossing
5. Specification for Pipeline Hydro test
6. Specification for Swabbing & Drying
7. Specification for Casing insulators & End seals
8. Specification for Pipeline Marker
9. Specification for Concrete Coating
11. Specification for HDD
12. Specification for CP System
13. HSE Specification
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1. Specification for Steel Pipeline Activity
Page 3 of 123
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TABLE OF CONTENTS
1. SCOPE
2. REFERENCE CODE AND STANDARD
3. SUBMITTAL BY CONTRACTOR
4. REQUIREMENTS OF RIGHT OF WAY ACCESS THERETO
5. RIGHT- OF- WAY
6. HANDLING, HAULING, STRINGING AND STORING OF MATERIALS
7. TRENCHING
8. BENDING
9. LINING UP
10. LOWERING IN TRENCH
11. BACKFILLING
12. SPECIAL INSTALLATION ON THE PIPELINE
13. WORKING SPREAD LIMITATIONS
14. CLEAN-UP AND RESTORATION OF RIGHT OF WAY
15. DOCUMENTATION
Page 4 of 123
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1. SCOPE
1.1 This specification covers the minimum requirements for the various activities to be
carried out by CONTRACTOR for the construction of Natural gas pipeline in CGD
Networks.
1.2 The various activities covered in this specification include the following work of
pipeline construction:
 Establishing and Preparation of Right of Way for Construction of pipeline with
reference to the route maps.
 Handling, Hauling, Storage and Stringing of pipeline and Materials.
 Trenching for laying of Pipeline.
 Forming of vertical and horizontal Cold Field Bends.
 Laying of pipe section in the Trench
 Pipe Laying through HDD
 Tie-ins of pipeline section
 Connectivity of newly laid network with existing charged network
 Hydro and Pneumatic testing
 Drying of Pipeline
 Commissioning of Pipe Line Network
 Backfilling of Trench.
 Restoration of ROW.
 Special Installation on the Pipeline
1.3 It is intended that all the work performed in accordance with this specification shall
meet or exceed the requirement of governing and reference standards & codes
1.4 This specification shall be read in conjunction with the conditions of all specification
and documents included in the CONTRACT between TGPL/TPIA and CONTRACTOR.
1.5 CONTRACTOR shall, with due care and diligence, execute the WORK in compliance
with all laws, by-laws, ordinances, regulations, etc., and provide all service and
labour, inclusive of supervision and all materials, excluding the material indicated as
TGPL supplied materials in the CONTRACT, equipment appliances or other things of
whatsoever nature required in or about the execution of the work, whether of a
temporary or permanent nature.
1.6 CONTRACTOR shall take full responsibility for the stability and safety of all operations
and methods involved in the work.
1.7 CONTRACTOR shall be deemed to have inspected and examined the work area(s) and
its surrounding and to have satisfied himself as far as practicable as to the form and
nature thereof, including sub-surface conditions, hydrological and climatic
Page 5 of 123
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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 (s). Extra care shall
be taken as and when work area is adjacent to Canal and crop.
1.8 CONTRACTOR shall be deemed to have obtained all necessary information on all
subjects as above mentioned as to risks, contingencies and all other circumstances,
which may influence the work.
1.9 CONTRACTOR shall, in connection with the work, provide and maintain at his own
costs, all lights, guard, fencing, watching etc., when and where necessary or required
by TGPL/TPIA or by any duly constituted authority and / or by the authorities having
jurisdiction thereof for the protection of the work and properties or for the safety
and the convenience of public and / or others.
1.10 Unless otherwise specified, all sections of this specification shall apply to all activities
referred in this specification.
2. REFERENCE CODE AND STANDARD

Following standards and codes of latest edition have been used in this
specification.
2.1 Governing Standard:
ASME B 31.8 Gas Transmissions and Distribution Piping Systems
PNGRB Regulations Technical standard specification including safety
standards for Natural Gas Pipeline (T4S)
ISO – 14001: 2004 Environmental Management System
ISO – 18001: 2007 Occupational Health & Safety Management System
2.2 Reference Standard:
API 1104 Standard for Welding Pipelines and Related Facilities
ASME SEC.IX Boiler and Pressure Vessel Code Welding & Brazing
Qualification
API 1109 Specification for Pipeline Marker
API RP1102 Liquid Petroleum Pipelines Crossing Rail Roads & Highways
IGE/SR/18 Part 1 Safe Working in the vicinity of Gas Pipelines, Mains &
Associated Installations operating at pressure in excess of 2 bar
IGE/TD/01 Steel Pipeline for High Pressure Gas Transmission
IGE/TD/03 Distribution Mains
IGE/TD/06 Transport, Handling and Storage of Steel Pipe, Valves & Fittings
Page 6 of 123
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OISD 141 Design & Construction requirement for cross-country

hydrocarbon pipeline
PFI ES – 24 Recommended Practice for Shop Fabricated Pipeline
SIS – 055900 Pictorial surface preparation standard for painting steel
surfaces
SSPC – SP1 Steel structure painting council.
HSE EXHIBIT Contractor Own Health, Safety, Security and Environment
(HSE) Management System, its HSE policy and its HSE Plan are
compatible with TGPL HSE policy, objectives and HSE
Management System.
In case of conflict between the requirement of this specification and that of above
referred codes, standards and specifications, the requirements of this specification
shall govern.
2.3 For the purpose of this specification the following definitions shall hold - The words
`Shall ' and `Must ' are mandatory. The words ‘should', `May' and `Will' are non-
mandatory advisory or recommended.
3.1 The CONTRACTOR shall submit the Procedures for EQT, WPS, Right of way, stringing,
Handling & Storage of Line Pipes, Trenching, Cold Field Bending, Lowering, Backfilling,
Crossing by open cut and HDD, Installation of SV and Restoration along with quality
records (Activity format, Inspection test plan), etc. at least one week prior to
commencement of the work for approval of TGPL/TPIA.
3.2 The CONTRACTOR shall submit Inspection test plans for all the activities compatible
to this specification at least one week prior to commencement of the work for
approval of TGPL/TPIA.
3.3 The CONTRACTOR shall submit the Procedure for mitigation of risks related to each
activities and the site for Right of way, Material loading, unloading and
transportation, stringing, Storage of Line Pipes, Trenching, Cold Field Bending,
Lowering, Backfilling, tie-ins, Installation of SV and Restoration along with HSE
records
4. REQUIREMENTS OF RIGHT OF WAY ACCESS THERETO
4.1 General
4.1.1 CONTRACTOR shall, before starting any clearing operations, familiarize himself with
all the requirements of the Applicable Authorities having jurisdiction over the Right
of way (ROW) for work along the pipeline routes or in connection with the use of
other lands or roads for construction purposes.
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4.1.2 CONTRACTOR shall notify TGPL/TPIA well in advance during work progress, the
method of construction for crossing road, pipeline, cable, railway, river, canal and
other existing obstacles. The risks associated with proposed pipeline, mains and
service routes shall be assessed to ensure that all reasonably practicable steps have
been taken to minimize the risks to people & property in the event of an unplanned
release of Gas.
4.1.3 CONTRACTOR shall commence work on such crossing after getting approval from the
authorities and landowners concerned to the satisfaction of TGPL/TPIA. The crossings
shall be installed to meet at all times the requirements and specification. In the
absence of any specific requirements by authorities, CONTRACTOR shall comply with
TGPL’s instructions.
4.1.4 The right of ingress and Egress to the ROW shall be limited to points where such
ROW intersects public roads. Arrangements for other access required by the
CONTRACTOR shall be made by him at his own cost and responsibility and for such
access the conditions of this specification shall also apply.
4.1.5 Where the ROW comes within 1.0 Meter of an existing line or facility, CONTRACTOR
shall propose and provide methods to safe-guard the existing line or facility (e.g. a
demarcation fence). No work is allowed in such area without TGPL/TPIA prior
approval.
4.1.6 Pipeline, which is constructed inside the area of high voltage lines, may be electrically
influenced by this high voltage line. The voltage caused by the influence may at times
be so high as to pose a danger to personnel working on the pipeline. It is imperative
therefore, that the instructions given in section 4.2 shall be strictly observed.
4.2 Instructions concerning HIGH VOLTAGE INFLUENCED SAFETY measures during
construction of pipelines inside the area influenced by high voltage lines
4.2.1 It is a prerequisite that all personnel working on the pipeline which is being laid in the
area influenced by the high voltage system, be given clear instructions on measures
to be taken.
4.2.2 Vehicle and equipment shall be earth-connected. This may be effected by attaching
an un-insulated cable or chain (which touches the ground) of adequate length to the
underside of the vehicle.
4.2.3 If it is not possible for plant and / or materials to come beyond 50m of the centre of
the high voltage system, special measures must be taken to prevent any approach
beyond that distance, unless section 4.3 is complied with.
4.2.4 During thunderstorms or when discharges are observed on insulators all personnel
shall leave the area of the high voltage line and pipeline
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4.2.5 To prevent electrical voltages in a non-buried section of the pipeline from rising to
dangerous values, the length of the pipeline section which has been welded together
before burial shall not exceed the length at which the max. admissible voltage may
be induced. This length may on calculated using an approved calculation method.
4.2.6 Before a pipeline section is lowered into the trench, the structure's earth electrodes
indicated in the drawings or determined with calculation method must have been
installed and connected both to the pipeline section already buried and to the
section which is about to be buried. The electrical connections, which serve the
purpose of preventing dangerous voltages, shall have a min. area of 35 mm2.
Side connections shall not be interrupted until after the permanent safety earth
connections have been installed and connected to the entire uninterrupted pipeline.
Personnel doing work inside the area influenced by the high voltage systems must
wear electrically insulating footwear (e.g. rubber knee boots) and wear insulating
rubber or plastic gloves.
4.3 Additional measures for work at less than 50m from the centre of the high voltage
system.
If work is done at less than 50m from the centre of the high voltage system, the
regulations below shall be complied with in addition to the rules specified in section
4.2
4.3.1 The work shall not be started until agreement has been reached with the authorities
who control the high voltage system, about the implementation of the safety
measures specified in this section (Lock-out & Tag out done & signed off)
4.3.2 Measures shall be taken to prevent excavating and hoisting equipment’s from
approaching high voltage lines to within any of the following distances. Adherence to
latest addition of The Indian Electricity Rules, 1956 is to be strictly maintained.
This distance depends on the voltage carried for individual connections the
distance must be:
0 to 50Kv - 3m
40 to 200Kv - 5m
200 to 380Kv - 8m
The measures taken may be as follows:
 Special selection of equipment, or limiting or blocking certain directions

of movement, or limiting the operational area, thereby making it
definitely impossible for any work to be done at a distance from the high
voltage line of less than the accepted minimum.
Page 9 of 123
DEC-2018
 In case the measures recommended as above are not feasible,

installation of clearly visible markers of sufficient height or laying out a
“no passage beyond this point” line of drums / hard barricades painted
bright red and white must prevent any work being done inside the danger
area. Furthermore, an inspector must be present all the time.
4.3.3 In the event that a vehicle, crane etc. should accidentally come into contact with a
live cable of a high voltage system or flash-over of electrical charge occurs, the
driver shall not leave his vehicle because this will pose a serious threat to his life.
The vehicle or cranes must break the contact WITHOUT ANY HELP FROM OUTSIDE.
The driver shall not leave his vehicle until he has managed to leave the dangerous
area, or alternatively, when the Electrically Authorities have given notice that the
cable(s) have been put out of circuit. In case a serious fire starts in the chemical, he
is permitted to jump from the vehicle, clearing it as far as possible, while the jump
should possibly be to a dry spot.
5. RIGHT- OF- WAY

The CONTRACTOR is required to perform his construction activities within the width
of RoW provided by TGPL for construction of pipeline, unless he has made other
arrangements with the landowner and / or tenant for using extra land. Variation in
this width caused by local conditions or installation of associated pipeline facilities or
existing pipeline will be identified in the field or instructed to the CONTRACTOR by
TGPL/TPIA. Any damages to crop/land which is out of specified width of ROW,
CONTRACTOR shall be fully responsible for such compensations, unless & until
CONTRACTOR shall get written approval from TGPL for such location well in
advance.
The RoW boundary lines shall be staked by the CONTRACTOR, so as to prepare the
strip for laying the pipeline. CONTRACTOR to complete the work and shall be
responsible for the accuracy of such lines and grades.
5.1 MONUMENTS
All shrines, monuments, border stones and stone walls shall be protected and when
required, removed for safe keeping and replaced in original condition after
construction as directed by TGPL/TPIA.
5.2 BARRICADING
CONTRACTOR shall provide proper Barricading of the Work area, whenever working
in a Populated / Urban / Industrial area, as per TGPL instruction.
 Hard barricading shall be provided inside city area / dense populated
area
 Bamboo barricading / Cordoning tape shall be provided at out skirts of
city area
Page 10 of 123
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 The Barricading shall be installed at Min. 1 Meter distance from the

edge of Trenching/Excavation
 Barricading shall be removed only after the Pipeline Laying & Back filling
work is completed.
5.3 ROW CLEARING AND GRADING
5.3.1 All stumps shall be grubbed for a continuous strip, with a width equal to trench
top width plus two meters on either side centered on the pipeline centreline.
Further, all stamps will be grubbed from areas of the construction RoW, where
RoW grading will be required. Outside of these areas to be graded and the
mentioned trench strip, at the option of CONTRACTOR, the stumps may either be
grubbed or cut off to ground level. Any stump cut off shall be left in a condition
suitable for rubber-tired pipeline equipment traffic.
5.3.2 All grubbed stumps, timber, bush, undergrowth and roots cut or removed for the
RoW shall be disposed of in a manner and method satisfactory to TGPL/TPIA,
landowner and/or tenant, and Government Authorities having jurisdiction and as
soon as practical after the initial removal. In no case it shall be left to interfere
with the grading and laying operations. Whenever stumps are grubbed and a
hole is left in the ground, CONTRACTOR shall back-fill the hole and compact it to
prevent water from gathering in it and making a big hole.
5.3.3 CONTRACTOR shall grade the pipeline RoW as required for proper installation of
the pipeline, for providing access to the pipeline during construction, and for
ensuring that the pipeline is constructed in accordance with the most up-to-date
engineering and construction practices.
5.3.4 CONTRACTOR shall grade sharp points to low points, without prejudice to
section 7.0 of this specification, to allow the pipe to be bent and laid within the
limit set forth in these specification and drawings as regards the minimum elastic
curvature permitted, and shall drill, blast or excavate any rock or other material
which cannot be graded off with ordinary grading equipment in order to make an
adequate working space along the pipeline.
5.3.5 No temporary or permanent deposit of any kind of material resulting from
clearing and grading shall be permitted in the approach to roads, railways,
streams, ditches, drainage ditches and any other position which may hinder the
passage and/or the natural water drainage.
5.3.6 The RoW clearing and grading operations shall in no case involve embankment
structures of any type and class without prior approval of the authorities having
jurisdiction over the same.
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5.3.7 In the case of natural or artificial deposits of loose soil, sand heaps of earth or
other fill materials, these shall be removed till stable natural ground level is
reached so as to ensure the construction of the pipeline ditch in stable ground.
5.3.8 In the case of RoW clearing and grading on the hillside or in steep slope areas,
proper barriers or other structures shall be provided to prevent the removed
materials from rolling downhill. The RoW cross fall shall not exceed 10%.
5.3.9 Wherever the pipeline RoW runs across, through or alongside farmyards, built-
up areas, groups of trees, groves, horticultural spreads, gardens, grass-fields,
ditches, dikes, roads, paths, railways or any other area with restrictions of some
kind, CONTRACTOR shall grade only the width of the RoW necessary for digging
the pipeline trench and constructing the pipeline. In the said place CONTRACTOR
shall carry out the work in such a way that damage resulting from the pipeline
construction is kept to a minimum.
5.4 PROVISION OF DETOURS
5.4.1 CONTRACTOR shall do all necessary grading and bridging at road, water and
other crossings and at other locations where needed, to permit the access for
men and equipment. It is understood that the CONTRACTOR has recognized such
restrictive features of the RoW and shall provide the necessary detours and
execute the works without any extra cost to TGPL. Public travel shall not be
inconvenienced nor shall it be wholly obstructed at any point.
5.4.2 CONTRACTOR, at his own cost, shall furnish and maintain at detour watchman,
lanterns traffic lights, barricades, signs, wherever necessary to fully protect the
public.
5.4.3 CONTRACTOR shall be responsible for moving its equipment and machineries on
or around watercourses. This may require the construction of temporary bridges
or culverts. Temporary bridging or access to fording required for RoW crossing
watercourse shall be constructed. CONTRACTOR shall ensure that such
temporary works shall not interfere with normal water flow, avoid overflows,
keep the existing morphology unchanged and shall not unduly damage the banks
of water course. No public ditches or drains shall be filled or bridged for passage
of equipment until CONTRACTOR has secured written approval of the Authorities
having Jurisdiction over the same. CONTRACTOR shall furnish TGPL/TPIA a copy
of such approval.
5.5 RIGHT–OF-WAY DAMAGES
5.5.1 CONTRACTOR shall confine all its operation within limits of the RoW. Any damages
to property inside or outside ROW shall be restored or settled to the
CONTRACTOR’s account.
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5.5.2 CONTRACTOR shall promptly settle all off RoW damage claims. If CONTRACTOR is
fails to do so, TGPL/TPIA shall give written notice to CONTRACTOR. If CONTRACTOR
does not settle such claims within seven days after such notice, TGPL’s shall have
the authority to settle claims from the account of CONTRACTOR.
In case of damage of the branch canal, CONTRACTOR shall get it repaired on his
own cost and as per farmer satisfaction. In no case, CONTRACTOR shall dump the
soil in farms or on the bank of the canal.
CONTRACTOR shall be fully responsible for the damage of the vegetation and crop
compensation.
CONTRACTOR shall ensure proper disposal of Bentonite as per vendor
recommendation.
Correctness of road level if damaged (due to poor quality of work) after raining or
water seepage shall also be addressed by CONTRACTOR on his own cost
immediately.
6. HANDLING, HAULING, STRINGING AND STORING OF MATERIALS

6.1 General
6.1.1 The CONTRACTOR shall exercise utmost care in handling line pipe and other
materials. CONTRACTOR shall be fully responsible for all materials and their
identification until such time that the pipes and other materials are installed in
permanent installation. CONTRACTOR shall be fully responsible for arranging and
paying for storage areas for the pipeline materials, however, method of storage
shall be approved by TGPL/TPIA.
6.1.2 CONTRACTOR shall reimburse the TGPL for the cost of replacement of all TGPL
supplied materials damaged during the period in which such materials are in the
custody of the CONTRACTOR. It shall be CONTRACTOR’s responsibility to unpack
any packing for the materials supplied by TGPL.
6.2 UNLOADING AND TAKING -OVER OF LINE PIPE
6.2.1 CONTRACTOR shall unload, receive and ` take over ' against requisition line pipe
from the TGPL’s designated places. CONTRACTOR shall perform visual inspection
of the bare pipe and coating of the 3LPE coated pipes. CONTRACTOR, at his
option, shall carry out holiday detection at a prescribed set Voltage and all
damages/holidays shall be recorded jointly with TGPL/TPIA at the time of taking
over. However, if CONTRACTOR proposes to perform only visual inspection of
coating, then the CONTRACTOR at no extra cost to TGPL, shall carry out repair of
all holidays found at the time of laying the pipeline. Repair of all damages after
taking over the delivery of the materials shall be to the CONTRACTOR’s cost.
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Damaged pipe shall be reported to TGPL immediately on receipt and same shall be
recorded.
CONTRACTOR shall notify TGPL/TPIA well in minimum one week in advance for
issue of line pipe from TGPL. In case of delays in takeover of TGPL supplied
materials due to non-availability of resources, CONTRACTOR shall be fully
responsible for the delay and rearranging means of transportation at no extra
cost to TGPL. Any claim by the transporter for undue delay in taking over of the
material shall be settled to contractor’s account.
Unloading, stacking of line pipe (at CONTRACTOR’s decided site stacking yard) on
proper sandbags, fencing and safe guarding of storage yard shall be the
responsibility of the CONTRACTOR. Material receipt register shall be maintained
at storage yard and daily receipt shall be intimated to TGPL/TPIA.
6.3 HANDLING OF LINE PIPE
6.3.1 To avoid damages to the pipe and Coating the CONTRACTOR shall
 Load, unload, transport and stockpile the coated pipes using approved
suitable means and manner.
 Use vacuum lifting equipment (suitable handling equipment’s with proper
length of booms). Hooks may also be used for handling the pipes provided
they are covered with soft material like rubber, Teflon or equivalent.
 Ensure Hoisting crane / wire ropes have sufficient inclination compared to
pipe axis so that they do not come into contact with external coating.
 Handle the pipes by means of belts of proper width made of non-
metallic/non-abrasive materials and pipes to be stacked separated row by
row.
 Not bump coated pipes against any other pipe or any other objects. Rolling,
skidding or dragging shall be strictly forbidden.
 Stack the pipe, completely clear from the ground so that the bottom row of
pipes remains free from any surface water. The pipe shall be stacked at a
slope so that driving rain does not collect inside the pipe. The line pipes shall
be stored so that there is no fouling with each other.
 Stack the coated pipes by placing them on ridges of sand / sand bags, free
from stones and covered with a plastic film. The supports shall be spaced in
such a manner as to avoid permanent bending of the pipes.
 Stack limited number of pipe layers so that the pressure exerted by the
pipe's own weight does not cause damages to the coating. Stack shall be
suitably secured against falling down and shall consist of pipe section having
the same diameter and wall thickness.
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6.3.2 Coated pipes stacked in open storage yards/dump yards shall be suitably
covered on top to avoid direct exposure to sunlight. The ends of the pipes
during handling and stacking shall always be protected with bevel protectors.
6.3.3 The trailer shall be equipped with adequate pipe supports having as many
round hollow beds as the number of pipe to be paved on the bottom of the
lorry bed. Supports shall be provided for at least 20% of the pipe length, using
suitable means and in a manner to avoid damages to the pipe and coating.
CONTRACTOR shall submit to Company a complete procedure indicating the
manner and arrangement used for handling and staking of coating pipes for
company approval prior to commencement of handling operation. All
stanchions of Lorries / Trailer 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 convex portions to prevent the
damage to the coated surface. Line pipes shall be entirely within the Lorries /
trailer so as to prevent case hardening / mechanical stresses due to cantilever
loading of the pipes.
6.3.4 Pipes which are damaged at the time of delivery or "taking-over" (when line
pipe is supplied by TGPL), particularly those which are dented, buckled, or
otherwise permanently deformed, must be stacked separately and may be
transported to the sites only when these defects have been repaired or
eliminated.
6.4 STRINGING OF PIPE
6.4.1 The CONTRACTOR shall exercise utmost care in stringing the line pipe to avoid
the damages. The CONTRACTOR shall adhere to the following as a minimum-
 Use side boom, Hydra or swinging crane or other suitable equipment
appropriate to site condition and available RoW. Dragging or sliding of
pipe shall not be permitted.
 Stringing of pipe shall only be carried out after clearing and grading.
 Pipe shall not be strung on the RoW in rocky areas where blasting may
be required, until all blasting is complete and the area cleared of all
debris.
 Pipes shall be strung on loose soft soil / sand filled gunny bags / straw
stacks / soft padded wooden skids, in such a way so as to match the
grade profile and trench profile.
 The stringing of the pipe on the RoW shall be done in such a manner as
to cause the least interference with the normal use of the land crossed
 The pipe length must be properly spaced in order to make easier the
handling during the welding phase.
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6.4.2 It shall be the responsibility of the CONTRACTOR that pipe is strung in

accordance with the approved drawings for the proper placement of pipe by
size, thickness, grade and other specifications. Any additional handling of pipes
resulting from failure to, comply with these requirements shall be at the
CONTRACTOR’s expense.
6.5 REPAIR OF DAMAGED PIPES
After the pipe has been strung, on the RoW it shall be inspected by the
CONTRACTOR and the TGPL/TPIA and all defective pipe ends repaired.
Defective pipe shall be repaired or rejected as directed by the TGPL/TPIA at no
extra cost.
6.6 MATERIALS OTHER THAN LINEPIPE, if any
6.6.1 CONTRACTOR shall receive and take over against requisition all TGPL supplied
materials from TGPL’s designated place(s) of delivery as defined in the
CONTRACT. CONTRACTOR shall notify TGPL/TPIA well in minimum one week in
advance of issue of material from TGPL.
6.6.2 CONTRACTOR shall;
Perform visual inspection and defects noted, if any, shall be recorded separately
 Perform the necessary loading, unloading, hauling from points designated
by the TGPL and storing, if necessary, of all materials.
 Store materials excluding line pipe in sheltered storage. Such materials shall
not be strung on the RoW but shall be transported in covered conveyances
for use only at the time of installation.
 Ensure that all valves and whenever applicable other materials are fitted
with suitable end covers of the type approved by TGPL. Materials with
worked surfaces such as flanges, pipe fittings, etc. must be stacked and
handled so as to avoid contact with the ground or with substances that
could damage them.
 Strictly comply with the manufacturer's instructions regarding temperature
and procedure for storing materials which are prone to alteration of the
original properties and characteristics due to unsuitable storage. If required,
an adequate heat conditioning shall be provided for these materials and
transported for use only at the time and in the quantities necessary for
immediate application.
Deteriorated materials shall not be used and replaced with no extra cost to
TGPL.
6.7 IDENTIFICATION
6.7.1 CONTRACTOR shall provide all pipes, bends etc. With serial numbers as soon as
possible and measure their length and state it on the pipes, etc.
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Pipes to be bent shall be measured prior to bending. Identification (i.e.

letter, number and length) shall be indelible. The contractor shall ensure
that the bending of the pipe does not result in addition of mechanical
stresses outside acceptable limits.
 All serial numbers shall be recorded in a list, which shall also state relevant
pipe numbers.
 Besides recording the stamped-in pipe numbers, length of pipe and
painting-on serial numbers, the stamped-in numbers of T-pieces, bends,
valves, etc. and the batch numbers of bends, T-pieces, valves, etc., and the
make of valves, shall also be recorded in said list.
 Before a pipe length, pipe end, etc. is cut, the painted serial number and
stamped-in pipe number shall be transferred to either side of the joint
which is to be made by cutting, and the change shall be recorded in the
above mentioned list stating the (new) length.
6.7.2 CONTRACTOR shall explicitly instruct his staff that parts which cannot be
identified must not be removed, except after permission by TGPL/TPIA.
As a general rule parts must be marked as described above before being moved.
In no conditions may unmarked parts be incorporated into the work.
7. TRENCHING
7.1 LOCATION
CONTRACTOR shall excavate and maintain the pipeline trench on the staked
centreline of the pipeline taking into account the curves of the pipeline.
7.2 EXCAVATION
7.2.1 CONTRACTOR shall, by the method approved by TGPL/TPIA, dig the pipeline
trench on the cleared and graded RoW. In cultivable land and other areas
specifically designated by the TGPL/TPIA, top 300mm of the arable soil on the
pipeline trench top width plus 500 mm on either side (for private ROW), shall be
excavated and stored separately to be replaced in original position after back
filling and compacting rest of the trench.
Suitable crossings shall be provided and maintained over the open ROW, care
must be taken where permit is necessary from general public, property owners
or his tenants to cross or move stock or equipment from one side of the trench to
the other side.
Care shall be exercised to ensure that fresh soil recovered from trenching
operation, intended to be used for back filling over the laid pipe in the trench, is
not mixed with loose debris of foreign material. The excavated material shall
never be deposited over or against the strung pipe.
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7.2.2 In steep slope areas or on the hillside, before commencing the works, proper
barriers or other protection shall be provided to prevent the removed materials
from rolling downhill.
7.2.3 On slopes wherever there is danger of landslide, the pipeline trench shall be
maintained open only for the time strictly necessary. Moreover, TGPL may
require excavation of trench manually, local route detouring and limiting the
period of execution of the work.
7.2.4 In certain sloppy sections, before the trench cuts through the water table, proper
drainage shall be ensured both near the ditch and the Right-of -way in order to
guarantee soil stability.
7.2.5 All sewers drain ditches and other natural waterways involved in the execution
of the work shall be maintained open and functional. The same applies to canals,
irrigation canals. Pipelines and buried facilities crossed by the ditch for which
temporary pipelines shall be laid, if required and proper temporary installations
provided.
7.3 NORMAL COVER AND TRENCH DIMENSIONS
7.3.1 The trench shall be excavated to a minimum width so as to provide, on both
sides of the installed pipeline, a clearance as indicated in the job
standards/drawings and to a depth sufficient to provide the minimum cover as
indicated below. The dimensions in the table below shall govern except as noted
herein or as shown on the job standards or detailed construction drawings or as
required by authorities having jurisdiction, whichever is greatest. Minimum
depth of cover shall be measured from the top of pipe corrosion/concrete
weight coating (as applicable) to the top of undisturbed surface of the soil or top
of graded working strip or top of road or top of rail whichever is lower. Fill
material in working strip shall not be considered to add to the depth of cover.
However, surface of full material placed to fill hollows may be used to determine
the depth of cover subject to prior approval by TGPL/TPIA.
SR. NO. LOCATION MIN. DEPTH OF COVER

In Meter
A Industrial, Commercial & Residential Areas 1.0
(Secondary
Roads)
B Normal / Rocky Terrain 1.0
C Minor Water Crossings & Canals / unlined 1.5*
canal / nala crossing / tidal areas and other
watercourses
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D Major River Crossings 2.5*

E Rivers with Rocky bed 1.5*
F Lined Canals / drains / nalas etc. 1.5*
G Drainage ditches at road and railroads 1.2
H Rocky Areas 1.0
I Cased / Uncased road Crossings 1.2
J State highway#
Cased & Boring 1.5*
Uncased & Open Cut 2.5*

K National highway - Cased & Boring# 1.5*
L Cased Railroad Crossings# 1.7*
M River Crossing - Un cased & Open Cut 3.0*
N River Crossing by HDD XX*
# Depth of Cover can be increased / decreased as per the requirement of the
Governing Authorities and TGPL instruction
* For All Cases where Depth of Excavation > 1.2 Mtrs, Clause for ‘Confined
Space Entry’ as per TGPL HSE Requirements, shall apply
Notes:
1. Cover shall be measured from the top of coated pipe to the top of the
undisturbed surface of soil or the top of graded working strip, whichever
is lower. The fill material in the working strip shall not be considered in
the depth of cover.
2. For river / watercourses that are prone to scour and / or erosion, the
specified cover shall be measured from the expected lowest bed profile
after scouring / erosion. Where scour level cannot be established, an
additional cover of minimum 1 meter shall be provided from the existing
bed of the river/water course.
3. The cover shall be measured from the top of road or top of rail, as the
case may be. Whenever the above provisions of cover cannot be provided
due to site constraints, additional protection in form of casing/ concreting
etc. shall be provided.
7.3.2 Wherever the Depth of Excavation required, for any Pipeline related activity
exceeds 1.2 Mtrs, the Trench will fall under ‘Confined Space’ as per TGPL HSE
requirements, and the following clauses shall apply:
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 Clause for ‘Confined Space Entry’ as per TGPL HSE Requirements

 ‘Permit to Work’ shall be required before carrying out any Construction
related activity.
 Provision of ladders / ramps / stairs shall be ensured at every 8m radius
from each person working inside the Trench, for safe Access / Egress
during emergency.
7.4 CUTTING AND REMOVAL OF PAVING

Whenever it is permitted by Authorities and/or TGPL/TPIA to open cut a paved
road crossing, or where the line is routed within the road pavement,
CONTRACTOR shall remove the paving in accordance with the restrictions and
requirements of the authorities having jurisdiction thereof or as directed by
TGPL/TPIA. The open cut for the road crossing shall be carried out only when the
section of pipeline to be laid is ready. All the area connected with the works shall
be temporarily restored. Throughout the period of execution of such works,
CONTRACTOR shall provide and use warning signs, traffic lights or lanterns,
barricades, fencing, watchman, etc. as required by the local authorities having
jurisdiction and/or TGPL/TPIA.
For all roads, walkways etc., which are open-cut, CONTRACTOR shall provide
temporary diversions of adequate strength and properly constructed to allow the
passage of normal traffic with the minimum of inconvenience and interruptions.
The paving shall be restored to its original condition after the pipeline is
installed.
7.5 EXTRA DEPTH AND CLEARANCE
At points where the contour of the earth may require extra depth to fit the
minimum radius of the bend as specified or to eliminate un-necessary bending of
the pipe according to customary good pipeline practice, or where a deep trench
is required at the approaches to crossings of road ways, rail roads, rivers,
streams, drainage ditches, and the like, CONTRACTOR shall excavate such
additional depth as may be necessary at no extra cost to the TGPL.
CONTRACTOR shall excavate to additional depth where the pipeline approaches
and crosses and / or runs parallel to other pipeline, cable, drain, telephone
conduits, and other underground structures so that the following two
requirements are met:
(a) When a buried steel pipeline or main has to cross any existing
underground pipeline, cable, drain or other services, the pipeline shall be laid
at least 500/1000 mm (as the case may be, as indicated in typical drawing)
below from such services.
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(b) When laid parallel to any existing underground cable, drain or other
utilities, the pipeline or main shall be laid with a clear distance of at least 500
mm from existing utility.
Where the pipeline crosses areas, whose easements specifically require greater
than normal depths of cover, the trench shall be excavated to extra depth in
accordance with right of way agreement.
CONTRACTOR shall excavate all such additional depths as may be necessary at no
extra cost to the TGPL.
7.6 GRADES, BENDS AND FINISH OF TRENCH
The trench is to be cut to a grade that will provide a firm uniform and continuous
support for the pipe. Bends shall be made in the pipe at significant changes in
grade of the trench. TGPL reserves the right to set the grade of the trench and
locate the bends if so desired, in which case CONTRACTOR shall excavate, at no
extra cost, the trench and bend the pipe to such a grade. TGPL/ TPIA may desire
to reduce to a minimum the required number of cold field bends to lay the pipe
to conform to the general contour of the ground and maintain normal cover.
OWNER intends that there will be a minimum of hand grading of the trench
bottom. However, to achieve this, CONTRACTOR will have to dig as square a
bottom of the trench as possible with his equipment. This in part can be
obtained by adjusting and adopting the crumbling shoe and digging teeth of the
trenching machines and by use of a drag behind the trenching machines or
manually dressing-up the same. CONTRACTOR shall do such handwork in the
trench as is necessary to free the bottom of the trench from loose rock and hard
clods and to trim protruding roots from the bottom and side walls of the trench.
7.7 PADDING
In all cases where rock or gravel or hard soil is encountered in the bottom of the
trench, requirement of bedding & padding will be decided by TGPL Site
engineer/TPIA. TGPL/TPIA will decide the exact extent of required trench
padding. The thickness of the padding at bottom shall not be less than 150 mm.
Acceptable padding shall be placed under the pipeline before its installation and
around after installation to establish at both sides and on top of the pipe a
permanent layer of padding. The thickness of the padding on the top shall be
minimum 300 mm. CONTRACTOR shall execute all such padding including supply
of suitable padding material. Padding shall be done by soft soil/sand.
7.8 PROTECTION OF THE TRENCH
CONTRACTOR shall keep the trench in good condition until the pipe is laid and no
claim is to be made to the TGPL by reason of its cave in either before or after
pipe is laid. CONTRACTOR shall de-water, if necessary, using well point system or
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other suitable systems, to excavate the trench and install the pipe, and backfill
the trench in accordance with the specifications.
7.9 PROTECTION OF UNDERGROUND UTILITIES AND SPECIAL METHODS
CONTRACTOR shall obtain plans and full details of all existing and planned
underground services from the relevant local authorities and shall follow the
relevant plans closely at all times during the performance of work. CONTRACTOR
shall be responsible for location and protection of all underground utilities &
structures and any damage to them shall be restored at his own cost. In special
locations the use of trenching machine may result in damage to property and
sub-surface structures likely to be encountered during excavation. At such places,
CONTRACTOR shall excavate the trench manually to same specification at no
extra cost.
Where the pipeline crosses other underground utilities/structures, the
CONTRACTOR shall first manually excavate to a depth and in such a manner that
utilities/structures are located.
Temporary under pinning or any other type of supports and other protective
devices necessary to keep the interfering structure intact shall be provided by
the CONTRACTOR at his own cost and shall be of such design as to ensure against
their possible failure.
Despite all precautions, should any damage to any structure/utility, etc. occurs,
the OWNER/AUTHORITY concerned shall be contacted by the CONTRACTOR and
at his expense under the direction and to the satisfaction of OWNER and the
concerned authority. If CONTRACTOR fails to repair in reasonable time, OWNER
reserves the right to have the repair executed at the cost of the CONTRACTOR.
7.10 ENCROACHMENT AND WORKING NEAR OTHER UTILITIES:
In location where the pipeline to be laid more or less parallel to an existing
pipeline, cable / or other utilities in the right of way, the work shall be performed
to the satisfaction of the concerned owner / authority of the existing
pipeline/cable/utilities.
7.11 PROVISIONS FOR NEGATIVE BOUYANCY TO THE PIPE
In case of water in the trench bottom when the pipeline is being laid, the trench
shall be drained to extent to make visual inspection of the bottom. Wherever up-
floating of the pipeline after back filling is expected, the same be reckoned with
proper anti-buoyancy measures. Anti-buoyancy shall be provided by
CONTRACTOR for areas indicated in the drawing or as may be encountered
during construction using one or more methods with prior approval from TGPL/
TPIA.
 By applying concrete coating by grunting.
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 Deeper burial of pipeline.

 Providing saddle weights.
8. BENDING
8.1 CONTRACTOR shall provide cold field bends for change of direction and change
of slope. Sag bends shall fit the bottom of the trench and side beds shall conform
and leave specified clearances to outside wall of the trench.
8.2 COLD FIELD BENDS: The CONTRACTOR shall exercise utmost care in cold field
bending to maintain the quality of Bends as per Pipe Fabrication Institute (PFI).
8.2.1 The radius of cold field bends shall not be less than 21 times the pipe diameter
and the degree of cold field bends shall not be more than 650.
8.2.2 CONTRACTOR shall use a bending machine and shall employ recognized and
accepted methods of bending of coated pipe in accordance with good pipeline
construction practice.
8.2.3 Bending machines shall be capable of making bends without wrinkles, buckle,
stretching and with minimum damage to the coating. Straight portions at end
shall be 2 m on either side.
8.2.4 Pipes with longitudinal welds shall be bent in such a way that the weld lies in the
plane passing through the neutral axis of the bend, which shall be installed
positioning the longitudinal weld in the upper quadrants. If horizontal deviations
are to be achieved by joining more adjacent bends, the bending of the pipe
lengths shall be made by positioning the longitudinal welds alternatively 70 mm
above and below the plane passing through the neutral axis in such a way that
the bends are welded with longitudinal welds displaced by about 150 mm and
situated in upper quadrant. In case of vertical bends formed from a number of
pipe lengths, the longitudinal welds shall be positioned on the plane passing
through the neutral axis of the bend to the right and left alternatively.
8.2.5 The ovalization caused on each pipe by bending shall be less than 2.5% of the
nominal diameter at any point.
8.2.6 A check shall be performed on all bends by passing two-gauge plate of Dia equal
to 97.5% ID of pipe and fitted 300mm apart.
8.2.7 Coating shall be checked for holidays. It must also be checked whether the
coating has dis-bonded from the pipe wall during bending by beating with a
wooden mallet along the outer radius. Any defects or disbonding of the coating
caused during bending shall be repaired at the Constructor’s expenses in
accordance with TGPL/TPIA approved procedures.
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8.2.8 Over bends shall be made in such a manner that the centre of the bend clears
the high points of the trench bottom.
8.3 NATURAL ELASTIC BENDS: The Minimum allowable radius for elastic bends in the
buried pipeline including that for continuous concrete weight coated pipe shall
be as per standards specification. The elastic bend shall be continuously
supported over its full length. A radius smaller than 21 times the pipe diameter
shall call for fabrication of cold bend.
8.4 MITER AND UNSATISFACTORY BENDS - All bends showing buckling, wrinkles,
cracks or other visible and harmful defects or which are in anyway in
disagreement, in whole or in part, with this specification shall be rejected. Each
Bend shall be marked with paint, Bend number, TP number, Degree, Left/Right,
Chainage, Heat Number, and Pipe Number at both ends of Pipe.
9. LINING UP
9.1 Each pipe is to be checked visually internally and externally for pipe / coating
damages, signs of corrosion. Each pipe shall be swabbed if required. Any
damages noticed shall be informed to TGPL.
9.2 PIPE DEFECTS
9.2.1 The maximum permissible depth of gauge in pipe shall not more than 3 mm from
the lowest point of the dent and a prolongation of the original contour of the
pipe dent may be removed by disc grinder and final wall thickness shall be
measured and verified from TGPL/TPIA.
9.3 PIPE HOLDING AND SKID SPACING
9.3.1 When lifting pipe, care must be taken not to kink or over stress it, proper pipe
slings shall be used.
9.3.2 Skid shall be at least 1.2 meters long and shall have width of 200 mm. Pipe
supports shall be stable, so that movement will not cause the supports to move.
Skids shall not be removed before lowering. The welded pipe shall be maintained
on skids at a minimum height of 500 mm to avoid back scattering during
radiography
9.3.3 Night caps: At the end of each day’s work or when welding operation are
interrupted, the open ends on the welded strings of pipe shall be capped.
CONTRACTOR shall arrange the caps as required at his own cost.
10. LOWERING IN TRENCH

10.1 Lowering shall start only in the presence TGPL/TPIA, after submission of section
pipe book and acceptance of the same for the section to be lowered. Entire
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trench bottom shall be checked for the presence of cuts, pipe supports, stones,
roots, debris, stakes, rock projections up to 15 cm below underside of pipe and
any other materials which could lead to perforation/ tearing of the coating is
removed.
10.2 Bottom padding shall be done as per site engineer instruction at places where
rock, gravel or hard soil is encountered. The thickness of the padding shall be at
least 150 mm all around the pipe. Initially a layer of 150 mm shall be spread in
the trench before lowering. Subsequent padding shall be done after lowering.
However, the thickness of padding on the top of pipe shall be 150 mm minimum.
10.3 A complete check by a full circle holiday detector, duly calibrated, for pipe
coating and for field joint coating shall be carried out and damages, if any, shall
be repaired. All points on the pipeline where the coating has been in contact
with either the skids or with the lifting equipment during laying shall be carefully
inspected for damages, denting or other defects and shall be completely
repaired. If, after checking, it becomes necessary to place the pipeline again on
supports at the bottom of the trench, these must be padded in such a way as to
prevent damage to the coating, thus avoiding necessity for further repairs when
the pipe is finally raised and laid.
10.4 The pipeline shall be lifted and laid using, for all movements’ necessary, suitable
slings of non-abrasive material having adequate width for the fragility of the
coating. Care shall be exercised while removing the slings from the coated pipe,
after it has been lowered into the trench. Any damage caused to the coatings
shall be promptly repaired. No sling shall be put around field joint coating.
10.5 Laying shall be carried out under safe conditions so as to avoid stresses and
temporary deformations of the equipment which may cause damage to the
pipeline itself and to the coating. In all localized points where the RoW is
restricted to the minimum necessary for the transit of mechanical equipment,
the laying shall be carried out using other suitable means.
The pipe section shall be placed on the trench bed without jerking, falling, impact
or other similar stresses. It shall be ensured that the pipe is laid gently following
the S’ curve within its elastic limit. Any damage caused to the coating shall be
promptly repaired and repair portion shall be checked by holiday.
10.6 Lowering shall not be permitted in or during bad weather.
10.7 Wherever the pipeline is laid under tension, as a result of undue stresses at
specific points, the trench shall be rectified to the satisfaction of TGPL/TPIA’s, so
that it fits in the excavated trench bed.
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10.8 The pipeline must be laid without interruption for the whole or the length of
section available. Where water is present, no laying shall be permitted until the
ditch has been drained to the extent and for the time necessary to make visual
inspection possible of the bed on which the pipe is to be laid. Following such
inspections, the presence of water will be permitted, provided that it is not so
high as to cause cave in of walls of the trench or floating of the pipeline before
backfilling, when weight is not provided for the pipe. CONTRACTOR shall take
precautions immediately after lowering in to prevent the movement of the pipe
in the trench.
10.9 Subsequent to lowering a pipe section, level of the trench bottom and level by
the side of the trench shall be taken at those locations where levels were taken
prior to lowering. Cover shall be ascertained based on the level difference.
Engineer-in- Charge’s approval of these levels shall be taken and the levels
recorded in pipe book. If the cover is not as per the requirements of this
specification, the lowered pipe section shall be removed from the trench and the
trench rectified, so that the available cover is as per the requirements of this
specification.
10.10 Post padding work shall start immediately after lowering.
11. BACKFILLING
11.1 Backfilling shall be done after ensuring that appurtenances have been properly
fitted and the pipe is following the ditch profile at the required depth that will
provide the required cover and has a bed which is free of extraneous material
and which allows the pipe to rest smoothly and evenly. Before any such work is
done, it shall be CONTRACTOR’s responsibility to first secure the approval of
OWNER. If any backfilling is done without OWNER’s approval, OWNER will have
the right for removal of the backfilling for examination, and the cost of such
uncovering and refilling shall be borne by CONTRACTOR.
11.2 Dewatering shall be carried out prior to back filling. No backfilling shall be
allowed if the trench is not completely de watered. Any saline water found
during Trenching/Backfilling shall be discharged in to Drain/canal at the nearest
location available. Dewatering on ROW shall not be allowed.
11.3 Prior to back filling it should be ensured that the coated portion been previously
Holiday checked, CONTRACTOR checked post padding of 300mm minimum thick
layer of soil is put over and all around the pipe immediately after lowering.
Warning mat to be placed after post padding and before backfilling in the trench.
11.4 Where, rock, gravel, lumps of hard soil or like materials are encountered at the
time of trench excavation, sufficient sand or select backfill materials shall be
placed around and over the pipe to form a protective cushion extending at least
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to a height of 300 mm above the top of the pipe. CONTRACTOR shall select the
backfill materials for padding that are acceptable to TGPL/TPIA, whether such
padding material would be taken from the adjacent spoil bank or imported from
elsewhere shall be directed by TGPL/TPIA. CONTRACTOR shall carry out all these
works at no extra cost to TGPL. Loose rock may be returned to the trench after
the required selected backfill material has been placed, provided the rock placed
in the ditch will not interfere with the use of the land by landowner, or tenant.
11.5 When the trench has been dug through driveways or roads, all backfill shall be
executed with sand or a suitable material as approved by TGPL/TPIA and shall be
thoroughly compacted. In certain cases, special compaction methods, such as
moistening or ramming of the back fill in layers may be required by TGPL/TPIA.
TGPL/TPIA and any public or private authority having jurisdiction over a road,
street or drive way may require that the surface of the backfill be gravelled with
crushed rock or some other purchased material and the road shall be repaved. In
such instances, CONTRACTOR shall comply with said requirements at no extra
cost to TGPL.
11.6 Trenches excavated in dikes which are the properties of railways or which are
parts of main roads shall be graded and backfilled in their original profile and
condition. If necessary, new and/or special backfill materials shall be supplied
and worked-up at no extra cost to TGPL. The materials required may include
gravel, special stabilization materials or stabilized mixtures. Moreover, special
processing and/or compacting methods shall require the approval of TGPL/TPIA
and/or competent authorities.
11.7 The trench in irrigated and paddy fields shall be backfilled to within 300mm of
the top, then rammed and further backfilled until the trench is completely
backfilled. Surplus material remaining after the operation shall be spread over
the ROW as specified in “Clean up and Restoration of RoW", of this specification.
11.8 At the end of each day's work, backfilling shall not be more than 200 meters
behind the head end of lowered-in pipe, which has been padded and approved,
for backfill. The backfill shall be maintained by CONTRACTOR against washouts
etc., until the completion and final acceptance of the work by TGPL/TPIA.
11.9 CONTRACTOR shall furnish materials and install breakers in the trench in steep
areas (slope generally 10% and more) for the purpose of preventing erosion of
the back fill. The type of breakers installed shall be as per the approval drawings.
Breakers shall be constructed of grout bags filled with a mixture of 4:1 Sand:
Portland cement at TGPL’s / TPIA direction. CONTRACTOR may propose other
methods such as foam dams’ etc. which shall be subject to approval of
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TGPL/TPIA. Such works shall be done at no extra cost to TGPL. CONTRACTOR

shall pay attention to the direction of back filling in such steep areas.
11.10 When back filling the trenches in sloping terrain’s or steep areas, where in the
opinion of the TGPL/TPIA the back fill may be washed out of the trench, sheet
piling or other effective water breakers across the trench shall be provided by
CONTRACTOR. This is to divert the flow of water away from the trench into
normal drainage followed before laying of the line. In no case, the water is to be
drained via the trench or via channels other than those followed before the line
was laid.
11.11 CONTRACTOR shall leave the pipe uncovered at certain locations to allow
TGPL/TPIA to survey the centreline of the pipe and the level of the pipeline in the
backfilled trench. Within 48 hours after backfilling, TGPL/TPIA shall carry such
survey and informed CONTRACTOR of any re-aligning, if required. Thereafter
CONTRACTOR shall compact the backfill material.
11.12 The CONTRACTOR shall carry out stabilization of backfill in sandy areas and other
such places, as directed by the TGPL/TPIA. CONTRACTOR shall carry out the
stabilization to have a consolidated cover over the pipeline at no extra cost to
TGPL.
The backfill shall be stabilized preferably with 150-mm layer of marl, mattresses
of batch other than straw or other stable materials. The width of stabilization
shall be at least 3.0 meters on either side of pipeline, plus one meter for every 10
meters height of dune (where the line passes through the dune areas).
11.13 Temporary markers shall be installed during back filling and the survey to locate
the pipeline axis. These markers shall then be replaced with permanent pipeline
markers. Backfilling shall be preferably carried out at the highest ambient
temperature.
12. SPECIAL INSTALLATION ON THE PIPELINE

12.1 GENERAL
12.1.1 In addition to construction of the pipeline, CONTRACTOR shall also install certain
other auxiliary facilities and appurtenances. CONTRACTOR shall do all work
necessary at each of the installations to provide facilities, which are complete in
all respects and ready for operations.
Without limiting the generality thereon, the work required to complete the
installations shall, where applicable, include all site surveys, site preparation,
filling, grading, fencing, foundations, installation of block valves, side valves,
pipe work, pipe supports, pressure gauges, mechanical facilities, civil work,
painting, installation of all electrical equipment’s, and fixtures, piping, valves
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and fittings; mount all instruments and make all piping and electronic
connections, etc.
On completion, all elements of each and entire installation shall be checked and
tested for full and correct operation in the presence of, and to the satisfaction of
TGPL/TPIA. All work shall be carried out strictly in accordance with the relevant
codes and as per the approved drawings.
CONTRACTOR shall fabricate all piping and install valves and fittings as required
by and approved by TGPL/TPIA. Stainless steel tubing will be "swaged" using
permanent fittings installed with a hydraulic device. Cold bending for the fitting
of 1/2" and 1/4" pipes is allowed when special bending tools are used with guides
to prevent flattening. The minimum radius allowed shall not be less than R = 10
D, where D = outside diameter of pipe. The bending tool shall be subject to
TGPL/TPIA approval.
CONTRACTOR shall ensure that the piping assemblies are not in a strain prior to
the final bolting or welding. CONTRACTOR shall also ensure that all equipment
and piping are thoroughly swabbed clean of all dust, refuse, welding- spatter,
scales, or any potentially detachable matter prior to the tie-in or final bolting by
means of cardboard blasting method or suitable method up to the satisfaction of
TGPL/TPIA.
12.1.2 Flanged connections
CONTRACTOR shall ensure that all flange faces are parallel and centered,
according to standard practice, prior to final bolting. CONTRACTOR shall not use
bolting forces as a means for attaining alignment. A gasket of proper size and
quality shall be installed between the flanges at each joint.
Bolts shall be tightened in diagonal sequence and shall be centered with equal
amounts of thread visible on both sides. Bolts shall be uniformly tightened to
produce a leak-proof joint. Bolts that yield during tightening shall be removed
and discarded. It is mandatory that a torque wrench is used for bolt tightening
12.1.3 Welded connections
Where the ends of the piping components being welded have an internal surface
misalignment exceeding 1.6 mm, the wall of the component extending internally
shall be trimmed by machining so that the adjoining internal surfaces will be
approximately flush.
12.1.4 Threaded connections
Damaged threads shall be cut from the end of thread and the pipe shall be
rethreaded.
CONTRACTOR shall properly align all threaded joints. Pipe entering unions shall
be true to centreline so the union will not be forced during wake-up. The
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threaded pipe shall not project through fittings to cause interference with valves
or other operating mechanisms.
Except for the threaded connections of instruments, which will require periodic
testing and maintenance, all threaded joints shall be seal welded. The latter
joints shall be made up without pipe joint compound and with a minimum of oil
from the thread cutter. Seal welds should taper into the pipe with as little
discontinuity as possible, and should cover all threads.
12.1.5 Civil work
Civil work shall be provided in accordance with specifications issued for the
purpose.
12.1.6 Painting
All exposed surfaces like piping, Valves structures and miscellaneous
appurtenances shall be painted in accordance with SSPC – SP 1 & SIS - 055900.
The corrosion coating on pipe surface will end approximately 0.3 meter above
the finished grade and it will be necessary for CONTRACTOR to provide a clean
interface at the junction of the protective coating and the paint.
12.1.7 Coating of buried Installations, etc.
All buried valves, insulating joints, flow tees, bends, other in line fittings and
appurtenances shall be coated (Heat Shrink Sleeve or Liquid Epoxy or equivalent).
CONTRACTOR shall submit to TGPL/TPIA, a report regarding the method of
application and the materials used along with the test certificates. Only after
obtaining written approval from the TGPL/TPIA. CONTRACTOR shall commence
coating work.
Multi-pass, pressure retaining welds may be coated prior to pressure testing with
the following exceptions:
 Unless prohibited by the design code
 Welds in in-plant piping systems as follows:
 Socket and seal welds
 Single or multi-pass, pressure retaining fillet welds
 All welds in systems subject to a sensitive leak test (where sensitive
leak test is permitted by Company)
 Other safety critical welds as designated by Company.
12.1.8 Clean-up
After all, required tests have been conducted satisfactorily; CONTRACTOR shall
clean up the site. The site finish shall be graded in accordance with the approved
drawings.
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12.2 INSTALLATION OF VALVES AND VALVE STATIONS

12.2.1 Block valve stations shall be installed as shown on the approved drawings. It is
CONTRACTOR’s responsibility to have the units completely assembled, tested and
made fully functional including all related instruments etc.
12.2.2 The civil and structural work shall be carried out in accordance with the relevant
specifications issued for the purpose and in accordance with the approved
drawings directed by TGPL/TPIA. This work as a minimum shall include clearing,
grading, fencing, foundations, etc. as required.
12.2.3 A suitable concrete foundation as directed by TGPL/TPIA shall be constructed on
which the valve shall be firmly installed, after embedding an insulating sheet of
hard polyethylene with a thickness of at least 10 mm or equivalent. Such
insulating sheet is also to be installed under pipe clamps, etc.
12.2.4 Valves with flow arrows shall be installed according to the normal flow in the
pipeline. During welding, the valves shall be in fully open position. Care shall be
taken to avoid entry of sand particles etc. to valve body, seals etc. during
transportation, storage, assembly and installation.
12.2.5 For valves and piping installed below ground and / or above ground, the anti-
corrosion coating/painting shall be applied. The anti-corrosion below ground
coating shall extend up to 300 mm above ground at the lowest point.
12.2.6 Sectionalizing valves shall be installed on sections of the pipeline in the horizontal
position only or with an inclination not greater than that allowed by the valve
manufacturer. Installation shall be done in such a way that there is no strain in
the welded joint while the pipeline at upstream and downstream side is straight.
12.2.7 All valves shall always be handled using appropriate equipment and methods to
avoid impact, shaking and other stresses. In particular, the equipment and tools
for lifting and handling shall never be done through hand wheel, valve flange
joints and other parts, which may suffer damage.
12.2.8 All sectionalizing valve and any other inline assemblies shall be prefabricated and
tested hydrostatically at site as per applicable specification. All such assemblies
shall be installed at the locations shown in the drawings only after successful
completion of the hydrostatic test and dewatering. Thereafter the ends of the
assembly shall be closed off. CONTRACTOR shall carry out necessary excavation,
cutting, bevelling and welding of the tie-ins required for the installation of such
assembly. The tie-in joints shall be 100% radio graphically examined and 100%
ultrasonically examined prior to back filling. All works shall be executed in
accordance with the relevant specifications issued for the purpose.
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12.3 INSTALLATION OF SCRAPER TRAPS STATIONS

12.3.1 Scraper stations shall be installed as per the approved drawings. It is
CONTRACTOR‘s responsibility to have the units completely assembled, tested and
made fully functional including all instruments & related piping.
12.3.2 The civil and structural woks for the scraper stations shall be carried out as per
the relevant specifications, in conjunction with the drawings and as directed by
the TGPL/TPIA. The work as a minimum shall include site survey, site preparation,
clearing, grading, fencing, foundations, etc. as required.
12.3.3 It shall be CONTRACTOR’s responsibility to maintain elevations shown on the
approved drawings and to carry out any pipe work adjustments, necessary for
this purposed. Field cuts shall be square and accurate and field welds shall not be
performed under stress of pipe ends.
12.3.4 The hydrostatic testing of the scraper stations shall be performed after
installation in accordance with the relevant specifications issued for the purpose.
12.4 INSTALLATION OF INSULATING JOINTS
12.4.1 Insulating joints shall be installed at the locations shown in the alignment sheets.
CONTRACTOR shall obtain approval from the TGPL/TPIA before installation of the
insulating joints.
12.4.2 Handling and installation of the insulating joints shall be carried out with all
precautions required to avoid damage and excessive stresses and that the
original pup length is not reduced.
12.4.3 External coating as per relevant specification issued for the purpose shall protect
the insulating joints and the welded joints.
12.4.4 The in-line inserting shall be made on the buried pipeline. Care shall be taken to
the pipeline operating temperature. The joint shall be inserted on straight
sections and laid on a fine sand bed.
12.4.5 During the execution of the in-line connection welding, the propagation of heat
shall be avoided. To achieve this, the joint shall be kept cold by means of rags
continuously wetted. Electrical conductance test shall be carried out using a
megger on insulating joint. Measurement of the insulation resistance across the
insulation joint shall be approximately one-mega ohms. Measurement of the
insulation resistance across the joint shall be repeated after installation and
welding of the joint into the pipeline to ensure that the assembly is undamaged.
13. WORKING SPREAD LIMITATIONS
CONTRACTOR shall, in general, observe the following maximum distances
between working main line spread:
 Between ROU grading, cleaning and backfilling: 1 Kms.
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 Between backfilling and final clean-up: 0.50 Kms.

The above limitations do not apply to point spreads such as continuous rock
blasting, river crossing etc. Any deviations from the above shall meet prior
approval of TGPL / TPIA. TGPL/ TPIA reserve the right to stop the work, in case
the approved spread limitations are exceeded and CONTRACTOR shall not be
paid any compensation for stoppage of work.
14. CLEAN-UP AND RESTORATION OF RIGHT OF WAY
14.1 After completion of backfilling, CONTRACTOR shall permanently reinstate all
areas disturbed as a result of works including surface, walls, fences and land
drains to the satisfaction of TGPL and concerned land owner or authority. All
surplus and defective materials supplied by TGPL, shall be collected by
CONTRACTOR and delivered to designated stockpile areas.
14.2 SURPLUS MATERIALS
The following stipulations shall apply in case CONTRACT provides for supply of
line pipe, bare and/or corrosion coated, by TGPL.
All surplus and defective materials supplied by TGPL shall be collected by
CONTRACTOR and delivered to designated stockpile areas.
All pipe-ends shorter than 2.0 m shall be returned to TGPL being scrap, all
pipes longer than 6.0 m shall be reconditioned (bevelling, lamination checking
by UT, coating, repairs, holiday check) provided to TGPL’s designated stockpile
materials. All pieces between 2.0 and 6.0 m shall be charged to the
CONTRACTOR by TGPL. CONTRACTOR shall record these returned materials in
the Material Account, to be prepared by him.
14.3 DISPOSAL
14.3.1 All surplus and defective materials supplied by CONTRACTOR and all trash, refuse
and spoiled materials shall be collected and disposed of by CONTRACTOR as per
the TGPL HSE requirement.
14.3.2 The ROW shall be cleared of all rubbish, broken skids, empty cans, cardboard,
sacks, trash, and leftover construction material. All burnable matter is burned,
but only after obtaining appropriate permits for such burning. If burning is not
allowed, CONTRACTOR shall haul the clean - up material to an approved dumping
area. All scrap metal and un-burnable material shall be disposed off, in an
appropriate manner as per TGPL HSE and ISO 14000 requirements, but never be
buried in the ROW.
14.3.3 Surplus soil can only be removed from the Owner's plot after authorization by
TGPL/TPIA.
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14.3.4 All dumping fees connected with the disposal of materials shall be to the account
of CONTRACTOR.
14.3.5 All loose stone and rock exposed by the construction operations and scattered
over the ROW and adjacent grounds shall be removed by CONTRACTOR and be
transported to a location considered suitable by the land - owner and or tenant,
or by authorities having jurisdiction, for satisfactory disposal.
14.4 TEMPORARY STRUCTURES
All auxiliary structures such as bridges, dams, culverts, sheet piling, posts, slings,
etc., which were erected or installed by CONTRACTOR as temporary measure,
shall be removed.
14.5 REPAIR OF DAMAGES

CONTRACTOR shall repair damages to roads, bridges, and private property. All
fences and other structures, which are damaged during construction, shall be
restored to original condition.
Slopes, watercourse sider or banks, which have been partially or totally
demolished during the execution of the works shall be properly consisted and
restored without waiting for their natural consideration and settling.
All boundary stones, which have been moved off, removed during "the Work
must be reset in their original location to the satisfaction of the landowner
concerned.
14.6 On completion of clean - up, the ROW shall be restored to such stable and usable
condition as may be reasonably consistent with the condition of ROW prior to
laying to pipeline. The TGPL/TPIA shall be completely indemnified and held
harmless by CONTRACTOR from any claims, demands, losses, expenses etc. that
may arise on its behalf or TGPL/TPIA may anyway suffer or sustain, relative to,
arising out of, or in connection with same. The TGPL/TPIA may require from the
CONTRACTOR signed releases from landowners regarding satisfactory
indemnification and restoration of their lands.
14.7 Special precautions shall be taken near steep slopes prone to erosions and
landslides. All necessary steps shall be taken to ensure the rapid growth of grass
by providing wicker barriers and by regulating the drainage of surface waters.
14.8 All cadastral or geodetic markers which may have been removed during the
execution of the woks shall be restored in their exact position.
14.9 Ditches for which no instructions for restoration have been issued, or restoration
cannot be done according to existing banks because of the absence of it, shall be
restored as instructed by TGPL/TPIA. The bed of ditches crossed by the pipeline
shall be cleaned over the full width of the ROW, also outside the ROW if
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necessary. This restoration might contain but is not limited to the supply and
installation of proper materials for back fill and protection, the sliding or other
precautions to prevent erosion or guarantee the stability. All has to be done after
deliberation and acceptance of the authorities and TGPL/TPIA. Other field drains
have to be restored manually and/or special equipment to be used for that
purpose as soon as possible and if necessary also outside the ROW.
14.10 Any substances, cave-ins, wash-outs, which have been caused during the pipeline
construction and maintenance, caused by whatever reason within the edge of
ditches and open drains, shall be repaired by CONTRACTOR immediately or at
first notice given by TGPL/TPIA.
14.11 After the clean-up, ROW of pastures has to remain fenced as considered suitable
by the tenant and to be removed during the maintenance period. When
agricultural and other traffic (requested by tenant) have to cross the ROW, the
cross-oversee have to be fenced with the same material as the ROW. If
necessary, special materials have to be used to allow traffic on the crossover.
Fencing of the RoW as specified shall not be removed until CONTRACTOR has
obtained written permission by TGPL/TPIA. In general, this has to be done during
the maintenance period.
14.12 All openings in or damage to the fences or enclosures shall be repaired by
installing new fencing of a quality which shall be at least equal to the parts
damaged or removed. Provisional gates shall be removed and replaced with new
fencing. All repairs to fences and enclosures shall be carried out to the complete
satisfaction of TGPL/TPIA, landowner and/or tenant.
14.13 If, in the opinion of TGPL/TPIA, the sod in pasture land had been damaged by
vehicles and wheel tracks are visible, the ROW shall be tilled with a disc-harrow
or rotary cultivator several times. The damaged sod shall be firmly cut up and
thoroughly mixed through the topsoil. In general, the ROW has also to be ripped.
After this procedure no closed-in layers must be found and sufficiently loose
topsoil 25 to 30 cm thick must be present. The whole procedure must be
approved by TGPL/TPIA. Subsequently, the entire ROW, which is part of
pastureland, shall be prepared for seeding and fertilized according to the
instructions of TGPL/TPIA.
14.14 In crop fields the tillage shall consist of passing over the land several times with a
disc harrow, cultivating with a spading machine, or plow, to a depth of approx.
20-cm. In general, the ROW has also to be ripped. After this cultivation process
no closed-in layers must be found any more in the ROW. The equipment used
and methods adopted shall require the approval of TGPL/TPIA. Ripping has to be
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done with rippers with a distance of 50 cm between the ripper blades. The type
to be used shall be approved by TGPL/TPIA.
14.15 A sapling of any plant/tree uprooted or cut during construction shall be planted
along the route as per the direction of the TGPL/TPIA and in accordance with the
forest preservation Act, 1981. The cost of sapling and its plantation shall be to
CONTRACTOR'S account.
14.16 The ROW and the backfilled trench in particular have to be finished in such a way
that after settlement of the soil, the fields are at their original level.
If during the maintenance period certain parts of the ROW are lower than the
original level, TGPL/TPIA can instruct the CONTRACTOR to bring these parts to
the original level.
If during clean-up operations soil shortages become apparent outside the trench,
CONTRACTOR shall supplement said soil shortage using suitable materials,
approved by TGPL/TPIA.
If site and/or climatic conditions should render this necessary, TGPL/TPIA shall
have the right to order CONTRACTOR to suspend certain parts of the WORK
related to the clean-up and postpone it to a later date.
14.17 SOIL SURPLUS
If on site, as a result of the work and after careful back filling and compacting, a
sub-soil surplus exists, this shall be worked up by grading and compacting below
the sub-soil top layer and as a rule this shall be done in the same plot of land. It
shall not be permitted to remove the surplus from the plot concerned, unless it
concerns rejected soil, which has to be removed. Working up surplus soil or
removal of rejected soil shall be considered to pertain to the ROW.
To work a soil surplus into the ground CONTRACTOR shall remove an additional
strip of topsoil beside the trench. Next, the upper layer of sub-soil shall also be
removed. Both soil strips shall be stored separately across a width depending on
the size of the soil surplus. The soil surplus shall then be distributed across the
trench thus widened, after which it shall be graded and compacted and
subsequently the top layer of sub-soil and the topsoil shall be replaced in the
correct order, in accordance with the specifications.
In case TGPL/TPIA has given prior permission for mixed excavation of the sub-soil
as well as in cases where TGPL/TPIA deems mixed excavation permissible, the
above provision of separate storage of the upper layer of sub-soil shall not apply
to the working up of the soil surplus.
In cases where the soil surplus can be worked up in other plots where soil
shortages have arisen due to the ROW, this shall only be done after prior
permission by landowner, land -user and TGPL/TPIA.
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14.18 SOIL SHORTAGES

If due to unforeseen circumstances during back filling and compacting there
should not be enough soil to fill the trench properly, or to install the crown height
as stipulated, CONTRACTOR shall supply the necessary backfill material. Soil
shortages shall be supplemented and applied before the topsoil is replaced.
The soil to be supplied shall be worked up in those locations and into those layers
where a soil shortage has been established. The quality of the supplemented soil
shall be equals to that of the shortage.
15 AS BUILT
The Company requires that all relevant construction data to be captured in an
electronic database. The database shall be used by the Company for operation
and management of the pipeline through Geographic Information System (GIS).
The Contractor shall record data and features as detailed in this section.
The data shall include full pipe traceability that permits the Company to locate
any individual pipe joint installed in the system.
The Contractor is required to capture the data and supply it to the Company in an
acceptable electronic format. Duly signed paper copies shall also be provided as a
formal record of an activity.
The Contractor shall ensure that all subcontractors and vendors are capable and
are resourced to comply with the approved data tracking system.
The use of the Data tracking system shall not replace the production and
compilation of records to be reviewed and endorsed during the execution of the
works and shall:
 Identify the location of the top of pipe in the ground, and the location of the
natural surface in x, y and z coordinates. This shall be achieved by surveying the
location of each weld joint by using a Differential Global Positioning System
(DGPS) of suitable accuracy. In locations where the ground conditions do not
permit the actual survey, the co-ordinates of the intermediate welds may be
determined by interpolation.
 Provide sufficient survey data to identify the location of the pipe at each
bend (horizontal and vertical). In addition, relevant as-built data shall be
provided to the Owner prior to commencement of backfilling at the
related pipeline section.
 Identify the location of each facility installed as part of the pipeline,
including cathodic protection test points, signs and markers, valves, future
off-takes and other appurtenances.
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 Provide a detailed survey and drawing at crossings, including road, rail,

river, creek, canal and any other location where pipeline installed using
specialized installation technique.
Identify the location of each service crossed by the pipeline, and the location of
the natural surface in x, y and z co-ordinates. The services shall be identified in
terms of type, owner/authority, size, orientation, product and appearance.
15. DOCUMENTATION
15.1 Quality record for each activity
 Procedure, ITP and Progress report of each activity.

15.2 Pipeline route alignment drawing
15.3 No objection certificate from Government / Concern authorities and Land owner.
15.4 Pipe book
15.5 Mechanical clearance of special installation
15.6 As built drawing of pipeline
15.7 As built drawing, plan and Isometric of special Installation
15.8 Batch certificate of all material
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2. Specification for Pipeline Welding
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TABLE OF CONTENT
1.0 SCOPE
2.0 REFERENCE CODE AND STANDARD
3.0 SUBMITTALS BY CONTRACTOR
4.0 BASE MATERIAL
5.0 WELDING CONSUMABLES
6.0 EQUIPMENT AND ACCESSORIES REQUIREMENT
7.0 WELDING PROCESSES
8.0 BEVEL CLEANING / BEVEL INSPECTION
9.0 ALIGNMENT AND SPACING
10.0 WEATHER CONDITIONS
11.0 WELDING
12.0 HEAT TREATMENT
13.0 INSPECTION AND TESTING
14.0 REPAIRS OF WELDS
15.0 DOCUMENTATION
16.0 ENCLOSURE
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1.0 SCOPE
This specification shall be followed for the fabrication of all types of welded joints
of mild steel pipe line & piping systems connected with the pipeline and related
facilities.
The welded pipe joints shall include the following.
a) All line pipe joints of the longitudinal and circumferential butt-welded and
socket welded types.
b) Attachments of flanges and other supports to pipes.
c) Welded manifold headers and other sub-assemblies.
d) Welded branch connections.
e) Joints in welded / fabricated piping components.
f) The attachments of smaller connections for vents drain drips and other
instrument tapping.
Any approval granted by the Engineer-in-charge/TPIA shall not relieve the
CONTRACTOR of his responsibilities and guarantees.
Following Standards and codes of latest edition have been used in this
specification.
2.1 Governing Standard
ASME B 31.8 - Code for Gas Transmission and Distribution Piping Systems
API 1104 - Standard for welding of Pipelines and Related Facilities -
2.2 Reference Standard
ASME Sec. II, Part – C - Specification for welding Electrodes and Filler Materials
ASME Sec. V. - Non Destructive examination
ASME Section IX - Qualification for welding and brazing
3.1 The CONTRACTOR shall submit the Welding Procedure Specification, Procedure
Qualification Record, Welder Qualification Test, Ultrasonic Testing Procedure,
Magnetic Particle Testing Procedure, Dye-Penetrant Testing Procedure and
Radiography Procedure along with quality records and Inspection Test Plan for
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welding and NDT compatible to this specification at least two weeks prior to
commencement of the work for the approval of TGPL/TPIA.
3.2 The CONTRACTOR shall submit Electrode and Welding Consumable Qualification
Records in respect of the electrodes tested by the CONTRACTOR, for obtaining
approval of the Engineer-in-charge/TPIA.
4.0 BASE MATERIAL
4.1 In general, use of MS Pipe & Fittings is envisaged. The details of material
specifications are given in the welding specification chart.
4.2 The CONTRACTOR shall provide the manufacture’s test certificates for every heat
of material, if any, supplied by the CONTRACTOR, also maintain the record of test
certificates of all the materials for the reference of the Engineer-in-charge/TPIA
5.0 WELDING CONSUMABLES
5.1 The CONTRACTOR shall provide at his own expense all the welding consumable
necessary for the execution of the job such as electrodes, oxygen, acetylene etc.,
and these shall bear the approval of the Engineer-in-charge/TPIA.
5.2 The SMYS of electrodes / filler wires shall be equal to or more than the parent
material to be welded.
5.3 Physical properties of the welds produced by electrodes recommended for the
welding of a particular base metal shall not be lower than the minimum values
specified for the base metal. The choice of electrode shall be the sole prerogative
of the Owner/Owner’s Representative.
5.4 The Contractor shall submit batch test certificates from the electrode
manufacturer giving details of physical and chemical tests carried out for each
batch of electrodes to be used.
5.5 For each batch, electrode qualification test report shall be submitted as per
Annexure to the Owner/ Owner’s Representative for approval.
5.6 The welding electrodes / filler wires supplied by the CONTRACTOR shall conform
to the class specified in the welding specifications chart. The materials shall be of
the make approved by the Engineer-in-charge/TPIA.
5.7 All electrodes shall be purchased in sealed containers and stored properly to
prevent deterioration. The electrodes removed from the containers (except
cellulose coated electrodes) shall be kept in holding ovens, at the temperature
recommended by the electrode manufacturer. Ovens shall be used for low
hydrogen electrodes only. Out-of-the oven time of electrodes before they are
consumed shall not exceed the limits recommended by the electrode
manufacturer. The electrodes shall be handled with care to avoid the any
damage to the flux covering. Different grades of electrodes shall be stored
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separately. Cellulose electrodes used shall however be used as per specific

recommendations of manufacturer.
5.8 The electrodes used shall be free from rust, oil, grease, earth and other foreign
matter, which affect the quality of welding.
6.0 EQUIPMENT AND ACCESSORIES REQUIREMENT
6.1 The CONTRACTOR shall have sufficient number of welding and cutting
equipment, welding clamp, auxiliaries and accessories of sufficient capacities to
meet the target schedules.
6.2 CONTRACTOR shall make necessary arrangements at his own expenses, for
providing the radiographic equipment, radiographic films, all the
equipment/material required for carrying out for satisfactory and timely
completion of the job. The CONTRACTOR has to carry out 100% X-ray testing for
all joints. Where ever radiography is not feasible due to weld / site condition,
same joints shall be examined through Ultrasonic examination.
6.3 All the equipment for performing the heat treatment, including transformers,
thermocouples, pyrometers, automatic temperature recorders with suitable
calibration arrangements, etc., shall be provided by the CONTRACTOR, at his own
expense and these shall bear the approval of the Engineer-In-charge/TPIA.
6.4 Redoing of any work necessitated by faulty equipment or operation used by the
CONTRACTOR shall be done at his own expense.
6.5 CONTRACTOR shall take prior approval before involving any SUB-CONTRACTOR
(including NDT agency) in the work.
7.0 WELDING PROCESSES
7.1 Welding of various materials under this specification shall be carried out using
Shielded Metal Arc Welding Process (SMAW) with the approval of the Engineer –
in – charge/TPIA.
7.2 The welding processes to be employed are given in the welding specification
chart. Any deviation desired by the CONTRACTOR shall be obtained through the
express consent of the Engineer – In – charge/TPIA and shall be documented in
Deviation Requests.
7.3 Welding technique shall be adopted as per the procedure qualified for welding of
pipe having diameter 4” and above which shall be held fixed with its axis
horizontal.
7.4 Upward technique shall be adopted for welding of fittings & pipe having
diameter less than 2”, as well as were ever is required as guided by Engineer–In–
Charge/TPIA.
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8.0 BEVEL CLEANING / BEVEL INSPECTION

Line pipe supplied by TGPL shall have bevel ends as specified in the applicable
specification for line pipe. Any modification thereto, if required by CONTRACTOR
due to his special welding technique shall be carried out by the CONTRACTOR at
his own cost.
Before welding, all rust and foreign matter shall be removed from the bevelled
ends by power operated tools. This shall be effected inside and outside and for a
minimum distance of 25 mm from the edge of the weld bevel. The bevels shall be
thoroughly inspected at this stage.
If any of the ends of the pipe joints are damaged to the extent that, in the
opinion of Engineer – in – charge/TPIA, the damaged ends shall be cut and
bevelled to the satisfaction of the Engineer – in – charge/TPIA with an approved
bevelling machine. A manual cutting and weld repair of bevels shall not be
allowed. If laminations, split ends or inherent manufacturing defects in the pipe
shall be discovered, the lengths of pipe containing such defects shall be removed
from the line to the satisfaction of Engineer-in-charge/TPIA. On pipes which have
been cut back, a zone extending 25 mm back from the new field bevel, shall be
ultrasonically tested to the requirement of the line pipe specification to ensure
freedom from laminations. The new bevel shall be 100% visual and 100% dye
penetrate / MPI tested. A report shall be written for all testing and records shall
be kept.
9.0 ALIGNMENT AND SPACING
Immediately prior to line up, CONTRACTOR shall inspect the pipe ends inside and
outside for damage, dents, laminations etc. Pipe for welding shall be set up,
correctly spaced; allowing for temperature changes during welding, in correct
alignment and shall in no circumstances be sprung into position.
Temporary attachments of any kind shall not be welded to the pipe. Welds are
joining the sections of the pipeline, Valve installation or similar welds classified,
as tie in welds shall be made in the trench. Otherwise the alignment and welding
shall be made alongside the ditch with the pipe supported on skids and back pads
or other suitable means approved by Engineer–in- charge/TPIA, at least 500 mm
above the ground unless approved by the Engineer-in-charge in specific cases.
Seam orientation of welded pipe shall be selected to ensure that at the
circumferential welds, the longitudinal welds shall be staggered in the top 90o of
the pipeline, or 250 mm whichever is the lesser. A longitudinal joint shall pass an
appurtenance of a structural element at a minimum distance of 50 mm. Should a
section of the line containing uncompleted welds fall from the skids, the
CONTRACTOR shall immediately inform Engineer-in-charge/TPIA.
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Every effort shall be made to reduce misalignment by the use of the clamp and
rotation of the pipes to the best fit. For pipe of same nominal wall thickness, the
offset/Hi-Low shall not exceed 1.6 mm. The offset/Hi-Low may be checked from
outside using Hi-Low Gauges. Any branch connection sleeve, etc., shall be at
least 150 mm from any other weld (Underground pipeline). The welds for fittings
shall be so located that the toe of the weld shall not come within 50 mm of any
other weld. Cold dressing is permissible only in cases of slight misalignment and
may only be carried out with a bronze-headed hammer. Hot dressing shall not be
permitted. When welding pipes of different wall thickness (as directed by
Engineer-in-charge/TPIA.) A special transition piece shall be used. This shall have
a minimum of 1:4 taper. The welds shall be subject to both ultrasonic and
radiographic inspection.
The root gap shall be accurately checked and shall conform to the qualified
welding procedure. The use of pipe clamp either internal or external is selected
considering requirements of pigging of pipeline in future. However, in some case
(tie in welds, flanges, fittings, diameter of pipe 10” etc.) where it is impossible to
use internal clamps, an external line up clamp may be used.
The internal line up clamp shall not be released before the entire first pass has
been completed.
When an external line up clamp is used, all spaces between bars or at least 60%
of the first pass shall be welded before the clamp is released and the pipe
remaining adequately supported on each side of the joint.
Segments thus welded shall be equally spaced around the circumference of the
pipe. Slag, etc. shall be cleaned off and the ends of the segments shall be
prepared by grindings as to ensure continuity of the weld bead.
10.0 WEATHER CONDITIONS
The parts being welded and the welding personnel shall be adequately protected
from rain and strong winds. In this absence of such a protection no welding shall
be carried out. The completed welds shall be suitably protected in case of bad
weather condition
11.0 WELDING
11.1 Root Pass
11.1.1 Root pass shall be made with electrodes / filler wires recommended in the
welding specification chart.
11.1.2 The size of the electrodes used shall be as per the approved welding procedure.
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11.1.3 The vertical down method of welding shall be adopted for welding pipe held fixed
with its axis horizontal.
11.1.4 The vertical up method of welding shall be used for the root pass of the tie ins,
special crossing, fittings and special parts, fillet welds, repairs and when an
external line clamp is used.
11.1.5 The root pass of butt joints shall be executed properly so as to achieve full
penetration with complete fusion of the root edges. Weld projection inside the
pipe shall not exceed 3 mm wherever not specified by the applicable code.
11.1.6 Any deviations desired from the recommended welding technique and electrodes
indicated in the welding specification chart shall be adopted only after obtaining
express approval of the Engineer-in-charge/TPIA by Deviation Requests.
11.1.7 Welding shall be continuous and uninterrupted during a pass.
11.1.8 On completion of each run, craters, welding irregularities, slag etc., shall be
removed by grinding.
11.1.9 While the welding is in progress care shall be taken to avoid any kind of
movement of the components, shocks, vibration and stresses to prevent
occurrence of weld cracks.
11.1.10 Fillet welds shall be made by shielded metal arc welding process irrespective of
the thickness and class of piping. Electrode size shall not exceed 3.15-mm
diameter for socket joints. At least two passes shall be made on socket weld
joints.
11.2 Joint Completion
The number of welders and the allowable welding sequences shall be as per laid
down in the qualified welding procedure specifications. Once the deposit of the
first pass has been started, it must be completed as rapidly as possible, reducing
interruptions to the minimum. The welding and wire speed shall be
approximately same as that established in the qualified welding procedure
specification.
The pipe shall always be adequately supported and must not be pumped or
shaken during welding. The clamp shall be removed, as indicated in clause 9.0
above. Before starting the second pass, the first pass shall be cleaned and
flattened with rotating grinders.
The interruption between completion of the first pass and starting the second
pass shall be as stated in the procedure specification, normally not exceeding
four minutes.
The Welding/Travel Speed selected shall enable production of a bead which is
sufficiently thick and which shows no undercutting.
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The time lapse between second and third pass shall be as stated in the procedure
specification, normally not exceeding five minutes. After completion of the third
or following passes, welding operations may be suspended, so allowing the joint
to cool down, provided that the thickness of the weld metal deposited is equal to
at least 50% of the pipe thickness. In any case, the welds shall be completed
within 24 Hrs, otherwise it shall be cut-out as per EIC/TPIA instruction. Upon
restarting, depending on the materials, wall thickness and welding process, a
preheating to at least 100oC shall be carried out. Subsequent passes up to weld
completion shall be protected to avoid rapid cooling, if meteorological conditions
so dictate. Cleaning between passes shall be done carefully so as to reduce the
possibility of inclusions.
Electrode starting and finishing points shall be staggered from pass to pass. Arc
strikes outside the bevel on the pipe surface are not permitted. Arc strike or arc
burn on the pipe surface outside the weld, which are caused accidentally by
electrical welding cable or welding cable round and the pipe shall be removed by
grinding in accordance with a procedure approved by Engineer-in-charge/TPIA
and the repair checked by ultrasonic, radiographic, magnetic particle or dye
penetrant tests which the Engineer-In-charge/TPIA feels necessary. The pipe wall
thickness after grinding shall not be less than the minimum thickness limit
permitted for the pipe. Repair of arc strikes by welding is prohibited.
The completed weld shall be carefully brushed and cleaned and shall appear free
from spatters scales, etc.
These requirements apply not only to completed welds but also to the bare strip
at least so wide as to allow full skid examination at both ends of the pipe to allow
a good ultrasonic inspection when it is required.
12.0 HEAT TREATMENT
12.1 Preheating: [Where ever applicable]
12.1.1 Preheating shall be performed using resistance or induction / heating methods.
Preheating by gas burners, utilizing acetylene or propane gas may also be carried
out. Oxy-propane gas may be used with the permission of the Engineer-In-
charge/TPIA under careful supervision.
12.1.2 Preheating shall extend uniformly to at least three times the thickness of the
joint, but not less than 50 mm, on both sides of the weld.
12.1.3 Preheating temperature shall be maintained over the whole length of the joint
during welding. The CONTRACTOR to check the temperature shall provide
temperature indicating crayons or other temperature indicating devices.
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13.1 General
13.1.1 The CONTRACTOR shall also afford the TGPL/TPIA inspector all means and
facilities necessary to carry out inspection. The TGPL/TPIA Inspector shall have
free access to all concerned areas, where the actual work is being performed.
13.1.2 The TGPL is entitled to depute his own inspector to the shop or field where pre
fabrication and erection of pipelines are being done, with (but not limited to) the
following objectives:
i) To check the conformance to relevant standards and suitability of various
welding equipment and the welding performance.
ii) To witnessed the welding procedure qualification.
iii) To witnessed the welders’ performance qualification.
iv) To check whether shop / field welding being executed is in conformity with
the relevant specifications and codes of practice followed in pipe construction.
13.1.3 As far as possible, all welder qualification and procedure qualification test shall
be conducted on the site. CONTRACTOR shall intimate sufficiently in advance the
commencement of qualification tests, welding works and acceptance tests, to
enable the Engineer-in-charge/TPIA to be present to supervise them.
13.2 Welding Procedure Qualification
13.2.1 The CONTRACTOR, at his expense shall carry out welding procedure qualification
in accordance with the relevant requirements of API 1104 latest edition or other
applicable codes and other job requirements. Qualification shall include
Toughness testing requirements as applicable.
13.2.2 Standard tests as specified in the code shall be carried out in all cases. In addition
to these tests, other tests like radiography, macro / micro examination, hardness
tests, dye penetrate examination (DPT); Charpy-V-notch etc. shall be carried out
on specimens (Refer Table 1). It shall be the responsibility of the CONTRACTOR to
carry out all the tests required to the satisfaction of the TGPL’s/TPIA Inspector.
The destructive testing of welded joints shall be as per Annexure - I.
13.3 Welders’ Qualification
13.3.1 Welders shall be qualified in accordance with the API 1104 and other applicable
specifications by the CONTRACTOR at his expense. The butt weld test pieces of
the qualification test shall meet the radiographic test requirements specified in
Clause 13.5 and Annexure - 3 of this specification. The TGPL’s or TPIA inspector
shall witness the test and certify the qualification of each welder separately. Only
those welders who have been approved by the TGPL’s or TPIA inspector shall be
employed for welding.
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13.3.2 The welders shall always have in their possession the identification card as
shown in Exhibit – D and shall produce it on demand by the TGPL’s/TPIA
Inspector. It shall be the responsibility of the CONTRACTOR to issue the identity
cards after it has been duly certified by the TGPL’s/TPIA Inspector.
13.3.3 No welder shall be permitted to work without the possession of identity card.
13.3.4 If a welder is found to perform a type of welding or in a position for which he is
not qualified, he shall be debarred from doing any further work. All welds
performed by an unqualified welder shall be cut and redone by a qualified
welder at the expense of the CONTRACTOR.
13.4 Visual Inspection
Inspection of all welds shall be carried out as per the latest editions of API – 1104
and other the applicable codes and specifications by the CONTRACTOR at his
expense. In addition to the requirements of API 1104, no root crack shall be
permitted. All finished welds shall be visually inspected for parallel and axial
alignment of the work, excessive reinforcement, and concavity of welds,
shrinkage, cracks, under cuts, dimensions of the weld, surface porosity and other
surface defects. Undercutting adjacent to the completed weld shall not exceed
the limits specified in the applicable standard / code.
13.5 Non-destructive Examination
The non-destructive examination shall mainly consist of examination using X-ray
radiography as detailed in Annexure - III.
Radiographic examination of one hundred percent (100%) butt welds will be
required by the TGPL’s/TPIA. Where ever radiography is not feasible due to weld
/ site condition, same joints shall be examined through Ultrasonic examination.
Welds shall meet the standards of acceptability as set forth in API 1104 as well as
the requirements laid in subsequent paragraphs. In addition, no root crack shall
be permitted; The CONTRACTOR shall make all the arrangements for the
radiographic examination of work covered by the specification at his expense.
The TGPL’s/TPIA will review all the radiographs of welds and inform the
CONTRACTOR regarding unacceptable welds. The decision of the TGPL’s/TPIA
shall be final and binding in this regard. All requirements mentioned in the
specification shall be arranged and executed by the CONTRACTOR through his
own resources. In addition, ultrasonic inspection is required in the following
cases as per Annexure II of this Specification.
a) When 20 mm or more are cut from the pipe end as supplied, the ends
shall be DPT, ultrasonically and Magnate particle test (MPT) inspected for an
additional length of 20 mm to assure no lamination exist.
b) When welds are repaired.
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c) When in the opinion of Engineer-in-charge/TPIA, ultrasonic inspection

is required to confirm or clarify defects indicated by radiography.
d) Pipe cutting by means of Grinding is strictly prohibited.
In addition, ultrasonic inspection may be required for certain critical welding of
the pipeline (i.e., tie-ins, welding of valves, flanges) randomly selected at
Engineer-in-charge/TPIA discretion. All fillet and groove welds other than those
radiographs shall be subjected to dye penetrate / MP inspection. The non-
destructive test system used for inspecting welds must be approved by the
Engineer-in-charge/TPIA.
Weld quality is judged on the basis of the acceptability criteria mentioned below:
Any weld which as a result of radiographic and /or ultrasonic examination in the
opinion of Engineer-in-charge/TPIA exhibits imperfections greater than the limits
stated in API 1104 latest edition shall be considered as defect and shall be
marked with an identification paint marker.
1) Any length of inadequate penetration of the root bead as defined by
API 1104 is not acceptable except that root concavity is allowed as per API -
1104.
2) Any amount of incomplete fusion at the root of the joint as per
referred standards, considered unacceptable.
3) All burn through areas is to be repaired.
4) In addition to the API 1104 requirements, the welds containing cracks
including crater cracks regardless of size or location are unacceptable.
Suitable records shall be maintained by the CONTRACTOR as desired by the
Engineer-in-charge/TPIA on the day to day work done on welding radiography,
ultrasonic testing. The CONTRACTOR shall present the records to the Engineer-in-
charge/TPIA on day to day basis and whenever demanded, for approval.
13.6 Destructive Testing

The Engineer-in-charge/TPIA has the authority to order the cutting of up to 0.1%
of the total number of welds completed for subjecting to destructive tests at no
extra cost to TGPL’s/TPIA. The destructive testing of weld joints shall be made as
per Annexure - I.
Destructive Testing of Welding Specimen during construction shall be as follows:
o 1 No after first 100 Production Joints
o 1 No after next 500 Production Joints
o 1 No for after 1000 Production Joint onwards till project completion
 Quantity may vary depending upon results
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The CONTRACTOR at his own expense shall carry out the sampling and the re-
execution of welds. If the results are unsatisfactory, welding operations shall be
suspended and may not be restarted until the causes have been identified and
the CONTRACTOR has adopted measures, which guarantee acceptable results. If
it is necessary in the Engineer-in-charge/TPIA opinion the procedure shall be re
qualified. The weld joint represented by unsatisfactory weld shall stand rejected
unless investigation proves otherwise.
14.0 REPAIRS OF WELDS
14.1 With the prior permission of Engineer-in-charge/TPIA welds which do not comply
with the standards of acceptability shall be repaired or the joint cut out and re-
welded.
A separate welding procedure specification sheet shall be formulated and
qualified by CONTRACTOR for repair welds simulating the proposed repair to be
carried out. Separate procedures are required to be qualified for
(a) Through thickness repair
(b) Partial thickness repair.
(c) Capping repair
Welders shall be qualified in advance for repairs. The root pass, for repairs
opening the root, shall be replaced by the vertical uphill technique. The
procedure shall be proven by satisfactory procedure tests to API 1104 including
the special requirements of the specification, and shall also be subjected to
metallographic examination, hardness surveys and Charpy tests to determine the
effects of repair welding on the associated structure.
Root sealing or single pass repair deposit shall not be allowed. Internal root
defects shall be ground thoroughly and welded with a minimum of two passes.
However, while grinding for repairs, care shall be taken to ensure that no
grinding marks are made on the pipe surface anywhere.
The repair shall be subjected, as a minimum requirement to the same testing
and inspection requirements as the original weld. The entire joint shall be re-
radiographed. A 100% ultrasonic test shall be done at the repaired area
externally. Any repaired area that is wide, irregular or rough shall be rejected
and a full cut out shall be done.
Re-repair of welded joints is not allowed. CONTRACTOR shall maintain a report
of all repairs. All repairs shall be carried out the day after initial radiography or
earlier. A full report of all repairs made shall be submitted every day to the
Engineer-in-charge/TPIA.
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14.2 Limitations on Repairs

Only one attempt at repair of any region is permitted. Repairs are limited to a
maximum 30% of the weld length. For internal repairs or external repairs, which
open the weld root, only 20% of the weld length may be repaired. Repairs
opening the root must only be carried out in the presence of Engineer-in-
charge/TPIA. The minimum length of a repaired area shall be 100 mm as
measured over the recapped length. Welds Containing cracks shall be cut out
and re- bevelled to make a joint. Engineer-in-charge/TPIA shall authorize all
repairs.
14.3 Weld rejected by accumulation of Defects

Where a weld is rejected by the accumulation of defect clause, as defined by API
1104 (Latest Edition) and this specification, repairs within these limitations are
permitted. Defects in the filling and capping passes shall be repaired
preferentially.
15.0 DOCUMENTATION
CONTRACTOR shall submit the following as minimum:
15.1 Batch Test Certificates, for the Electrodes used, obtained from the electrode
manufacturers.
15.2 Quality records of each process
15.3 Calibration certificate of measuring instruments and testing equipment.
16 ENCLOSURE
 ANNEXURE – I- Guideline Destructive testing of welded joint
 ANNEXURE – II Guideline for Ultra Sonic inspection
 ANNEXURE – III Radiography
 EXHIBIT A - Electrode qualification test record
 EXHIBIT B - Record form for welding procedure approved test
 EXHIBIT C - Record form for welder approved test
 EXHIBIT D - Welder’s identification card
 EXHIBIT E - Format for radiography procedure
 TABLE 1 - Number of specimen for destructive test
 Welding Specification Chart.
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ANNEXURE - I
1.0 DESTRUCTIVE TESTING OF WELDED JOINT - BUTT WELDS

1.1 Preparation
Having passed the visual and non-destructive inspection, the test weld shall be
subjected to mechanical test.
After satisfactory completion of all visual and non-destructive testing, the
procedure test weld shall be set aside for a period not less than 24 hours. No
further work on the test weld and no cutting of test specimens from the weld
shall be performed until a period of at least 24 hours has expired.
Weld specimens shall be taken from the positions indicated in Fig. 1 and Fig. 1A
of this specification from areas as free from defects as possible; for this reason, it
is necessary to take the previous non-destructive tests into account. The
minimum number of tests to be carried out is given in Table 1 of this
specification.
The test shall be carried out at laboratories approved by TGPL/TPIA. The
specimens shall be prepared in accordance with the figures given in the
paragraphs, which refer to the individual test.
1.2 Tensile Strength
Specimens shall be taken from the position indicated in Fig. 1 and Fig. 1A. Two
ISO type specimens and two API type specimens shall be taken.
The ISO test specimens are shown in figure 2 of this specification.
1.2.1 Method
The test shall be carried out in accordance with ISO 375.
1.3. Nick Break Test
1.3.1 Preparation
Specimens for nick break test with notches thus worked can break in to base
metal, instead of in the fusion zone; therefore, an alternative test piece may be
used after authorization by the TGPL/TPIA with a notch cut in the reinforcement
of outside weld bead to a maximum depth of 1.5 mm, measured from the surface
of the weld bead.
1.4 Macroscopic Inspection
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1.4.1 Preparation
Specimens shall be taken from the positions indicated in Fig. 1 of this
specification and shall be prepared in accordance with ASTM E2 and E3.
The width of the macro section has to be at least three times the width of the
weld. The section is to be prepared by grinding and polishing and etched to
clearly reveal the weld metal and heat affected zone.
1.4.2 Method
Specimens shall be carefully examined under the microscope, with a
magnification of at least 25 times (25:1). TGPL/TPIA may ask for a macrograph
with 5 times (5:1) magnification, for documentation purposes.
1.4.3 Requirements
Under macroscopic examination, the welded joints shall show good penetration
and fusion, without any defect exceeding the limits stated in the evaluation
criteria of the nick break test.
1.5 Hardness Test
1.5.1 Preparation
The prepared macro section is to be used for hardness testing using the Vickers
method with 10 Kg. loads. Indentations are to be made along traverses each
approximately 1 mm below the surface at both side of the weld.
In the weld metal a, minimum of 6 indentations equally spaced along the
traverses are to be made. The HAZ indentations are to be made along the
traverses for approximately 0.5 mm each into unaffected material, and starting
as close to the fusion line as possible.
One indentation at each side of the weld along each traverse has to be made on
parent metal. Reference is made in this specification. The indentations are to be
made in the adjacent region as well as on the opposite side of the macro section
along the specified traverses.
1.5.2 Method
The test shall be carried out in accordance with Recommendation ISO R81,
Vickers hardness, using a laboratory type machine, controlled as pre
recommendation of ISO R 146 and using a diamond pyramid penetrator set at
2.37-rad (1360C) with a load of 10 Kg.
1.5.3 Requirements
Hardness value shall not exceed the maximum limit. In case of a single reading,
slightly (+ 10 HV) higher than the specified limit, further indentations shall be
made to check if the high value was an isolated case.
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All the hardness values contained from the heat-effected zone shall not exceed
100 HV with respect to the average hardness of the values obtained for the base
metal.
1.6 Charpy-V-Notch Impact Test
1.6.1 Specimens shall be taken from the position indicated in this specification. The
test specimens will be prepared in accordance with ISO R 148. Charpy V notch
specimens shall have dimensions as given in Fig. 4 of the specification.
Three test specimens shall be taken from each sample and they shall be cut and
worked so that their length is transversal and perpendicular to the weld bead
with the notch position as per the specification. The notch shall be perpendicular
to the roller surface. The test specimen width shall depend upon the pipe wall
nominal thickness as following:
Nominal wall thickness in Test specimen width in mm mm

Over 12 10.0
Over 9.5 and up to 12 7.5
From 7 up to 9.5 5.0
Less than 7 2.5
1.6.2 Test Method
The test shall be carried out as indicated in ISO R 148 Beam impact test V notch.
Test pieces shall be immersed in a thermostatic bath and maintained at the test
temperature for at least 15 minutes. They shall then be placed in the testing
machine and broken within 5 seconds of their removal from the batch.
The test temperature shall be -100 C.
1.6.3 Requirements (Note 1)
The impact energy shall be
Test Average of three Minimum single value
Specimen Specimens (Joules)
in mm Joules(Min)
10.0 27.0 22.0
7.5 21.5 17.5
5.0 18.5 15.0
2.5 10.0 8.0
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Note 1: Only one value is permitted to be lower than average value up to the
value specified.
1.7 Bend test requirements

The Bend Test Specimens shall be made and tested as per the requirements of
API- 1104 Nineteenth edition, May 1999 except that the dimensions of the Jig for
guided bend test Fig. 9, API 1104 shall be modified as follows:
Radius of the Plunger - A = 2t
Radius of the die - B = 3t + 1.6 mm
Radius of the die - C = 50.8 mm
The acceptance criterion shall however be as per para 5.643 and 5.653 of API
1104 Sixteenth edition May 1999.
Note: t = thickness of specimen.
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ANNEXURE – II
ULTRASONIC INSPECTION
1.0 Ultrasonic Inspection
In addition to the radiographic inspection, ultrasonic inspection is
required as per conditions listed in paragraph 13.5 of this specification.
This section covers manual ultrasonic inspection. However ultrasonic
inspection by automatic equipment may be used if approved by the
TGPL/TPIA.
1.1 Equipment and Operators
The Contractor who carries out the ultrasonic inspections shall have sufficient
qualified personnel, equipment and instruments at his disposal to be able to
affect the tests without hindering or delaying the pipeline assembly operations.
The operators shall be fully qualified as per a recognized standard (ASME Sec. V
or equivalent) and they shall have qualified as a minimum level II. The operators
shall be able to:
 Calibrate the equipment; Perform an operational test under production
conditions;
 Interpret the screen picture;
 Evaluate the size and location of reflectors/discontinuity.
 Interpret the type of defects detected.
TGPL/TPIA has the option of checking the ability of personnel employed for
ultrasonic testing by means of qualification tests.
The Contractor appointed to carry out ultrasonic inspections shall supply all the
instruments necessary for their execution on site.
1.2 Specification for Ultrasonic Testing Procedure Qualification
Before work begins, the Contractor shall present a specification describing the
proposed U.T. procedure qualification.
This specification shall state, as an indication only but not limited to the following
information:
 Type of U.T. equipment used

 Type and dimensions of Transducers
 Frequency range
 Details for calibration
 Coupling Medium
 Inspection Technique
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 Record details
 Reference to the welding procedure where it is intended to adopt the
specification.
 Temperature range of the joints to be inspected.
1.3 Qualification of Ultrasonic Inspection Procedure
The ultrasonic inspection procedure shall be approved by TGPL/TPIA. Before
inspection begins, TGPL/TPIA may require the qualification test of the ultrasonic
inspection procedure. This test consists in testing (under normal operating
conditions) some welds made according to the same production procedure,
where there are typical defects the test intends to detect. This test shall be
conducted in the presence of TGPL/TPIA.
1.4 Test Procedure
Circumferential welds shall be inspected from both sides using angled probes.
The surface with which the probe comes into contact shall be free of metal
spatter, dirt, iron oxide, and scales of any type. Therefore, it shall be necessary to
clean a strip at least 150 mm wide on both sides of the weld with steel wire
brushes and strip must be wide enough to allow full scale examination. The weld
shall be tested from both sides and testing shall include the adjacent area of weld
for laminations, scanning for transverse indication in weld and base material. The
probe movement shall not exceed 100mm/sec.
Manual ultrasonic testing equipment is applicable for pulse echo technique and
for double probe technique and shall cover as a minimum frequency range from
2 to 6 MHz, have a calibrated gain regulator with maximum 2dB per step over a
range of at least 60 dB, allow echoes with amplitudes of 5% of full screen height
to be clearly detectable under test conditions. For flaw detection the corrected
primary gain may be increased by maximum 6 db. Defect size evaluation is not
being performed at this increased gain level. The indications are to be
investigated by maximizing the echoes with different angle probes and by
rotating the probes. All indications exceeding 20 % of the reference curve are to
be investigated and all indications exceeding 50 % are to be reported.
Investigation is to be performed to the extent that the operator can determine
the shape and location of the indication. For dimensional evaluation either the
“20 dB -drop “method, time of flight or maximum amplitude method is to be
used. The half value drop method is to be used for length determination only.
Acceptance criteria for visual examination and surface method testing shall be as
per API 1104 Section 6 and Clause 13.5.
If, during the test, echoes of doubtful origin appear, it shall be necessary to
inspect a convenient area on the pipe surface, close to the weld, with a straight
beam transducer in order to check whether any manufacturing defects are
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present which could have interfered with the ultrasonic beam. By way of an
example, the equipment shall include but not be limited to the following:
 Ultrasonic equipment and coupling medium.
 Sample sections for calibration of instruments.
 Equipment for cleaning of surface to be examined.
 Rules calibrated in centimetres for exact location of the position of defects.
The characteristics of the above listed instruments and equipment shall
guarantee:
a) That the required standards of the inspection procedure, as previously
established and approved by TGPL/TPIA, are satisfied.
b) Continuous operation:
All the instruments and equipment shall be approved by the TGPL/TPIA before
being used. TGPL/TPIA has the authority to reject any item, which is considered
unsuitable. The decision of TGPL/TPIA is final. The Contractor appointed to carry
out ultrasonic inspections shall also ensure the operational efficiency and
maintenance of the instruments and equipment, and shall immediately
substitute any item rejected by TGPL/TPIA.
All the instruments and equipment necessary for carrying out ultrasonic
inspection on site shall satisfy the requirements laid down by the public boards of
institutions which regulate safety at work.
1.5 Ultrasonic Instruments
The ultrasonic instrument shall be each pulse type, able to generate, receive and
display, on the screen a cathode ray tube (CRT), pulse at frequencies between 2
and 6 MHz. The useful part of the CRT screen shall be at least 70 mm wide and at
least 50 mm high.
 Shall have variable amplification, with steps of 1 or 2 dB over a range of
at-least 60 dB.
 The regulation control shall be accurate to within +1 dB and the
Instrument may be powered by a battery or an electric generator.
Manufacturer shall certify this accuracy. In the first case, the autonomy of
operation (endurance) of the instrument shall be sufficient to carry on
working without frequent interruptions, and the instrument shall be
equipped with an automatic switch which switches it off when the battery
runs down; in the second case, there must be a voltage stabilizing device
with a tolerance of +2 Volts.
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1.6 Probes
The probes used shall have dimensions, frequencies, and a refraction angle
suited to the type of steel, the diameter the thickness of the pipeline and to the
joint design.
1.7 Reference Sample Pieces
The efficiency of the equipment used, the effective refraction angle of the probe,
and the beam output point, shall be checked using a V1 and V2 sample block, IIW
type or the calibration block ASTM E- 428.
For the calibration of runs and the regulation of detection sensitivity during the
test, a calibration piece shall be used. This piece shall be taken from the
production material and will be at least 150 mm long (measured in the direction
of the axis), and at least 50 mm wide (measured in the direction of the
circumference) See Fig. 6 of this specification. In the middle of the inside and the
outside surface of the calibration piece a groove shall be made. The groove will
have a rectangular cross section, a flat bottom and the following dimensions:
- Depth: 1 + 0.1 mm
- Breadth (measured parallel to the 150 mm side): 1+01 mm.
- Length (measured parallel to the 50 mm side): not less than 30 mm.
In addition, the calibration piece shall have a hole, 2 mm in diameter, passing

through its thickness, and positioned so that during calibration the echoes
returning from the two grooves do not interfere with those returning from the
hole.
1.8 Calibration
For a precise check of the sound paths necessary for a full inspection of the weld
joint, the probe shall be moved (half skip and full skip distance). The relevant
defect limits the path lengths on the time base scale distance) until internal and
external notches on the test piece are detected (See Fig. The calibration of
reference sensitivity is obtained by utilizing the through drilled test hole in the
thickness of the reference block to draw the distance - amplitude correction
curve relevant to the test probe. Calibration shall be carried out according to the
following procedure: place its internal vertex until the maximum height of echo is
displayed on the screen; this echo is adjusted to 80% of full screen height by
means of the sensitivity adjuster set in dB. Without varying the amplification, the
probe placed at full skip distance from the hole is moved to detect the external
vertex of the hole until the maximum height of echo is obtained. The straight line
connecting the peaks of the two echoes obtained by the above procedure
represents the 100% reference level, while the one connecting the two points at
half height of the same echoes represents 50% reference level. The two straight
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lines shall be marked on the screen with a pen. Calibration shall be repeated each
time tests are re-started; at intervals not longer than 30 minutes during normal
operations; each time the conditions fixed in advance are altered. This calibration
is applicable provided that the crystal of the probe is 8 x 9 mm size. Should this
size of the crystal be different, the value of the sensitivity obtained from the
calibration by a crystal of a different size shall be brought to the value of
sensitivity obtained from the calibration by a 8 x 9 mm crystal. The sensitivities of
the two different size probes shall be compared through the echoes obtained on
the notch of the test piece with the probe position at half skip of the distance.
1.9 Regulation of Amplification during Production Testing
The amplification during production testing shall be obtained by adding 2 - 6 dB
(according to the surface condition of the pipe and its cleanness) to the
reference amplification.
1.10 Qualification of Ultrasonic Testing Operators
Before the inspection begins or during the same inspection, TGPL/TPIA may
require a qualification test for the ultrasonic equipment operators
1.11 Evaluation of Indications Given by Ultrasonic Tests
Each time the echoes from the weld bead appear during production testing, the
instrument amplification shall be altered to coincide with the reference
amplifications and the probe shall be moved until maximum response is
obtained, paying attention all the time to the probe tube coupling.
If, under these conditions, the height of the defect echo is equal to or greater
than that of the reference echo, the defect shall be evaluated according to clause
1.12.5 of this Specification. If the defect has also been detected by the
radiographic and/or visual examination, the dimensions shall be judged
according to the type of examination, which detects the greater defect. Returns,
which are less than 50% of the reference echo, will not be considered. If returns
are above 50% but lower than 100% of the reference echo, and if the operator
has good reasons to suspect that the returns are caused by unfavourably
oriented cracks, he shall inform the TGPL/TPIA.
Moreover, when there is a defect to be repaired, such defect shall be removed
for a length corresponding to the one where no more return echo is given.
1.12 Other Equipment
The use of rules calibrated in centimetres, attached if possible to the probe, for
the precise location of the position of welding defects, is recommended. Defect
location is effected by measuring the projection distance between the probe
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output and the reflecting surface. The operators carrying out the tests shall have,
besides the probing instrument, tools for cleaning the pipe surface (Files,
Brushes, etc.) as well as the coupling liquid or pastes appropriate for the
temperature of the section to be examined.
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ANNEXURE - III
RADIOGRAPHY
1 SCOPE
This Annexure covers the radiographic inspection of all types of welded joints of
the pipeline.
The welded joints shall include the following:
i) 100% of all Butt Weld Joints.
ii) Full girth welds on the mainline construction including double jointing of
pipe, if adopted.
iii) Welds for installation of block valves, insulating joints and other
appurtenances and tie-ins.
iv) Welds at scraper launching and receiving barrels.
v) Terminal Piping.
2 APPLICABLE STANDARDS
This specification shall apply in conjunction with the following (all latest edition):
1. API 1104, Standard for welding Pipelines and related facilities.
2. ASME B 31.8, Code for Gas Transmission and Distribution Piping Systems.
3. ASTM E 94, recommended practice for Radiographic Testing.
4. ASTM E 142, Standard Method for Controlling Quality of Radiographic
Testing.
5. The American Society for Non-destructive Testing. Recommended
Practice No. SNT-TC-1A supplement A.
6. ASME BPV – Boiler and Pressure Vessel Code – Section IX
7. BARC rules for radioactive isotopes handling.
8. ASME Section V non-destructive examination.
3 PROCEDURE
3.1 The radiographic examination procedure to be adopted shall be submitted by the
Contractor as per Exhibit - E.
3.2 The procedure of radiographic examination shall be qualified to the entire
satisfaction of TGPL/TPIA prior to use. It shall include but not be limited to the
following requirements:
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i) Lead foil intensifying screens, at the rear of the film shall be used for all
exposures.
ii) Type 2 and 3 films as per ASTM E - 94 shall be used.
A densitometer shall be used to determine film density. The transmitted film
density shall be 2.0 to 3.5 throughout the weld. The unexposed base density of
the film shall not exceed 0.30.
iii) Radiographic identification system and documentation for radiographic
interpretation reports and their recording system.
3.3 The Contractor shall qualify each procedure in the presence of the TGPL/TPIA
prior to use.
3.4 The procedure of radiographic examination shall produce radiographs of
sufficient density, clarity and contrast so that defects in the weld or in the pipe
adjacent to the weld, and the outline and holes of the penetrameter are clearly
discernible.
3.5 All butt welds in the Pipeline and all the girth welds of mainline shall be subjected
to 100% radiographic examination. The Contractor shall furnish all the
radiographs to TGPL/TPIA, immediately after processing them, together with the
corresponding interpretation reports on approved format. The details of the
radiographs along with the joint identification number shall be duly entered in a
register and signed by the Contractor and submitted to TGPL/TPIA for approval.
3.6 When the radiation source and the film are both on the outside of the weld and
located diametrically opposite each other, the maximum acceptable length of
film for each exposure shall not exceed the values given in API 1104. The
minimum film overlap, in such cases, shall be 40 mm. The ellipse exposure
technique may be used on nominal pipe sizes of 2 inch and smaller provided that
the source of film distance used is a minimum of 12 inch.
Three copies of each acceptable radiographic procedure (as per Exhibit - E) and
three copies of radiographic qualification records shall be supplied to TGPL. One
set of the qualifying radiographs on the job shall be kept by the Contractor’s
authorized representative to be used as a standard for the quality of production
radiographs during the job. The other two sets shall be retained by TGPL/TPIA for
its permanent record.
Three copies of the exposure charts relating to material thickness, kilo voltage,
source of film distance and exposure time shall also be made available to
TGPL/TPIA by the Contractor.
The Contractor shall, on a daily basis, record for each radiograph
(1) radiograph’s number,
(2) approximate chainage of weld location,
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(3) whether or not the welds meet the specified acceptance standards and
(4) the nature and approximate location of unacceptable defects observed.
It must be possible to relate back to a particular butt weld and welder on piping
drawing and pipe line alignment drawing.
Each day’s production of processed radiographs shall be properly packaged
separately, identified by at least the
(1) date,
(2) radiographic unit,
(3) job locations,
(4) starting and ending progress survey stations and
(5) shall include original and three copies of the daily radiographic record.
The package shall be submitted to the TGPL/TPIA daily when possible, but in no
event later than noon of the following day.
The Contractor shall provide all the necessary facilities at site, such as a dark
room with controlled temperature, film viewer etc. to enable the TGPL/TPIA to
examine the radiographs.
The Contractor, if found necessary, may modify the procedure of radiographic
examination suiting to the local conditions prevailing. This shall, however, be
subject to the approval of the TGPL/TPIA.
3.7 TGPL/TPIA shall have free access to all the Contractor’s work facilities in the field.
3.8 Any approval granted by TGPL/TPIA shall not relieve the Contractor of his
responsibilities and guarantees.
4 RADIATION SOURCE
4.1 Radiographic examination shall be carried out using X-Rays only. Radiographic
examination by Gamma Rays can be done prior approval of TGPL/TPIA.
4.2 Whenever possible, pipeline welds will be inspected by placing the radiation
source inside the pipe, on the pipeline axis, with a radiation of 6.28 rad. (360 oC)
crawler type of x-ray machine shall be used for all main line joints.
If it is impossible to place the radiation source inside the pipe, the weld will be
inspected with the source on the outside. An overlap of at least 40 mm at the
ends of each film shall be required to ensure that the first and last location
increment numbers are common to successive films and to establish that no part
of a weld has been omitted.
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5 LEVEL OF QUALITY
The quality level of radiographic sensitivity required for radiographic inspection
shall be at least equivalent to the values specified in ISO standards (IQI Sensitivity
curve).
6 PENETRAMETERS
6.1 The image quality indicator (abbreviation: IQI) shall be used for the qualification
of the welding procedure and during normal line production.
Radiographic sensitivity shall be measured with the wire image quality indicator
(Penetrameter). The Penetrameter shall be selected according to DIN 54109 or
ISO 1027. For radiographs made with the source on the outside, a Penetrameter
shall be placed on each side of the film with the smaller wire of the
Penetrameter turned towards the end of the film itself. When a complete weld is
radiographed in a single exposure using a source inside the piping, 4
Penetrameter approximately equally spaced around the circumference shall be
used. During the procedure qualification, IQI shall be placed both on the source
side and on the film side. The sensitivity obtained with IQI on the source side
shall not be less than the values shown in the specification.
The sensitivity limit may be considered to have been reached when the outline
of the IQI, its identification number and the wire of the required diameter show
up clearly on the radiograph.
TGPL/TPIA may authorize use of types of IQI other than those planned, provided
that they conform to recognized standards and only if the Contractor is able to
demonstrate that the minimum sensitivity level required is obtained. For this
demonstration, a test shall be carried out comparing the IQI specified and the
Contractor’s. To show up the identification number and other details of the
proposed IQI, this must be visible in the test radiograph.
7 FILM IDENTIFICATION MARKERS
All films shall be clearly identified by lead numbers, letters, and/or markers. The
image of the markers shall appear on the films, without interfering with the weld
interpretation. These marker positions shall also be marked on the part to be
radiographed and shall be maintained during radiography.
8 PROTECTION AND CARE OF FILM
8.1 All unexposed films shall be protected and stored properly as per the
requirements of API 1104 standard and ASTM E-94.
8.2 The exposed and unexposed film shall be protected from heat, light, dust and
moisture. Sufficient shielding shall be supplied to prevent exposure of film to
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damaging radiation prior to and following the use of the film for radiographic
exposure.
9 RE-RADIOGRAPHY
9.1 The weld joints shall be re-radiographed in case of unsatisfactory quality of the
radiographs, at the expense of the Contractor.
9.2 All the repaired weld joints shall be re-radiographed at no extra cost to the TGPL
in the same manner as that followed for the original welds. In addition, the
repaired weld areas shall be identified with the original identification number
plus the letter R to indicate the repair.
9.3 When evaluating repair film, radiographers shall compare each section
(exposure) of the weld with the original film to assure repair was correctly
marked and original defect removed.
TGPL/TPIA will review prior to any repair of welds, all the radiographs of welds,
which contain, according to the Contractor’s interpretation, unacceptable
defects. The final disposition of all unacceptable welds shall be decided by
TGPL/TPIA.
10 QUALIFICATION OF RADIOGRAPHERS
10.1 Pipeline radiographers shall be qualified in accordance with the requirement of
API 1104 and to the full satisfaction of TGPL/TPIA.
10.2 Certification of all the radiographers, qualified as per clause 10.1 above, shall be
furnished by the Contractor to TGPL/TPIA before a radiographer will be
permitted to perform production radiography. The certificate record shall
include
i) Background and Experience Record
ii) Training Course Record.
iii) Doctor’s report on radiographer’s Oaecuer 0-1 acquity eye test.
iv) Date of qualification.
10.3 The radiographers shall be required to qualify with each radiographic procedure
they use, prior to performing the work assigned to him in accordance with the
specification.
11 PRESERVATION OF RADIOGRAPHS
11.1 The radiographs shall be processed to allow storage of films without any
discoloration for at least Five years. All the radiographs shall be presented in
suitable folders for preservation along with necessary documentation.
11.2 All radiographs shall become property of TGPL at the end of project.
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12 EQUIPMENT AND ACCESSORIES

12.1 Contractor shall make necessary arrangements at his own expense, for providing
the radiographic equipment, radiographic films and all the accessories for
carrying out the radiographic examination for satisfactory and timely completion
of the job.
12.2 For carrying out the mainline radiographic examination, Contractor shall be
equipped with suitable mobile / stationary type dark rooms. These shall have all
the required facilities for film processing. Film viewer used shall be equipped with
the film illuminator that has a light source of sufficient intensity and suitably
controlled to allow viewing film densities up to 4.0 without damaging the film.
13 RADIATION PROTECTION
13.1 Contractor shall be responsible for the protection and personal monitoring of
every man with or near radiation sources.
13.2 The protection and monitoring shall comply with local regulations.
13.3 In view of visual hazards in the handling of Radioactive source of material,
Contractor shall be solely responsible for complying with all rules and regulations
set forth by Atomic Energy Commission or any other Government agencies of
India in this regard and TGPL/TPIA shall not be responsible and shall be kept
indemnified by the Contractor for default (s) of whatever nature by the
Contractor. Safety equipment as considered adequate by TGPL/TPIA for all
necessary personnel shall be made available for use and maintained for
immediate and proper use by the Contractor. Storage of radioactive isotopes and
related items shall be followed by Contractor as per atomic energy commission
rules.
14 DISPLAY OF SAFETY INSTRUCTIONS:
The safety provisions shall be brought to the notice of all concerned by display on
a notice board at prominent place at the work spot. The Contractor shall name
the person responsible for the Safety.
15 ENFORCEMENT OF SAFETY REGULATIONS
To ensure effective enforcement of the rules and regulations relating to safety
precautions, the arrangement made by the Contractor shall be open to
inspection by TGPL/TPIA or its representative.
16 FIRST AID AND INDUSTRIAL INJURIES
16.1 Contractor shall maintain first aid facilities for its employees and those of sub-
Contractors.
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16.2 Contractor shall make outside arrangements for ambulance service and for
treatment of industrial injuries. Names of those providing these services shall be
furnished to TGPL/TPIA prior to start of work and their telephone No. shall be
posted prominently in Contractor’s field office
All critical industrial injuries shall be reported promptly to TGPL/TPIA and a copy
of Contractor’s report covering each personal injury requiring the attention of
physician shall be furnished to TGPL/TPIA.
17 NO EXEMPTION
17.1 Notwithstanding the above there is nothing in these to exempt the Contractor
from the operation of any other act or rules in force.
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EXHIBIT - A
ELECTRODE QUALIFICATION TEST RECORD
A: Tested at
Date :
(Site Name) :
Manufacturer’s Name :
Brand Name :
Batch Number :
Size tested Classification & Code :
Intended for welding in positions :
In Combination with (If any) :
Code of Reference (Used for testing) :
Special requirements (If any) :
B: All-Weld Tensile Test

Base Material Used :
Pre-Heat Temp. :
Post weld Heat Treatment Details :
Visual Examination :
Radiographic Examination Results :
Tensile test Results :
Identification No. U.T.S Yield Point Elongation Remark
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C: Impact Test Results

Test Temperature : Notch in :
Type of Specimens (Charpy) : Size of Specimens :
————————————————————————————————————
Specimen No. Impact Value Average
————————————————————————————————————
1.
2.
3.
4.
5.
-——————————————————————-—————————————
D: Chemical Analysis Results:
Electrode Size Used :
Batch No. :
—————————————————————————
%C %S %P %Si %Mn %Cr %Ni %Mo Other
—————————————————————————
E: Fillet Weld Test Results:
Welding Positions :
Base Materials :
Size of Electrode Used :
Visual Inspection Results

1) :
2) :
3) :
Macro Test results :

Fracture test results :
Remarks :
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F: Other Test Results:

Transverse Tensile Test :
In combination with
Base Material Used
Position of welding :
Preheat Temperature :
Post weld heat treatment:
Radiography :
Identification No. U.T.S. Fracture in Remarks
2. Guided Bend Test:

—————————————————————————————————————————
Position ID No. Root, Face or Side Bend Remarks
—————————————————————————————————————————
1)
2)
3)
4)
5)
—————————————————————————————————————————
Any other tests :
Conclusions :
---------------------- ---------------------- ----------------------

PREPARED BY REVIEWED BY APPROVED BY
(CONTRACTOR) (CONTRACTOR) (OWNER/TPIA)
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EXHIBIT - B
Example of Record form for Welding Procedure Approval Test:
Project/Contract :
Contractor :
Pipe and Fitting Material :
Process :
Outside Diameter :
Pipe Thickness :
Joint design (Sketch Attached):
Make and Type of filler metal:
Diameter :
Current :
Voltage :
Root :
Second Run :
Other Runs :
Other electrical characteristics:
A.C./ D.C :
Electrode Negative / Positive :
Shielding Gas :
Type of Mixture :
Flow :
Shielding Flux :
Position :
Direction of Welding :
Root : Vertical up* / Vertical Down
Second Run : Vertical up* / Vertical Down
Other Runs : Vertical up* / Vertical down Number of Welders :
Root :
Second Run :
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Other Runs :
Time Lapse between Commencements of Root and Commencement of Second Run:
Time lapse between commencement of second run and commencement of other runs:
Minimum number of runs before point allowed to cool:
Maximum time between commencements and completion or weld:
Type of line-up clamp :
Removal of clamp after : Run
Lowering off after : Run
Cleaning
Preheating
Minimum temperature 0C : Ambient Temperature 0C :
Type of heater to be used
Inter pass temperature 0C
Minimum 0C : Maximum 0C :
Post weld heat treatment
Speed of travel : Test Results :
[State acceptable non-acceptable (with reasons) or give numerical results]:
Non-destructive tests :
Visual :
Destructive Test 1 2 3 4
Transverse tensile
Tensile strength (with units)
Fracture location
Test temperature
Macro examination
Fillet weld fracture
Hardness survey
Hardness range
Parent Metal
Heat affected zone
Weld
Chary V-notch impact tests
Specimen location and size
Notch location
Test temperature
Results (With units)
Type Load Location of hardness measurements (Sketch)
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Additional test(s) and results, e.g., chemical analysis, micro-examination, CTOD tests, Bend
tests, Nick-Break Tests.
The test joints were prepared, welded and tested in accordance with the
requirements of specification.
The statements in this record are correct.
Contractor Inspector
Designation Witnessed by
Date Date
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EXHIBIT - C
Example of record form for welder approval test
Welder test certificate : Test No. :
Project/ Contract : Date :
Contractor : Inspector :
Welder’s Name :
Address :
Pipe material :
Pipe thickness :
Pipe outside diameter :
Welding Process For Root: For Filler and Cap:
 Root Current : Voltage :
 Second run Current : Voltage :
 Filler & Cap Current : Voltage :
Direction of travel
Root :
Filler and cap :
Reason for failure :
Visual :
Non-destructive testing :
Butt joint :
Fillet Weld :
Number of attempts :
Comments :
Accepted Date & Time :
Contractor’s Sign :
Inspector’s Sign :
* Delete as necessary.
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DEC-2018
EXHIBIT - D
WELDER’S IDENTIFICATION CARD
TGPL CO. LTD.

WELDER’S IDENTITY CARD
Name Welding Position
Welder No. Material
Date of Testing Diameter
Valid up to Wall thickness
Approval of Welding Type of welding Consumables
W.P.S. Nos. Thickness Range Qualified
Diameter Range Qualified

APPROVED BY TGPL/TPIA
VALID FROM: VALID TILL:
TGPL SITE ENGINEER THIRD PARTY AGENCY
SIGN SIGN
DATE DATE
NOTE:
1) Validity Period of Welder shall be up to the satisfactory performance / 1 year whichever
is lesser.
2) Repair percentage for any welder should be 5% max., minimum of 25 joints shall be
welded by any welder for calculating repair percentage calculation.
3) Contractor shall track the repair percentage of welders and report shall be made
available to TGPL/TPIA on monthly basis. In case, the repair percentage for any welder is
more than the specified limit as mentioned above, at any point of time, contractor shall
terminate the welder immediately.
4) Welder after qualification, if is not performing any welding work due to any reasons for
more than 90 days, welder requalification shall be done.
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EXHIBIT - E
RADIOGRAPHIC PROCEDURE FOR PIPE WELDING
1. Location
2. Date of Testing
3. Name of Supervised Contractor
4. Material
5. Dia. and Thickness
6. Type of Weld Joint
7. Radiation Source (X-ray, iridium)
8. Type of equipment (External / Internal)
9. Intensifying screens and material
10. Filter type and placement mask, Diaphragm Lead screen etc. adjacent to radiation source
or specimen.
11. Geometric relationship (Source local spot size, max and min source strength, object to
film distance, radiation angle with respect to weld and film).
12. Limit of film coverage
13. Film type and make
14. Exposure time
15. Processing (time temperature for development, stop bath or rinse, fixation, washing,
drying etc.)
16. Density
17. Sensitivity
18. Type of Penetrameter
19. Essential wire to be seen on source side.
20. Essential wire accepted for film viewing
Approval of the TGPL/TPIA Signature of Contractor with seal
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TABLE 1
NUMBER OF SPECIMENS
PIPE SIZE, OUTSIDE
TENSILE TENSILE NICK ROOT FACE SIDE MACRO HARD IMPACT TOTAL
DIAMETER
API ISO BREAK BEND BEND BEND NESS
INCHES
WALL THICKNESS – ½” INCH UNDER (12.7 mm)
UNDER 2 3/8 0 0 2 2 0 0 0 0 0 4
2 3/8 – 4 ½ 0 0 2 2 0 0 0 0 0 4
OVER 4 ½ - 12 ¾ 2 0 2 2 2 0 2 2 12 24
12 ¾ AND OVER 2 2 4 4 4 0 2 2 24 44
WALL THICKNESS – ½” INCH OVER (12.7 mm)
4 ½ AND SMALLER 0 0 2 0 0 2 0 0 0 4
OVER 4 ½ LESS THAN 12 ¾ 2 0 2 2 0 2 2 2 12 24
12 ¾ AND OVER 2 2 4 0 0 8 2 2 24 44
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WELDING SPECIFICATION CHART
PIPE WELDING PROCESS FILLER METAL
SR.NO. ITEM MATERIAL NDT
DIA./THK.
ROOT FILLER ROOT FILLER
1 Pipe to Pipe SMAW SMAW
1.1 Pipe API 5L Gr. X52 ALL SIZE 100 %

UP Hill/ Down UP Hill/ Down E 6010 E 7010
Radiography
Hill Hill
1.2 Pipe API 5L Gr. X52 ALL SIZE
2 Pipe to Fitting SMAW SMAW
2.1 Pipe API 5L Gr. X52 ALL SIZE 100 %

Radiography
2.2 Fitting MSS SP WPHY 52 OR ALL SIZE Uphill Downhill E 6010 E 7010
ASTM A 694 F 52
3 Pipe to Flange 100 %
3.1 Pipe API 5L Gr. X 52 ALL SIZE Radiography

UP Hill UP Hill
3.2 Flange MSS SP F 52 OR ALL SIZE
E 6010 E 7010
ASTM A694 F 52
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DEC-2018
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DEC-2018
3. Specification for Field joint coating
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TABLE OF CONTENTS
1.0 SCOPE
4.0 MATERIAL AND EQUIPMENT REQUIREMENTS
5.0 PROCEDURE OF APPLICATION
6.0 INSPECTION & TESTING
7.0 MARKING, PROTECTION, STORAGE AND HANDLING
8.0 REPAIRS
9.0 DOCUMENTATION
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1.0 SCOPE
This specification covers minimum requirements of materials, manpower,
equipment, application, inspection and testing of field joints corrosion coating
for pipeline and in-field joint coating of onshore pipelines.
1.1 It shall be read in conjunction with the conditions of all specifications and
documents included in the contract.
1.2 Contractor shall, with care and diligence, execute the work in compliance with all
laws, by-laws, ordinances, regulations, etc. and provide all services and labour,
inclusive of supervision thereof, all materials, excluding the materials indicated
as TGPL supplied materials in the Contract, equipment, appliances or other
things of whatsoever nature required in or about the execution of the work,
whether of a temporary or permanent nature.
specification
2.1 Governing Standard:
DIN 30672: 1991: Coating of corrosion protection tapes and Heat Shrinkable
Products for pipelines for Operational Temperature up to 500 C.
2.2 Reference Standard:
SIS – 055900 : Pictorial surface Preparation Standard for Painting Steel
Surfaces.
SSPC – SP 1 : Solvent Cleaning, Steel Structure Painting council.
SSPC SP10 / NACE 2: A joint standard between the Steel Structures Painting
Council and NACE International for Near-White Blast
Cleaning
ISO 8501-1 : International Organization for Standardization Very
through blast cleaning to SA 2 ½.
SSPC SP 1 : Steel Structure Painting Council for Solvent Cleaning
SSPC-VIS 1-89 : Steel Structures and Painting Council for Visual Standard
for Abrasive Blast Cleaned Steel
In case of conflict between the requirements of this specification and that of
above referred documents, the requirement of this specification shall govern.
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3.1 Prior to procurements of coating materials, Contractor shall furnish four copies
of, but not limited to, the following for qualification of the manufacturer and
materials.
a) Complete descriptive technical catalogues or data sheet describing the
materials offered along with samples of corrosion coating materials, its
properties and application instruction as applicable specifically to the
project.
b) Test certificates and results of previously conducted tests, for all
properties of this specification.
c) Reference list of previous supplies of the similar material indicating
the project details such as diameter, quantity, operating temperature
year if supply, project name, contact person and feedback on
performance.
Once the TGPL/TPIA approval has been given, any change in material or
manufacturer shall be notified to TGPL/TPIA, whose approval in writing of all
changes shall be obtained before the materials are used.
3.2 The Contractor shall submit the coating procedure along with quality records
and Inspection test plan compatible to this specification at least one week prior
to commencement the work for approval of TGPL/TPIA.
4.0 MATERIAL AND EQUIPMENT REQUIREMENTS
4.1.1 General
4.1.2 The Contractor shall be responsible to provide the coating material at site in
compliance with the requirement of this specification.
4.1.3 Test Certificates shall be available to TGPL/TPIA for review before

commencement of work.
4.1.4 The material and equipment like joint coating material, material for blasting,
primer, blasting hopper, air compressor, burners etc. shall be approved by
TGPL/TPIA. Sand blasting is not allowed.
4.1.5 Contractor shall be responsible for arranging all manpower required for
application, testing and inspection of coating in the filed in accordance with this
specification
4.1.6 Coating material shall be capable to withstand a maximum service temperature

of + 600 C. The material shall possess high dielectric strength, good tensile
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strength and good resistance to thermal ageing as mentioned in Table-1 & Table-
2 of this specification. Material shall be purchased from vendor approved by the
TGPL.
4.2 Field joint corrosion coating material
4.2.1 Heat shrinkable wraparound sleeve
a) Heat shrinkable sleeve shall consist of radiation cross-linked thermally

stabilised, ultraviolet resistance, semi-rigid backing, with a uniform
thickness of high shear strength and thermoplastic / copolymer hot melt
adhesive.
b) The joint coating system shall utilise a solvent free epoxy primer applied to
the pipe surface prior to sleeve application. The backing shall be coated
with thermo-chrome paint that will change colour when the desired heat
during shrinking process is attained.
c) The wraparound sleeve shall be either in pre-cut form for a particular

diameter or in bulk form to be field cut to a specific length depending upon
the diameter of the pipe / fitting to be coated.
4.2.2 Cold applied tapes
Cold applied tapes shall be made of polyethylene backing with a uniform

thickness of self-adhesive elastomeric compound. The primer used in joint
coating system shall be dried quickly on the pipe surface prior to application of
joint coating material, Cold applied tapes shall be used in areas as directed by
TGPL/TPIA and they are not meant to replace heat shrinkable wraparound
sleeve.
4.2.3 The minimum thickness of field joint coating shall be 2.5 mm on the complete
finished field joint coating. Whereas, the thickness at the apex of weld seam shall
not be less than 2.2 mm.
4.2.4 The filed coating material shall be supplied with minimum following physical,
chemical & electrical properties.
4.2.4.1 Properties of Backing
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Table – 1: Properties of Backing
A. Physical Properties
Sr. Specified Test
Properties Unit Test Method
No. Requirement Condition
1 Tensile Strength MPa > 15 250 C ASTM D 638
2 Ultimate Elongation % > 400 250 C ASTM D 638
3 Impact Resistance N-m > 5.7 230 C ASTM G 14
B. Chemical Properties
24 hours at
1 Water Absorption % 0.05 max ASTM D 570
250 C
Resistance to Thermal Change in
2 % 1000 C DIN 30672
Ageing Elongation, < 25
C. Electrical Properties
1 Volume Resistivity Ohm-cm > 1016 250 C ASTM D 257
1000 volt / DIN 30672 / ASTM

2 Dielectric Strength kV > 30
sec D149
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Table – 2: Properties of Coating System (As Applied)

Sr. Properties Unit Specified Test Condition Test Method
No. Requirement
1 Impact Resistance N-m No Holidays 230 C & 30 Blows DIN 30672

2 Resistance to peel
2.1 With metal surface > 15
With mill coating >8 230 C
At layers overlap N/cm > 15 DIN 30672

2.2 With metal surface >3
With mill coating >2 500 C
At layers overlap >3
Sr. Specified Test
3 Resistance to indentation mm > 0.6 Remaining
500 C DIN 30672
thickness
4 Lap shear strength between
Wrapping & metal surface
N/cm2 ≥ 5 500 C DIN 30672
Wrapping & Mill Coating
B. Chemical Properties
Sr. Specified Test
1 mm ≤ 30 30 days, test
Cathodic Disbondment (Radius of
method A at ASTM G-42
Disbondment)
600 C
C. Electric Properties
Sr. Specified Test
1 Dielectric Strength kV > 30 1000volt /sec DIN 30672 / ASTM D0149
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NOTE: Contractor shall obtain prior approval form TGPL/TPIA regarding the
manufacturer of the joint coating, Complete technical details along with tests
certificates complying the requirements shall be submitted to company for the
purpose.
4.3 A fully automatic full circle adjustable holiday detector with a visual and audible
signal shall be used for inspection of coating for pinholes.
5.0 PROCEDURE OF APPLICATION
5.1 The Contractor shall follow joint coatings application procedure as per
manufacturer’s recommendation and guidelines or the minimum requirements
specified in this specification whichever is more stringent. The contractor shall
prepare procedure indicating mixing ratio and qualify the same procedure
through vendor and TGPL.
The personal performing the job shall be trained enough and shall be having
sufficient experience to perform the job.
The Coating Insulators shall be trained, tested and certified by the

manufacturer’s (Heat Shrink Sleeve) representative in presence of TGPL/TPIA.
5.2 The Contractor shall submit and demonstrate to TGPL/TPIA, the proposed
materials and work procedures. The proposed procedures, materials and
equipment shall be approved by TGPL/TPIA.
5.3 Surface cleaning and preparation
5.3.1 Contractor shall remove oil, grease, salts and other contamination on the steel
pipe surface by wiping with rags soaked with suitable solvents such as naptha or
benzene. Kerosene shall not be used for cleaning. The solvent cleaning
procedure shall be in accordance with SSPC-SP-1.
5.3.2 Prior to surface cleaning, the surface shall be completely dried. The uncoated
steel surface shall be then cleaned by shot blasting to SA 2½ of Swedish standard
SIS-055900 and have profile of 60-80 microns roughness. The roughness shall be
checked by PRESS-O-film or by other means as agreed by TGPL/TPIA. Shot
blasting shall be stopped, in case, when Relative Humidity (RH) in the
atmosphere observed is equal to or more than 85%.
5.3.3 The ends of existing pipe coating shall be inspected and chamfered prior to
application and cleaned as per requirement. The unbounded portion of coating
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shall be removed and then suitably trimmed. Portions where parent coating is
removed shall also be prepared as specified in this specification.
5.3.4 The joint coating shall be applied immediately after completion of surface
preparations. The time lapse shall not be more than 30 min.
5.4 Application of Primer
5.4.1 Mixing of Epoxy Primer
The approved epoxy primer shall be properly mixed as per manufacturer’s

instructions. The mixing shall be carried until a homogeneous mixture is obtained.
5.4.2 Immediately after completion of surface preparation, the approved primer shall
be applied over the entire steel surface as per instructions given by manufacturer.
The primer shall be wet and tacky when the sleeve is applied. Necessary care shall
be taken to protect the primed surface from the atmospheric dust particle. If the
primer is damaged, the damaged area shall be cleaned and re-primed. The wet
film thickness shall be 100 microns, measured to ensure the requirements as per
manufacturer’s recommendations.
5.5 Application of Heat Shrinkable Wraparound Sleeves
5.5.1 The wraparound sleeves shall be of a size such that a minimum overlap of 50 mm
is ensured (after shrinking) on both side of mill applied coating of the pipes.
5.5.2 In case where carrier pipe installed by direct boring/jacking, the overlap on the
mill coating for the leading edges of the joints shall not be less than 200 mm (after
shrinking). When this extra overlap is achieved by providing an additional patch of
heat shrink tape/ wraparound, it shall be applied in such a manner that the square
edge of the patch on the joint coating is in the direction opposite to the direction
of boring /jacking.
5.5.3 The bare steel surface shall be preheated over the surface to remove the mist
before centring the wraparound sleeve. The minimum temperature for preheating
shall be as recommended by manufacturer. The temperature of preheat surface
shall be checked by using pyrometer or thermos-crayons or digital thermometer
and shall be recorded.
5.5.4 The wraparound sleeve shall then be entirely wrapped around the pipe positioning
the closure patch to one side of the pipe in 10 o’clock or 2 o’clock position and the
edge of the undergoing layer facing upward. Overlap between the sleeve and
closure patch shall not be less than 50 mm (after shrinking).
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5.5.5 A heat shrinking procedure shall be applied to shrink the sleeve in a manner such
that all entrapped air is removed with the help of gloved hands and hand rollers.
The complete shrinking of the entire sleeve shall be obtained without undue
heating of mill coating and providing due bonding between pipe surfaces, sleeve
and pipe coating. The resulting coating shall be free from wrinkles, cold spots, pin
holes and weld profile shall be visible on the sleeve.
5.6 Application of Cold Applied Tapes
5.6.1 Cold applied joint protection tapes shall be such that it can be applied by spirally
wrapping on the pipe.
5.6.2 Approximately 100 mm of tape interleaving paper shall be peeled back and tape
shall be applied with the compound side to the pipe. Whilst continuously
removing the interleaving paper, the tape shall be spirally applied to provide a
minimum of 55% overlap. Sufficient tension shall be applied to ensure good
conformation, avoiding air pockets and also continuously smooth out as the
wrapping proceeds. The wrapping shall start and finish to give a minimum of 75-
mm overlap on to the adjoining yard applied coating.
In the case where carrier pipe is installed by direct boring/jacking, the overlap on
the mill coating for the leading edges of the joints shall be minimum 200 mm.
The direction of spiral wrapping in these cases shall be such that the square edge
of the wrapping with the joint coating is in the direction opposite to the direction
of boring/jacking.
6.0 INSPECTION & TESTING
6.1 Visual inspection

6.1.1 A visual inspection shall be carried out for following:
a. Mastic extrusion on either ends of the sleeve shall be examined (applicable
for heat shrink wraparounds).
b. There shall be no sign of punctures of pinholes or bend failure. The
external appearance of the sleeve shall be smooth, free of dimples, air
entrapment or void formation.
c. Weld bead profile shall be visible through the sleeve.
d. Position of closer patch should be either 10 or 2 O’ Clock position.
e. The entire closure patch shall have changed colour uniformly (applicable
for heat shrink wraparounds).
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6.2 Holiday inspection

6.2.1 The holiday detector used shall be checked and calibrated daily with an accurate
or calibrated DC voltmeter.
6.2.2 The full circle holiday detector shall be approved by TGPL/TPIA. The test voltage
shall be 25 kV. Inspection of the sleeves shall be conducted only after the joint
has cooled (applicable for heat shrink wraparounds).
6.2.3 No field joint coatings shall be covered or lowered in the trench until it has been
approved by the TGPL/TPIA.
6.3 Testing
6.3.1 TGPL/TPIA reserves the right to remove and test, one of every 25 joint coatings
or one joint coating of every day's production whichever is more stringent for
peel test. Contractor shall provide all assistance in removing and testing of field
joint coatings.
Peel Test shall be carried out after 24 hrs from the time of application.
6.3.2 From each test sleeve, one or more strips of size 25 mm x 200 mm shall be cut
perpendicular to the pipe axis and slowly peeled off. This test shall be conducted
between wrapping and metal & mill coating and between layers at overlap with
joint coating (where applicable). The Peel Test shall be carried out in presence
TGPL/TPIA and Contractor shall record the results.
6.3.3 The required peel strength shall meet the requirements as specified in Table – 2
of this specification, applicable for 230 C or 500 C whichever is feasible. After
removal of strip, the bulk of adhesive shall remain adhered to the pipe showing
no bare metal, otherwise, test shall be considered as failed.
The adhesive layer that remains on the pipe surface shall be free of voids
resulting from air or gas inclusion.
6.3.4 If the sleeve taken away for test does not meet the requirements of clause 6.3.3,
the adjacent two sleeves shall also be removed and inspected.
6.3.5 If the adjacent two sleeves are acceptable the test rate shall be increased to one
sleeve every 12 joints until TGPL/TPIA is satisfied. The test rate can then be
reduced as per clause 6.3.1.
6.3.6 If either or both of the adjacent two sleeves do not meet requirements of clause
6.3.3, the field coating shall be stopped. (Refer clause 7.0).
6.3.7 TGPL/TPIA reserves the right of 100% removal of sleeves if they are not
convinced that the requirements of clause 6.3.3 are achieved.
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6.3.8 Coating thickness shall be checked by non-destructive methods for each field
joint. Ten measurements over the cut-back including one over the girth weld
shall be taken and minimum thickness of 2.2 mm shall be guaranteed on apex
and average thickness of 2.5 mm on pipe shall be measured only after the
setting of joint, preferably after 24 hrs.
7.0 MARKING, PROTECTION, STORAGE AND HANDLING
7.1 Contractor shall ensure that the Manufactures have carried out all quality
control tests on each batch of material supplied. All such test certificates/
reports shall be submitted with each batch of the materials.
7.2 Materials shall not be older than their period of validity at the time of
application. Deteriorated and decomposed materials shall be disposed off and
replaced by Contractor at his own expense.
7.3 Contractor shall ensure that the coating materials supplied by supplier are
properly packed and clearly marked with the following:
- Manufacturer’s name
- Materials Description
- Batch Number
- Date of Manufacturing and date of expiry
- Specific storage and handling instructions.
7.4 All materials shall be stored and handled by the contractor in such a manner and
types so as to prevent damage or deterioration.
7.5 Contractor shall provide and maintain mobile facilities equipped with all
necessary equipment and it spares for cleaning, coating, repairs, inspection and
tests.
8.0 REPAIRS
8.1 If the field joint is detected to be unacceptable after testing as per clause 6.0 of
this specification, the Contractor shall, at his own cost,
a. Determine the cause of the faulty results of the field coating;
b. Mobilise the expert of manufacturer, if required;
c. Stop field coating until remedial measures are taken against the causes of
such faults, to the entire satisfaction of the TPIA.
8.2 Contractor shall replace all joint coating found or expected to be unacceptable as
per clause 6.0 of this specification.
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8.3 Contractor shall, at his own cost, repair all areas where the coating has been
removed for testing by the TGPL/TPIA.
8.4 After the coating work on welded joints, fittings and repairs, it shall be tested
with a spark tester before lowering or jacking the pipeline.
8.5 TGPL/TPIA shall be entitled to check the coating on buried pipelines or parts of
pipelines with equipment / instrument such as the “Pearson meter” and the
resistance meter. If coating defects are observed, the Contractor shall be
responsible for excavation at such points, repairing the coating, spark testing and
backfilling the excavations without any extra charge.
9.0 DOCUMENTATION
Contractor shall provide the following as minimum.

9.1 Test certificates/results as per Manufacturer’s Quality Control Procedure for
each batch of materials.
9.2 Calibration certificates of measuring Instrument, testing Equipment.
9.3 Insulator qualification record certified by manufacturer.
9.4 Process qualification records.
9.5 Quality records.
Procedure for field joint coating
ITP
Progress Report
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4. Specification for Pipeline Crossing
Page 97 of 123
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TABLE OF CONTENTS
1.0 SCOPE
2.0 REFERENCE CODES AND STANDARDS
3.0 SUBMITTAL BY CONTRACTOR
4.0 GENERAL
5.0 ROAD & RAIL ROAD CROSSING
6.0 CROSSING OF BURIED SERVICES
7.0 MINOR WATER COURSE CROSSINGS
8.0 DOCUMENTATION
Page 98 of 123

STEEL PIPELINE NETWORK ACROSS OUTER PUNE
DEC-2018
1. SCOPE
This specification covers the minimum requirements of various activities to be
carried out by the CONTRACTOR for and about the safe installation of pipelines
crossing highway, railroads & Canal and River etc., by boring or through open cut
method.
The provisions of this specification are not applicable for pipelines crossing
watercourses, which are specifically designated as "Major Water Courses" in the
CONTRACT or BID. For such crossings, separate document to be prepared by
contractor and submitted to TGPL / TPIA for review & approval.
This specification shall be read in conjunction with the conditions of all
specifications and documents included in the CONTRACT between TGPL/TPIA and
CONTRACTOR. Unless specified otherwise, all sections of this specification shall
apply to all specifications referred in this specification.
2. REFERENCE CODES AND STANDARDS
Following standard has been used in this specification.
ASME B 31.8 -Gas Transmission and Distribution Piping Systems
API RP 1102 -Recommended Practice for Liquid Petroleum Pipelines Crossing
Railroads and Highways.
ASME B 31.4 -Liquid Petroleum Transportation Piping Systems
Part 192 -Transportation of Natural and other Title 49 Gas by Pipeline (US
Department of Standards) Transportation - Pipeline Safety
Part 195 -Transportation of Liquids by Pipeline US Department of
Transportation - Pipeline Safety Standards)
API 1104 -Specification for Welding Pipeline and Related Facilities
OISD - Design and Construction Requirement for Cross Standard 141
Country Hydrocarbon Pipeline
TGPL HSE -TGPL HSE Management System Manual and - TGPL Security
Manual
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3.1 The CONTRACTOR shall submit the Procedure for open cut and cased road
crossing, river and water ways crossing, along with activity report / records at
least one week prior to commencement of the work for approval of TGPL/TPIA.
3.2 The CONTRACTOR shall submit construction drawing and Inspection test plans
for all the activities compatible to this specification at least one week prior to
4. GENERAL
4.1 Crossing of roads, buried Services, canals and minor water crossing with
equipment and / or personnel shall be 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.
Where overhead or above ground crossings are required, an appropriately
detailed Risk assessment shall be carried out to ensure that all HSE and integrity
risks are evaluated and adequately mitigated. This shall include consideration of
all long term O&M issues and activities.
All statutory clearances before commencement of work as required from various
authorities having jurisdiction thereof viz. PWD, Forest, Railways, Irrigation,
Traffic, Police, P & T, Electricity Board and MIDC etc., shall be obtained by TGPL
principally and CONTRACTOR shall co-ordinate & obtain necessary approval from
such authority to cross the highway/ Railway & Canal by Push jack boring / HDD /
Open Cut or as approved method by TGPL / TPIA & Authorities having
jurisdiction for timely completion of crossing.
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
TGPL/TPIA 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.
All Civil and Mechanical works associated with or incidental to the installation of
pipeline crossings shall be carried out in accordance with the approved
procedures.
4.2 TGPL/TPIA reserves the right to demand for individual crossings from the
CONTRACTOR a separate detailed report for approval, containing:
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 Time Schedule
 Working method with equipment
 Test procedure
 Manpower deployment
 Calculations of temporary works
 Soil investigations, etc.
 Such details shall be provided without additional cost to TGPL.
4.3 Pipeline crossings for road, railroad, canals and rivers etc., shall be hydrostatically
pre-tested, ex-situ, without joint coating and prior to lowering, whenever,
 Crossing is executed by boring of casing pipe
 Installation of carrier pipe into casing pipe.
 River Crossing pipes which are to be continuously concrete weight
coated (to be tested prior to concrete coating)
 Whenever the Authorities having jurisdiction over the utility insist upon
pretesting of carrier pipe. The section of the pipeline for the crossings shall be
tested as a single string. Unless specified otherwise in the CONTRACT, the test
pressure shall be the one resulting in hoop stress corresponding to 90 % of
SMYS of pipe material. Test pressure shall be retained in the pipeline for
minimum period of 4 hours or as per approved procedure. Test section shall
be visually examined for leaks / defects, etc.
5. ROAD & RAIL ROAD CROSSING

5.1 The work under crossings shall include necessary clearing, grading and trenching
to required depths and widths, welding of casing (when required) and carrier
pipes, coating, lowering-in, back filling, clean-up, restoration to the original
condition and further strengthening and protective works, testing, installation of
assemblies, insulators, end seals, and temporary works such as sheet pilling,
bridges, etc.
The work shall be carried out in accordance with the approved drawings and job
standards, as directed by TGPL/TPIA and to the satisfaction of TGPL/TPIA 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,
latest edition.
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 TGPL/TPIA for safety of traffic. Adequate
traffic warning signals and/or traffic lights and suitable diversions shall be
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provided as directed by TGPL/TPIA/Authority having jurisdiction over these areas.

Such diversions shall not cross the pipeline where it has already been installed,
unless proper safeguarding at TGPL/TPIA’s opinion is ensured.
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. Method of
Installation of the crossing shall be as approved by Authorities having jurisdiction.
Railroad crossings shall always be bored / jacked.
Well pointing arrangements shall be made during boring in all wet areas, without
any additional cost.
5.2 The bottom of the trench and / or the pit for at least twelve (12) meters at the
approach to each end of a casing shall be graded and if necessary back filled with
clean sand and compacted up to at least 95%, proctor density to an elevation that
will provide sufficient and continuous support to the pipeline so that the pipeline
remains correctly aligned at the casing ends during and after back filling.
5.3 The diameter of the hole for a bored section shall have a hole diameter as close
as practicable to the outside diameter of the casing pipe. If excessive void or too
large hole results, or if it is necessary, in the opinion of TGPL/TPIA, 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 TGPL/TPIA and
Authorities having jurisdiction thereof at no extra cost to TGPL/TPIA. Equipment
used for installation of casing pipe shall be of the type approved by TGPL/TPIA.
An installation consisting of hydraulic jacks shall be provided with easily readable
pressure gauges (in bar) and suitable pressure limits. Their proper operation shall
be demonstrated before the work is started. TGPL/TPIA can request that the
maximum pressing force be limited.
5.4 Casing Pipe Diameter shall be minimum two pipe sizes bigger than the carrier
pipe or as per concerned authority. 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 radio graphed. However, pipeline qualified welder shall only
be engaged; 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.
5.5 In 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 me laid with a single
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gradient in order to allow for an easy insertion and, if necessary at a future date,
to allow for the removal or replacement of the pipeline, leaving the casing
undisturbed.
The assembly of vent pipe units as approved by TGPL/TPIA shall be carried out by
the direct insertion and welding to the ends of the casing pipe before
introducing the carrier pipe. 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 back filling
as per relevant specification.
5.6 The casing pipe shall be considered ready for installation of the carrier pipe, after
passing a gauge plate of diameter equal to 95% ID of pipe and careful inspection
of internal cleaning with the removal of soil, mud, stones and other foreign
materials.
5.7 Insulators, as approved by TGPL/TPIA, 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 the drawings or at 2.5 mtr. centre (whichever is more stringent).
At the end of both sides of the casing, a double set of insulators shall be
installed.
5.8 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.
5.9 After installation of the carrier pipe section in the casing and the appurtenances
(but prior to making tie-in welds and back filling), the CONTRACTOR in the
presence of TGPL/TPIA shall conduct an electrical continuity test between casing
pipe and carrier pipe & soil. These tests shall show at least a resistance of
minimum 100,000-ohm m2. After back filling and compaction, additional tests
shall be conducted to determine if the casing is found to be shorted,
CONTRACTOR shall make the necessary corrections and repairs at his cost, unless
a test to the satisfaction of the TGPL/TPIA is obtained.
For new systems, strategic valves shall normally be installed either side of special
crossings (including major river crossings), at off takes for pressure reduction
installations, and at other locations where required for network isolation
purposes (based on risk assessment).
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6. CROSSING OF BURIED SERVICES

6.1 The pipeline under construction may pass above or below the existing buried
facilities such as pipeline, cable, drain or other services. The minimum clearance
required between pipeline and the existing facilities shall be as recommends by
authority having jurisdiction and the pipeline shall be laid mm below / above
from such services as per the recommendations by the authority. Type of
crossing shall be such that a minimum depth of covers as required in the drawing
and specifications are guaranteed.
6.2 Whenever buried services in the ROW are to be crossed by CONTRACTOR,
CONTRACTOR shall safeguard the buried facilities and the required protecting
precaution shall be executed as approved by owners of the buried services and
TGPL/TPIA.
6.3 For buried services to be crossed by boring / jacking the relevant provision shall
apply.
7. MINOR WATER COURSE CROSSINGS
7.1 Minor water crossings includes crossings of ditches, canals, watercourses, Nalas,
streams etc., whether the bed(s) contain(s) water or not, and not being specified
as `Major water Crossings' in the CONTRACT / BID.
7.2 All works of the pipeline minor water crossing shall be performed in accordance
with the approved construction drawings. Section profile details shall be
prepared and submitted to TGPL/TPIA. Procedure and other applicable
documents as per CONTRACT, and as directed by TGPL/TPIA., shall be prepared
and submitted to TGPL/TPIA.
7.3 Whenever minor water crossings in the ROW are to be crossed, CONTRACTOR
shall install bridges and further comply with the provisions as laid down in this
specification.
7.4 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 favourable period for executing the
work.
7.5 In case of crossings of watercourse 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.
Whenever required by TGPL/TPIA, CONTRACTOR shall execute a soil
investigation before start of construction. Based on this soil investigation, he
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shall prepare a construction drawing, work method and time schedule for
approval by TGPL/TPIA.
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 with dimensions
60 x 60 mm and having a flat bottom. The minimum force to be exerted shall be
36 Kg.
CONTRACTOR shall take special care to check with the responsible authorities for
special condition applying to working on, over, under or through minor water
crossings and CONTRACTOR, shall comply with any such conditions. Written
arrangements with authorities shall be drawn up in cooperation with TGPL/TPIA.
7.6 The minimum cover over the pipe shall be 1.5 meter plus the highest water level
or specified in the relevant approved drawings and job standards. For river /
watercourses that are prone to scour / erosion, the specified cover shall be
measured from the expected lowest bed profile after scouring / erosion.
7.7 For crossings beneath the bed of watercourses, the pipe section shall be made in
such a way that it confirms 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.
7.8 Whenever the crossing requires a straight section of pipe between the lower
bends coinciding with the riverbed, this section shall be laid at a single horizontal
level.
7.9 For crossings of ditches, canals, banked channels, etc. by boring, the pipe section
shall be prepared, laid and tested in accordance with the applicable specification.
7.10 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
TGPL/TPIA.
7.11 Banks and trenches of minor water crossings shall be back filled with soil which is
to be approved by TGPL/TPIA 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 TGPL/TPIA. 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 back filled initially around and over the pipe to provide a
protective padding or cushion extending to a minimum thickness of 300 mm
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around the pipe before back filling remainder of the trench with excavated or
other material as per approved drawings and standards.
After the trench has been back filled and during the clean-up works, the minor
water crossing shall be cleaned at least across the whole of the ROW.
When specified in the CONTRACT, CONTRACTOR shall repair the ditch bank with
materials to be supplied by himself as per Civil Specification
8. DOCUMENTATION
CONTRACTOR shall submit following documents as minimum.
8.1 Quality records
 Procedure for Crossing
 Pipeline Crossing Report
 Inspection and test Plan
 Inspection Reports.
8.2 Detail drawings of Crossing.
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5. Specification for Pipeline Hydro test
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TABLE OF CONTENTS
1.0 SCOPE
4.0 GENERAL
5.0 HYDROSTATIC TEST PROCEDURE
6.0 TEST DURATION AND PRESSURE
7.0 EQUIPMENT AND INSTRUMENTATION
8.0 PROCEDURES
9.0 ACCEPTANCE
10.0 TERMINATION
11.0 MEASUREMENTS
12.0 CALCULATIONS
13.0 PRECAUTIONS DURING THE TEST
14.0 PRESERVATION OF PIPELINE
15.0 DOCUMENTATION
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1. SCOPE
1.1 This specification covers the minimum requirements of supply, works and
operations to be performed by CONTRACTOR for hydrostatic testing of steel
pipelines in CGD Networks transporting hydrocarbons in gaseous phase under
high pressure. This specification does not cover the requirements of drying / pre-
commissioning of the tested pipelines.
1.2 This specification shall be read in conjunction with the conditions of all
specifications and documents included in the CONTRACT between TGPL /TPIA
and CONTRACTOR. Unless specified otherwise, all sections of this specification
shall apply to all specifications referred in this specification.
specification.
ASME B 31.8 : Gas Transmission and Distribution Piping Systems.
API RP 1110 : Pressure Testing of Liquid Petroleum Pipelines.
ASME B 31.4 : Liquid Petroleum Transportation Piping Systems.
ASME Sec. VIII : Boiler & Pressure Vessel Code Div.1
OISD Standard 141 : Design and Construction Requirements for Cross-country
Hydrocarbon Pipelines
IS 2490 (Part-I) : Tolerance limits for industrial effluents Discharged into the
land surface water
In case of conflict between the requirements of this specification and that of the
above-referred codes, standards and specifications, the requirements of this
specification shall govern.
The Contractor shall submit the cleaning, flushing, filling and testing procedure
along with activity report / records and Inspection test plan compatible to this
specification at least one week prior to commencement of the work for approval
of TGPL/TPIA
4. GENERAL
4.1 Hydrostatic test shall be performed on the entire length of the pipeline.
Hydrostatic test shall be performed in accordance with approved Hydrostatic
Test Diagrams for each test section. The maximum length of each test section
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shall not exceed 25 kms. For pipeline sections to be tested pipeline profile, with
the line elevations clearly indicating highest and lowest points shall be
submitted.
4.2 Hydro static test for individual sections in case of laying by HDD method shall be
as follows:
General
The pressure tests shall prove the resistance and tightness of the pipeline.
Testing shall be performed in accordance with applicable standard.
The Contractor will transmit all the records of the tests to the TGPL and TPIA.
Pre-testing
Pipe and fittings shall be pre-tested prior to the pullback operation and weld
joint coating a compulsory strength and leak test shall be performed. The
minimum duration for strength testing shall be 4 hours (see tightness test for the
test pressure).
The Pneumatic testing will be carried out using dry air or inert Gas of a minimum
pressure of 0.1 bar less than existing pipeline pressure (see weld points shall be
distempered with soapy water and visually examined (soap bubble test).
Final Test preparation
Tightness test shall be performed with water. The water shall be clean, with a
corrosion inhibitor added if necessary. The pipe shall be filled using pigs to
prevent the formation of air pockets.
The tests should normally be carried out with trenches adequately back-filled, if
any, to avoid the influence of temperature changes. If the ground temperature in
the immediate vicinity of the pipes is less than 2°C, antifreeze shall be added.
On completion of filling operations, time should be allowed for the water in the
sections to stabilise. The water pressures to be maintained and the location and
characteristics of the measuring apparatus (thermometers, dead-weight pressure
gauges etc.) shall be defined before testing commences.
The measuring instruments shall have undergone certified periodic calibration.
Pressure-recording instruments shall be installed in a sheltered place.
4.3 Hydrostatic test shall commence only after mechanical and civil works
completion, i.e., all welds have been accepted and the pipeline has been laid and
back filled according to the specifications. Testing of any pipe section shall
commence only after acceptance / sign-off of Pipe book by TGPL and TPIA.
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Hydrostatic test shall include those sections, which have been previously tested,
viz. Rail / Road crossings, major water crossings including test on banks and in
place after installation and scraper traps at the terminals. CONTRACTOR shall
perform all works required for hydrostatic testing after obtaining prior written
approval from the TGPL /TPIA.
5. HYDROSTATIC TEST PROCEDURE
The procedure shall strictly comply with the requirements of these specifications
and shall be submitted to TGPL / TPIA for approval. The procedure manual shall
include all temporary materials and equipment, but not limited to the following
items.
5.1 For the systems to be tested, a diagram indicating all fittings, vents, valves
temporary connections, relevant elevations and ratings. The diagram shall also
indicate injection locations and intake and discharge lines. Approved Pipe Book
shall also be made available.
5.2 Estimated amount of test water, water sources, including required concentration
of corrosion inhibitors and additives, procedure for inhibitor injection and
control of concentration.
5.3 Filling and flushing procedures, including a complete description of all proposed
equipment and instruments (including spares), their location and set-up.
5.4 The type and sequence of pigs and the pig tracking system for filling, testing &
dewatering. Pig inspection procedures, including procedure to be followed in
case the Gauge pig indicates damage.
5.5 Procedures for stabilization after filling and pressurization and to allow for
temperature stabilization.
5.6 Pressure testing procedure including a complete description of all proposed
equipment and instruments (Including spares), their location and set-up, and
proposed system for observation and recording of data during the pressure test.
5.7 Procedure for detection and location of leaks.
5.8 Procedure for de-watering the pipeline section(s) after testing, including a
complete description of all proposed equipment and instruments (including
spares), their location and set-up, the type and sequence of pigs and the pig
tracking system along with the pig specifications. Procedures to cover removal of
liquids shall be provided. This will cover both planned (e.g. following hydro
testing) and unplanned (e.g. groundwater ingress) situations.)
5.9 Forms for recording the test data.
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6. TEST DURATION AND PRESSURE

6.1 The duration of hydrostatic test shall be minimum 24 hours after stabilization
and the test pressure shall be as indicated in the approved hydrostatic test
diagram.
6.2 All buried steel pipelines and mains shall be pressure tested after installation
using water as a test medium. Minimum test pressure shall be equal to 1.4 times
Maximum Allowable Operating Pressure. Appropriate allowances shall be made
for “Creep” of polyethylene systems.
6.3 Unless specified otherwise in the CONTRACT, the maximum test pressure shall
not be higher than the one resulting in a hoop stress corresponding to 90 % of
SMYS of pipe material. Based on the minimum wall thickness in the test section
and minimum test pressure shall not be lower than the one resulting in a hoop
stress corresponding to 85% of SMYS of pipe material based on the minimum
wall thickness in the test section.
7. EQUIPMENT AND INSTRUMENTATION
7.1 The CONTRACTOR shall furnish all necessary equipment for performing the work
as stated in cleaning, flushing, filling, levelling, stabilizing, testing and de
watering procedures.
7.2 This shall include, but not be limited to, the following equipment and
instruments:
7.2.1 Pigs in filling, cleaning:
 Medium/Low Density Foam Pigs for Cleaning and Water Filling
7.2.2 Fill pumps:
The CONTRACTOR shall determine the type and number of fill pumps in order to
guarantee the following:
Differential head 20% greater than the maximum required.
Flow rate: 400m3 / hr. min.; 1000m3 / hr. max.
If single pump is used a standby unit must be available.
7.2.3 Variable speed positive displacement pumps equipped with a stroke counter to
pressurize the line with a known stroke and capable of exceeding the maximum
test pressure by at least 20 bar.
7.2.4 Two positive displacement meters to measure the volume of water used for
filling the line. These meters shall be provided with a calibration certificate not
older than one month.
7.2.5 Portable tanks of sufficient size to provide a continuous supply of water to the
pump during pressurizing.
7.2.6 Bourdon pressures gauges of suitable pressure range and accuracy.
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7.2.7 Dead weight tester with an accuracy of 0.01 bar provided with a calibration
certificate not older than one month, which shall be traceable to National
Physical Laboratories.
7.2.8 Two 48 hours-recording pressure gauges with charts and ink gauges tested with
dead weight tester prior to use. These shall be installed at the test heads.
7.2.9 Pressure recording charts.
7.2.10 Two temperature recorders for fill water.
7.2.11 Thermocouples (surface contact type) for measuring the pipe wall temperature
& for soil temperature measurement
7.2.12 Two laboratory thermometers 0oC to 60oC range, accuracy + 0.01 degrees duly
calibrated.
7.2.13 Injection facilities to inject additives into the test medium in the required
proportions
7.2.14 Communication equipment suitable for a continuous communication between
the beginning and the end of the test section and with the inspection team along
the line, in accordance with the requirements of Local Authorities
7.2.15 The temporary scraper traps (Testing Headers) shall be installed according to the
testing sections agreed in the test procedure manual. Proper piping and valve
arrangements shall be available to allow launching and receiving of each pig
independently. The test heads shall be sized in conformity with ASME
specification Section VIII, Division 2 with particular reference to Appendices 4
and 5.
Thermocouples (Surface Type Contact) for measuring the temperature of the

pipe wall shall be installed on the pipeline to be tested:
- 1 thermocouple at about 500 m distance from the pumping head.
- 1 thermocouple every 2500 m of the pipe.
- 1 thermocouple at about 500 m distance from the terminal head.
Thermocouples shall be attached on the external surface of the pipe after

removal of external coating area (50 x 50 mm) and shall be adequately
protected. After acceptance of test, the area opened, repaired and shall be
documented as per coating specification and TGPL/TPIA instruction.
7.3 A well maintained, air conditioned test cabin shall be made available at pumping
head site by contractor. The test cabin shall include all instrumentation & their
controls and proper communication & safety facilities.
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8. PROCEDURES
8.1 Equipment and / or parts which need not or must not be subjected to the test
pressure, or which must not be tested with water, must be disconnected or
separated from the pipeline to be tested.
8.2 If the difference of minimum and maximum atmospheric temperature should
cause thermal instability on the pipe section directly exposed to atmospheric
condition, the scraper (Testing Headers) traps and above ground pipeline shall be
properly protected.
The pipeline test shall exclude long segments of line exposed to atmospheric
conditions, viz. aerial lengths on piers, suspension bridges, etc., which sections
shall be tested separately.
8.3 The test medium shall be soft non-aggressive water furnished by the
CONTRACTOR. The water to be used shall be filtered, shall not be contaminated,
and free from sand or silt. CONTRACTOR shall submit laboratory test reports of
water used for testing. CONTRACTOR shall provide TGPL/TPIA approved
corrosion inhibitors (remidol - 4000), oxygen scavengers and bactericides to be
added to the test water.
The CONTRACTOR shall furnish and install all temporary piping which may be
necessary to connect from source of water to its pumps and manifolds / tank
ages. The CONTRACTOR shall provide Material Test Certificate to TGPL/TPIA prior
approval before furnishing and installing temporary piping.
8.4 AIR PIGGING

Before filling operation, Contractor shall clean the pipeline by sufficient numbers
of air driven pigs. Air pigging shall be preferable in sections.
Note: -
Cleaning of line shall be evaluated by TGPL/TPIA.
8.5 WATER FILLING
The section, which is planned for water filling, shall be cleared from NDT, air
cleaning and gauging. A detailed pipe book for the section to be tested shall be
submitted by Contractor to TPIA for review before commencement of water
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filling activity. Filling header shall consist of Minimum 3 pigs and the headers are
to be pre-tested before welding to main line. During filling, the volume of water
used for filling shall be measured by turbine meter / flow meter at every one-
hour interval.
8.6 THERMAL STABILIZATION
After a check has been made to confirm if the pressure has attained at least 1 bar
(g) on the highest section, the thermal stabilization can be started.
Thermal equilibrium between the pipeline and environment shall be checked
through the thermocouples installed on the pipeline.
Temperature readings shall be made at 2 hours - intervals. Thermal stabilization
shall be considered to have been achieved when a difference not higher than 1OC
is attained between the average values of the last two readings from pipe to soil
Thermal stabilization completion shall be approved by TGPL / TPIA.
8.7 PRESSURIZATION
The pressurization shall be performed in the presence of TGPL /TPIA at moderate
and constant rate not exceeding 2 bars / min. One pressure recorder shall be
installed in parallel with the dead weight tester. Volume of water used to reach
the test pressure shall be recorded periodically throughout the pressurization by
recording no of stroke. The pressurizing shall be cycled according to the following
sequence:
- Each 5 bar increments up to 80% of test pressure as recorded by the dead
weight tester.
- Each 2 bar increment between 80% of test pressure as recorded by the
dead weight tester.
- Each 0.2 bar increments between 90% of the test pressure up to full test
pressure as recorded by dead weight tester.
Pressure cycling and Air volume ratio calculations requirements:

i) Pressurise to 50% of test pressure, hold pressure for 1 hour, and collect water
for air volume calculations.
ii) Drop pressure to static head of test section at test head.
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iii) Re-Pressurise to 75% of test pressure, hold pressure for 1 hour, and collect
water for air volume calculations.
iv) Drop pressure to static head of test section at the test head.
v) Re-pressurise to test pressure and hold for stabilization.
During the pressurization to each test pressure, two tests shall be carried out for
the calculation of air volume in the pipeline under test.
In case, during the hold pressure periods indicated above, a decrease in pressure
is observed, the operations shall not be repeated more than twice, after which
the line shall not be considered capable of test, until the CONTRACTOR has
isolated and eliminated the cause for the lack of water tightness.
8.8 AIR VOLUME CALCULATION
In order to check the presence of air in the pipeline, two separate consecutive
pressure lowering of 0.5 bar shall be carried out.
For calculation of air in the pipeline the second pressure lowering shall be used,
and the relevant drained water shall be accurately measured (V1). This amount
measured shall be compared to the theoretical amount (V2) corresponding to
the pressure lowering that has been carried out, by using the procedure outlined
in the specification.
If no air is present in the length under test:
V1
--- = 1
V2
The above ratio is acceptable, provided it shall not differ from ‘1’ by more than
6% (i.e. 1.06).
If ratio is found to be above within limits, then pressurization can proceed. If not,
water refilling shall be carried out by another run of batching pigs after
depressurizing the pipeline.
The test shall be repeated as per the above procedure until above estimated
tolerances are satisfied. The pressurizing can then continue, to reach the value of
test pressure.
8.9 MECHANICAL STRENGTH TESTING
After the section has been pressurized and the air volume test has given
acceptable results the test pressure shall be held for a minimum of 24 hours
after stabilization. After temperature and pressure has stabilized, the injection
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pump shall be disconnected and all connections at the test heads shall be
checked for leakage. The pressure recorders shall then be started with the charts
in a real time orientation for continuous recording throughout the test.
During the testing period the following measurements shall be recorded:
- every one-hour pressure measurements form dead weight testers.
- every two hours the ambient temperature and the pipe temperature at the
thermocouples.
All data shall be recorded on appropriate forms attached to the hydrostatic test
procedure manual. Care shall be taken that the maximum test pressures are not
exceeded.
Bleed-off water shall be accurately measured and recorded.
9. ACCEPTANCE
9.1 The hydrostatic test shall be considered as positive, if pressure has kept a
constant value throughout the test duration, except for change due to
temperature effects. Such changes shall be evaluated as described under clause
12.2 of this specification.
The pressure change value as a function of temperature change shall be

algebraically added to the pressure value as read on the meters. The pressure
value thus adjusted shall be compared with the initial value and the test shall be
considered as acceptable if the difference is less than or equal to 0.3 bar. In case
of doubt, the testing period shall be extended by 24 hours.
9.2 If test section fails to maintain the specified test pressure after isolation,
CONTRACTOR shall determine by searching the location of leakage or failure. All
leaks and failures within the pipe wall or weld seam shall be repaired by
replacement of entire joint or joints in which leakage or failure occurs. In those
cases, where leaks occur in circumferential welds the method of repair shall be
determined by the TGPL / TPIA.
CONTRACTOR shall comply with instructions of the TGPL /TPIA whether to

replace a section of the line pipe that includes the line leak or whether to repair
the circumferential weld. Where failures occur in pipeline field bends, bends
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shall be replaced with same degree of bends. After completion of repairs, the
hydrostatic test shall be repeated in full, as per this specification.
9.3 The cost of repairs or replacements, followed by refilling and re-pressurizing the
line, due to poor workmanship, shall be borne by the CONTRACTOR. In the event
of leaks or failures resulting from faulty TGPL furnished materials, CONTRACTOR
shall be reimbursed for furnishing all labor, equipment, materials, except those
materials furnished by the TGPL and transportation necessary to repair and re-
pressurize the section of the pipeline to the pressure at the time of recognition
of leak or line failure.
CONTRACTOR shall be entitled for compensation as per the provisions of the

CONTRACT.
All work of reinstalling line pipe, to replace failures, shall be done in accordance
with the relevant Specifications included in the CONTRACT.
9.4 CONTRACTOR shall haul and stockpile all damaged and defective pipes to storage
locations designated by the TGPL / TPIA. All cracks and splits resulting from
failures shall be coated with an application of grease to preserve the
characteristics of failures from corrosion. Joint of failed pipes shall be marked
with paint, with a tag indicating failure details, date and location of failure and
pressure at which failure occurred.
10. TERMINATION
After the positive results of testing and all the data have been gathered, the test
shall be terminated upon written approval given by the TGPL / TPIA.
10.1 DEPRESSURIZATION AND DEWATERING
The pipeline shall be slowly depressurized at a moderate and constant rate as
instructed by TGPL /TPIA.
CONTRACTOR shall de-water the tested line as per the following requirement
after test acceptance.
Using four-cup pigs (polycups) and foam shall carry out the de-watering.
Pigs shall be driven by compressed air.
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The detailed de watering procedure shall be developed by the

CONTRACTOR in such a way as to provide adequate control of pigs during
de-watering.
Pigs and equipment required for dewatering the line shall be furnished by
CONTRACTOR and shall be approved in advance by the TGPL /TPIA.
Four-cup pigs shall first be passed through the line to displace the water.
Foam pigs shall then be passed in order to complete the line de-watering.
CONTRACTOR shall use a number of pigs each in different colours /
numbered for this purpose. The line shall be considered de-watered when
a negligible amount of water is flushed out by the last pig and approval is
given by the TGPL / TPIA.
10.2 During dewatering, care shall be taken to properly dispose the discharging water
in order to avoid pollution, damages to fields under cultivation and / or existing
structures and interference with the traffic. As chemical have been added to
water, dewatering shall be done in such a way that the composition of the
efficient water does not exceed the limit set in IS 2490 (Part-I) tolerance limits
for industrial effluents discharged into in land surface water. Hence, dewatering
circuit shall include chlorination before letting the water out of the pipe section
to the environment.
10.3 Upon completion of the testing and dewatering operation, any provisional traps
for pigs and all other temporary installation relating to the test shall be removed.
Subsequently, the individual sections of the line already tested shall be joined in
accordance with the requirements of relevant specifications issued for the
purpose. Upon completion of dewatering, swabbing shall be followed by using
foam pigs.
Weight of last pig received, shall not be more than 10 % of initial weight.
11. MEASUREMENTS
11.1 WATER AMOUNT MEASUREMENT
The water volume added to the section to be tested shall be measured during
the filling stage through a positive displacement meter (a turbine meter may also
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be used). Calibration certificates shall not be older than one month. Satisfactory
performance on site to be established
In the calculation, as per clause 12.1 of this specification, use shall be made of
the geometrical volume of the section. The water amount that has been let into
the section shall be measured during the pressurization stages through positive
displacement meters or turbine meters.
11.2 PRESSURE MEASUREMENT

Pressure shall be measured with a dead weight tester that shall permit readings
of at least 0.05 bar. During the test the pressure shall be recorded by means of a
recording pressure gauge featuring the following specifications:
Accuracy : + 0.1% of the full scale vale
Recording : Continuous on tape or disk, graph width 100 mm
Feed : 20mm/h for tape diagrams, 7.5 o /h for disk diagrams.

Recording range : To be such as to record pressure between 50% and 90% of
the Diagram width.
The recording pressure gauge shall be checked by means of dead weight test at
the beginning, during and at the end of the hydrostatic test.
11.3 TEMPERATURE MEASUREMENT:
11.3.1 Water temperature shall be taken at every 2 hours through the thermocouples
that have been installed along the section under test on the pipe wall.
Further, the temperature measurement shall be taken:

During the filling operation
During the thermal stabilization stage
During the hydrostatic test
The thermocouples’ sensitivity shall enable temperature readings with accuracy
of ± 0.2oC.
11.3.2 Water temperature shall also be measured on the pump delivery by means of a
recording thermometer throughout the filling stage.
11.3.3 The recording thermometer shall feature the following characteristics:
Accuracy : + 1% of the scale range
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Scale : -10o C to + 40o C

Recording : Continuous on tape or disk, diagram width 100 mm
Feed : 20 mm /h for tape diagrams, 7.5 degree/h for disk
diagrams.
Ground temperature shall be taken by measuring pipe temperature at the
thermocouples prior to starting the filling operation.
11.3.4 Environmental temperature shall be recorded from the beginning of
pressurization to the end of the test by means of a recording thermometer
featuring the following characteristics:
Accuracy : + 1% of the scale range
Scale : 0o C to + 60o C
Recording : Continuous on tape or disk, diagram width 100 mm
Feed : 20 mm / h for tape diagrams, 7.5 degree/ h for disk Diagrams
12. CALCULATIONS
12.1 The theoretical water amount that is necessary for filling the section to be tested
shall be obtained from the geometrical volume of the section considering the
pipe tolerances.
The theoretical water amount that is necessary for pressurizing the section shall
be calculated by means of the following formula:
Vp = (0.884 x ri/ti + A) x 10-6 x Vt x ∆P x K.

Where,
Vp = Compound water amount required to raise by P the pressure in the section
to be tested (m3) or amount to reach the test pressure (m3).
Vt = Geometrical volume of the section including the pipe traps (m3)
∆P = pressure change (bar)
ri = Average nominal inner radius of the pipe (mm)
ti = Average nominal pipe thickness(mm)
A = Isothermal compressibility value for water at the pressurization temperature
in the P range (bar-1)
K = A dimensional coefficient that is equal to a value of 1.02 for longitudinally
welded pipe.
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12.2 The pressure change due to a water temperature change shall be calculated
through the following Formula:
∆P = B x ∆T/(0.884 * (ri/ti) +A)
Where,
∆P = Pressure change resulting from temperature change (bar)
∆T = algebraic difference between water temperature at the beginning of the
test and water temperature as measured at the end of the test (ºC)
B = value of the difference between the thermal expansion of water at the
pressure and temperature as measured at the end of test and that of steel (0°C-1)
x 10-6
A = Isothermal compressibility value of water as estimated at the pressure and
temperature values obtained at the end of the test (bar –1) x 106
ri = average nominal inner radius of the pipe (mm)
ti = average nominal pipe thickness (mm)
13. PRECAUTIONS DURING THE TEST
In addition to all that has been expressly described in the procedures for carrying
out the tests, the following additional requirements shall be complied with:
13.1 Provision shall be made for the installation of no-admittance signs to
unauthorized personnel from the roads to the R.O.W.
13.2 Signs stating “PIPE UNDER TEST KEEP OFF” with local language translation shall
be placed where the pipeline is uncovered, and particularly where the
provisional traps and stations are located. Such areas shall be suitably fenced in
such a way as to prevent access of unauthorized personnel. No unauthorized
personnel shall be closer than 40 m to the pipeline or equipment under test
13.3 Provisional scraper traps shall be installed in compliance with methods and
suitable locations so that their rupture cannot cause any injuries to the
personnel or third parties.
13.4 The test station shall be placed in such a location as to prevent it from being
affected by a catastrophic failure in the test head.
13.5 Once dewatering is over, the sectionalizing valves and other valve assemblies
tested previously, shall be installed at locations shown in the drawings and in
accordance with the procedures contained in the relevant specifications. All
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thermocouples installed in the pipeline shall be removed and damaged corrosion

coating shall be repaired using TGPL / TPIA approved materials and procedure.
14. PRESERVATION OF PIPELINE
Preservation of pipeline, if required, by filling the pipeline system with nitrogen

at a positive pressure of 2 bar G as per the direction of EIC.
15. DOCUMENTATION
Contractor shall provide following as minimum
15.1 Schematic layout of cleaning, filling and testing facilities.
15.2 Calibration certificate of measuring instrument and testing equipment.
15.3 A profile of the pipeline that shows the test sites, all instrument and injection
connection.
15.4 Pipe filling logs and records.
15.5 Additive specification, required concentration and additive injection records.
15.6 Pig inspection records including photographs of the damages.
15.7 Records of gauging pig, calliper pigging (intelligent pigging) and photograph, if
occurs.
Pipeline cleaning, Water filling, Thermal stabilization, Pressurization, Pressure
Holding, De pressurization, De watering report.
Inspection and Test Plan
Test procedure for cleaning, flushing, filling and testing.
15.9 Air-volume calculation
15.10 Pressure change due to temperature change calculation.
15.11 Records and photograph of all leaks.
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6. Specification for Swabbing & Drying
Page 1 of 109
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TABLE OF CONTENTS
1.0 SCOPE
2.0 REFERENCE CODES & STANDARDS
4.0 GENERAL
5.0 SWABBING
6.0 DRYING
7.0 DOCUMENTATION
Page 2 of 109
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1. SCOPE
This Specification covers the Swabbing & drying of Pipeline after completion of
hydro testing.
2. REFERENCE CODES & STANDARDS
ASME B 31.8 - Gas Transmission and Distribution piping system
2.2 Reference Standard : Nil
The CONTRACTOR shall submit the swabbing & drying procedure along with
activity report / records and inspection test plan compatible to this specification
at least one week prior to commencement of the work for approval of
TGPL/TPIA.
4. GENERAL
After acceptance of Hydro test, the section shall be de-watered, followed by

swabbing operation. Drying shall be carried out by propelling foam Pigs with dry
air, which is from the outlet of drying unit.
4.1 Drying shall be carried out using dry air method and the out let of drying unit
shall give a dew point of – 45°C. The drying unit shall be mobile type (desiccant
type) fitted with oil separator. The discharge capacity of drying unit should be of
adequate capacity to dry the pipeline.
4.2 A digital dew point meter (with self-calibration and with valid calibration
certificate) shall only be used for checking the reading.
4.3 Dryer shall achieve a dew point of -8 to -100C in the entire pipeline by propelling
foam pigs from Launcher to Receiver.
5. SWABBING
5.1 To ensure smoother and speedy final drying operation of entire pipeline length,
CONTRACTOR shall conduct preliminary drying separately on each Hydrotest
section after swabbing operation.
5.2 Following steps shall be taken for Swabbing/drying,
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5.2.1 Poly pigs followed by high and medium density foam pigs shall be propelled with
compressed / Dry air for removal of Residual water for swabbing operation.
5.2.2 For checking the contents of water, each pig shall be weighed before launching
and after receiving and recorded.
5.2.3 The difference in weight of receiving foam pig shall be 10% of initial weight of
same foam pig to ensure that there is no physical water in line. If more than one
foam pig is launched at same time, then at least one of the received pig should
qualify the weight criteria for satisfactory swabbing.
5.2.4 During the above operation log of pigging shall be maintained at site.
5.2.5 Drying shall be carried out round the clock, once started after the swabbing
operation. If possible, the swabbing shall be preferably conducted using
drying air to reduce the drying time.
5.2.6 Valves, tap off, launcher, receiver etc. as coming in the section shall be tied
up before start of drying operation.
5.2.7 Mainline valves shall be kept fully open during operation and by passes shall
be used only to check drying stage in between length and drying of valves.
5.2.8 CONTRACTOR shall provide communication facility at both launching and
receiving ends.
5.2.9 Skilled, semi-skilled manpower shall be provided for 24 hrs operations.
5.2.10 Adequate lighting arrangement shall be provided for operation in night.
6. DRYING
After completion of swabbing and tie-in of valves, tap off etc. in each Hydro
test section, following operations shall be carried out for the drying.
6.1 Air pigging header shall be installed at both launching and receiving ends and
connections shall be made.
6.2 A sequence of three nos. of foam pigs, High, Medium & Low density (7 to 10-
kg ranges) shall be launched with the super dry air at the interval of 30
minutes each.
6.3 The discharge of drying unit shall be measured at every 06 hours using digital
dew point meter and – 45°C at the outlet of dryer shall be maintained.
6.4 The foam pigs when received at other end shall be removed and vents shall
be kept open on receiving end to ensure min. backpressure. The dry air shall
be allowed to flow continuously till – (8 to 10°C) is achieved at the receiving
end.
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6.5 The drying time calculation shall be conducted using temperature– moisture
chart for reference calculation.
6.6 All pre-dried sections shall be finally tied up and final drying of entire
pipeline shall be conducted in similar manner using super dry air by
propelling with foam pigs between pig launching and receiving station. The
final drying shall be conducted to achieve –10°C at receiving end.
7. DOCUMENTATION
CONTRACTOR shall submit the following document as minimum.
7.1 Calibration certificates of measuring instrument
7.2 Quality records
7.3 Drawing indicating swabbing & drying operation connection
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7. Specification for Casing Insulator & End seals
Page 6 of 109
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TABLE OF CONTENTS
1.0 SCOPE
3.0 FUNCTIONAL REQUIREMENT
4.0 DESIGN REQUIREMENT
5.0 MATERIAL REQUIREMENT
7.0 DOCUMENTATION
Page 7 of 109
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1. SCOPE
This specification covers the minimum requirement of design, material,
manufacture and supply of casing insulators and casing seals intended to be
used for pipeline crossing.
2. SUBMITTALS BY CONTRACTOR
2.1 Prior to procurements of casing insulators and casing seals, Contractor shall
furnish copies of, but not limited to, the following for qualification of the
manufacturer and material
i. Complete descriptive technical catalogues or data sheet describing the
materials offered along with samples of materials, its properties and
application instruction as applicable specifically to the project.
ii. Test certificates and results of previously conducted tests, for all properties
of this specification
iii. Reference list of previous supplies of the similar material indicating the
project details such as diameter, quantity, operating parameter, year of
supply, project name, contact person and feedback on performance.
Once the TGPL/TPIA approval has been given, any change in material or
manufacturer shall be notified to TGPL/TPIA, whose approval in writing of all
changes shall be obtained before the materials are used.
2.2 The Contractor shall submit the Installation procedure and Inspection test
plan compatible to this specification at least one week prior to
3. FUNCTIONAL REQUIREMENT
3.1 The pipeline insulator shall be used to support the carrier pipe inside the
casing pipe and electrically isolate the carrier pipe from the casing pipe for
the cased crossing The casing insulators shall:
 Resist cold flow and will not soften at design temperature
 Resist corrosion
 Resist mechanical damage while being pulled into the casing
 Have high electrical insulating value and low water absorption, thus
preventing leakage and ensure required electrical isolation between
carrier and casing pipes
 Have high compressive strength in order to assure a permanent support
to the carrier pipe
3.2 Casing end - seals are intended to be used for sealing the annular space
between casing pipe and carrier pipe at casing ends so as to prevent ingress
of moisture and water.
Page 8 of 109
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4. DESIGN REQUIREMENT
4.1 The arrangement of insulator shall be generally in accordance with
recommendations of authority having jurisdiction if not specify it shall be as
per Dwg. TGPL/E&P/STEEL/CROSSING/08. It shall be made in segments duly
held together with cadmium-plated bolts and nuts, to be supplied along with
casing insulators.
The numbers of segments shall be two for pipe Diameters up to 12”
(generally). For larger Diameters, the numbers of segments may be more
than two, but their number shall be kept minimum, as directed by
TGPL/TPIA.
The assembly height shall be such that it is slightly less than the value
obtained by following formula,
= Casing internal Dia - Carrier outer Dia
2
Contractor shall obtain prior approval from TGPL/TPIA on casing insulators
drawing / design.
Bolting used in casing insulation shall be cadmium coated and it shall not
touch casing pipe.
4.2 The seals shall be suitable for the casing and carrier pipe diameters as
applicable for each case.
The casing end seal shall be flexible to cater for the expansion and
contraction of carrier and casing pipes and shall be able to tolerate both
angular and concentric misalignment of casing pipe without loss of
sealing efficiency.
The design of the casing end seals shall permit easy installation of the seal
to the cased pipeline crossing.
Contractor shall obtain prior approval from TGPL/TPIA on casing end seals
drawings / designs.
5. MATERIAL REQUIREMENT
5.1 Casing insulators shall be made of injection moulded high density

Polyethylene or other material equivalent or superior as approved by
Page 9 of 109
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TGPL/TPIA. Insulators shall be of Heavy duty HDPE materials and shall meet
the following specification:
Test
Sr. No. Property Acceptance Criteria Test Method
Condition
1 Dielectric strength 450 – 500 Volts/mil - ASTM D – 149
Compressive
2 3200 psi - ASTM D – 695
strength
3 Tensile strength 3100- 5000 psi - ASTM D – 638,651
4 Impact strength 4.0ft.lb/inch of notch - ASTM D – 256
5 Water Absorption 0.01 % - ASTM D - 570
5.2 The casing end seals shall be made of heat shrink high-density radiation cross
linked polyethylene with an adhesive having a melt point suitable for the
pipeline service temperature and ambient temperatures foreseen during
construction. End seals material shall be resistant to heat, cold, vibration,
impact, abrasion, corrosive fluids, disbonding, organic and bio -
deterioration. Contractor shall ensure the compatibility of end seals with
carrier pipe coating.
Casing end seals shall meet following minimum property requirement.
Casing end seals shall be of only ReyChem RPG Limited and equivalent made.
Service provider shall conform the same prior to purchase
Page 10 of 109
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Casing end seals shall meet the following specification:
Acceptance
Sr.No. Property Test Condition Test Method
Criteria
Backing (sleeves and closures

1
Path)
1.1 Tensile strength 2200 psi min. - ASTM D – 638
1.2 Ultimate Elongation 400 % min. - ASTM D – 638
No visual
1.3 Heat Shock flow cracks, Flow or At 225 0C, 4 hrs D – 2671
drips
2 Adhesive
2.1 Ring and ball softening point 90o C - ASTM E - 28
2.2 Lap Shear 60 0C – 25 psi & ASTM D - 1002

23 0C – 250 psi (2
inch/min)
3 System (as applicable)
3.1 Peel strength (To casing and 5 psi (10 ASTM D –1000
carrier pipe and closure patch) inch/min)
6. INSPECTION AND TESTING

Contractor shall furnish material test certificates of the components used in
the assembly of casing insulators and casing end–seals as per the
requirements of clause 5.0 of this specification.
7. DOCUMENTATION
Contractor shall provide the following as minimum.
7.1 Test certificates/results as per Manufacturer’s Quality Control Procedure for
each batch of materials.
7.2 Calibration certificates of measuring Instrument, testing Equipment.

 Installation Procedure
 Inspection & Test Plan
 Inspection Report
Page 11 of 109
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8. Specification for Pipeline Marker
Page 12 of 109
DEC-2018
TABLE OF CONTENT
1.0 SCOPE
2.0 REFERENCE CODES AND STANDARD
4.0 GENERAL REQUIREMENTS
5.0 DIRECTIONAL AERIAL MARKERS
6.0 KILOMETER MARKERS
7.0 ROW BOUNDARY MARKERS (RCC)
8.0 PIPELINE WARNING SIGNS
9.0 NAVIGATION WATERWAY PIPELINE CROSSING WARNING SIGN
10.0 DOCUMENTATION
Page 13 of 109
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1. SCOPE
1.1 This specification covers the minimum requirements for supply, fabrication and
erection of pipeline markers to be installed by CONTRACTOR at various locations
along the route of a pipeline.
1.2 This specification shall be read in conjunction with the conditions of all
specifications and documents included in the CONTRACT between TGPL/TPIA and
CONTRACTOR.
2. REFERENCE CODES AND STANDARD
Following standards of latest edition have been referred in this specification:
API RP 1109-Recommended Practice for Marking Liquid Petroleum Pipeline Facilities
2.2 Reference Standard – Nil
The CONTRACTOR shall submit the Installation procedure of markers along with
activity report / record and inspection test plan compatible to this specification
at least one week prior to commencement of the work for approval of
TGPL/TPIA.
4. GENERAL REQUIREMENTS
4.1 CONTRACTOR shall supply, fabricate and install the Pipeline Markers along the
pipeline route. The locations of markers shall be based on AS BUILT chainage and
as directed by TGPL / TPIA.
4.2 The pipeline markers shall be fabricated and installed in accordance with the
standard drawings. Before start of fabrication of the markers, CONTRACTOR shall
prepare and submit for TGPL/TPIA approval the detailed scheme for the marker
plates as applicable for the project.
The pipeline markers shall be installed, as far as possible, at locations such that
no hindrance is caused to the regular uses of the land or to the traffic.
5. DIRECTION AERIAL MARKERS
Direction Aerial markers shall be installed along the pipeline route at every 5 Km
intervals and or at places specified by TGPL/TPIA as per Ref. Drg. No.
TGPL/E&P/STEEL/MARKER/02.
Aerial markers shall be installed at 1000 mm to the left of the pipe centreline
viewing towards the direction of flow.
6. KILOMETER MARKERS
These shall in general be installed along the pipeline between the aerial markers
at every one-kilometre interval. These shall indicate cumulative distance in km
for the reference base station or as desired by TGPL / TPIA.
Page 14 of 109
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KILOMETER post shall be 1000 mm to the left of the pipe centreline viewing
towards the direction of flow and as directed by TGPL/TPIA as per Drg. No.
TGPL/E&P/STEEL/MARKER/01.
7. ROW BOUNDARY MARKERS (RCC)
Right-of-way boundary markers shall be fabricated and installed as per the
drawings at every 250 mtrs interval along the entire pipeline route. These shall
be installed on the side of the pipeline alignment to define the ROW boundary.
These shall also be installed at pipeline turning points to maintain the continuity
of the ROW limits. Refer Drg. No. TGPL/E&P/STEEL/MARKER/08.
8. PIPELINE WARNING SIGNS

Pipeline warning signs shall be installed at:
 National and state highways crossings 2 No.
 Other road crossings (Metalled Black Top) 2 No.
 Railway crossings 2 No.
 Minor water crossings (6 to 10 m width) 1 No.
 Major water crossings (more than 10 m width) 2 No.
 Major water crossings (Navigable) 2 No.
 Valve station 1 No.
 Cased crossings 2 No.
 Other pipeline crossing Marker 1 No
And any other location as shown in the approved drawings and as directed by the
TGPL / TPIA.
Pipeline warning signs shall identify the existence of the pipeline and display the
name of the OWNER with an emergency telephone, and a Warning - “High
Pressure Gas Line, Dial before Digging” etc. as per standard documented drawing
Drg.No. TGPL/ E&P/STEEL/MARKER/03.
Warning sign shall be installed to the left of the pipeline center viewing in the
direction of flow at 1000 mm from pipeline.
Page 15 of 109
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9. NAVIGATION WATERWAY PIPELINE CROSSING WARNING SIGN
Navigable Waterway pipeline crossing warning sign shall be installed at both

bank of navigable watercourses where pipeline is crossing, in lieu of the pipeline
warning signs. Refer Drg. No. TGPL/E&P/STEEL/MARKER/07.
Painting and stencilling for all the aforesaid shall be done as indicated in
respective standards.
10. DOCUMENTATION
Quality records
 Marker Installation Reports

 Inspection & Test Plan
Page 16 of 109
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9.0 Specification for Concrete Coating
Page 17 of 109
DEC-2018
TABLE OF CONTENTS
1.0 SCOPE
4.0 MATERIALS & EQUIPMENT REQUIREMENTS
5.0 APPLICATION PROCEDURE
6.0 INSPECTION AND TESTS
7.0 COATING OF FIELD WELDS
8.0 REPAIRS
9.0 MARKING, PROTECTION, STORAGE, TRANSPORTATION, UNLOADING, HAULING
AND HANDLING
10.0 DOCUMENTATION
Page 18 of 109
DEC-2018
1. SCOPE
1.1 This specification covers the minimum requirements for the materials,
application, inspection, handling and other activities for external continuous
concrete weight coating of pipelines.
1.2 It shall be read in conjunction with the conditions of all specifications and
documents included in the contract between TGPL and Contractor.
1.3 Contractor shall, with care and diligence, execute the work in compliance with all
laws, by-laws, ordinances, regulations, etc. and provide all services and labor,
inclusive of supervision thereof, all materials, excluding the materials indicated as
Owner supplied materials in the Contract, equipment, appliances or other things
of whatsoever nature required in or about the execution of the work, whether of
a temporary or permanent nature.
1.4 Unless otherwise specified, all sections of this specification shall apply to all the
specification referred in this specification.

IS-269: Indian Standard Specification for ordinary and Low Heat Portland Cement.
IS-8112: Indian Standard Specification for High Strength Ordinary Portland
cement.
IS-383: Indian Standard Specification for Coarse and Fine Aggregates from
Natural Sources for Concrete.
IS-2386 (Parts I to VIII): Indian Standard Methods of Test for Aggregates for
Concrete.
ASTM A-185: Welded Steel Wire Fabric for Concrete Reinforcement.
ASTM C-642: Specific Gravity, Absorption and Voids in Hardened Concrete.
ASTM C-138: Unit Weight, Yield and Air Content of Concrete.
ASTM C-309: Liquid Membrane Forming Components for Curing Concrete.
ASTM A-82: Specification for Steel Wire, plain, for concrete Reinforcement.
ASTM C-39: Compressive Strength of Cylindrical concrete specimens.
ASTM C – 641: Zinc Coated (Galvanized) carbon steel wire.
Page 19 of 109
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2.2 Reference Standard - Nil
In case of conflict between the requirements of this specification and that of the
above referred codes and standards, the requirements of this specification shall
govern.
The Contractor shall submit the Concrete Coating procedure along with quality
records and inspection test plan compatible to this specification (Refer Annexure
II) at least one week prior to commencement of work for approval of TGPL / TPIA.
4. MATERIALS & EQUIPMENT REQUIREMENTS
The Contractor shall supply all the materials and equipment necessary for the
performance of the work.
Materials for concrete coating shall comply with following requirements. All
materials supplied by the Contractor, which in the opinion of TPIA / TGPL, do not
comply with the appropriate specifications shall be rejected and immediately
removed from site by Contractor at his expense.
4.1 CEMENT
Portland Cement (conforming to IS-269), or High Strength Ordinary Portland
Cement (Conforming to IS-8112) shall be used. Cement which has hardened or
partially set or which has become lumpy shall not be used. Test certificates from
the cement Manufacturer shall be supplied to the TPIA / TGPL for all cement
delivered to site.
4.2 AGGREGATES
Aggregates shall comply with the requirements of IS:383 and shall be tested in
accordance with IS:2386.
Fine Aggregates
Fine aggregates shall mean any of the following, as defined in IS: 383:
a) Natural sand;
b) Crushed stone sand;
c) Crushed gravel sand;
Sand shall be well-graded from fine to coarse in accordance with table 4 of IS:383
Coarse Aggregates
Use of coarse aggregates shall be subjected to TPIA/TGPL approval.
Aggregates shall be clean and free from injurious amounts of salt, alkali,
deterious substances or organic impurities.
Page 20 of 109
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4.3 WATER
The water shall preferably be limpid, fresh and clean and shall be free from
injurious amounts of oils, acids, alkalis, salts, sugar, organic materials or other
substances that may be deterious to concrete or steel. It shall not contain
chlorides, sulphates, and magnesium salts. Water from doubtful sources shall be
tested by the Contractor at his expense and approved by TPIA/TGPL before use.
4.4 REINFORCEMENT
Concrete coating shall be reinforced by a layer or layers of steel reinforcement
according to the provisions described here after.
Reinforcement shall consist of welded steel wire fabric manufactured in flat
sheets or in rolls (ribbon mesh) and shall conform ASTM A-185. Wires shall
conform to ASTM A-82.
Steel wires shall be galvanized at finished size as per ASTM A - 641. The
diameter of the wire and spacing of wires (mesh dimensions) shall be selected
according to the following criteria.
Wire fabric manufactured in rolls (ribbon mesh) shall be 1 x 2.5 inches of 14
gauge U.S. Steel wires (2 mm wire). The above dimensions will be applied unless
otherwise specified by designs. Ribbon mesh (rolls) shall be used when concrete
coating is applied by impingement method.
4.5 COATING
Pipes shall be concrete coated to a thickness as specified in the drawings and
documents. The concrete unit weight shall be minimum 2245 kg/cm 3 (140
pounds per cubic foot) and the compressive strength shall not be less than 200
kg/cm2 in 28 days and 140 kg/cm2 in 7 days. Concrete coating shape shall be
circular and concentric to pipe outside diameter. Other concrete coating shapes
are not acceptable.
Contractor shall be permitted to select any proportion of materials to achieve the
specified requirements of concrete density and weight.
4.6 EQUIPMENT
The equipment used for performing the concrete coating shall be capable of
doing so with a reasonable degree of uniformity with respect to thickness,
Page 21 of 109
DEC-2018
density and strength. The proportioning equipment and procedure shall be of the
type to assure consistently proportioned materials by weight. Concrete shall be
mixed in a mechanical mixer, which shall ensure thorough mixing of all materials.
Any equipment that tends to separate the ingredients shall not be used.
5. APPLICATION PROCEDURE
5.1 PROCEDURE QUALIFICATION
Before commencement of the work, Contractor shall perform all tests, either in
laboratory or in field and trials necessary to properly select type of mix, which
meets the requirements of section 4.5 of this specification.
5.1.1 The type of mix, i.e. the correct combination of the cement, aggregates and
water which results in the desired properties of concrete shall be at first
determined. For each mix the following shall be accurately checked and
recorded:
 Proportions and weights of the respective materials used;
 The water / cement ratio;
 The grading of the aggregates.
Samples shall be prepared and tested in accordance with ASTM C-642 to
determine the dry specific gravity of the concrete.
In parallel, test according to ASTM C-138 shall be performed so as to determine
the expected correlation between concrete weight after placing and dry specific
gravity (28 days after placing).
 Test for concrete specific gravity at intermediate time (7 days after coating)
shall be performed.
 When the results of the above tests do not meet the requirements, the mix
shall be modified and concrete samples tested until a proper mix has been
determined.
 The mix so determined, shall then be used for sampling of concrete to be
submitted to compressive strength tests as per ASTM C39.
 Frequency of sampling for tests for density and compressive strength of
concrete shall be as follows:
 “Quantity” of Concrete in the Work Number of Samples
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Up to 25 m3 03
26 to 50 m3 04
3
51 m and above 04
Plus one additional sample for each additional 50 M3 or part thereof.
Quantity means the volume of concrete to be used for each qualified mix.
5.2 APPLICATION METHOD

Concrete coating shall be applied using impingement method. Any alteration or
modifications to the methods described in this specification shall be submitted to
the TPIA/TGPL for approval. The application method shall however ensure the
basis characteristics of concrete coating in compliance with the minimum
requirements of this specification.
Contractor shall submit to the Company, prior to commencement of work, the
procedure/method of application for approval.
Wherever practical, the total thickness of coating shall be applied in a single pass.
5.3 APPLICATION OF REINFORCEMENT AND CONCRETE COATING
Two test cubs each per day shall be obtained from batches and tested after
end of 7 days after coating, for compressive strength and specific gravity.
The moisture content of the aggregates used shall be such as to maintain a
satisfactory control on the water / cement ratio of the concrete mix.
To maintain the water / cement ratio constant at its correct value, determination
of moisture contents in both fine and coarse (if used) aggregates shall be made
as frequently as possible, the frequency for a given job being determined by the
TPIA/TGPL according to weather conditions.
5.3.1 Pipe Length Preparation
Prior to placing of reinforcement, the protective coating of each pipe length shall
be carefully inspected visually and by holiday detectors and, if damages are
found, they shall be repaired before start of the work. Foreign matters, if any,
shall be removed from the surface of the protective coating.
5.3.2 Reinforcement Application
Reinforcement shall be placed around the pipe in such a way as to cover the
whole pipe length or sections to be concrete coated. In areas where concrete
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coating of girth weld joints shall be required. The reinforcement shall protrude a
minimum 50 mm from the finished concrete coating.
Reinforcement shall rest on synthetic resin spacers forming a “Crown” whose
number shall be such as to avoid any contact with the pipe’s protective coating.
Spacing between the two consecutive “crown” centers, shall be 500 to 1000 mm.
Splices and attachments shall be done by binding with steel wire having 1.5
mm diameter. Circular and longitudinal joints of wire fabric in sheets shall be
lapped at least for one mesh while the spliced lap shall be three meshes.
One layer of reinforcement steel shall be provided for concrete thickness less
than 50 mm. The reinforcing steel shall be embedded approximately midway in
the concrete coating thickness. For concrete thickness 50 mm and above two
layers of reinforcing steel shall be provided. If application method requires more
than one pass concrete, one reinforcement layer for each pass concrete is to be
applied independently from concrete coating thickness.
5.3.3 Concrete Placing.

Concrete shall be placed within a maximum of 30 minutes from the time of
mixing (adding water to mix) and shall be handled in such a way so as to prevent
aggregate segregation and excessive moisture loss. Concrete containers shall
continuously be kept clean and free from hardened or partially hardened
concrete.
In impingement method, placement of concrete shall be upto the specified
thickness in one continuous course, allowance being made for splices of
reinforcement and providing reinforcement in the right location.
No passes shall be stopped for more than 30 minutes. Before placing fresh
concrete against the joint, the contact surfaces shall be carefully cleaned and
wetted to obtain a good bond between the fresh material and the previously
placed material.
Suitable means shall be provided to ensure that the temperature of the
concrete, when placed, does not exceed 320C.
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All pipes shall be kept clean and free from cement concrete and grout either
inside or outside of the uncoated sections.
 Bevel protectors shall be kept in place throughout the coating application and
after.
 The coating at each end of the pipe shall be bevelled to a slope of
approximately two-to-one (2:1). It shall terminate about 50 mm short of the
end of the corrosion coating applied on the pipe surface.
5.3.4 Curing
Immediately after concreting, the exposed surfaces of the concrete shall be
protected during hardening from the effects of sunshine, drying winds, rain, etc.
and then after the initial set has taken places, the concrete coating shall be
properly cured. The coated pipe sections shall be handled gently by suitable
means to prevent undue distortion.
Curing shall be started after completion of initial setting time of cement or
after hardening of surface or as instructed by TPIA /TGPL. The pipe surface shall
be kept wet during daylight hours for seven days after application of the concrete
coating. The concrete coating shall not be allowed to dehydrate. Prior approval
of “TPIA/TGPL” shall be taken by Contractor for using admixture/chemical in
concrete mix, in order to increase / decrease setting time, strength of concrete
mortar.
Before handling and hauling the concrete coated pipes, a check shall be made
to make sure that the concrete coating is properly cured. Stacking and shipment
of the coated pipes shall be initiated only after seven days provided that the
concrete coating suffers no damage.
6. INSPECTION AND TESTS
6.1 After curing, every length of concrete coated pipe shall be non-destructively
tested by means such as “ringing” to determine if any suspected defects are
present. In case this indicates faulty coating, cores shall be removed from coating
and inspected. When defective coating, appears from cores, the concrete coating
shall be removed from the pipe lengths.
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6.2 Every length of concrete coated pipe shall be checked to verify insulation
between steel reinforcement and pipe by means of a megger or equivalent
device. To this purpose provisions shall be made during placing of concrete such
as to leave at least a point of exposed steel reinforcement whenever the latter
shall terminate inside of concrete coating.
6.3 During the tests as per clause 6.2 above, and before transporting of concrete
coated pipes, every length shall be visually inspected to detect whether any
damages and/or defects are present. Possible damages and/or defects with their
allowable limits are described in clause 8.0. Repairable Concrete coatings shall be
clearly marked while the non-repairable ones shall be removed from the pipe
length
7. COATING OF FIELD WELDS

7.1 The Contractor shall coat the uncoated pipe surface at field welds in accordance
with methods approved by TPIA/TGPL. Contractor shall submit a detailed
procedure for field joint concrete coating for TPIA/TGPL approval.
7.2 The reinforcement for the field welds shall be same as that for line pipe coating
with the same number of layers and the same space between layers as for the
existing coating. The edges of this netting must be carefully secured with
galvanized wire to the reinforcement extending from the existing coating.
The reinforcement shall not make direct of electrical contract with the pipe.
Synthetic resin spacer blocks or equivalent shall be used to keep the
reinforcement free from the pipe coating. The Contractor shall supply the moulds
used for applying the concrete coating.
7.3 The composition of the concrete shall be the same as that of the concrete
coating of the pipe.
When using moulds, the Contractor shall prevent air being trapped by applying
mechanical vibrators or by striking the outside of the moulds with sticks or
equivalent.
7.4 If the moulds remain around the pipe, e.g. in the case of submerged pipes floated
into position, the Contractor shall take appropriate measures to prevent too
much water entering the mould. This can be achieved by clamping strips of
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burlap between the ends of the mould and the existing concrete coating. After
the mould has been filled with concrete the filling opening must also be closed
off by clamping a strip of burlap under the sealing cover.
8. REPAIRS
The following are repairs that will be permitted to coating due to unavoidable
damage in handling and in storage (This applies only to concrete that has
hardened).
8.1 Spelling due to compression or shearing caused by impact against other object.
Spelling is defined as damage, which causes a loss in concrete of more than 25
percent of the total thickness of the coating at the point of damage.
8.2 Damage due to spelling of an area of less than 0.1 m2 (1 square foot) where the
remaining concrete is sound will be accepted without repairs.
8.3 Damage due to spelling of an area of more than 0.1 m2 and less than 0.3 m2 shall
have the concrete remaining in place over that area removed as necessary to
expose the reinforcing steel throughout the damaged area. Edges of the spelled
area shall be under-cut so as to provide a key lock for the repair material. A stiff
mixture of cement, water and aggregate shall be trowelled into and through the
reinforcement and built up until the surface is level with the coating around the
repair. The pipe shall then be carefully laid with the repaired area at the top and
shall be moist cured for a minimum of thirty-six (36) hours before further
handling.
8.4 If damaged area be more than 0.3 m2, coating shall be removed around the
entire damaged area. A repair shall be made by satisfactorily restoring the
reinforcement, forming the area with a metal form and pouring a complete
replacement of materials similar to that from which the coating was made. The
mixture shall be one (1) part of cement to three (3) parts of aggregate and
necessary water to produce a slump not to exceed 100 mm (four inches). The
resulting coating shall be equal in weight, density, uniformity, thickness, strength
and characteristics to the originally applied coating. The pipe shall then be
carefully laid in a position where it shall be allowed to remain for a minimum of
36 hours before further handling.
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9. MARKING, PROTECTION, STORAGE, TRANSPORTATION, UNLOADING, HAULING

AND HANDLING
9.1 MARKING
Every concrete coated pipe length shall be clearly marked by a suitable type of
paint (i.e. red and / or white lead paint). Markings out of concrete coating shall
be made inside of pipe close to bevel end, in such a way that the area involved by
welding operations is not affected by paint.
For each concrete coated pipe length, at one of the two ends, the field
identification number and the date of concrete placing shall be marked, while the
dry as well as the wet weight along with number of days after coating shall be
marked at the other end.
9.2 STORAGE & PROTECTION
Materials other than pipes and which are susceptible of deteriorating or
suffering from damages especially due to humidity or other adverse weather
conditions shall be suitably stored and protected.
Pipe Stacks shall consist of a limited number of layers such that the pressure
exercised by the pipes own weight does not cause damages to coating. Stacking
with more number of layers shall be agreed upon with the TPIA/TGPL provided
that each pipe section is separated by means of spacers suitably spaced so as to
avoid stresses and compressed points of contact on the coated surfaces.
During loading, transport, unloading and hauling of inert aggregates, any
contact and mixing with mud, earth, grease and any other foreign materials shall
be carefully avoided. Precautions shall be taken to prevent contamination to
maintain the cleanliness and against effects of hot or cold weather or other
adverse climate condition.
9.3 TRANSPORTATION, UNLOADING & HANDLING
Once the pipe sections have been taken in charge, the Contractor complying
with provisions of the contract, shall execute their transport together with other
material, either supplied by him or by the TPIA/TGPL, from the site of receipt to
the coating yard and after concrete coating completion and acceptance, to
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delivery point at laying field or storage areas as previously established. Thus,
providing each time the necessary storage.
During the operations of loading, unloading and stock piling, the pipe sections
shall be handled in such a way so as to avoid dents, cuts, cracks and other
damages especially at bevelled ends or damages to protective and/or concrete
coating.
10. DOCUMENTATION
The CONTRACTOR shall submit following as minimum.
 Test Certificates
 Quality records
 Procedure of concrete Coating
 Concrete coating report
 Inspection and test plan
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TABLE OF CONTENTS
1.0 INTRODUCTION
2.0 Quality Goals, Objectives and Critical Success Factors
3.0 Quality Management Organization and Responsibilities
4.0 SUBMITAL BY CONTRACTOR
5.0 QUALITY ASSURANCE SYSTEM REQUIREMENTS: ANNEXURE – I
1.0 QUALITY ASSURANCE / DEPARTMENTAL ACTIVITY CONTROL MANUAL
1.2.1 General:
1.2.2 Procurement:
1.2.3 Procedure:
1.2.4 Construction:
1.2.5 Pre Commissioning activity:
2.0 QUALITY PLAN:
2.1 For Procurement and Construction:
2.2 For Pre-commissioning:
ANNEXURE – II
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1. INTRODUCTION
1.1 This specification establishes the Quality Assurance requirements to be met by
the CONTRACTOR during execution of work. In case of any conflict between the
requirements of this specification and other documents such as technical
specifications, contract conditions etc. and the latter shall generally take
precedence. The CONTRACTOR shall notify TPIA of all such conflicts for final
resolution.
1.2 Requirements stipulated in this specification conform to ISO: 9000, 9001, 9002,
9003 and 9004.
1.3 Quality Goals, Objectives and Critical Success Factors
2. Goal:
To generate and maintain an overarching culture of quality throughout all project
activities conducted within Project Management Team and the associated
contractors and suppliers.
Objective:
 To undertake all Quality assurance inspections in accordance with the Quality
Assurance Plan
 To close out all non-conformances on procured items prior to deliver
 To close out all non-conformances within PMT and Contractors’ Project
(Quality) Management Systems
 To complete the Third Party Verification Scheme, documenting that all
performance standards have been met, prior to start of commissioning
 Quality Critical Success Factors:
 To apply the ‘Plan – Do – Check – Act’ cycle of quality management to all
aspects of the project, including undertaking suitable quality assurance
inspections of the PMT and of principal contractors and subcontractors, and
conducting QC surveillance of contractors’ own QC activities based on
criticality of the product
 To provide suitable numbers of QA/QC personnel to ensure that the quality of
the project processes followed and all project deliverables is suitable
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 To maintain management support of the Quality Management Process,
including rigorously supporting the Quality Assurance function and
maintaining the pressure for closure of non-conformances
 To co-ordinate and proactively drive the Third Party Verification Scheme to
completion.
3. Quality Management Organization and Responsibilities
A. Project Quality Plan.
Material Supplied by Contractor

1. QAP approvals : TGPL/TPI
2. In process inspection : Contractor /TGPL/ TPI
3. Review Material test certificate : Contractor /TGPL/ TPI
4. Material test certificates review & Accept : TPI
5. Recording of Material identification number : Contractor – TPI
6. Acceptance of test result of Material : TPI

Construction
1. QAP approvals : TGPL/TPI
2. Preparing of standards operating procedure : Contractor
3. Review and approvals of SOP : TPI – TGPL
4. Procedure Qualification : Contractor
5. In process inspection : Contractor – TPI
6. Monitoring Quality of in process inspection : TGPL/TPI
7. Corrective and preventive action for Non-Conformance : Contractor
8. Pipeline Strength testing approvals : Contractor
9. Installation of special equipment as per P&ID : Contractor
10. Ensuring functional test of all the installed equipment : TGPL
B. Contractors' key quality and verification personnel;
1. Project /Construction Manager
2. Site supervisors
3. QA / QC Manager with ASNT level II Certification
4. ASNT level II technicians
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C. Sharing quality related information:
1. Electrode qualification test result : Contractor to TPI and TGPL
2. Welding Qualification test result : Contractor to TPI and TGPL
3. Field joint coating procedure qualification records: Contractor to TPI and TGPL
4. Welder performance reports : Contractor to TPI and TGPL
5. Repetitive quality non-conformance and corrective actions: TPI to TGPL
6. Measuring instruments calibration requirements: TPI to contractor
7. Line pipe coating damage / holiday report : Contractor to TPI and TGPL
8. In adequacy in activity reports : TGPL and TPI to Contractor
4. SUBMITAL BY CONTRACTOR
The following documents shall be submitted along with the bid for evaluation.
4.1 Quality Assurance plan and /or Departmental Activity Control procedure l.
A. Quality Plans
Guidelines to Bidder for coverage of above documents are given in Annexure-I.

Performa for Quality plan shall be submitted by bidder & approved by TPIA/TGPL.
B. After the award of contract (Prior to start of job):
The CONTRACTOR shall obtain approval on his Quality Assurance plan and / or
Department activity control procedure and Quality Plans. The Contractor shall
participate in the kick-off meeting with TPIA to finalize “Quality Plans “as regards
to the following:
a. Standard practices specified by the Contractor.
b. Hold (witness), Random check (verification) and Review point.

c. TPIA review / audit requirements.
C. During job execution:
a. Implement approved Quality Assurance Program including but not limited to:
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Performance of internal quality audits, preparation of audit reports
and submission for TPIA’s review.
Generation of Q. A. records (mostly inspection and test plans) as per

Quality Plan and submission for TPIA’s review.
b. Facilitate TPIA in the quality audit at his works.
c. Certify “QA Program” documents of Sub-Contractor and submission to TPIA

for review.
d. Carry out audits / inspection at Sub-Contractor’s works as per approved QA

Program and submits the reports for TPIA’s review.
e. Team Qualitative Record
5. QUALITY ASSURANCE SYSTEM REQUIREMENTS:
5.1 Requirements stipulated in this specification shall be fulfilled by the Contractor /

Sub-Contractor. All other features of QA system (not specified here in) shall be
in-line-with any of the following standards (latest revisions).
IS : 10201
ISO :9000, 9001, 9002, 9003, and 9004
ANSI/ASQC :Q90, Q91, Q93, and Q94
5.2 The CONTRACTOR shall ensure that the quality system is clearly understood and
faithfully implemented at all levels in his organization.
5.3 The CONTRACTOR shall develop quality consciousness among all personnel
working for the contract.
5.4 Non-conformance Handling (Internal Sources):
Non-conformances brought out by Contractors’ / Sub-Contractor’s own review /
audit shall be resolved by Contractors’ / Sub-Contractor’s themselves. One level
higher than those responsible to carry out the activity shall resolve the non-
conformities. Such resolution shall be in full knowledge of Departmental
Manager. Corrective action shall be initiated at the earliest. Report of such
resolution shall be submitted to TPIA for satisfaction of the quality.
5.5 Non-conformance Handling (External Sources):
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Non-conformance brought out by TPIA or its engaged agencies through any of
the following but not limited to:
Technical Reviews
QA Reviews and Surveillance
Inspection and External Audit (TPIA)
Corrective Action Report (CAR)
NC shall be resolved by the Contractor / Sub-Contractor. Such corrective actions
shall be submitted to TPIA for review. However, corrective action shall be
implemented within weekdays.
5.6 The CONTRACTOR shall evolve a comprehensive system of planned and
documented audit to verify whether various performed activities comply with
detailed procedures, specifications, guidelines etc., and to determine the
effectiveness of Quality System. Scope of such internal audits shall be furnished
to TPIA for review.
5.6.1 Verifiable documents shall be generated during audit and submitted periodically
to TPIA for review. Audits shall be carried out by independent engineers not
responsible for execution of the activity to be audited. Whenever so desired,
TPIA may join in the above audit as observer.
5.7 Throughout all stages of the scope of contract, the Contractor’s procedures,
documents, activities, products and services and those of his Sub-Contractor’s
shall be subjected to Quality surveillance and audit by TPIA. Such surveillance and
audit are optional and shall not relieve the Contractor of his contractual
obligations and liabilities.
5.8 The CONTRACTOR shall submit all quality records (generated during activity
execution) and audit results on well-laid formats / Proforma for TPIA review. The
rights of such review are reserved by TPIA. TPIA may review it in full, parts or
selectively. However, complete correctness of the QA records shall be the sole
responsibility of the Contractor irrespective of its review by TPIA.
5.9 The CONTRACTOR shall get similar QA System implemented at his Sub-
Contractor’s works/office. Q A records from the sub-Contractor shall be reviewed
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and certified for compliance by the Contractor before submitting to TPIA for
information.
5.9.1 CONTRACTOR shall carry out audits at Sub-Contractor’s office / works and shall
submit the report to TPIA for information. Whenever so desired, TPIA shall have
accessibility to Sub-Contractor’s offices/works.
5.10 All personnel shall be assigned tasks commensurate with their qualification &
experience. Specialized operators shall be qualified and certified.
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ANNEXURE – I
GUIDELINES TO BIDDERS FOR COVERAGE OF DOCUMENTS
1. QUALITY ASSURANCE / DEPARTMENTAL ACTIVITY CONTROL MANUAL
1.1 This document is applicable to all the contracted activities performed at

Contractor’s / Sub-Contractor’s works / office. The document shall cover the
following:
Company Organizational Structure, including Q. A. Organization Structure.
Personnel responsibilities (as regards QA)
Various operational procedures*
*These procedures are not required to be submitted along with the bid.
1.2 The Contractor shall implement these procedures and maintain them in
auditable formats such that these are available for TPIA review any time during
the job execution. Given below is the list of some important procedures. The list
is not exhaustive / complete and does not mean to limit all the procedures
required for the job execution.
1.2.1 General:
Document control
Non-conformance resolution
Output identification and traceability
Internal audit
1.2.2 Procurement:
Vendor short listing

Manufacturing / fabrication process control
Preservation
Transportation
1.2.3 Procedure:
Activity Procedure / or Method, along with daily Progress / inspection Reports

shall be prepared for Checking, review and approval:
WPS/PQR
Clearing, Grading of Right of Way.
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Handling & storage of Materials.
Stringing of line pipes.
Trenching.
Cold field bending.
Concrete coating.
Cased crossing.
Open cut crossing.
Lowering.
Main line welding.
Weld joint numbering.
Weld repair.
Post heat treatment
Radiography.
Dye penetration test.
Ultrasonic test.
Tie in welding.
Field joint coating pipe to pipe and pipe to bends / tee.
Field joint repair.
Back filling.
Minor water crossing.
Pre hydro-testing
Hydro-testing Dewatering
Marker installation
Cleaning, swabbing and drying
Special installation (SV’s, Pig Launcher & Receiver, Metering skid, Hook-up
fabrication)
Restoration
Painting of above ground piping
Pre-commissioning
Reconciliation
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Inspection / Test plans for all specific and mandatory tests (as per drawings and
codes) with clear indication of witness, verification and hold points shall be
submitted along with relevant procedures.
1.2.4 Construction:
Pre-construction activities viz., incoming material control, Approval of
procedures and process etc.
Storage and identification of Received materials
Certifications and approval of Contractor supplied materials
Calibration certificates of Instruments
Approval of Construction drawing for crossings
Welding qualification and repair
Waste Management
1.2.5 Pre Commissioning activity:
Swabbing and Drying

All Inspection and Test Plans are required to be submitted for finalization and
approval by TPIA immediately after award of the contract (before kick-off
meeting).
2. QUALITY PLAN:
These documents (mostly in tabular formats) define the specific quality practices
and flow of every identifiable activity of a Contractor. The entire scope as per
the bid package is covered. These plans must tentatively indicate:
2.1 For Procurement and Construction:
Activity description.
Procedure number / Inspection and Test Plan number.
Conformance code.
Testing and inspection code.
Type of surveillance.
Internal audit scope.
2.2 For Pre-commissioning:
Activity Description
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Procedure / Inspection and Test plan number
Type of Surveillance.
Internal audit scope
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ANNEXURE – II
GLOSSARY OF TERMS USED IN THE SPECIFICATION
1. WITNESS POINT
1.1 An activity designed by TPIA, which requires witnessing by TPIA as the activity be
performed.
1.2 After proper notification has been provided (notification modalities and period
shall be communicated in kick-off meeting) the Contractor is not obliged to hold
further processing if TPIA is not available to witness the activity or does not
provide comments before the date notified. Basis of acceptance shall be as per
relevant technical specification.
2. VERIFICATION POINT
2.1 Point where TPIA plans to audit, monitor or witness an in-process activity.
2.2 Basis of acceptance shall be as per relevant technical specification.
3. REVIEW DOCUMENT POINT
3.1 “Review” means checking, identifying & certification of the documents for
conformance of standards & specifications.
3.2 A point, at which Contractor requires verification and acceptance from

TGPL/TPIA for further processing.
3.3 The Contractor shall not process the activity / item beyond a review point,
without written approval by TPIA except where prior written permission for
further processing is available.
4. QUALITY SURVEILLANCE
4.1 Monitoring or making observations to verify whether or not material items or

services conform to specified requirements. Surveillance activities may include
audit, inspections, witness of testing, review of Quality documentation,
personnel qualifications etc.
5. Q. A. RECORDS:
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5.1 Documents which demonstrate achievement of required quality and verify
effective operation of Quality System, viz., but not limited to:
Inspection reports (All Construction activities)
Test data / inspection test plans
Qualification reports
Validation reports
Audit reports
Material Test Certificates
Calibration Reports
Quality cost report
Pipe Book
Rework/ Rejection Report
6. QUALITY AUDIT:
6.1 A systematic examination of the acts and decisions by people with respect to
quality in order to independently verify or evaluate and report degree of
compliance to the operational requirements of the quality Program, or the
specifications or contract requirements of the product or service.
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11. SPECIFICATION FOR HDD
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TABLE OF CONTENTS
1.0 Scope
2.0 References
3.0 Specifications
4.0 Design and Engineering
5.0 Installation Procedure
6.0 Drilling profile
7.0 Bentonite Disposal Scheme
8.0 Rights of way and work space
9.0 Rights of way
10.0 Quality and Inspection Plan
11.0 Pre Reaming Operation
12.0 Pipe line Installation Operations
13.0 Inspection and Testing
14.0 Special Instructions
15.0 As-built records
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1. SCOPE
The specification covers the minimum requirements of various activities to be
carried out by the Contractor for engineering and “Laying of Pipeline through
Horizontal Directional Drilling” under the contract.
2. References
2.1 SPECIFICATIONS AND CALCULATION:

 ASME- B 31.8
 PNGRB Technical standard
 API RP 1102
2.2 LAWS - CODES - RULES & STANDARDS
 Basically, the following is applicable
 Basic Laws - Codes - Rules & Standards, mandatory by law in the country
concerned. Specification for HDD as amended from time to time
 Peculiar Codes & Standards as per Section 2.3.
 The "Rules of good Practice" commonly used by the world-wide gas industry;
 The "Rules of Art" and "Sound Practices" of the Engineer.
 In general, the HDD has to be built in accordance with the best states of
Engineering practice.
In case of contradiction, the above shall prevail in descending order of
precedence.
2.3 PECULIAR CODES & STANDARDS

The Codes - Rules and Standards applicable in specific cases are provided in
tender document TENDER DOCUMENT.
Except if otherwise specified TENDER DOCUMENT elsewhere in the tender
document, the following shall serve as basis:
 ASME B.31.8 "Gas Transmission and Distribution Piping Systems" - Last edition
and all Codes it refers to.
 Codes - Rules and Standards that are already mandatory as per regulatory
authority. In case of contradiction, the most stringent of the above shall be
applied.
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3. Specifications
 Pipeline Size = Different thickness as mentioned in specification
 Pipeline Material = Specifications as mentioned in specification
 Anti-Corrosion Coating = Specifications as mentioned in specification
 Joint Coating= For HDD Joint Coating fibre glass reinforced heat shrinkable
sleeve certified to Stress class C60 type CANUSA-TBK or COVALENCE / DlRAX
shall be used. Directional drilling kit, multilayer sleeve system or equivalent
to be approved by Owner / Engineer.
4. Design and Engineering
INTRODUCTION
The following calculations shall be done and examine the stress imposed on a
pipeline during the installation of a horizontal directionally drilled crossing prior
to pullback during pullback and post installation to confirm that the pipeline will
not fail.
The calculations are based on the following:
 Pipe empty on conveyors
 Pipe full of water on conveyors
 Pipe Pull back- empty
The following stresses are considered

 Spanning Stress
 Curvature Stress
 Pulling Forces
 External Pressure
The pipe will be pulled empty.

PIPE & PROFILE DATA BASIS
PIPE WEIGHTS
STRESS ANALYSIS
Spanning Stress
Curvature Stress
Tensile Stress
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Hoop Stress
Stress summery
PERMISSIBLE OVERBURDEN
PULLING CAPACITY AND RIG CAPACITY

The contractor to consider the number of segments of HDD based on above
parameters, other mandatory requirement of Isolation valves as per alignment
sheets and concerned authority instructions, etc. in their proposed execution
methodology which shall be reviewed/approved by Owner/TPIA appointed by
Owner.
PIPELINE calculation
The Contractor will submit for approval to the Third Party Inspection agency the
stress calculation as described in the Deutsche standard NEN 3650 and NEN 3651
or equivalent.
The following phases should be analysed in the pipeline design process:
Predisposition of the launching catenary:
Before the pulling operation, the pipeline is outside the bore-hole and has a
configuration which allows it to enter the hole. During this phase, the only
bending moment is due to the curvature of the catenary and the weight. The
pipeline should be designed so that it behaves elastically.
Pull-back operation:
In this phase the pipeline will be pulled back through the bore-hole. The
following forces should be considered: bending moment due to curvature of the
hole; Friction force between the pipe and drilling mud including the friction due
to extra cables/sleeves attached to the string; Friction force inside the hole, at
the location where the soil reaction occurs; stress due to soil reaction; The
Contractor will specify the means he intends to use in order to reduce the friction
during the pull-back operation. The resultant stress should be calculated and the
pipeline designed to behave elastically.
Operating conditions:
In this phase the loads acting on the pipeline are:
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Bending moment due to curvature of the hole; internal pressure of the gas;
temperature difference of the line between the pipe-laying and operating
conditions; dead loads Vertical soil load at the top of the pipe can be calculated
for different pipe laying conditions.
The following effects should be combined for the purposes of calculating the
resultant stress:
calculated longitudinal effects on the entire pipeline system;
Calculated effects on the cross-section of the pipeline.
The stress/strain shall not exceed the relevant allowable stress. The effects of soil
load on the cross-section of the pipe may be analysed. This analysis should be
carried out at the deepest point reached in drilling.
5. Installation Procedure METHOD OF INSTALLATION

After a detailed study of the soil investigation of the River, the following
installation method has been formulated to provide a successful installation
using horizontal directional drilling.
Contractor proposes to execute this project titled “Installation of pipeline across
by Horizontal Directional Drilling Method” for TGPL LIMITED as detailed in the
following method of work.
Detailed Engineering Calculations
The ground profiles, soil investigation report, technical specifications and all
other relevant data were studied and the necessary calculations are done
ensuring the basic design requirements are satisfied. Required calculations are
enclosed which comprise the part of this package
Geological data
It is the responsibility of Contractor to proceed, at its costs, to any additional

surveys that it deems necessary.
Mobilization:
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Drilling Equipment shall be mobilized to site through access roads to Entry point
and Exit point. Necessary grading shall be done for the placement of pipe string
and drilling spread
The Contractor will supply with his tender the different documents listed here
below.
 Key staff organization chart.
 Curriculum vitae of his key staff
 A complete description of the anti-corrosion pipe wraps he intends to use for
pipeline field joints and repairs.
 A description of the major drilling equipment as
Drill rig specification
Maximum dynamic torque
Pull back capacity
Drilling fluid trailer tank specification
Control cab
Pipe racks
Workshop
Generators
Positioning system
Drilling head
Ancillary equipment.
A complete description of the directional drilling working method as: The
positioning record system and procedure Drilling of the pilot hole and wash over
pipe. Hearing operation (type and size of the reamer) Mix compound of the
bentonite mud.
Soil cuttings/Bentonite mud separation and treatment process and reuse of the
Bentonite.
Pipelines pull back operation.
Alignment and positioning of the pipe string.
Rollers support used. The support will be designed so as not to damage the pipe
coating. Detail drawing showing the theoretical profile, the final design profile,
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the position of the pipe string (with support arrangement) before pull back
operation
The method he intends to use for controlling the integrity of the pipeline coating
as well as "anticorrosion" pipe-wraps.
The method he intends to use for verification of the pipeline final profile after
the pull-back operations.
Installation of pipeline
Documents to be supplied by the contactor before and during the execution of

the HDD and after his completion
Before and during the HDD execution
Before starting the activity, the Contractor will submit for approval to the
Owner the final profile of the HDD including any deflexion of the drilling head.
The Contractor can start the operation only after the Owner approval.
This document needs to demonstrate that after completion (operating condition)
and under internal pressure (MOP and test pressure), soil load and hydrostatic
load the section of the pipeline will not have a radius of curvature smaller than
those permitted by the design.
The document shall also indicate the pulling force on the pipe at the beginning,
during and at the end of the process and the rate of progress of the pipe.
During the different execution phases of the HDD the Contractor will record
all the information regarding the different operations which includes, among
others:
The measurements of mud pressure, mud flow rate, pulling force, X-Y-Z of the
drill head recorded during drilling and any other relevant statistics.
Stand-off during operations and the reasons thereof
After the HDD execution
After completions of the HDD the Contractor will transmit to the Owner the
horizontal drilling operation record of the relevant activities which includes.
Concerning the drilling mud quantity of mud used; mud pressure (at the drilling)
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the density of the drilling fluid and soil cuttings;
The localisation of storage site for the waste from the drilling operation and the
measures taken to comply with environmental constraints.
During drilling operation (per drill pipe element) the maximum force applied
(push/pull/torque); time duration for assembling 2 elements; the drilling head
position in X-Y-Z- co-ordinates; deviation compared to the required position; The
proposed corrective measures.
During drill pipe pull-back (per drill pipe element) pull-back duration per
element;
Maximum pulling force per element.
 An alignment sheet with length profile of the pipeline (scale 1/500) showing
the location of each weld joint and their X-Y-Z co-ordinates.
 An official certificate concerning the discharge of the drilling operations
tailings approved by the relevant Authorities.
Pipeline installation is broadly categorized in this section.

Pipe string fabrication
Fabrication of line pipe, its NDT shall be under Contractor’s scope. Pull head shall
be welded on the pipe string after successful completion of hydro testing. Prior
to pulling operation, coating shall be done and check for coating damage shall be
made by means of holiday detector and if any damage reported shall be repaired
by coating repair material shall be done by Contractor.
HDD OPERATION
The following details the methodology of Horizontal Directional Drilling (HDD)
works.
HDD is a two-stage process. The first stage will consist of drilling a small diameter
pilot hole along a designated directional path. The second stage involves
enlarging this pilot hole to a diameter that will accommodate the carrier pipe and
pulling carrier pipe back into the enlarged hole.
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Pilot Hole
Rig up shall be done, after mobilizing the equipment at drill location. Rig shall be
anchored at the specified angle as per the approved drawing before start of pilot
hole with dead men in ground.
The pilot hole shall by drilled with a Horizontal Directional drilling rig, to enter
the ground at an angle of entry as specified in the drawings. Pilot hole directional
capability is accomplished by using a Drill Bit. The offset creates a steering bias in
its direction and plane. If a change in direction is required, the same will be done
by pushing drill string so that the direction of bias is the same as desired change
in direction.
Mechanical cutting action can be achieved by the bit attached to the offset drill
string.
The actual path of the pilot hole will be monitored by a state-of-art magnetic
guidance system (attached). The actual path of the pilot hole is monitored during
drilling by taking periodic readings of the inclination and azimuth of the leading
edge. These readings, in conjunction with measurements of the distance drilled
since the last survey, are used to calculate the horizontal and vertical co-
ordinates along the pilot hole relative to the initial entry point on the surface and
profile is plotted for the actual path being taken along the proposed alignment.
Readings are taken at every joint (normally a road length). When the bit
penetrates the surface at the exit point, the pilot hole is complete.
Ream and Pull Back
After the completion of pilot hole, depending on the drilled cuttings and actual
soil encountered during the pilot hole, combinations of Cutters /Reamers will be
used to enlarge the hole.
The Cutter / Reamer will be fixed to the drill string will be rotated and
pulled/pushed through the pilot hole. The cutter will cut through the hole with
the cutting action of bentonite pumped through the drill string. On completion of
first pass other Reamer (sizes may vary as per actual condition) shall be used to
enlarge the hole. Cleaning passes as required shall be done depending on the soil
conditions encountered. It is to be noted that the passes mentioned in the
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schedule are tentative and might change as per the soil conditions encountered
as per the pilot hole logs. It will be decided at the site to use various combination
of down hole tools as per the requirement by the Driller. Also the sizes of
Reamers/Cutters and sequences to use these can be varying as per actual site
conditions.
Once the cutting passes are complete a non-rotating swivel will be attached to
the pull head welded to the pipeline section to prevent torsional stress on the
pipeline. The drill string is aligned with the product pipe, upon completion of
hydro testing and field joint coating. An overhead bend will be formed by lifting
the product pipe to the correct height to allow smooth entry in the borehole. As
the pipeline section is drawn towards the drill rig the pipeline section will be
adequately cradled with rolling cradles IUM) to facilitate a stress free line-up with
the pre-reamed hole. Product pipe shall be placed on rollers to minimize the
friction during pulling.
Bentonite will be pumped during pullback. Bentonite slurry and returns from the
drilled hole shall be disposed off either in the river through the small ditch or in
the mud pit to be excavated at site. Bentonite to be used does not contain any
constituents hazardous to the environment. During drilling process check shall be
maintained to check the viscosity and mixing of mud shall be controlled as per
the soil conditions in countered. Upon reaching rig side, the final reamer and pull
back swivel are removed and the pulling head cut from in the product pipe. After
completion of pull back, the rig down shall be done and the equipment is
demobilized after clearing/cleaning the work area.
Drilling Accuracy
The instrument used to survey the pilot hole during drilling is magnetic and
therefore subject to some inaccuracy. Additionally, some deviation from the
designed drilled path may be experienced due to soil reaction. Therefore, we
generally anticipate a deviation in actual verses designed pilot hole course of +/-
0.5% of the horizontal and vertical directions drilled length. The error, when it is
unacceptable, can be largely eliminated by re drilling after "punch out" in the
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right of way limits. Best drilling standards shall be followed to minimize the
deflection as per the client’s requirements.
Performance of the down hole survey system is monitored during drilling by
diagnostic system which confirms the suitability of the transmitted signal.
Additionally, the accuracy of the surveyed hole can be determined by comparing
the actual exit point with the anticipated exit point. Any error measured in this
manner is then distributed linearly over the entire length of the pilot hole to
produce an accurate as built survey. Immediately after completion of pilot hole
reaming operation shall start without any delay.
5 Drilling profile
The Owner will provide a basic profile drawing and the constraints and
particularities of the obstacle to be crossed.
The Contractor shall specify and submit to the Owner for approval his final profile
and the different parameters or their limited value which define the location and
configuration of the drilled path.
These parameters are:

 entry point
 exit point
 entry angle
 exit angle
 PI elevation
 Radius of curvature.
It is acceptable that the entry and exit will vary from the design proposed
location. They have to be located inside an area (5 x 10 m) centred around the
proposed location, 10 m shall be measured parallel to the HDD alignment.
Except if otherwise specified in the tender document, the minimum radius shall
be not less than 1000 times the Nominal Diameter (ND). The predetermined
theoretical profile shall be closely adhered to when drilling the pilot hole. The
permitted deviation shall not exceed 2 m laterally and 1 m vertically from the
approved theoretical profile.
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6 Bentonite Disposal Scheme
Bentonite slurry and returns from the drilled hole shall be disposed off in the
mud pit to be excavated at site. Bentonite to be used does not contain any
constituents hazardous to the environment.
7 Rights of way and work space

Prior to any HDD activity or pipeline construction work the top soil will be
removed and The temporary access road to the work sites will be determined
jointly by the Owner and the Contractor and granted by the Owner.
The cost of improvement or execution of temporary accesses will be borne by

the Contractor.
8 Rights of way
The working space and the site location is specified in the TENDER DOCUMENT.
The right to use the specified working space will be granted by the Owner.
Should Contractor require more space, it will be Contractor's responsibility to
negotiate such additional space in close co-ordination with the Owner.
Contractor shall support all relevant costs.
9 Quality and Inspection Plan

Contractor will maintain Quality Assurance program for its Horizontal Directional
Drilling Activities based on the three major components of the technology. These
three components and the guidelines for Quality Assurance are detailed below as
follows:
Horizontal Survey Control
In order to assure proper horizontal and vertical alignment of the HDD crossing, a
computerized survey system is utilized. This survey system allows for real time
readings measured from a steering device located in the tip of the drill bit. Real
time readings are produced and generated back to a lap top computer operated
in the control room. A qualified steering tool technician operates this survey
equipment and assures that the drilled alignment is consistent with the proposed
profile provided in the engineering and design data. Quality Assurance is
maintained by plotting on the approved design profile the actual horizontal and
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vertical alignment taken at each road length intervals. The steering tool
technician is responsible for this Quality Assurance activity. This activity is
conducted during pilot hole installation.
10 Pre Reaming Operation

The Drilling Supervisor is responsible for the Quality Assurance activities
associated with the pre-ream operations. Pre-reaming refers to the process
where in the borehole is enlarged in a step-wise progression to enable the
installation of the carrier pipeline. It is the Driller’s responsibility to assure proper
drilling mud viscosity's, to ensure that the cuttings are being removed from the
drilled hole, and that a proper mud cake is lining the interior of the hole walls. It
is also the Driller’s responsibility to monitor the torque and pullback forces being
exerted by the drill rig during pre-reaming operations. Although a specific
standard does not exist, the Driller’s past experience and knowledge is the basis
for adjusting drilling mud viscosity as well as monitoring rig torque and pullback
forces.
11 Pipe line Installation Operations

Once the drilled hole has been enlarged and is ready to accept the pipe string,
pullback operations commence. Pullback operations refer to the process wherein
the pipe string is installed in the drilled hole utilizing the cranes/side booms and
pipe rollers to assure proper alignment and entry angle into the hole. It is the
Driller’s responsibility to ensure proper quantity of cranes/side booms and pipe
rollers are maintained and on the job site to complete this operation. The entry
angle is calculated and included as part of this engineering and design package. It
is the Driller’s responsibility to assure that this entry angle is maintained during
pullback operations. Once the pipeline has been successfully pulled into the
drilled hole, the pull head is removed from the pipe string.
After pulling the pipeline across the drilled crossing, CONTRACTOR shall cut the
extended portion of the pipeline at the entry and exit points. Thereafter, the
drilled portion of the pipeline shall be cut at suitable location/depth and
extended on either bank by installing a cold field bend with minimum bend
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radius of 40 times the pipe O.D. and a straight pipe of sufficient length, such that
at the ends the top of the pipeline is minimum 2.5 m below the natural ground
level.
The drill rig will be demobilized and the job site secured. These activities are also
a part of the Quality Assurance responsibilities of the Driller.
12 Inspection and Testing
Contractor will maintain the Inspection and Testing procedure for the HDD works
at site as mentioned below:
i) Daily Maintenance
ii) Bentonite Inspection/Testing
iii) Profile Inspection
12.1 Daily Maintenance

Daily maintenance of equipment is the most important and essential part of our
Inspection and testing procedure. It is very important for our site supervisor to
maintain all the drilling equipment in best of maintenance with the Mechanic
crew. Depending upon the drilling hours per machine, oil and filters maintenance
is done. Care is taken to maintain the inventory of spares and tools required
keeping the equipment in good running condition.
12.2 Bentonite Inspection and Testing

Quality check is maintained during drilling operation by checking viscosity and
yielding power. Mud man maintains the record of bentonite being used and the
quality of the bentonite. Also the returns of cuttings are checked to keep track of
soil being encountered and to check the same with the soil investigation data
provided by the client.
12.3 Profile Inspection

Profile to be drilled is maintained and checked by state-of-the-art steering tool
system that gives a driller the actual path being followed at every joint of pipe.
The steering system gives the driller the information of drilling bit or jet in
reference to ground level in terms of depth, azimuth and inclination.
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13 Special Instructions
For access route to the working strip the Contractor will be responsible to
negotiate with the relevant Owner, tenant or authorities. Any deemed
compensation will be borne by the Contractor.
Contractor proponent shall have to preserve top soil dug and shall be restored to
original condition on completion of the work wherever required / as required.
Contractor shall construct the pipeline and other infrastructure by adopting
safety measures as per the standards & specification laid down by the concerned
agencies from time to time. All the safety and personnel protection measures
shall be properly provided to meet any mishap / hazard / during operation and
HDD method.
Contractor proponent is required to comply with the manufacturing, Storage and
Import of Hazardous Chemicals Rules-1989 framed under the Environment
(Protection) Act-1986.
On completion of all temporary work structures, surplus materials and wastes
shall be suitably disposed off.
14 As-built records
As work advances, the position of the pipe shall be surveyed and plotted on the
drawings.
"As-Built" Documentation containing all documents (drawings, design

calculations, welding log etc) which enable location and description of the pipe
shall be compiled on completion of the work.
"As-Built" documents shall maximise the use of CAD, computer database (Access
2007 and Excel) and digital records in such a way to allow later integration in a
"Geographical Information System" (GIS).
All equipment shall be duly traced with reference to initial supplier Identification
Reference (ID) - weld log-book - Certificates - etc.
The exact position "As-built" of these elements shall be accurately located with
reference to ID and geographical co-ordinates.
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12. Specification for Cathodic Protection
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TABLE OF CONTENTS
1.0 Codes and Standards

2.0 Corrosion Data
3.0 System Details
4.0 Testing and Inspection at Works
5.0 Testing and Commissioning of TCP System
6 .0 Equipment and Instruments
7.0 Documentation
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TECHNICAL REQUIREMENTS FOR TEMPORARY CATHODIC PROTECTION
1 Codes and Standards

The system Design, Material Specification and all the procedures shall be
prepared in conformance to the requirements of latest relevant applicable
standards but not be limited to the following:
 ANSI and ASTM specifications
 NACE publications
 THIRD PARTY INSPECTION AGENCY Publications
 OISD specification
 DIN publications
 IS Specifications
NOTE: In case of conflicting requirements amongst any of the above standards,

the publication having most stringent requirement shall be governing. SERVICE
PROVIDER to furnish a set of relevant standards for TGPL’s records
2 Corrosion Data
 Graphical representation of existing structure / pipe to soil potential records,
T/R unit current / voltage readings.
 Remedial measures existing on foreign pipeline / services to prevent
interaction.
 Possibility of integration / isolation of TCP & PCP system
 Crossing and parallel running of electrified and non-electrified traction (along
with information regarding operating voltage, type AC / DC etc.,) as well as
abandoned tracks near ROW having electrical continuity with the tracks in
use.
 AC Interference Survey
 Crossing or parallel running of any HT AC / DC overhead line (existing /
proposed) along with details of voltage, type AC / DC etc.
 Voltage rating, number of cores and sheathing details of underground power
cables, along ROW or in its vicinity.
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 Information on existing and proposed DC/AC power sources and system
having earth as return path, in the vicinity of the entire pipeline route such as
HV DC sub stations and fabrication yards with electric welding etc.
 Any other relevant information that may be needed in designing and
implementing proper protection scheme for the proposed pipeline.
 If required, SERVICE PROVIDER shall conduct necessary potential gradient
survey for any existing anode ground bed that may interfere with the TCP
system of the pipeline covered under this Bid.
c. CONTRACTOR shall submit a report after completion of all fieldwork

incorporating all the results generated from surveys for the details mentioned
above and details of additional data collected shall be furnished. The report shall
also contain detailed interpretation of survey results and data enclosed, probable
interference prone areas etc. to form design basis for the design of cathodic
protection System. This report shall also include various drawings prepared
concerning the above work. The soil resistivity values shall be plotted on semi log
graph sheets.
3 System Details
The system shall include the following major equipment / sub systems unless
otherwise specified.
 Sacrificial anodes for TCP
 Zinc anode for HT crossing
 Test stations for TCP
 C.P system at cased crossing
 Surge diverted / Grounding cell / Polarization cell
 Interconnecting cables
 Cable to pipe connections
All equipment shall be new and supplied by approved reputed manufactures
Equipment offered should be field proven. Equipment requiring special
maintenance or operation shall be avoided as far as possible and prototype
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equipment shall not be accepted. Make and construction of all materials shall be
subject to TGPL/TPIA’s approval.
SERVICE PROVIDER shall furnish the detail specification of each system and
equipment. However, certain minimum requirements for the major equipment
are highlighted in this document.
As far as possible, equipment including test stations, anode etc., shall be located
in safe area. All equipment located in hazardous areas shall be of flameproof type
as per IS: 2148 for gas groups IIA, IIB and temp. Class T3, EX-d Type (Explosion
Proof).
Approved make of equipment/component for TCP system
a. Test Station (TLP)/Junction boxes
M/s Ex Protecta, Mumbai
M/s FCG Limited Mumbai
 M/s Flexpro, Navsari
 M/s Baliga Lighting Equipments, Chennai
 M/s Underground pipeline & NDT services, Noida
 M/s Corrosion Control Services, Mumbai
 M/s Corrtech International, Ahmedabad
b. Sacrificial Anode (Mg & Zn with backfills)
 M/s Metal Founders Mumbai
 M/s Shakti Enterprises Ahmedabad
 M/s Protech Alloy Anodes Karaikudi
 M/s Scientific Metal Engineers Karaikudi
 M/s Corpen Anodes
 M/s Electro – protection services
c. Reference Electrode – Cu CuSO4
 M/s Harco USA
 M/S MC Miller USA
 M/s Borin USA
 M/s Electrochemical Devices USA
d. Cables
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 M/s Netco Cables
 M/s Fort Gloster Cables
 M/s Cable Corporation of India Ltd.
e. Pin Brazing
 M/s Safetrack
f. Thermit weld/Cad weld
 M/s Erico Europa
g. Surge Diverter
 M/s Dehn GmbH
 M/s CITEL
 M/s Mc Miller
 M/s Control Technology
 M/s Dairyland Electrical Industries
 M/s International Corrosion Control Inc.
 M/s Raychem
h. Polarization Cell/AC Decoupling device (Solid State)
 M/s Kirk Engineering
 M/s International Corrosion Control Inc.
 M/s Elk Engineering associates Inc.
 M/s Metricorr
a. Sacrificial anode
CONTRACTOR shall decide the type of sacrificial anode as per design & detail
engineering and provide the same. It shall be Mg, Zn or ribbon with necessary
backfills. Location of sacrificial anode installation shall be decided considering no
underground utilities.
CONTRACTOR shall install it vertically, depth shall be as per design, from the
bottom of pipeline at the specified distance from skin of pipeline laid. In case of
multiple anode installation distance between two anodes shall be kept as per
design/2-3 Mtr.
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b. Grounding Cell
The Grounding cell shall compose of 2 Nos. of high purity Zn anodes with tail
cables and will be pre-packed in a cotton bag with special backfill. Insulated
spacers shall separate the two anodes.
c. Test Stations
Test stations shall be provided along the pipeline ROW for monitoring the
performance of the cathodic protection system at intervals not exceeding 1000
meters unless otherwise specified. In addition to above, test stations shall also be
provided at the following locations:
a) At both sides of major road crossings
b) At all insulating joints
c) At vulnerable locations with drastic changes in soil resistivity.
d) At connections of surge diverts, grounding cells and polarization cells.
e) At HT AC/DC overhead lines crossings and selected locations where HT
overhead line is in the vicinity of the pipeline.
f) Both side at railway line crossings and running parallel to the pipeline.
g) At both sides of major river crossings.
h) At high voltage cable crossings or along routes where HV cables are running in
parallel.
i) In the vicinity of DC networks or grounding system where interference
problems are suspected
j) At crossings / parallel running of other pipelines / structures.
k) At both sides of cased crossings.
l) At any other locations considered vulnerable / locations where interference is
expected.
m) At any other locations considered necessary by TGPL / TPIA.
 Test stations for bonding shall be provided with shunt and resistor as a means
to monitor and control current.
 Test stations used for sacrificial anodes shall have shunt for measurement of
anode current, and provision for resistance insertion to limit the anode
current output.
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 Test station with current measuring shall be provided at each intermediate CP
station drainage point (to measure pipeline current on any one side of
pipeline from drainage point), at interference prone areas, on both sides of
major river crossings and at least at two additional locations along the pipeline
ROW between two CP stations.
 All test stations shall have weatherproof enclosure, having degree of
protection IP 55 with hinged lockable shutter. IP-55 uses as a Weather and
Dust proof.
 Enclosure shall be made of sheet steel of at least 3 mm thickness and shall be
suitable for M. S. post mounting. The test stations shall be designed with
terminals required for permanent CP system and shall be suitable for total life
of permanent CP system.
 The test stations shall be installed with the front of the test station facing the
pipeline. The nameplate of test stations shall in minimum carry following
information.
 Test station number
 Chainage in km.
 Test station connection scheme type
 Distance from pipeline in meters
 Direction of product flow
 The installation of the test station shall be as per attached Specifications.
 The location of all the test stations shall be marked with their connection
schemes and other relevant information’s on alignment sheets. A detailed test
station schedule shall be prepared.
 Test station shall be post-mounted type of 100 mm MS pipe with base plate.
The Test station box will be fabricated from 3 – mm thick MS sheet having
weatherproof enclosure and hinged lockable shutter and having degree of
protection IP 55.
 The Test station box size shall be 250 X 200 X 230 mm fitted with necessary
terminals, Inside the box, a Bakelite plate of 6 mm thickness will be provided with
necessary brass studs and washer of size M6 x 50 for cable connection. The cable
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entries will be through bottom bend provided in the foundation casting. The
height of Test station will be 1.0 m from ground level.
d. CP at Cased Crossing (Wherever Required)
At cased crossings where casing is coated, the casing shall be protected by

sacrificial anode installations. The sacrificial anode installations shall be provided
at both ends of casing. The anode installation shall be sized based on the
permanent C. P. design parameters specified for the main pipeline. The design
life of CP at cased crossing shall be 40 years.
The carrier pipe inside coated casing shall be protected by zinc ribbon anodes
well connected to the outer surface of bottom of carrier pipe extending up to
hour hand positions of 4 and 8 o’clock. The anodes shall be placed at close
intervals as per design calculations and sized based on the permanent CP design
parameters.
All casing pipes (uncoated) shall be protected by suitable cathodic protection
system supported with design calculation and shall be approved by TGPL /TPIA.
e. Cables
Cables shall be stranded copper conductors, PVC insulated 1100 volt grade, Steel
Armoredt.
 Grounding Cell / Bonding Cable : 10 sq. mm single core/as per

design
Application : Grounding cell to test station.
 Measurement Cable : 6 sq.mm single core/as per design
(Potential / Reference cell)
Application : TLP to pipe measurement Circuit.
Laying of underground / aboveground cable includes chipping, clamping,
plastering and drilling of walls to pass the cable. The work shall include
excavation (1000x400 mm), back filling of earth, consolidation of the loose earth
after back filling, removing surplus earth away from the site and installation of
cable route marker at road crossing, turning and on cable route for identification
of cable route at appropriate locations.
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The cables shall be laid in the excavated trench of 400 mm wide at a minimum
depth of 1000 mm along with fine sand bedding & padding with brick layer
f. Permanent Cu / CuSo4 Reference cell
At each TCP location 1 No. of Permanent copper-copper sulphate Reference cells
will be installed to measure the pipe to soil potential. Reference Cell will consist
of High purity Cu element embedded in chemical grade CuSo4. The assembly will
be housed in unglazed ceramic pot to contain the Cu element surrounded by
chemical grade CuSo4 crystals. The assembly will be pre-packaged in cotton bag
with chemical backfill.
The reference cell will be installed at the bottom level of the pipeline at an
approximate distance of 300mm from the pipeline. If the pipeline has already
been backfilled the reference electrode may be installed on the top of the
pipeline approximately 100 mm above the pipeline.
The reference cell will be installed horizontally. The reference cell will be soaked
in clean water for 24 hours before installation. The area around the pre-packaged
reference cell cable will be routed along the top of the carrier pipe and strapped
to the pipe with adhesive tape at an approximate interval of 3m. The cable will
be routed to test station box.
g. Thermite weld / Cad weld
Thermite / Cad welding will be used for cable to pipe connections. Typically,
Thermite weld equipment would comprise of
Graphite mould with handle.
Weld metal + starting powder and metal disc.
Grinder or a file for exposing a good pipe surface.
Flint Gun.
15 gm of charge powder
Thermite welding of cable to pipe shall be carried out in the following steps.
Cable Preparation
25mm of the protective sheathing and insulation shall be removed from the
cable end. The bare conductor shall be clean, bright and dry.
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Surface Preparation
The cable connection to pipe shall be at least 150mm from any field joint coating.
The protective coating and any mastic, adhesive or primer shall be removed from
the top of the pipe to provide an exposed steel surface area suitable for the cable
connection.
Cable Connection
The cable connection shall be carried out as follows.
1. Position the conductor over the centre of the cleaned pipe surface
area.
2. Locate the mould over the conductor so that conductor can be seen
through the hole in the bottom of the mould.
3. Place metal discover hole.
Open charge cartridge and pour the powder into the mould. Tap the side of the
cartridge to ensure that all the powder is emptied from the container. Continue
to shake and tap the cartridge to ensure placement of the ignition powder on top
of the charge powder.
4. Close the mould and ignite the ignition powder with a flint igniter.
5. Open the mould and remove after (approximately) 10 seconds
minimum.
Test after Thermite welding
The following tests shall be carried out before repairing the coating of the
finished cable connections.
1. Remove flux and any other debris using a hand or power wire brush
2. Check all the conductor is incorporated in the weld metal
3. Check the mechanical integrity of the weld
4. Check the continuity of the bare cable conductor to the pipe.
5. Coating Repair and its documentation.
6. All bare conductors shall be covered by the coating repair.
7. Two-part epoxy will be used for coating repair at Thermite weld
location. The boundary of epoxy with pipe coating will be covered
Page 70 of 109
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with mastic. Care will be exercised not to damage original coating,
Cable insulation.
4 Testing and Inspection at Works

a. Test certificates including test records, performance curves etc., shall be
furnished. All test certificates shall be endorsed with sufficient information to
identify equipment to which the certificate refers to and must carry project
title, TGPL’s name and purchase order details etc.
b. TGPL/ TPIA reserves the right to ask for inspection of all or any item under the
contract and witness all tests and carry out inspection or authorize his
representative to witness test and carry out inspection. SERVICE PROVIDER
shall notify the TGPL / TPIA at least 30 days in advance giving exact details of
tests, dates and addresses of locations where the tests would be carried out.
5 Testing and Commissioning of TCP System

A. Pre commissioning Checks
After completing the installation of all Cathodic protection equipment, the Pre-
commissioning checks will be carried out to ensure that all the equipment has
been installed as per specifications and drawings.
The Pre-commissioning checks will comprise of:
Physical Inspection: To verify that the equipment has been installed as per
specifications.
Testing: The operational fitness for the equipment will be verified by carrying
the field test.
a) Test station
 Check the type of test station

 Check the foundation
 Check the cable termination
 Check the cable tagging/ferule /identification
 Door locking
 Cable hole sealing
 Schematic cable termination diagram
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 Test station identification as per TGPL requirement
b) Anode
 Check location of anode
 Check depth of anode
 Measure and record resistance of anode
 Check termination and tagging of anode cables
 Check anode markers and cable markers
 Check reference cells have been installed and cables terminated as per
specification
c) Reference Cell CuCUSO4
 Location of ref cell installation
 Cable termination in test station
d) Cables
 Check cable number, cable size, cable tag, voltage grade.
 Check cable depth
 Ensure that bricks and cable tiles have been installed as per the drawing
 Measure and record insulation resistance between core and earth
 Check cable termination
e) Insulating Joints
 Measure and record the insulation resistance across the insulating joint
 Measure and record pipe-to-soil potential across the joint before and after
energization of CP System.
f) Surge Diverter
 Check and verify the location

 Check and record rating of surge diverter
 Check the insulation of surge diverter
 Check for proper termination
g) Grounding Cell
 Check and verify location. Number of anodes

 Measure and record resistance of grounding cell
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 Check for proper termination
h) Polarization cell
 Check location of polarization cell

 Check the zinc anode
 Check the cable size & termination
 Check the cable tagging
B. Commissioning
 Check and Record Natural Pipe-To-Soil Potentials
A complete set of natural pipe-to-soil potential readings will be recorded.
The system will be allowed to polarize and a complete set of fairly stabilized
potentials will be recorded.
The final pipe to soil potential at each test station will be minimum protective
potential, (-) 0.85V is achieved at all the points. The maximum potential will be (-
) 1.2V (OFF) for 3LPE coated pipeline.
A full set of potentials will be recorded.
6 Equipment and Instruments
The following equipment and instruments shall be available on site as a minimum
requirement.
 Manual Voltmeter / Multi-meter

 Portable ref cell
7 Documentation
SERVICE PROVIDER shall furnish the Complete Total Design Document for
Temporary Cathodic Protection System, which shall include but not, limited to
following:
7.1 Reports:
1.1 Corrosion Survey
1.2 TCP Design Document
1.3 Soil Resistivity and Additional Data Collection
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1.4 Soil Resistivity Review and Interpretation
1.5 Interference Problem and Mitigation
7.2 Procedures:
2.1 Corrosion Survey
2.2 TCP Design
2.3 Installation, Testing and commissioning
2.4Interference Problem and Mitigation
2.5 PSP Monitoring
2.6 QA/QC, Inspection Procedure and Formats
7.3 TCP Design
3.1 As Built Drawings
3.2 Commissioning
3.3 Interference and Mitigation
3.4 Material test certificate Inspection report
3.5 Data Sheets for all Equipment and Material
3.6 All reporting formats for various Activities
3.7 QA/QC Plan
7.4 Installation Report
4.1 All reporting formats for various Activities
4.2 QA/QC Plan
7.5 Commissioning Report

7.6 Performance Report
7.7 Detailed Cost Estimates for Material and Installation of TCP System
One copy of all above Reports (Documents), Drawings and one Soft copy each on
Compaq Disc (CD) shall be submitted. No extra payment shall be made to Bidder
for the preparation of Report (Documents) and Drawings.
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13. HSE Specifications
Page 75 of 109
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1 Steel Laying Safety

Sr.
Work Instructions – Grading, Stringing, Joint Welding, Lowering, Tie-In, Backfilling
No
1 As per PTW Matrix, Permit to be obtained if required.
2 Proper supervision as per PTW matrix for execution & safety to be ensured.
3 TGPL WPI as per permit to work requirement to be followed. Deploy trained people at site.
4 Tool Box talk to be performed prior to start job.
5 All Hazards to be identified through site specific risk assessment on daily basis, carry out
HIRA & ensure all control measures at site.
6 Rescue arrangements ensured in case of an emergency.
If required, lanterns, traffic lights & watchman, barricades, warning signs shall be provided
7
for protection of public & vehicular traffic.
Precautions against overhead electrical lines to be taken so as to ensure that booms of the
8 crane does not touch the electric lines and electrocution takes place to operator or nearby
working crew.
9 Grading equipment checked before use and found in safe condition.
10 Operator trained and have license to operate the machine.
11 Material, tools and tackles and combustible fuels storage etc to be properly stored on site.
When ROW comes with an area of influence of high voltage electrical installations, the
minimum distance of pipeline from footing of the transmission line shall depend on the
voltage. The following shall be the minimum clearance from power transmission lines:
12
0-50 KV = 3m
50-200 KV = 5m
200-380 KV = 8m
Unless otherwise stated in particular cross section drawings, the clear spacing between the
gas pipeline and utilities will be between min 500 mm at crossing point and min. 3.0 mtr
13 when the pipeline is running parallel to the utilities (OISD 141). Wherever it is possible the
minimum distance must be increased. When such clearance cannot be maintained due to
unavoidable reasons, extra precautions shall be taken as per site specific risk assessment.
14 ROW boundary limit shall be identified & temporary marked and all statutory permissions
are ensured.
Centerline of pipeline shall be established between TP to TP and shall be demarcated by
15 staking of wooden pegs at an interval not more than 100mtr for straight sections & 10mtr
for TPs.
16 Route marking done. (covered in point 14)
17 All dry vegetation needs to be removed from the site of before hot work.
18 Back horn ensured for grading machine and crane in use.
19 Signaler ensured for crane operation & grading machine
20 Pipes are stacked at safe place along the route at minimum height of 500 mm from ground.
Page 76 of 109
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21 Stacking of pipe done in safe manner by crane or mechanical means.
Traffic control ensured. Pipes are staked (on wooden planks with groves or on sand bags) so
22
that they don`t roll back on road and harm the public.
23 If blasting is required at some hard rocky area, the work shall be carried out as per approved
procedure and check the near by utility should not effected and be sure that in this area
stringing shall be done after trenching. No blasting is allowed within 15m of any existing
pipeline or structures (either above or below ground). All approvals related to blasting as per
Explosives acts and Rules or others as necessary shall be checked with the vendor allotted
with the job
Underground/above ground utility shall be notified & demarcated. Official permissions, if
24
required, from concerned authorities shall be obtained
At the crossing like road and railway, before start of trenching, trench and near by area use
for heavy equipment, area shall be checked with cable locator and pipe locator and also
identify the all under ground exiting utility and obstacle. The areas to be identify and mark
25
them with the temporary painted post. And expose/uncovered them by manually. Using an
excavator bucket is not allowed. In any case of damage of any cable or pipeline, work should
be halt immediately and inform to the TGPL and concerned company without any delay.
26 Trenching activity shall be carried out as per approved procedures/drawings only.
27 Soil is stacked minimum 300 mm away from the trench edge. No vehicle parked within 1 m
distance of the pit.
28 Crossover plates provided for pedestrian safety.
Flow of any Channel/Drain/Nala/river etc. shall not be obstructed for movement of
29
construction machinery without obtaining necessary permission from concerned authorities
30 Trenching planning shall be done according to lowering in spools, & shall be done near by
time of lowering.
31 For lowering proper lifting plan to be in place. Check SWL & load radius indicator of crane.
Standard pipe cradle can be used and a demonstration shall be carried out that pipe coating
is not damaged.
32 Alternatively non-abrasive pipe belts shall be used and care must be taken while removing
the belts. Wire rope slings or other material which may damage the PE coating shall not be
used to the lift the pipes. No slings shall be put around the field coated joints.
Before lowering in a complete check by a circle holiday detector for pipe coating (PE Coating)
33 and for field joint coating (HTLP 80 Sleeve) shall be carried out at 25KV, the damages if any
observed during the examination shall be repaired as per the approved procedure.
Where water is present, no lying shall be permitted. However, water shall be removed to the
extent and for the time necessary to make visual inspection possible of the bed on which the
pipeline is to be laid. Following such inspection the presence of water is permitted provided
34
it is not so high as to cause cave-in of the walls of the trench or floating of the pipeline
before backfilling, when weighting is not provided for the pipe. Care shall be taken to
prevent the floating of pipe section before backfilling.
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Hydra/Cranes as required minimum numbers shall be used for holding the pipeline in gentle
35 S curve maintaining the minimum elastic bending radius as specified in the job standard. The
pipeline must be laid without interruption of whole section length available
Leveling of bottom of trench will be maintained by dumpy level & recorded at distance
36
interval of approx 12 to 15 meter or as per site condition
In all cases where rock is encountered in the bottom of the trench, at least 150mm sand /
37
soft soil bedding shall be done
38 Immediately after lowering level of pipe to be checked with level machine, same to be
recorded for as –built
When ever the pipe sections are left open at intervals to be tied in at a later date under
39 road, marshy locations etc shall be capped with a securely closed metal caps to prevent
entry of dirt, water or any foreign matter into the pipe section. Barricade the open trench.
40 Immediately after lowering back-filling shall be started as per approved procedure.
Minimum depth of cover shall be measured from top of pipe corrosion coating as applicable
41 to the top of undisturbed surface of the soil or top of graded working strip or top of rail or
top of road whichever is lower.
Backfilling shall be carried out immediately after the pipeline has been laid in the trench, so
as to provide a natural anchorage for the pipeline, thus avoiding long exposure of coating to
high temperature, damaging actions of adverse weather conditions, sliding down of trench
42
sides and pipe movement in the trench. If immediate filling is not possible, a covering of at
least 200mm of earth, free of rock and hard lumps shall be placed over and around the pipe
and coating.
The backfill material shall contain no extraneous material and/or hard limps of soil which
43
could damage the pipe/coating or leave voids in the backfilled trench.
When backfilling the trenches in sloping terrains or steep areas, the backfill may be washed
out of the trench, sheet piling or other effective water breakers across the trench shall be
44
provided. This is to divert the flow of water away from the trench into normal drainage
followed before laying the line.
First 300 mm backfilling shall be done by manually / by JCB/ excavator. Once post padding /
45 backfilling is complete surplus excavated soil should be placed over the trench so as to avoid
setting of the earth at the pipeline trench which may affect proper covering of the pipe.
2, Machine Boring Safety
Sr.
Work Instructions
No
1 As per PTW Matrix, Permit to be obtained.
3 TGPL WPI as per permit to work requirement to be implemented.
Ensure to protect employees from falling into the entrance or exit pit by the placement of
5
a guardrail or fence at ground level around the pits/provide barricade around trench.
Page 78 of 109
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6 Be sure all personnel have complete understanding of all safety signs.
7 Ensure that earthing is properly provided to machine.
8 The cable strike alarm must be in working condition and checked.
Always remove machine from tracks before lifting, then lift machine and tracks separately.
9
Before transporting, always secure machine to tracks with dogs engaged.
10 Always secure auger in casing before lifting.
11 No work shall be done on any part of the auger while the power source is running.
12 Make sure that all protective guards, doors, etc. are in place and secure.
13 Ensure that out riggers are proper and placed on rigid ground.
14 Start and operate the machine only from the operator’s station.
15 Always turn the engine off before leaving the operator’s station for any reason.
16 Never leave operator station while machine is in operation.
17 Avoid loose fitting clothing, loose or uncovered jewellery.
18 Remove all loose objects stored in or on the machine. Remove all objects which do not
belong in process.
19 Make sure all personnel know and stay in their prescribed areas to ensure a safe operation.
20 Do not start machine until all personnel are clearly away from any rotating or moving
parts.
21 In built / external cranes for machine must be proper, inspected & certified.
22 Relieve pressure in hydraulic system before servicing.
23 Shut down machine at first sign of malfunction or hazardous condition.
24 Shut down power source and relieve system pressures before doing any maintenance.
Engine must be turned off before:
- Opening spoil ejector door
- Working in casing
25
- Working in exit pit
- Doing any maintenance.
- Doing any Servicing
26 Do not refuel while engine is running, or while the engine is hot.
27 Do not smoke or permit open flames (which includes welding) while fuelling or near
fuelling operation.
28 Do not refuel to tank capacity. Allow room for fuel expansion.
29 Be aware that machine may move without warning while in operation.
30 Know and obey all statutory, state, and local codes and regulations.
31 Know and use the hand signals required for particular jobs and know who has the
responsibility for signaling.
It is the operator’s responsibility to know that all underground utilities have been located
32
before the bore is started, and to avoid them by using proper boring techniques.
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It is the responsibility of the operator to read and understand the Operator’s Manual and
33 other information provided and uses the correct operating procedure. Machines should be
operated only by qualified operators and trained helpers.
It is the operator’s responsibility to point out each of the safety signs on the machine and
34
ensure the crew understands the importance of adhering to each of the safety signs.
35 No crew shall consist of less than two persons.
It is recommended that the exit pit be excavated at the beginning of the boring process. If
36
not possible adequate distance for pit to be kept for doing excavations.
Always perform a pilot test that ensures that pilot is indicating it’s correct position &
37
values in tracker before executing HDD operation
38 Disengage rotation of the auger during spoil removal from entrance pit.
39 All engine exhaust must be vented to the open atmosphere.
In some instances venting of exhaust may be required. It is the operator’s responsibility to
40
be sure that the exhaust fumes have been properly vented.
41 Do not modify this machine.
3 Shot blasting, field joint, coating, holiday testing, charged pipeline buffing, painting
3.1 Grinding
Sr.
Work Instructions
No
3 TGPL WPI as per permit to work requirement to be followed.
5 All Hazards to be identified through site specific risk assessment. Cordoning to be as per
site condition.
6 Rescue arrangements ensured in case of an emergency
7 Special care to be taken while overhead grinding, proper space to be ensured for sitting
and doing grinding.
8 Ear protecting equipment (Ear muff/plug) shall be used.
Inspection of grinding wheel and machine to be done & damaged wheel to be replaced.
9
Machine guard to be ensured. Electrical supply to be with ELCB boards only.
10 Care shall be taken to ensure that no grinding marks are made on pipe surface anywhere
3.2 Cutting/Welding of Steel Pipeline
Sr.
Work Instructions
No
Page 80 of 109
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TGPL WPI as per permit to work requirement to be followed. Cordoning of site as per site
3
condition.
5 All Hazards to be identified through site specific risk assessment.
7 Minimum persons to be kept near work place.
8 First Aid arrangements and Fire Extinguishers to be placed on site.
9 If required fire water arrangements to be done.
10 At public places proper risk assessment to be done prior to start of hot jobs.
11 Precaution for burn injuries for welding, hot coating workneeds to be ensured.
12 Welding huts to be ensured for welding purpose provide proper earthing during the
welding.
13 Quality of welding rods ensured.
For tie in proper holding arrangements to be in place. It should be ensured that pipes
14
don`t get dislocated and injure the nearby working crew members.
15 Adequate space needs to be ensured for welder to perform welding work.
16 Precautions for gas escape (if project is on existing gas network) and monitoring to be
ensured before any hot work on the pipelines construction.
17 Inspection of hose connection, flash back arrestor of gas cutting set.
All air/ gas pipe lines and air/ gas hoses are frequently inspected. Air/gas hoses shall not be
18
used for de-dusting or cooling purposes.
19 Ensure electrical cables, extension boards; machines are free from electric shock hazard.
Oxygen cylinders must not be stored near other cylinders containing gas or oil, grease or
20
other combustible materials.
21 While cylinder is in use, the cylinder valve, key or wrench must be placed on the valve
spindle.
22 Before a cylinder is moved, the cylinder valve must be closed.
Gas cylinders should not be stored near furnaces, cupolas, stove or any other source of
23
heat. The cylinders lying in the open should be protected from direct rays of the sun.
Gas cutting torch must be lighted by means of friction flames or similar other methods and
24
not with matches. Flash back arrester must be used.
Gas cylinders should be placed in locations where sparks or flame from welding or cutting
25
work cannot contact them.
26 All dissolved Acetylene cylinders should be kept in upright position whenever in use. (in
trolley)
The unloading and loading of gas cylinders must be carried out with utmost care:
Cylinders should not be allowed to drop or come into violent contact with one
27 another.
 Adequate arrangement should be made to prevent cylinders falling from the
vehicles.
Page 81 of 109
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Rolling of gas cylinders should be avoided and they should be transported by
proper trolleys.
Oxygen and Acetylene cylinders should not be stored together. Stored cylinder to be
28
chained and should be in upright position. (in trolley)
Application of oil, grease or any other lubricating materials to regulators, valves or fittings
29 of gas cylinders is STRICTLY PROHIBITED. Cylinders and fitting should be kept free from oil
or grease to avoid ignition and explosion.
In case of leakage from regulators, valves or others fittings of the gas cylinders, the
30
cylinders should be immediately removed and sent for necessary repair.
31 When torches are being changed or welding stopped for short time, all cylinder valves
must be closed.
32 The coloured lenses used for welding or gas cutting must be of proper shade for the work
being done.
Before any heavy structural member is gas cut, it should be ensured that it is cleared and
33
supported by ropes, cables, chains or any other means to prevent its dropping or swinging.
Substantial and non-combustible screen must be used below or near the welding
34 operations, if there is a possibility of a spark falling on other workmen engaged in work
close by.
Proper protective clothing and appliances such as goggles, face shield, leather gloves,
35
leather apron etc should be worn for protection against radiating heat and spark.
36 One should not watch an arc-welding operation with naked eyes.
When arc-welding operations are performed in an area not enclosed or isolated, workers
37 or other persons connected with arc -welding job should wear coloured or welder’s goggles
or face shields
38 It is preferable to provide portable shields in the area where arc -welding is carried out.
39 When welding or gas cutting is performed in a confined space, the cylinders should be left
out side.
40 Suitable fire extinguishers in working condition should be kept closed to all welding and
gas cutting operations.
In confined spaces, where the means of exit is a manhole other small opening, means
should be provided, such as life belt and lift-line for quickly removing the workers in case
41
of an emergency. An attendant should be stationed outside the exit at all times while the
work is in progress. No entry inside the pipeline is allowed in any case.
In case of electrical extension is required, only ELCB/RCCB electrical extension board with
42
proper wire length is to be use. (ELCB/RCCB of 30mA sensitivity to be used)
Welding procedure qualification shall be carried out in accordance with the relevant
43 requirements Section 5 QUALIFICATION OF WELDING PROCEDURES CONTAINING FILLER
METAL ADDITIVES of API-1104, 2005 edition and TGPL Specification.
All welding procedure specification shall be submitted to TGPL for review & release and for
44
Page 82 of 109
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releasing the procedure for procedure qualification test.
Once welded specimens cleared visually it shall be subjected to radiographic testing and
45 subsequently to destructive testing. Destructive testing shall be done as per TGPL
Specification and Section 5.6 for manual welding of API 1104, 2005 edition.
A complete set of test results shall be submitted to TGPL for approval immediately after
46
completing the procedure qualification tests.
Prior to start of fit-up bevel cleaning shall be carried out using power brush for a width of
47 25 mm from the edge of bevel for inside and outside of pipe. Bevel shall be visually
inspected for any dent/damage or improper machining.
Before start the welding full weld joint if required it should be cover with temporary booth
48 which contains fire resistance cloth to protect welding space from weather until the weld
completed.
Pipes shall be checked for correct thickness, dia. and spec, with respect to the approved
alignment sheets. The first pipe shall be positioned on skids of appropriate height from the
ground Supports shall be minimum two per pipe and skid shall have soft pads placed over
49 them to avoid damage to the PE coating, Pipes shall be locked to prevent their rolling from
the skids. External clamp shall be loaded outside. The second pipe shall be held by side
boom/ crane and shall be aligned with the first pipe and the external clamp shall be
actuated. The root gap shall be checked as per qualified WPS.
When an external line-up clamp is used, all spaces between bars or minimum 60% of the
50 root pass length shall be welded before the clamp is released. The remaining pipe shall be
adequately supported on each side of the joint.
The root pass of butt joints shall be executed properly so as to achieve full penetration
51 with complete fusion of the root edges. Welding shall not be interrupted during a pass and
shall be completed as early as possible. Penning shall not be permitted.
The time lapse between second and third pass shall be as stated in the procedure
specification, normally not exceeding 4 to 5 minutes. Welding can be suspended, so as to
allow the joint to cool down, provided that the thickness of the weld metal deposited is at
52 least 50% of the pipe thickness. Upon restarting, Pre-heating to at least of 100°C shall be
carried out. Subsequent passes tip to weld completion shall be protected to avoid rapid
cooling, if meteorological conditions so dictate. Cleaning between passes shall be done
carefully so as to reduce the possibility of inclusions.
53 Only one welder shall be used for main line welding up to the 8” Dia. Pipeline and two
welders shall be used for main line welding work above 8” dia. Pipeline.
In case of two welders to be used, Welder No. 1 shall start from 12'O' clock position and
proceed towards 6'O' clock, In respect to Anti-clock wise direction Welder No.2 shall start
54
from 3Ò`clock position and proceed towards 6Ò`clock and then start from 12 o’clock to 3
o’clock, in respect to clock wise direction
All finished welds shall be visually inspected for excessive reinforcement, concavity of
55 welds, shrinkage, cracks, undercuts, dimensions of weld surface porosity and other surface
defects. If any such defects are noticed they shall be rectified
Page 83 of 109
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For welded pipes, circumferential weld seam and longitudinal weld seams of adjoining
pipes shall be staggered such that a minimum distance of 100 mm is maintained along the
56 circumference and both longitudinal welds or at top 90ºC quadrant of the pipeline
whichever is lesser (Except for bends). A longitudinal joint shall pass an appurtenance of a
structural element at a minimum distance of 50 mm.
The branch connection sleeve, etc. shall be minimum 150 mm from any other weld. The
welds for fittings shall be so located that the toe of the weld shall not come within 50mm
57
of any other weld. Cold dressing is permissible only in cases of slight misalignment and may
only be carried out with a bronze headed hammer. Hot dressing shall not be permitted.
Pipe shall be pre-heated using open flame heating. Preheat temperature of 100ºC
Minimum shall be maintained prior to commencement of root run and subsequent runs.
58 Preheating shall extend to 3 times the thickness of the joint & preheating shall be applied
on not less than 50mm on both sides of the weld. Preheating shall be checked by using
temperature indicating crayons/thermo pens. Max inter pass temperature shall be 250C
59 Earthing clamp shall be used for connecting pipe to welding machine terminal.
3.3 Holiday Testing of Steel Pipeline
Sr.
Work Instructions
No
TGPL WPI as per permit to work requirement to be followed. Cordoning as per site
3
condition to be performed.
7 Trained and experience person shall do this work. Keep person away from pipe for holiday
tests.
8 No one allowed sitting, crossing or touching the pipe section during test.
9 Electrical safety precautions to be taken. Electrical supply to be from ELCB/RCCB boards
only.
10 Holiday detector can be used to detect for cracks in the coating generated due to corrosion
on Cold bent pipes
It is carried out before lowering in a complete check by a circle holiday detector for pipe
coating (PE Coating) and for field joint coating (HTLP 80 Sleeve) shall be carried out at
11
25KV, the damages if any observed during the examination shall be repaired as per the
approved procedure.
12 The holiday detector used shall be checked and calibrated daily before the commencement
of work with an accurate D.C. voltmeter. The detector electrode shall be in direct contact
with the surface of coating to be inspected.
The entire surface of the coated field joint shall be inspected by means of a full circle
13
holiday detector with a visual & audible signal. The test voltage shall be 5 KV + 5 KV/mm of
Page 84 of 109
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total thickness of coating, subject to a maximum of 25KV. Inspection of the sleeves shall be
conducted only after the joint has cooled below 50ºC.
3.4 Coating, buffing and painting

Sr.
Work Instructions
No
3
condition to be performed.
6 Coating material to be stored properly on site.
7 All required tools and tackles to be tested and fit for use purpose on site.
8 Precautions for fire safety and first aid arrangements for burn injuries to be available on
site.
9 Contractor to supply all test certificates, coating material related safety precautions on
site.
10 Coating to be done by trained and experienced technician of the contractor.
Contractor to submit MSDS of coating material and Method statement/Procedure for the
11
process of field coating.
For buffing on charged pipeline it is to be ensured that there is no gas leak nearby in
flanges or installations, no drains are nearby if are there then those should be leak proof
checked. It is to be ensured for above ground or underground piping. Pipe thickness to be
12 ensured, no grinders to be used instead spark retardant wire brush may be used or water
sprinkled to avoid generation of sparks. For buffing by machine all rotating parts to be
guarded, machine to be earthed, electrical safety to be ensured (ELCB/RCCB use etc).
Precautions at bends must for erosion/corrosion.
The painting/coating on the vent pipes shall be applied before backfilling as per relevant
13
specifications/approved procedures
14 Painting/coating shall not be performed prior to weld joint testing.
For underground steel structure coal tar epoxy panting of min. 300 micron thickness
shall be applied
15 For over ground steel structure one coat of Epoxy primer and two coats of specified
HB Epoxy yellow paint shall be applied, collect paint waste at site and dispose if
suitably.
3.5 Shot Blasting
Sr. No Work Instructions

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3 TGPL WPI as per permit to work requirement to be followed. Areas to be cordoned off &
barricaded if called for.
6 Silica free shots to be used and chlorides in it to be as per accepted limits.
Compressed air use is done for shot blasting and hence all the components of the system
to be inspected for robustness (no wear tear or cracks etc in hoses or air carrying
7
arrangements) before start of the procedure. Air to be free from moisture, oil etc
contaminants.
8 Any chemical use to be used for surface cleaning should be done by proper care in
respect of applicable PPEs.
There could be exposure to noise, vapours, fumes, dust etc in the operation and hence
9
proper cordoning, PPE use and warning signs must be put on site.
10 Care must be taken for electrical hazards and static charge generation.
3.6 Non Destructive Testing

TGPL WPI as per permit to work requirement to be followed. Cordoning/barricading of
3
area is must with warning signs.
Non-destructive testing of welds must be performed by Radiography (X-ray or Gama
7 Rays), other than trepanning, that will clearly indicate defects that may affect the
integrity of the weld.
No tests shall be carried out on strings, which are still being welded even if the usual
8
deadlines are compromised as a result.
Non-destructive testing of welds must be performed:
The standards of acceptability as per API 1104 2005 edition
9 In accordance with written procedures;
By persons who have been trained and qualified in the established procedures and
with the equipment employed in testing (BARC Approved agency).
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When non-destructive testing is required, the following percentages of each day's field
butt welds, selected at random by the operator, must be non-destructively tested over
their entire circumference; In Class 1 location, except offshore, at least 10 percent.
In Class 2 locations, at least 15 percent.
10 In Class 3 and Class 4 locations, at crossings of major or navigable rivers, offshore,
and within railroad or public highway rights-of-way, including tunnels, bridges, and
overhead road crossings, 100 percent unless impracticable, in which case at least
90 percent.
At pipeline tie-ins, including tie-ins of replacement sections, 100 percent.
Procedures must be established for the proper interpretation of each non-destructive
11 test of a weld to ensure the acceptability of the weld.
The welds containing following repairs are not acceptable under Non-Destructive Test
Cracks Cracks of any type size and shape including crater
cracks are Not acceptable
Incomplete root penetration Not acceptable
Lack of fusion at the root Not acceptable
12
Burn through Un-repaired burn through are not acceptable
Excess weld penetration > 2mm Not acceptable
(1ntcnial)
Excess weld reinforcement > 3mm Not acceptable
(External)
Except for a welder whose work is isolated from the principal welding activity, a sample of
13 each welder's work for each day must be non-destructively tested, when non-destructive
testing is required as per standard or statutory requirements.
When non-destructive testing is required, each operator must retain, for the life of the
pipeline, a record showing by milepost, engineering station, or by geographic feature, the
14
number of girth welds made, the number non-destructively tested, the number rejected,
and the disposition of the rejects.
4. Non-Destructive Test by Gama Rays & X-Rays

TGPL WPI as per permit to work requirement to be followed. Cordoning/barricading of
3
area is must with warning signs.
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Reduce Exposure. Minimizing short-term exposure to radiation sources such as X-ray
devices and gamma emitting materials is one of the most effective ways to avoid long-
7
term radiation accumulation. Table-A indicates the most common methods of reducing
exposure to harmful radiation.
All Radiography Technicians shall have responsibilities to ensure to evacuate the public
and Non-Classified worker to the safe distance (Minimum 25 to 30 meters from radiation
8
source but to be finalized as per time of survey) and the area where radiography is being
performed. If Required Effective radiography area has to be barricaded.
All Radiography Personnel shall have responsibilities to themselves and other persons with
9 regard to safety and shall ensure site facilities are adequate with regard to lighting,
scaffolding and the like prior to commencement of operations.
Qualified personals of ASNT recommended practice SNT-TC-1A is engaged for avoidance of
10
radiography work Injuries. Provide personal dosimeter for radiograph workers.
11 Working Crew informed about Hazards due to Radiation.
12 Radiography team shall have a personal TLD for determining the personal dose.
If the TLD badge evaluation shows exposure to be in excess of the allowable limits of a
13 member, then non-radiation work shall be given to him until return to active radiographic
work as per BARC guidelines.
14 Use of Calibrated Radiation Survey meter for marking/cordoning of radiation exposure
zone shall be done.
15 A radiation survey shall be conducted during the activation of the source.
A long-standing, reliable safety tool for industrial radiographers is the film badge Carried
17 around in a protective container, the film badge is an exposure measurement tool used
for a finite period of time.
Lead cones (collimators) on the X-ray machine should be used to confine the beam to a
18
single direction and angle for maximum effectiveness in usage.
In gamma ray situations, distance is an important factor when operating in the field;
Proper signage around the testing area will alert personnel and third parties of radiation
19
activity. The safety zone to be decided based on the capacity of the source indicated on
the source.
Common isotopes such as Selenium-75, Iridium-192, and Cobalt-60 emit gamma rays that
20 can be extremely harmful when used without proper safety consideration, so safety must
be reviewed on top priority.
Use of Selenium-75 must be considered as its energy spectrum poses less of a risk of
21
radiation exposure to workers and the public.
The intensely penetrating nature of gamma rays forces scrutiny on not only shielding and
22
protection methods, but also distance from the source.
An “exclusion” zone is roped off around the location of the radioactive material, and
23 personnel are forbidden to enter the zone while the source is exposed. Proper signage
should be placed liberally near the testing site to warn third parties.
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The radiographer and agency must be approved by BARC and we must check the
24
documents related to it. The camera and the source must be approved for our site use.
The dose contamination of the radiographer and its check date to be ensured and
25 radiographer whose dose limit has crossed the approved limit must not be allowed on
site.
26 These tests must be done during night hours to avoid exposure to general public and
workers nearby.
This Procedure describes Radiographic Testing of welds by using X-Radiations from
27
respective Source for detecting the discontinuities of pipeline butt welds.
All butt weld joints of pipeline shall be subjected to 100% radiography.
Radiographic examinations of pipe to pipe butt weld shall be carried out using X-
28 radiations only.
Radiographic examinations of pipe to fittings and fittings to fittings butt weld shall
be carried out using Gamma-radiations only.
Pipeline radiographers shall be qualified in accordance with the requirement of API 1104
29
and to the full satisfaction of TGPL and as per ASNT-TC-1A Level 2
I.Q.I. Selection (mage Quality Indicator):
Image Quality Indicator shall be as per ASME Section V article 2 Table T 276 for ASTM
WIRE TYPE PENETRAMETER. The reference table is as follow:
Pipe Wall Thickness
Essential Wire Dia
or Weld ASTM SET DIN SET
(mm)
Thickness(mm)
30 0-6.4 0.20 A 10 ISO 16
6.4-9.5 0.25 A OR B 10 ISO 16
10 ISO 16 OR
9.5-12.7 0.33 B
6 ISO 12
12.7-19.1 0.41 B 6 ISO 12
19.1-25.4 0.51 B 6 ISO 12
25.4-50.8 0.64 B 6 ISO 12
Film Selection:
31 Radiographs shall be obtained using Industrial Radiography films. The Films used (D7 or
equivalent); Fine grain, High contrast Film
32 Lead screen of thickness 0.005”/0.1 to 0.15 mm and 0.2 to 0.25 mm front & back
respectively shall be used.
Surface Penetration: As far as possible all irregularities from the surface (to the extent of
33 coverage of films) shall be removed for better results and interpretation
Prevention of Back Scattering:
To achieve Radiography definition, it is required to check back scattering by placing lead
34
no. B on the backside of film holder to ensure the back scattering does not harm the film
quality. In such case, it is advised to place lead sheets on the backside of holder.
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Placement of Marker & I.Q.I.:
Lead markers shall be kept to identify the test Object, Date of Radiography, area of
interest of the object, the weld numbers location of the Radiographs and any
other information as specified by the TGPL.
I.Q.I. shall be placed approximately 25mm away from the location marker such that
the thinnest wire of the ASTM/DIN type penetrameter shall be far most from the
35 source side. In case of Panoramic Exposure Techniques, minimum 4 Nos. of IQI’s
shall be placed equal distant along the circumference.
All films shall be clearly identified by lead numbers, letters, and/or markers. The
image of the markers shall appear on the films, without interfering with the
interpretation. These markers positions shall also be marked on the part to be
radiograph and shall be maintained during radiography.
Film Loading:
Film shall be loaded in the dark room under proper safe light, Filter. Films shall be cut
36
carefully without any damages, scratches or finger marks/Nail marks. Sandwich the film
between pair of screens & loaded into tight PVC cassettes or holders.
Number of Exposures:
The number of Exposures will be such that the area of Interest is completely covered and
37 when multiple films are used the overlap between any 2 films will be a minimum of
40mm. One exposure shall be taken for single wall single Image and Minimum of three
exposures for Double Wall single Image technique for Pipeline joints.
Film Processing:
Film shall be process in a dark room under safe light. The temperature of the chemical
38 shall be 20°C ± 1°C or as specified. The film shall be unloaded in hangers/ spools carefully
to avoid any marks.
Film Viewing:
The films shall be viewed under a high intensity Film Viewer capable of reading
39 Radiographs of Density up to 4 & with adjustable light intensity. Viewing shall be done
under subdued background lighting of an intensity that will not cause troublesome
reflection.
Film Contrast:
Contrast of the film shall be adequate to manifest on the Radiograph even the smallest
40
thickness differential.
Better the contrast; better the visibility of discontinuity during interpretation
Film Sensitivity:
41 The film sensitivity shall be better than 2 % & shall be confirmed by computing or in
accordance with ASME Section V, Article 2, and Table 276 equivalent wire size.
Interpretation:
All indications that are equal to or greater than rejection level described in acceptance /
42 rejection criteria of API 1104 or as agreed by client’s inspector shall be considered
representing defects and may be cause of rejection or repair of the weld or base metal. All
Radiographs showing film marks in the area of interest shall be reshoot in accordance with
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this procedure
ACCEPTANCE OR REJECTION CRITERIA:

Acceptance or rejection criteria shall be in accordance with API 1104. Radiographic
43 examination of all girth welds with 100% coverage of the weld shall be done as per
requirement. All welds shall meet the requirement of criteria as in API 1104 & TGPL
specification
Film Storage:
44 Films shall be stored in dry place with humidity less than 80% in proper storage boxes with
identification. Methylene blue test shall be carried out to find out its archive life.
Table A: Common Methods for Reducing Harmful Exposure
Sr. Particulars Common Method
No.
1 Radiation Shielding Use appropriate shielding at all test sites and on all persons
2 Distance Maintain adequate distance between radioactive sources and
persons
3 Duration Minimize time spent near or within radiation fields
4 Utilize the smallest amount of radioactive material possible to
Quanta
accomplish the job
5 Radiographers Maintain properly calibrated devices to use in all testing
activities.
5. Hydro Testing of Steel Pipeline

3
requirement to be done
Put information of each valve that pipeline under hydrostatic tested for preventing
7
unauthorized personnel operates it.
Suitable precautions in the event of piping system rupture shall be taken to eliminate
8
hazards to personnel in the proximity of lines being tested.
9 Warning sign and board will be displayed in the area.
Only the concerned parties will be allowed to enter the test area, to prevent unwanted
10
person to enter the area, a site engineer together with a safety man of the contractor if
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required will be positioned at site.
11 If the location of testing close to other activities, barricade area with rope.
12 Nobody standing behind end of pipe that being tested.
13 Persons on site to be at safe distance from testing areas
14 For hydrostatic testing the test medium shall in general be fresh water.
15 All pressure gauges and pressure recorders to be used for testing shall be calibrated.
The chloride ion content of the water used for pressure testing stainless steel lines shall
16 be less than 150ppm and the line shall be properly drained soon after testing. pH value of
the water shall be between 6.5 and 7.5.
17 Check the thickness of temporary blind, flange or spool piece as per design.
18 The thickness of plate, which will be used for temporary blind, shall be attached on the
test package.
19 All flange connection shall be checked to avoid the loose bolt that it can cause injury.
20 During test, the pressure shall be closely monitored by an engineer as a safety precaution.
Equipment that is not to be subjected to pressure test shall be either disconnected from
21
the piping system or isolated by blanks or similar means of suitable pressure class.
The strings shall be filled in full and ensured that there is no air entrapment. For all bolted
22
fittings spiral wound shall be used.
All equipment that is removed from lines during hydrostatic testing (particularly control
23 valves) must be disconnected by qualified mechanic, technicians and protected with
wooden plugs or plastic caps.
24 All drains, vents, sample point shall be isolated or plugged prior to hydrostatic test.
The test pressure shall be maintained for a sufficient length of time to permit visual
examination to be made of all surfaces, welds and connections, but not less than thirty
minutes. One-hour test duration shall apply for piping systems with pressure rating class
25
600# and above. Care shall be taken to ensure that over pressuring due to static head
does not take place. The piping systems shall not show any sign of plastic deformation or
leakage. Dispose off the water after hydro testing properly.
Duration of Testing:
The test duration mentioned above is a thumb rule but if any statute, standard or
regulation requires other duration same should be followed, confirmation in this regards
to be ensured before planning by Design &
Technical Dept/ Project Dept/O&M dept as required Pressure at which to be Tested:
26 ASME B31.8 specifies the test pressure factors for pipeline operation at hoop stress of
code also limits the maximum hoop stress permitted during tests for various class
locations if the test medium is air or gas. There are different factors associated with
different pipeline class and division locations. During planning of hydro test pressure
should be decided and mentioned in plan.
Pressurizing Method:
27
Pressurization shall be done in the presence of the TPIA/Contractor /TGPL at a moderate
Page 92 of 109
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and cons exceeding 2 bar/min and pressurize up to the final test pressure as per
Specification.
Pressure shall be applied by means of a suitable test pump, which shall not be
connected to a system until ready to test. In bringing the system up to the test
pressure. An authorize operator shall attend to the pump constantly, during the
test. The pressure shall be allowed to stabilize for a period of 15 min after
attainment of test pressure during which pressure shall be established i.e. checked
and test pump shall be disconnected the test section shall be completely isolated
and all connections shall be checked for leakage. The test pressure ‘hold period
‘shall be 4 hours. Test section shall be visually examined for leaks/defects etc.
Pressurize to test pressure i.e. 75 Kg/cm2
During the test, care shall be taken that the hydrostatic test pressure never exceeds
119 Kg/cm2. Water shall be bleed off, if required
Acceptance:
Hydrostatic test shall be considered as positive if no abrupt drop in the pressure is
28 observed through the test du except for a change due to temperature effects as per the
applicable specifications. It should also be observing there is no evidence of sweating
before, during and after the ‘hold period’ on all the weld joints.
De-Pressuring Method:
The line and equipment shall be completely drained by suitable means after completion of
29 hydrostatic test of the system. Vent shall be opened before draining the section.
Subsequently, de-watering operation shall be carried out. Water shall be disposed off at
suitable location.
6. Pneumatic Testing of Steel Pipeline by Air or Nitrogen

1 As per PtW Matrix, Permit to be obtained.
2 Proper supervision as per PtW matrix for execution & safety to be ensured.
3
requirement to be done
All Hazards to be identified through site specific risk assessment. Proper exclusion zones
5
to be identified and cordoned off
Pneumatic pressure testing of piping and systems at moderate-to-high test pressures or
7 at low test pressures with high volume is more hazardous than hydrostatic pressure
testing because the stored energy is much greater with compressed gases.
Hazards from loss of containment during pneumatic pressure testing include both blast
8 overpressure and missiles. So proper pressure class to be ensured for used components
and piping.
Schedule tests at optimum times to ensure safety. The risk of injury resulting from a test
9 system failure can be dramatically reduced by testing at night or on weekends when
fewer personnel are on (and possibly off) site.
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Test procedures must clearly define the points in time during the test when test
personnel are permitted to leave sheltered areas and enter the exclusion zone. Prior to
proving the system at the full pneumatic test pressure, it is suggested that personnel
enter the exclusion zone only when the circumferential stress in the piping is no greater
than 50% of the specified minimum yield strength (SMYS) of the piping materials in the
test system, and only after prescribed holding times at such pressures. As per availability
10 exclusion zone to be decided if possible at least 5 mtr zone must be in place by putting
cordoning and warning signs.
When the system test pressure results in circumferential stresses that exceed 50% SMYS,
test personnel should enter the exclusion zone only after the test system has first been
proven for the prescribed time period at full test pressure. Test personnel should never
enter the exclusion zone when the test pressure exceeds the piping system design
pressure.
Materials must be procured only from manufacturers that have been determined to
11
adhere to suitable, documented quality control and production processes.
12 Materials received must be carefully checked to ensure compliance with material
specifications.
The project must have a suitable positive material identification procedure in place that
13
effectively ensures proper materials in the fabricated piping.
Pressure design calculations for both operating and test pressures must be documented
14
and checked for all piping.
For pneumatic testing, the test media shall be oil free, dry air or any inert gas (N2 -
nitrogen). The use of air for testing shall be limited to a maximum pressure of 7.0 barg.
15
Above this pressure nitrogen shall be used. The extent of pneumatic testing shall be
approved.
The limits of each test system must be clearly defined in test package documentation,
and the methods of isolation (test blinds, etc.) must be well defined. Test blind designs
16
must be checked to ensure suitability for the system test pressures. The proposed design
of test systems must be checked by qualified personnel.
17 All piping shall be adequately supported / anchored before the pressure test.
Unless otherwise noted, all valves are to be through body tested. First block valve for
18
pressure instruments shall be included in the test.
Piping containing check valves shall have the source of test pressure on the upstream
19
side. If this is not possible, the check valve disc shall be removed or jacked open.
Ball valves shall be pressure tested in the half open position. Other valves shall be tested
20
in the fully open position.
Where the test pressure to be applied to the piping is greater than the maximum
21 allowable test pressure for valves, the valves shall be blinded off on the side to be tested,
or removed and replaced by dummy spools.
22 Compressors and vessels shall be blinded off prior to pressure testing.
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A list shall be prepared for sensitive equipment that shall be removed, blocked off or
23 isolated during testing, such as relief valves, inline instruments, compressors and vessels.
This list shall be a part of the test procedure.
24 Formalized check lists must be utilized to document that pre-test preparations have been
completed.
Minimum of one gauge shall be positioned at the highest point and one recorder to be
25
positioned at the lowest point.
Accuracy of pressure gauge shall be at least 1-2% at full scale and 1-2% for the recorder.
26 The test pressure shall be within 60% of the gauge range (20% from top and 20% from
bottom).
If there is a deviation of more than 2% between gauge and recorder during test, the test
27
shall be stopped and the equipment recalibrated.
Pressure gauges and recorders used to indicate and record test pressure shall be dead
28
weight tested for accuracy according to a procedure, dependent of type of equipment.
The use of non-destructive examination (NDE) must be maximized to ensure the quality
29 of all welded joints in the system. Butt welded joints should be 100% ultrasonically or
radio graphically tested.
The intended use of “golden welds” (i.e., welds that are not proven by pressure testing)
30 to join sections of pre-tested piping must be carefully reviewed to ensure guaranteed
quality of the weld joint.
The following are excluded from pressure tests:
All small bore instrument control piping downstream of the first piping block valve.
31
Open drains and vents to atmosphere (leak test only).
Piping joints and welds shall not be insulated or physically covered until satisfactory
completion of testing in accordance with this specification, except for painting of
32
prefabricated welds.
7. Sequence of pressure testing of the installation.

The project or concerned engineer(s) has cleared all NDT/Traceability records and the
1
Test Pack has been signed accordingly.
2 All pre-test punch list items have been completed and the Test Pack signed off.
3 The latest revisions of isometrics are included in the Test Pack.
4 Correct thickness of test spades, blinds and gaskets are installed.
5 Ensure that all components of the piping system are of proper pressure class.
A pressure of 0.5 barg shall be introduced in the system and a leak test performed. The
6 pressure shall gradually be increased to 50% of the specified test pressure and kept for
minimum 10 minutes to equalize strain.
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The pressure shall then be increased in steps of 10% of the specified test pressure, until
7 the specified test pressure is reached. At each step, the pressure shall be kept for 10
minutes minimum to equalize strain.
The specified test pressure shall be kept for one hour. The pressure shall then be reduced
8
to the design pressure before examining for leakage.
9 The piping systems shall not show any sign of plastic deformation or leakage.
The test duration mentioned above is a thumb rule but if any statute, standard or
10 regulation requires other duration same should be followed, confirmation in this regards
to be ensured before planning by Design & Technical Dept.
8. Commissioning of Steel Pipeline With Odorized Gas

As per PTW Matrix, Permit to be obtained. Ensure TGPL Venting, Purging and
1
Commissioning Procedure is followed.
3 TGPL WPI as per PTW requirement to be followed. Cordoning of the site is must.
7 Ensure adequate fire extinguisher & fire fighting equipments are available.
8 Ensure earthing to vent pipe.
9 Any spark produced material shall be kept at least 15 meters distance.
10 Use of wet cloth to be ensured by welder to avoid static charge.
11 Ensure proper communication facilities are available in case of emergency
12 Ensure purity of nitrogen gas inside cylinder
13 Ensure relevant third parties are informed before executing work.
Ensure NG commissioning plan is prepared & approved by respective zonal head much
14
advance before executing date.
15 Ensure each & every activity is being performed as per approved plan.
Schematic drawing of network to be commissioned shall be made available to O & M
16 team/HSE officer. It shall be reviewed from point of required isolation valves before
commissioning of any network.
Required isolation shall be identified and readiness for isolation in case of any incident shall
17 be ensured by deputing personnel at the isolation location with proper communication
facility.
18 Gas isolation places shall be identified before starting the work
19 Ensure proper gas detectors are available at site which are in range of calibration duration.
20 Ensure proper charging assembly is in place & charging is done in controlled manner.
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21 Gas percentage & pressure monitoring in charging line is performed constantly.
22 Gas venting to be done in controlled manner at 3 meters height from working level.
23 O&M person should be present at charging site till completion of all the work.
Other safety Precautions to be as per Section 7.8 below, for pre-commissioning,
24
commissioning of gas in to steel pipelines without odorant.
9. Commissioning of Steel Pipeline/DRS with Un-Odorized Gas

All mpts needs to be done to ensure that Pipelines/ DRS/ Skids etc are not Commissioned with
atte un-odorized gas, but
if at t is to be done then for un-odorized gas entry following precautions must be taken; A
all i proper leak test is must as explained below in pre-commissioning checks.
No portion of the gas pipeline to be exposed, all excavation needs to be back filled.
The DRS to be at safe distance from the population and not on public places, also proper
fencing with safety distances from the boundary to be maintained, the fence should be so
that no-body can jump in or enter the premises, it must have proper gates and locking
system. Only Authorized persons of TGPL should be able to enter the premises.
There must be warning signs all around the premises(in all Directions) warning the
presence of Un- Odorized gas in the facility.
The entry gate must have safety instructions and hazards of Un-odorized gas and
emergency contact details of responsible site personnel of TGPL.
The other compliances need to be as follows which should be followed step by step before
starting the
commissioning job.
3 TGPL WPI as per PTW requirement to be followed. Cordoning to be done.
It is to be ensured that all pre-commissioning work is completed and test certificates
7
available, excavations are properly back filled.
8 All the material required for pre-commissioning and commissioning process are staked on
site properly with cordoning and warning signs displayed.
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In case of line is pigable following to be ensured for pigging, swabbing, drying and flushing
adequate precautions are taken i.e. launcher, receiver ends are cordoned and un-
authorized entry/exit restricted. The adequate space provided for launching and receiving
of pigs.(If pigging is not envisaged or not possible other safety precautions applicable from
these instructions to be followed).
Swabbing operation:
The swabbing operation shall be done subsequent to dewatering operation for
removal of residual water in the pipeline prior to final drying, inertisation and
9
commissioning of the pipeline system. This is done by driving number of suitably
designed absorbent pigs propelled by oil free compressed dry air. For the purpose
of swabbing, air compressors of required capacity, after-coolers and driers should
be deployed.
Acceptance Criteria : Swabbing operation shall be considered to be complete when
there is no free water left in the pipeline as pig runs & indicated by increase in
weight of less than 10 percent of the original weight (prior to launching) of the last
retrieved pig or when pigs are received in touch dry condition.
GENERAL Procedures shall be established for pre-commissioning and commissioning
activities. These shall consider the characteristics of the gas being conveyed, the need to
isolate the pipeline from other facilities and the transfer of the pipeline for operation. The
procedures and devices shall be such that nothing, that is, incompatible with the gas being
10 conveyed or with the materials in the pipeline components is introduced into the pipeline
system. Pre-commissioning shall be commenced only on completion of all activities
related to the pipeline construction which includes hydrostatic testing, complete
backfilling, installation of field instruments/equipments and suitable Cathodic protection
system.
The commissioning of the pipelines shall essentially consist of the following operations:
Pre-commissioning checks shall be carried out for the pipeline system up to first isolation
valve to ascertain that the pipeline system has been mechanically completed in all
11
respects. These checks-shall cover the main pipeline including distribution network
system, dispatch and receipt stations, intermediate pigging stations, sectionalizing valve
stations and the hook up points.
The pre-commissioning checks shall include the following:
Checking of pipe cover -- Cover-check over pipeline for every 500 m with suitable
instruments (like pipe current measurement, PCM; etc) shall be carried out.
Low Pressure Leak Check for Above Ground Piping: The above the ground piping
sections of the pipeline system shall be checked for leaks at flange points of piping and
12
equipment, instrument impulse tubing points, etc. This shall be done by pressurizing the.
Piping system/equipment with dry compressed air (for this purpose, oil free air
compressors shall be used) and testing by means of soap solution/suitable digital gauge
for leaks. The leak check operation shall be considered to have been completed when the
piping system/ equipment is free of leaks when tested at a pressure of 6.0 kg/cm2 System
Page 98 of 109
DEC-2018
checks:
The entire facilities shall be checked against drawings documents and other design
specifications. Any observation requiring correction/corrective action shall be
recorded and complied with.
Checking of field instrumentals/equipment, the field instruments like actuated valves,
control valves, shut down valves, transmitters, solenoid valves, shut down
switches, alarms etc, shall be checked physically and also for their intended
application. It will also include checking of different meters, gauges, actuated
valves, control valves, shut down valves, etc.
Pipeline survey -- This shall be performed to confirm that proper fittings/supports,
Cathodic protection system, route markers, warning signs, fencing around
sectionalizing valve stations, crash barriers, etc, have been installed along the
pipeline and crossings.
Communication system -- Communication systems shall be checked for adequacy to
ensure uninterrupted communication.
Electrical distribution system -- Electrical instrumentation system shall be checked to
ensure an uninterrupted power supply during start up and normal pipeline
operation. Earth resistance of all earth pits and equipment, towers, lightning
arresters, etc, shall also be carried out. Electrical fixtures shall be checked for their
compliance to the area classification requirements for such purpose.
Checking -of instruments control and interlocks -- This check shall be carried out to
ensure that instrument controls and interlocks are functional as per the normal
operating conditions.
Utilities -- Utilities like power, UPS, water, air, instrument air conditioning, etc,
shall be checked.
Alarm systems -- Setting off alarms and its functioning shall be ensured.
Safety-- Identification of possible emergencies and preparedness for its mitigation
shall be checked.
Any other checks as considered necessary shall also be carried out.
COMMISSIONING (In the subsequent serial numbers i.e. magnetic cleaning, electronic
geometry pigging etc if not applicable for the pipelines the other safety instructions
mentioned in these serial numbers to be followed as applicable) :
General Commissioning of a pipeline shall be considered to be complete when the line has
13
been charged with product natural gas at-the operating pressure and the entire system
has been operated at operating parameters for a minimum period of 72 h with all
instruments, controls and interlocks working at normal operating conditions.
Commissioning shall include magnetic cleaning, drying, inertisation, gas-in, stabilization
Page 99 of 109
DEC-2018
and 72 h run.
Magnetic Cleaning (If magnetic cleaning is in scope of work):
In order to ensure that the pipeline is free from metallic debris, the magnetic
cleaning shall be carried out using a train of hi-directional brush magnetic pigs after
the completion of swabbing and tie in. The operation shall be carried out using
14
super dry air. A detailed procedure and the sequence of the operations shall be
prepared before starting the operation.
The magnetic cleaning of the section will be acceptable if the total ferrous debris
collected is less than 50gms/ 1 km in the last pig.
Electronic geometry pig runs (IF Electronic geometry pig runs are planned in scope of
work):
The electronic geometry pig should be capable of recording the entire length of each
segment that is, from the launcher to receiver, in one single run and therefore its
electronic recorder system should have the requisite data storage capacity. The
measurement shall cover the entire (360 degree) of internal pipe wall
circumference using properly oriented and sufficient quantity of sensors. The tool
shall be capable of identifying and locating the following features: individual girth
weld; dent, ovality, buckles or any other out of roundness; change in pipeline
internal diameter and difference of thickness; and valves.
Detailed report of the running of the electronic geometry pig including but not
limited to the operational and functional details;
Detailed description of the type, size and location of individual mechanical defects.
The location and orientation of each defect should be suitably listed with reference
15 to permanent pipeline features, girth weld number, relative and absolute distance;
A detailed report in respect of each defect for which sizing has to be done, indicating
its length, depth and axial location suitably referenced;
Preliminary site report for each pipe segment for each running of magnetic cleaning,
and electronic geometry pig runs, stating the comments/observations of each run,
pig condition, operating parameters, and total time required; and
Velocity plot of the electronic geometry pig along the length of the segment.
The following information/performance shall be expected out of the electronic
geometry pig inspection: Inspection of entire length of each segment to be
completed in one single run; and Tools of a minimum detection level of 2 percent
of internal diameter shall be selected. The accuracy of measurement shall be 1
percent of the internal diameter and 2.5 percent of the measured value. The
location accuracy of the axial measurement shall be 0.1 percent from permanent
features. The tool shall be capable of negotiating a minimum bend of 3 times the
diameter and a 15 percent reduction in internal diameter of the pipe.
Pipeline Drying:
16 The pipeline system including the underground pipelines and the above ground
piping at dispatch and receipt stations, sectionalizing valve station, intermediate
Page 100 of 109

DEC-2018
pigging stations and hook-up/tap-of points need to be dried prior to charging
natural gas. Drying is required to prevent internal corrosion of the pipeline over a
prolonged period of operation and to meet the supply specification of the product
natural gas and also as a means of preservation of the pipeline sections subsequent
to the pre-commissioning activities. The pipeline shall be dried by using super dry
air or by any other suitable method (for example, vacuum drying process). A
detailed procedure and the duration of the operation shall be prepared and
approved before start of drying operation.
The drying operation shall be complete before proceeding to the next step of
inertisation. The drying of the pipeline system shall be considered to have been
complete on attaining a water dew point of 100 C at atmospheric pressure. The
pipeline system shall then be left at a pressure of 2.0 kg/cm2 with dry air at this
dew point after the drying operation and maintained at this pressure and dew
point till the commencement of the subsequent commissioning activities of
inertisation and gas-in.
Alternatively, nitrogen can be purged to break the vacuum for inertisation after
attainment of the desired dew point of 100 C in the pipeline and a dew point profile
test, provided that the gas-in is carried out immediately after breaking of the
vacuum by nitrogen.
Commissioning Checks:
Commissioning checks -including pre-startup safety review prior to start of
commissioning activities shall be carried out to achieve a ready for commissioning
17 status for underground pipeline and above ground piping system at dispatch and
receipt stations, above ground piping system at intermediate pigging stations,
sectionalizing valve stations and hook-up/tap-off points and before pressurized
entry of natural gas into the new pipeline facility.
Inertisation:
The inertisation of the entire pipeline system including underground pipeline and the
above ground piping at dispatch and receipt stations, intermediate pigging stations
and hook-up/tap-off points shall be carried out using nitrogen gas.
Inertiiation of the pipeline may be accepted if the required quantity of nitrogen with
adequate number of batching pigs has been introduced into the pipeline. For above
ground piping at dispatch and receipt stations, sectionalizing valve stations,
intermediate pigging station and hook-up/tap-off points, the inertisation may be
18
accepted when the residual oxygen content in the piping-is below 1 percent
(vol/vol).
During the inertisation operation, the dry air left in the pipeline shall be replaced by
dry nitrogen before admitting the natural gas into the pipeline for safe
commissioning. Depending on the commissioning plan/strategy, sections of the
pipeline system shall be taken up for commissioning in steps. It is recommended
that nitrogen slugs separated by pigs be used for inertisation of the underground
pipeline. The amount of nitrogen shall depend on the length of the pipeline portion
Page 101 of 109

DEC-2018
to be taken up for commissioning. In general, the totalized length of the nitrogen
slugs must be at least 10 percent of the total length of the pipeline under
consideration. The nitrogen in the pig train shall be propelled by natural gas (during
commissioning. stage of the pipeline). For above ground piping at dispatch and
receipt stations, sectionalizing valve stations, intermediate pigging stations and
hookup/tap-off points, the piping shall be purged with nitrogen till the residual
content in the pipeline is below 1 percent (vol/vol). Nitrogen used for inertisation
purpose of the pipeline and above ground piping shall be of such purity level as to
satisfy the acceptance criteria for residual oxygen content. Nitrogen gas at ambient
temperature (not liquid nitrogen) and in compressed, vaporized and gaseous state
shall be used as the inertising medium. In case the source of gaseous nitrogen is
from liquid nitrogen tankers, then all precautions (including verification of the
lowest tolerable temperature of all components in the system under
commissioning) should be ensured. Due precautions in working with and in
releasing of nitrogen shall be undertaken.
During the introduction of natural gas into the pipeline, the gas shall be the motive
fluid for driving the last pig of the nitrogen slug train. The pig train speed shall be
maintained at 3 to 4 kmlh. Maintenance of proper back pressure shall control pig
train speed. Venting shall be controlled at thepig-receiving end to achieve the
desired dynamics. The desired portion of the pipeline shall be commissioned in this
manner. The pipeline system shall subsequently be slowly pressurized up to its
operating conditions and high pressure leak checks of the pipeline system at flange
points, instrument points, etc, shall be carried out with soap solution at regular
19 intervals during the course of pressurization of the pipeline system. Once the
pipeline system is pressurized at its operating conditions, normal gas flow shall be
established in the pipeline system. Commissioning shall also include establishing
the process control parameters and turn down as per the design value stipulated.
As a part of commissioning, all pipeline monitoring and control equipment shall be
fully function tested, especially safety systems such as pig-trap interlocks, pressure
and flow monitoring systems, and emergency pipeline shut down systems.
Consideration shall also be given to performing a final test of pipeline valves prior
to the introduction of natural gas to ensure that they operate correctly.
The system shall be considered to have been commissioned successfully when the pipeline
system including the underground pipeline and the above ground piping at dispatch and
receipt stations, sectionalizing valve stations, intermediate pigging stations and hook-up
tap-of points is charged with natural gas, is free of leaks and have run successfully for a
20 minimum period of 72 hrs. at stable operating conditions and instrumentation/control
systems, process utilities and support systems taken on line. The commissioning of
pipeline system shall include commissioning of branch lines and associated facilities
including auxiliary facilities and above ground piping.
Page 102 of 109

DEC-2018
Commissioning documentation records of the following: shall include;
Inertisation; and Gas-in and commissioning activities (including pressurization of
pipeline system, high pressure leak check, establishment of flows and 72 h run).
Pre-commissioning checks; Residual dewatering and swabbing; Low pressure leak
21 check of above ground piping system with dry compressed air; Documents related
to magnetic cleaning and EGP;
All these documents should be prepared covering all aspects of health, safety and
environment (HSE), quality assurance and quality control plan.
10. Hot Tapping in Steel Pipeline

Sr.
Work Instructions
No
3 TGPL WPI as per Permit to Work requirement to be followed, cordoning done.
Hot taps must be done by skilled, qualified and experienced personnel only, other
precautions can be as follows to be checked in the procedure submitted by the Hot
Tapping Agency awarded the job to; Hot tap fittings should be tested to 1.1 of the
7
internal pressure.
Min. and max flow rate in gas and liquid hydrocarbons should be considered.
Do not perform hot taps in stagnant gas and pipelines having liquid hydrocarbons.
Hot tap fittings (branches) should comply with ASME B31.3 (equal tee or weld out let WOL)
8
depends on the size of the main and the branch.
9 Metallurgy of main pipe and hot tap fitting and welding electrodes should be compatible.
Before hot tapping is attempted, the machine, cutter, pilot bit to be carefully inspected.
10 During hot tapping, consideration must be given to the possibility of operational upsets
which may alter the process temperature or pressure.
11 The two primary concerns when welding on in service piping and equipment are burn
through and cracking. Burn through will occur if the un melted area beneath the weld pool
can no longer contain the pressure within the pipe or equipment. Weld cracking results
when fast weld cooling rates produce a hard, crack susceptible weld microstructure. Fast
cooling rates can be caused by flowing contents inside the piping and equipment which
remove heat quickly.
Page 103 of 109

DEC-2018
The metallurgy of weld materials, the hot tap fitting, and the weld rod must be compatible
with the metallurgy of the equipment to be welded or hot tapped. For metal thickness less
12
than 1/4th inch (6.4mm), some flow during hot tapping minimizes the potential of several
undesirable conditions. Higher flow increases the cooling rate and the risk of cracking.
For metal thickness between ¼ inch (6.4 mm) and ½ inch (12.8 mm), flow also increases
13 the weld cooling rate and risk of cracking. Minimizing the flow rate reduces the risk of
cracking and keeps the risk of burn through low.
For metal thickness greater than ½ inch (12.8 mm), the effect of flow on both weld cooling
14
rates and risk of burn through is negligible
10.1. Before Starting The Hot Tap
Sr.
Work Instructions
No
Each of the Following should be satisfied before starting Hot Tape.
Review/follow manufacturer`s instructions.
Have the contents of the line to be hot tapped or welded been assessed, and MSDS`s
reviewed for health hazards, to assure procedure is appropriate?
Is the material inside the line stable in hot condition?
Has the connection been designed?
Do the flanges, bolts, gaskets, pipe and valve to be installed meet the code for line to be hot
tapped?
Has the welding procedure specification been developed as covered with the standard?
Have approved Permit to Work obtained.
Review manufacturer`s instructions to ensure that the hot tapping machine has suitable
pressure, temperature rating and adequate cutter travel for this job.
Have the valve been pressure tapped and the cover fitted to assure that it will work and fit
properly?
1
Has the location of hot tap been identified and marked on the line?
Has the area to be welded been inspected for thickness and freedom from existing welds,
laminations, hydrogen attack, or other metallurgical imperfection?
If the laminations, defects have been found, has a thorough engineering evaluation been
made to determine if and how to proceed with the work.
Has the metallurgy of the line or vessel been established, and is it compatible with the
connecting fitting?
Can the area support the weight of the hot tapping machine, and is there adequate housing
and support for the hot tapping machine and subsequent piping?
If the PWHT (post weld heat treatment) of the welded area is required, was an appropriate
review conducted.
Is there sufficient external clearance to install the hot tapping machine and extract the
cutter through the valve?
Is there sufficient internal clearance to retract the cutter and coupon through the valve?
Page 104 of 109

DEC-2018
Is the hot tap fitting of the proper length to accommodating operation of hot tapping
machine?
Have oxygen, combustible gas, and toxic atmosphere tests been conducted in the hot tap
area?
Has a fire watch been assigned and appropriate fire-fighting equipment provided/ inform
to nearly fire station.
Have all personnel in the area been provided with appropriate PPEs?
Is there adequate storage area and room for operational and emergency access?
Has a procedure been prepared and in place to isolate the work area in the event of a
failure, are personnel trained to implement the procedure?
Have the requirements been defined for weld inspection and for pressure testing, and is
all of the equipment on hand and in good working condition?
10.2 Before Welding

Sr.
Work Instructions
No
Each of the following condition to be satisfied before welding:
Are the welders qualified for the welding procedure approved for the job?
Is a pre-heat of the weld area required?
Is the fitting properly positioned so that misalignment of the hot tapping machine will
1
not occur?
Have the pressure and temperature of the contained materials been reduced as much
as the process operation will allow?
Have the flow, pressure and level considerations are considered?
10.3 Before Cutting
Sr.
Work Instructions
No
Each of the following conditions needs to be satisfied before cutting:
Has the weld been inspected and tested?
Has the hot tap fittings been pressure tested?
Have the hot tap valve, packing, gasket and bolts been checked for leakage?
Has the packing or seals on the hot tapping machine been checked?
Has the bleed valve been checked to assure it will hold, is operable, and is not
1
obstructed? Are all bolts on the pilot and cutter bit tight?
Is the coupon catcher on the pilot bit?
Is the valve centered on the flange?
Has the cutting depth end calculated to avoid cutting the opposite side of the pipe?
Has the boring bar been run through the valve to assure free passage?
Have the hot tapping machine and valve been purged, if recommended?
Page 105 of 109

DEC-2018
10.4 Before Removing Hot Tapping Machine

Sr.
Work Instructions
No
Each of the following conditions needs to be satisfied,
Have the manufacturer`s instructions been followed to be sure that the boring bar is
fully retracted before closing the hot tap valve?
Has the hot tap valve closed?
1 Has the bleeder valve opened?
Has all the pressure been bled off of the hot tapping machine before removing the
bolts from the flange?
Have provisions been made to contain or control any liquid or gas in the hot tapping
machine?
10.5 After Removing Hot Tapping Machine
Sr.
Work Instructions
No
1 The hot tap machine should be cleaned, removing the hydrocarbons/chemicals from the line
equipment.
2 All rags, absorbent pads, and other cleaning materials must be disposed of properly.
11 . Lifting, Loading &Unloading of Heavy Equipments
Sr.
Work Instructions
No
1 As per PtW Matrix, Permit to be obtained.
2 Proper supervision as per PtW matrix for execution & safety to be ensured.
3 TGPL WPI as per Permit to Work requirement to be followed, cordoning done.
Page 106 of 109

DEC-2018
Many accidents occurred due to unsecured loads or loads that slipped off during lifting, so
7
ensure those are secured properly.
Many accidents occurred due to either structural failure of the load bearing part of the crane
8
or toppling or collapsing of cranes when they became unstable.
The duties and responsibilities of a lifting supervisor include:
Co-ordinating and supervising all lifting activities in accordance with the Lifting Plan.
Briefing all lifting team members (i.e., crane operators, riggers and signalmen) on the
Lifting Plan, risk control measure and safe lifting procedure before the
commencement of any lifting operation;
Ensuring that only registered crane operators, appointed riggers and appointed
9 signalmen participate in any lifting operation involving the use of mobile cranes;
Load to be properly ascertained and position of centre of gravity as well as load
transfer at slinging point to be thought of before handling any equipment.
Ensuring that the ground conditions are safe for any lifting operation to be performed
by mobile cranes; be present during all lifting operations; and if unsafe conditions
are reported to him, to take suitable measures to rectify the conditions so that the
lifting operation can be conducted safely.
The following are some common hazards associated with lifting of loads (test certificates
must for all lifting machines and lifting tackles):
Defective or damaged lifting gears such as slings, hooks, inserts, eyes, shackles;
10
Improper rigging of loads;
Lack of proper receptacles for loose loads such as bricks; or under capacity of lifting
gears
The following are some common hazards associated with lifting operations involving mobile
cranes.
Structural failure of crane component such as the boom, jib, hydraulic rams or wire
rope due to the crane being loaded beyond its loading capacity.
The stability of the cranes can be affected by:
I. Poor ground conditions (e.g., unstable ground);
II. Failure to use or fully extend outriggers or stabilizers;
III. Failure to level the crane;
11
IV. Rapid derricking, slewing or maneuvering;
V. Overloading of cranes;
VI. Bypassing of safety devices; or VII. High wind conditions.
Contact or collision due to insufficient safe clearance space between mobile crane
and other buildings or structures (e.g., other cranes, overhead power lines, etc).
Falling objects as a result of improper securing of loads during lifting operations, or
during erecting or dismantling activities. Falling objects present a risk of injury to
workers and the public.
Page 107 of 109

DEC-2018
The purpose of a Lifting Plan is to facilitate common understanding amongst the lifting team
for a safe lifting operation. A typical Lifting Plan incorporated with PTW addresses some key
factors affecting safe lifting operations such as:
Details of the load;
Details of the lifting equipment/ lifting gears used;
12
Means of communications;
Personnel involved in the lifting operation;
Physical and environmental considerations;
Sequence/ special precautions; and
Sketch of the zone of operation.
The lifting supervisor must stop the lifting operation immediately if it deviates from the
13
Lifting Plan that has been approved by the project manager.
Under the Factories Rules Regulations, lifting equipment such as cranes, lifting appliances
and lifting gears shall be inspected by an authorized examiner:
14 At least once every 12 months; or
At least once every six months for lifting equipment carrying persons.
An authorized examiner must also be engaged to inspect the lifting equipment:

After modification or repairs of its load bearing components;
15 When there is a change in equipment configuration, such as alteration of the boom
length or tower crane height; or after an incident or accident involving the lifting
equipment.
Lifting supervisor must ensure that the crane operator conduct pre-use inspection before
each lifting operation to ensure that the equipment is suitable, safe and correctly installed
for the lifting operation. The pre-use checks must include:
16 Visual inspection of the lifting equipment;
Functional test of the lifting equipment;
Functional test of the safety system and devices; and
Functional test of the emergency stop device.
Lifting gears must also be inspected to ensure that they are free of any faults or defects
17
before any lifting operation can begin.
Lifting supervisor must not allow the lifting operation to be carried out if any defects are
spotted during the preuse checks by the crane operator until all the faults of the cranes are
18
fully rectified. Similarly, lifting gears must not be used if defects are spotted and reported
by the riggers.
Factors affecting the choice of lifting gear for each lifting operation are:
Weight and type of load & Available lifting points;
19 Position of the centre of gravity of load;
Mode of use i.e. type of sling arrangement two leg, single leg etc; and
Environment factors (e.g., wind speed conditions)
Page 108 of 109

DEC-2018
The following may be used as a general guidance to estimate the weight of load going to be
lifted in the lifting operation.
Check if the weight is marked on the load.
20
Check if the weight is indicated on any documentation (e.g., shipping documents).
Check if the weight is indicated on the construction drawing of the load.
If the load is still on a trailer or truck, weigh it physically over a bridge.
Estimate the weight using Table-B given below (note that factors such as site conditions,
21 water content, decomposition, irregular shapes and residues in system, cylinders etc can
affect the accuracy of load weight to be estimated).
Table B: Average Weight of Various Material (1,000 kg = 1 Ton)

Sr. Particulars Weight (Kg/ M3)
1 Oil 800
2 Concrete 2,400
3 Brick 2,100
4 Water 1,000
5 Steel and Iron 7,700
6 Aluminium 2,700
7 Earth 1,600
8 Paper 1,120
9 Copper 8,800
10 Lead 11,200
11 Wood 800
Page 109 of 109

WARNING
MAHESH GAS PIPELINE
HIGH PRESSURE GAS
PIPELINE CH:000.000 KM
BEFORE EXCAVATING OR IN EMERGENCY
PHONE :
MAHESH GAS
PUNE
MAHARASTRA
TORRENT GAS PVT. LTD

SECTION 1-1
DIMENSION DETAILS OF VALVE CHAMBER DIMENSION DETAILS OF FITTINGS

SR. NO. X/X1 Y Z A B SR. NO. PIPE DIA. FITTINGS DETAILS
1
2
4"
8"
305
419
1605
1719
6"
10"
2230+O.D. OF PIPE
2230+O.D. OF PIPE
1
2
4"
8"
1"
2"
3 12" 648 1948 14" 2230+O.D. OF PIPE 3 12" 2"
Two Piece Construction Four Piece Construction

MIN.
X

Datasheet _Fittings TGPL-TS-STEEL-DS-004
Data sheet for flanges 150#, 300#, 600# LOW TEMP.:

CLIENT Torrent Gas Pvt. Ltd. TAG NO. *
QUANTITY As per Requirement SIZE As per Requirement
DESIGN CLASS : 150#, 300#, 600#

DESIGN CODE : B -16.5, B 16.47-B & ASME B 16.48
FLUID : NATURAL GAS
DESIGN PRESSURE AND TEMPERATURE: 19 BARg for 150#, 49 BARg for 300#, 98 BAR g for 600# @ -20 to
65 °C
HYDRO TEST PRESSURE As per Relevant ASME Code
MATERIAL OF CONSTRUCTION : A 350 Gr.LF2
FLANGE TYPE: WELD NECK FLANGE, BLRF
FLANGE FACING RAISED FACE 125 AARH

PWHT *
CHARPY IMPACT TEST Yes (at -20 deg C)

End Connection THK. (mm) : *
TOTAL MIN. THK : N.A.
FOR FITTINGS 150#, 300#,600# LOW TEMP

CLIENT Torrent Gas Pvt. Ltd. TAG NO.
QUANTITY As per Requirement SIZE As per Requirement
DESGIN DATA
DESIGN CLASS : 150#, 300#, 600#
DESIGN CODE : MSS SP 75 & ASME B 16.9
FLUID : NATURAL GAS
19 BARg for 150#, 49 BARg for 300#, 98 BAR g for 600# @ -29
DESIGN PRESSURE AND TEMPERATURE:
to 65 °C
HYDRO TEST PRESSURE As per Relevant ASME Code

MATERIAL OF CONSTRUCTION : A 350 Gr. LF 2 / A 420 Gr. WPL 6-W
PWHT *
CHARPY IMPACT TEST Yes (at -20 deg C)
End Connection THK. (mm) : *
TOTAL MIN. THK : N.A.
Page 1 of 1 CONTRACTOR Sign & Stamp

Datasheet _Globe Valve TGPL-TS-STEEL-DS-002
CLIENT Torrent Gas Pvt. Ltd. PROJECT: CITY GAS DISTRIBUTION PROJECT
SIZE/QUANTITY
DATA SHEET FOR GLOBE VALVES –800# (LOW TEMP.)
Process Fluid NG ANSI Rating 800#
Design Temperature ( -20 to 65 deg C) Design Pressure 98 barg
Design Standard API 6D Piping Class D2
Size, mm (inch) 1/2" to 1- 1/2" -SW (S.B) 2 "-FLG (L.B)
Bore Full Bore
End Connection Type SW / FLG Standard ASME B.16.34/BS 5352
Flanged Finish RF 125 AARH
Locking Device Reqd. *
VALV E DESIGN CONDITIONS
Corrosion Allowance 1.5 mm Design Factor 0.5
Installation Aboveground Stem Ext Length, mm N.A.
Seat Parabolic Disc / Bi-Directional
Gland Type Bolted Bonnet – Non Rotating System
Pattern Straight Through Globe
Valve Operation Hand Wheel
VALVE MATERIAL SPECIFICATION
PART DISCRIPTION MATERIAL
SPECIFIED
Body, Bonnet & Yoke Material A 350 Gr. LF2 (S.B.) / A 352 Gr. LCB (L.B.) * OFFERED
DISC (Plug) A350 Gr. LF2 / A351 Gr. CF8M / SS 410 + STELLITED * (Equivalen
Seat Ring A350 Gr. LF2 / A351 Gr. CF8M / SS 410 + STELLITED * t or
Stem ASTM A276 TP410 / ASTM A479 GR SS316 / (17-4) PH (NO * Higher)
Handle Wheel Carbon Steel CASTING) *
Gasket and Packing Spiral Wound AISI 304, Filling Pure GRAPHITE, Centering Ring CS *
Stud Bolts A320 Gr. L 7 *
Nuts A194 Gr. 4 *
TESTING REQUIREMENT
Hydrostatic Test Pressure As per API 598 or relevant standard
Fire safe test As per API 598 or relevant standard
Air Test Pressure 7 bar or As per API 598 or relevant standard
Anti-Static Testing As per API 598 or relevant standard
Hardness Test Requirement 248 HV 10
Charpy Impact Test/Temperature Yes (at 0 deg C)
Fire Safe Test As per API 6FA
Valve Painting Specification Suitable for Corrosive Industrial Environment
Manufacturer's Painting Specification Number *
Notes
1.This Data Sheet Shall be read in conjunction with the Technical Specification, which are enclosed along with this requisition.
* To be filled by Vendor.
Abbreviations: SB - Small Bore, LB - Large Bore, BW - Butt welded, FLG - Flange

DATASHEET_ BALL TGPL-TS-STEEL-PTS-009
Valve
CLIENT Torrent Gas Pvt. Ltd.
PROJECT: CITY GAS DISTRIBUTION PROJECT
SIZE/QUANTITY
DATA SHEET FOR BALL VALVES – 150#, 300#, 600# (LOW TEMP.)
Process Fluid NG ANSI Rating 150#, 300 #, 600#
Design Temperature ( -20 to 65 deg C) Design Pressure 19 barg, 49 barg, 99 barg
Design Standard API 6D Piping Class A2, B2, D2
Size, mm (inch) 1/2" to 1- 1/2" (S.B) 2 " (L.B)
Body Construction Floating type Ball Trunion mounted Ball
Double Block & Bleed *
Bore & Construction Full Bore, bolted Construction
End Connection Type B.W./ FLG Standard ASME B16.25/ B 16.5
Pup piece length/Flng Finish 300mm (for 2") / RF 125 AARH Vent, drain &
Special Requirement
Locking Device Reqd. * Sealant
VALV E DESIGN CONDITIONS connection
Corrosion Allowance 1.5 mm Design Factor 0.5 Anti-Blow out
Installation Aboveground Stem Ext Length, mm N.A. system
Opening/Closing time *
Body SPECIFIED
A 350 Gr. LF2(S.B. ) / A 352 Gr. LCB (L.B. ) * OFFERED
Ball A350 Gr. LF2 + 75 micrometer (0.003") ENP/ A351 Gr. CF8M * (Equivalent or
Seat Rings A 350 Gr. LF2 + 0.075 mm ENP * Higher)
Seat Seal VITON A ED O-RING *
Stem AISI 4140 + 75 micrometer (0.003") ENP/ AISI 410 *
Stem Seal PTFE / VITON *
Nuts A194 Gr. 4 *
TESTING REQUIREMENT
Hydrostatic Test Pressure As per relevant ASME Standard
Air Test Pressure 7 bar
Anti-Static Testing Requirement As per API 6D Latest Edition
Hardness Test 248 HV 10
Charpy Impact Yes (at 0 deg C)
Fire Safe Test Test/Temperature As per API 6FA
Notes
2. Valve shall be joined with a pup piece integrally welded (in controlled factory conditions only) to the valve whose provide
strength shall be equivalent to attached pipe specification.

Datasheet _Plug Valve TGPL-TS-STEEL-DS-003
CLIENT Torrent Gas Pvt. Ltd.

PROJECT: CITY GAS DISTRIBUTION PROJECT
SIZE/QUANTITY
DATA SHEET FOR PLUG VALVES – 800# (LOW TEMP.)
Process Fluid NG ANSI Rating 800#
Design Temperature ( -20 to 65 deg C) Design Pressure 99 barg
Design Standard API 6D Piping Class A2, B2, D2
Size, mm (inch) 1/2" to 1- 1/2" -SW (S.B) Above 2"-FLG (L.B)
Bore & Construction Full Bore, Wrench Operated
End Connection Type B.W./ FLG Standard ASME B16.34/ B 16.5
Flanged Finish RF 125 AARH
Locking Device Reqd. *
VALVE DESIGN CONDITIONS
Corrosion Allowance 1.5 mm Design Factor 0.5
Installation Aboveground Stem Ext Length, mm N.A
Opening/Closing time *
Body SPECIFIED
A 350 Gr. LF2 (S.B.) / A 352 Gr. LCB (L.B.) * OFFERED
Ball A350 Gr. LF2 / A351 Gr. CF8M + 75 micrometer (0.003") ENP * (Equivalent
or Higher)
Cover A 350 Gr. LF2 (S.B.) / A 352 Gr. LCB (L.B.) *
Stem AISI 4140 + 0.003” ENP / AISI 410 *
Stem Seal PTFE / GRAPHITE / VITON *
Nuts A194 Gr. 4 *
TESTING REQUIREMENT
Hydrostatic Test Pressure As per relevant ASME Standard
Air Test Pressure 7 bar
Air Seat Test As per API 6D Latest Edition
Anti-Static Testing Requirement As per API 6D Latest Edition
Hardness Test 248 HV 10
Charpy Impact Yes (at -20 deg C)
Fire Safe Test Test/Temperature As per API 6FA
Notes
2. Valve shall be joined with a pup piece integrally welded (in controlled factory conditions only) to the valve whose provide
strength shall be equivalent to attached pipe specification.

FABRICATIOIN AND TGPL-TS-STEEL-PTS-007
ERECTION OF PIPING
TORRENT GAS PVT. LTD. (TGPL)
CITY GAS DISTRIBUTION PROJECT
TECHNICAL SPECIFICATIONS
FABRICATIOIN AND ERECTION OF PIPING
Doc. No: TGPL-TS-STEEL-PTS-007
Rev Date Prepared By Verified By Approved By

ERECTION OF PIPING
TABLE OF CONTENTS
1.0 SCOPE .................................................................................................................................... 3

2.0 SCOPE OF WORK OF CONTRACTOR ......................................................................................... 3
3.0 BASIS FOR WORK.................................................................................................................... 5
4.0 FABRICATION ......................................................................................................................... 7
5.0 ERECTION ............................................................................................................................. 10

ERECTION OF PIPING
1.0 SCOPE
This specification covers general requirements of fabrication and erection of
above ground and trench piping systems at site. The specification covers the
scope of work of contractor, basis of work to be carried out by contractor and
standards, specifications and normal practice to be followed during fabrication
and erection by the contractor.
ABBREVIATIONS:
PMI - Positive Material Identification

NDT - Non Destructive Testing
P&ID - Process and Instrumentation Diagram
A.S. - Alloy Steel
C.S. - Carbon Steel
C.I. - Cast Iron
S.S. - Stainless Steel
LTCS - Low Temperature Carbon Steel
NACE - National Association of Corrosion Engineers
2.0 SCOPE OF WORK OF CONTRACTOR
2.1 Generally the scope of work of contractor shall include the following:
2.2 Supply and Transportation of required piping materials (pipes except 4”, 8” and
12”), pipe support, valves below 4” NB and all other necessary piping materials
from Owner’s storage point (on chargeable basis) or contractor’s storage point
(contractor’s scope of supply) to work site/shop including raising store
requisitions for issue of materials in the prescribed format & maintaining an
account of the materials received from Owner’s stores.
2.2.1 Piping materials include the following but not limited to the same.
a. Pipes - All sizes (except 4”,8”, 12” and 16” pipes) and schedule
b. Flanges - All sizes, types & Pressure ratings.
c. Fittings - All sizes, types and schedule.
d. Valves - All sizes (below 4” NB), types and Ratings.
e. Gaskets - All sizes, types & Ratings.

ERECTION OF PIPING
f. Bolts, Nuts or M/C Bolts - All types.
g. Specialty items like online filters, ejectors, sample coolers, steam traps,
strainers, air traps etc.
h. Online instruments like control valve, orifice flange, rotameter, safety
valves etc.
2.3 Shop & field fabrication and erection of piping in accordance with documents
listed under ‘BASIS OF WORK’ including erection of all piping materials
enumerated above.
2.4 Fabrication and erection of pipe supports like shoe, saddle, guide, stops,
anchors, clips, cradles, hangers, turn buckles, supporting fixtures, bracket
cantilevers, struts, tee-posts including erection of spring supports and sway
braces.
2.5 Guidelines
2.5.1 Fabrication of piping specials like special radius bends, reducers, etc.
2.5.2 Fabrication of plain and threaded nipples from pipes as required during erection.
2.5.3 Fabrication of swage nipples as and when required
2.5.4 Fabrication of odd angle elbow like 60º, 30° or any other angle from 90/45°
elbows as and when required.
2.5.5 Fabrication of flange, reducing flange, blind flange, spectacle blinds as and when
required.
2.5.6 Fabrication of stub-in connection with or without reinforcement as and when
required.
2.5.7 Grinding of edges of pipes, fittings, flanges etc. to match mating edges of
uneven/different thickness wherever required.
2.6 Modifications like providing additional cleats, extension of stem of valve, locking
arrangement of valves etc. as and when required.
2.7 Preparation of Isometrics, bill of materials, supporting details within the unit
battery limit and get subsequent approval from Engineer-in-Charge before
starting of job, as and when called for.

ERECTION OF PIPING
2.8 Obtaining approval for drawings prepared by contractor from statutory
authority, if required.
2.9 Spun concrete lining of the inside of pipes 3” NB & above including fittings and
flanges as required in accordance with specification.
2.10 Rubber lining inside pipes, fittings, flanges as and when required, in accordance
with specification.
2.11 Radiography, stress relieving, dye penetration, magnetic particle test etc. as
required in specification.
2.12 Performing PMI using alloy analysers as per Standard Specification at
Construction Sites.
2.13 Casting of concrete pedestals and fabrication & erection of small structures for
pipe supports including supply of necessary materials.
2.14 Providing insert plates from concrete structures and repair of platform gratings
around pipe openings.
2.15 Providing Neoprene sheets between Insert Plates and Valves or other structure
to be erected on Insert Plates, as and when required.
2.16 Making material reconciliation statement and return of Owner’s supply left over
materials to Owner’s storage.
2.17 Flushing and testing of all piping systems as per standard specification for
inspection, flushing and testing of piping systems.
2.18 Pickling (as and when applicable) as per standard specification for chemical
cleaning of C.S. suction piping of compressors.
2.19 Submission of job execution procedure for review and approval of Engineer-in-
charge covering all above activities.
3.0 BASIS FOR WORK

3.1 The complete piping work shall be carried out in accordance with the following
3.1.1 “Approved for Construction” drawings and sketches (prepared by Contractor and
approved by Owner) - Plans and/or Isometrics.
3.1.2 Approved Process licensor’s standards and specifications.

ERECTION OF PIPING
3.1.3 Drawings, sketches and documents prepared by contractor duly approved by
Engineer-in- Charge (such as isometrics of small bore piping and offsite piping
etc.)
3.1.4 Approved construction job procedures prepared by Contractor and approved by
owner.
3.1.5 Specifications/documents will be required for execution as below:
a. Process and Instrument Diagram.
b. Piping Materials Specification.
c. Piping support standards.
d. Line list
e. Piping support indices (only in offsite), if supports are not shown in plan.
f. Standard specification of Non-destructive Requirement of Piping.
g. Welding specification charts for piping classes.
h. Standard specification for Pressure Testing of Erected Piping System.
i. Welding specification for fabrication of piping.
j. Any other or OTHER specifications attached with Piping Material
Specification or special condition of contract (such as standard for
cement lining of pipe, standard of jacketed piping, standard for steam
tracing, Dimensional Tolerances etc.)
k. Procedure for storage, preservation and positive identification of
materials at Contractors works/ stores.
3.2 Following codes, standards and regulations

a. ASME B 31.3: Process Piping
b. ASME B 31.4: Pipeline Transportation System for Liquid Hydrocarbons
and Other.
c. ASME B 31.8: Gas Transmission and Distribution Piping Systems.
ERECTION OF PIPING
d. ASME Sec. VIII: Code for unfired pressure vessel.
e. IS: 823: Code for procedure for Manual Metal Arc Welding of Mild Steel
(for structural steel).
f. NACE Std.: Code for Sour Services material requirements MR-0 1-75
g. PNGRB NOTIFICATION: Technical Standards and specifications including
safety standards for Dated: 27/08/08 city or local natural gas distribution
network.
Schedule-1
Note: All codes referred shall be latest edition, at the time of award of
contract.
3.3 Deviations
Where a deviation from the “Basis of Work and approved job procedure
described above is required or where the basis of work does not cover a
particular situation, the matter shall be brought to the notice of Engineer - in -
Charge and the work carried out only after obtaining written approval from him
in each case.
4.0 FABRICATION
4.1 Piping Material
Pipe, pipe fittings, flanges, valves, gaskets, studs bolts etc. used in a given piping
system shall be strictly as per the “Piping Material Specification” for the “Pipe
Class” specified for that system. To ensure the above requirement, all piping
material supplied by the Owner/Contractor shall have proper identification
marks as per relevant standards/specifications/Licensors specification.
Contractor shall provide identification marks on left over pipe lengths wherever
marked up pipe lengths have been fabricated/ erected. Material traceability is to
be maintained for C.S., S.S., LTCS, material, i.e. hard punching or other method as
per approved procedure. This shall be in addition to colour coding for all piping
materials to avoid mix-up. For the purpose of common understanding the
construction job procedure, to be submitted by the contractor, shall include
proposal for - Maximizing prefabrication, inspection and testing at fabrication
shop with minimum field joints.

ERECTION OF PIPING
4.3 Positive material identification, handling, storage & preservation. Dimensional
Tolerances
Contractor shall be responsible for working to the dimensions shown on the

drawings. However, the Contractor shall bear in mind that there may be
variations between the dimensions shown in the drawing and those actually
existing at site due to minor variations in the location of equipment, inserts,
structures etc. To take care of these variations “Field Welds” shall be provided
during piping fabrication. An extra pipe length of 100 mm over and above the
dimensions indicated in the drawing may be left on one side of the pipe at each
of the field welds. During erection, the pipe end with extra length at each field
weld shall be cut to obtain the actual dimension occurring at site. Isometrics, if
supplied may have the field welds marked on them. However, it is the
responsibility of the Contractor to provide adequate number of field welds. In
any case no extra claims will be entertained from the Contractor on this account.
Wherever errors / omissions occur in drawings and Bills of Materials it shall be
the Contractor’s responsibility to notify the Engineer-in-Charge prior to
fabrication or erection.
4.4 Pipe Joints
The piping class of each line specifies the type of pipe joints to be adopted. In
general, joining of lines 2” and above in process and utility piping shall be
accomplished by butt welds. Joining of lines 1-1/2” and below shall be by socket
welding/butt welding/threaded joints as specified in “Piping Material
Specifications”. However, in piping 1-1/2” and below where socket
welding/threaded joints are specified butt - welds may be used with the approval
of Engineer-in-Charge for pipe to pipe joining in long runs of piping. This is only
applicable for non-galvanized piping without lining.
4.5 Screwed Piping
In general, Galvanized piping shall have threads as per IS: 554 or ANSI B2.1 NPT
as required to match threads on fittings, valves etc. All other piping shall have
threads as per ANSI B2.1, tapered unless specified otherwise.
Threads shall be clean cut, without any burrs or stripping and the ends shall be
reamed. Threading of pipes shall be done preferably after bending, forging or
heat treating operations. If this is not possible, threads shall be gauge checked
and chased after welding heat treatment etc.

ERECTION OF PIPING
During assembly of threaded joints, all threads of pipes and fittings shall be
thoroughly cleaned of cuttings, dirt, oil or any other foreign matter. The male
threads shall be coated with thread sealant and the joint tightened sufficiently
for the threads to seize and give a leak proof joint.
Threaded joints to be seal-welded shall be cleaned of all foreign matter, including

sealant and made up to full thread engagement before seal welding.
4.6 Flange Connections
All flange facings shall be true and perpendicular to the axis of pipe to which they
are attached. Flanged holes shall straddle the normal centrelines unless different
orientation is shown in the drawing.
Wherever a spectacle blind is to be provided, drilling and tapping for the jack
screws in the flange, shall be done before welding it to the pipe.
4.7 Branch Connections
Branch connections shall be as indicated in the piping material specifications. For

end preparation, alignment, spacing, fit-up and welding of branch connections
refer welding specifications. Templates shall be used wherever required to
ensure accurate cutting and proper fit-up.
For all branch connections accomplished either by pipe to pipe connections or by

using forged tees the rates quoted for piping shall be inclusive of this work.
Reinforcement pads shall be provided wherever indicated in drawings/

specifications etc.
4.8 Forging and forming
Forging and forming of small bore fittings, like reducing nipples for piping 1-1/2”
and below, shall be as per ASME B 31.3.
4.9 Cutting and Trimming of Standard Fittings & Pipes
Components like pipes, elbows, couplings, half-couplings etc. shall be

cut/trimmed/edge prepared wherever required to meet fabrication and erection
requirements, as per drawings and instructions of Engineer-In-Charge. Nipples as
required shall be prepared from straight length piping.
4.10 Shop Fabrication / Prefabrication

ERECTION OF PIPING
The purpose of shop fabrication or pre-fabrication is to minimize work during
erection to the extent possible. Piping spool, after fabrication, shall be stacked
with proper identification marks, so as facilitate their withdrawal at any time
during erection. During this period all flange (gasket contact faces) and threads
shall be adequately protected by coating with removable rust preventive. Care
shall also be taken to avoid any physical damage to flange faces and threads.
5.0 ERECTION
5.1 Cleaning of Piping before Erection
Before erection all pre-fabricated spool pieces, pipes, fittings etc. shall be
cleaned inside and outside by suitable means. The cleaning process shall include
removal of all foreign matter such as scale, sand, weld spatter chips etc. by wire
brushes, cleaning tools etc. and blowing with compressed air/or flushing out with
water. Special cleaning requirements for some services, if any shall be as
specified in the piping material specification or isometric or line list. S.S jacketed
piping requiring pickling shall be pickled to remove oxidation and discolouring
due to welding.
5.2 Piping Routing
No deviations from the piping route indicated in drawings shall be permitted

without the consent of Engineer-in-Charge.
Pipe to pipe, pipe to structure / equipment distances / clearances as shown in

the drawings shall be strictly followed as these clearances may be required for
the free expansion of piping / equipment. No deviations from these clearances
shall be permissible without the approval of Engineer-in-Charge. In case of
fouling of a line with other piping, structure, equipment etc. the matter shall be
brought to the notice of Engineer-in-Charge and corrective action shall be taken
as per his instructions.
5.3 Vents and Drains
High point vents and low point drains shall be provided as per the instructions of
Engineer- in-Charge, even if these are not shown in the drawings. The details of
vents and drains shall be as per piping material specifications / job standards.
5.4 Valves
Valves shall be installed with spindle / actuator orientation / position as shown in

the layout drawings. In case of any difficulty in doing this or if the spindle
orientation / position is not shown in the drawings, the Engineer-in-Charge shall
ERECTION OF PIPING
be consulted and work done as per his instructions. Care shall be exercised to
ensure that globe valves, check valves, and other uni-directional valves are
installed with the “Flow direction arrow “on the valve body pointing in the
correct direction. If the direction of the arrow is not marked on such valves, this
shall be done in the presence of Engineer-in-Charge before installation.
Fabrication of stem extensions, locking arrangements and interlocking
arrangements of valves (if called for), shall be carried out as per instructions of
Engineer-in- Charge.
5.5 Instruments
Installation of in-line instruments such as restriction orifices, control valves,

safety valves, relief valves, rotameters, orifice flange assembly, venture meters,
flow meters etc. shall form a part of piping erection work. Fabrication and
erection of piping up to first block valve / nozzle / flange for installation of offline
Instruments for measurement of level, pressure, temperature, flow etc. shall also
form part of piping construction work.
Flushing and testing of piping systems which include instruments mentioned

above and the precautions to be taken are covered in flushing, testing and
inspection of piping. Care shall be exercised and adequate precautions taken to
avoid damage and entry of foreign matter into instruments during
transportation, installation, testing etc.
5.6 Line Mounted Equipment/ Items
Installation of line mounted items like filters, Regulators, valves, terminal piping
and ancillaries etc. including their supporting arrangements shall form part of
piping erection work.
5.7 Studs, Bolts and Nuts
The Contractor shall apply molycoat grease mixed with graphite powder (unless
otherwise specified in piping classes) all Studs, bolts and nuts during storage,
after erection and wherever flange connections are broken and made-up for any
purpose whatsoever. The grease and graphite powder shall be supplied by the
Contractor within the rates for piping work.
5.8 Pipe Supports
Pipe supports are designed for and located to effectively sustain the weight and
thermal effects of the piping system and to prevent its vibrations. No pipe
shoe/cradle shall be offset.
FOR FLANGES TGPL-TS-STEEL-PTS-005
FOR FLANGES

TABLE OF CONTENTS
1. SCOPE .................................................................................................................................... 3
2. REFERENCE DOCUMENTS ....................................................................................................... 3
3. MANUFACTURER’S QUALIFICATION........................................................................................ 4
4. MATERIALS............................................................................................................................. 4
5. DESIGN AND MANUFACTURE ................................................................................................. 4
6. INSPECTION AND TESTS .......................................................................................................... 5
7. Hydrotest ............................................................................................................................... 5
8. TEST CERTIFICATES ................................................................................................................. 6
9. MARKING ............................................................................................................................... 6
10. DOCUMENTATION.................................................................................................................. 6
11. PACKING, SHIPPING & HANDLING........................................................................................... 6

1. SCOPE
This specification covers the minimum requirements for the design, manufacture
and supply of following carbon steel flanges of size to be installed in pipeline
systems handling Natural Gas.
- Flanges such as weld neck flanges, blind flanges, spectacle blinds, spacers and
blinds, etc.
2. REFERENCE DOCUMENTS
Reference has been made in this specification to the latest edition of the
following codes, standards and specifications:
ASME B3 1.3 - Process Piping
ASME B3 1.4 - Pipeline Transportation System for Liquid Hydrocarbons and
Other Liquids
ASME B3 1.8 - Gas Transmission and Distribution Piping Systems
ASME B 16.5 - Pipe Flanges and Flanged Fittings
ASME B 16.9 - Factory Made Wrought Steel Butt Welding Fittings (1/2” to 24”)
ASME B 16.25 - Butt-welding Ends
ASME B16.47 - Large Diameter Steel Flanges (26” to 60”)
ASME B 16.48 - Steel Line Blanks
ASME Sec VIll/IX - Boiler and Pressure Vessel Code
ASTM A 370 - Standard Test Methods and Definitions for Mechanical Testing of
Steel Products.
MSS-SP-25 - Standard Marking System for Valves, Fittings, Flanges and Unions
MSS-SP-75 - Specification for High Test Wrought Welded Fittings.
MSS-SP-97 - Forged Carbon Steel Branch Outlet Fittings- Socket Welding,
Threaded and Butt Welding Ends. In case of conflict between various
requirements of this specification and reference standard mentioned above, the
more stringent requirement shall apply.

3. MANUFACTURER’S QUALIFICATION
Manufacturer of flanges must possess the records of a successful proof test, in
accordance with the provisions of ASME B 16.9/ MSSSP- 75, as applicable. These
records shall be submitted for approval.
4. MATERIALS
4.1 The basic material for flanges shall meet the requirements specified hereinafter.
4.2 The Carbon steel used for the manufacture of Flanges shall be fully killed.
4.3 Each heat of steel used for the manufacture of flanges shall have carbon
equivalent (CE) not greater than 0.45 % calculated from check analysis in
accordance with following formula:
CE = C + Mn + Cr + Mo + V + Ni+Cu
6 5 15
Carbon contents on check analysis shall not exceed 0.22%.
4.4 Unless specified otherwise, Charpy V-notch test shall be conducted for each heat
of steel, in accordance with the impact test provision of ASTM A370 at 0°C. The
average absorbed impact energy values of three full- sized specimens shall be 32
joules.
The minimum impact energy value of any one specimen of the three specimens
analysed as above, shall not be less than 80% of the above- mentioned average
value.
When Low Temperature Carbon Steel (LTCS) materials are specified in, the
Charpy V-notch test requirements of applicable material standard shall be
complied with.
4.5 For flanges specified to be used for Natural Gas service, hardness test shall be
carried out in accordance with ASTM A 370. Hardness testing shall cover at least
10% per item, per size, per heat, per manufacturing method. A full thickness
cross section shall be taken for this purpose and the maximum hardness shall not
exceed 248 HV10.
5. DESIGN AND MANUFACTURE
5.1 Flanges such as weld neck flanges and blind flanges shall conform to the
requirements of ASME B16.5 up to sizes DN 300 mm (12”).

5.2 Type, face and face finish of flanges shall be as specified in Purchase Requisition.
5.3 Flanges manufactured from bar stock are not acceptable.
5.4 Repair by welding on flanges and parent metal of fittings is not permitted.
6.1 The Manufacturer shall perform all inspection and tests as per the requirement
of this specification and the relevant codes, prior to shipment at his works. Such
inspection and tests shall be, but not limited to, the following:
6.1.1 All flanges shall be visually inspected. The internal and external surfaces of the
fittings shall be free from any earth strikes, gauges and other detrimental
defects.
6.1.2 Dimensional checks shall be carried out on finished products as per ASME
B16.5/MSS-SP - 44/ASME B16.47 as applicable for flanges, ASME B 16.48 for
spacers and blinds and ASME B16.9/MSS-SP-75/MSS-SP-97 as applicable for
fittings and as per this specification.
6.1.3 Chemical composition and mechanical properties shall be checked as per
relevant material standards and this specification, for each heat of steel used.
6.2 Purchaser’s Inspector reserves the right to perform stage wise inspection and
witness tests at Manufacturer’s Works prior to shipment.
Manufacturer shall give reasonable notice of time and shall provide, without
charge, reasonable access and facilities required for inspection, to the
Purchaser’s Inspector.
Inspection and tests performed/witnessed by Purchaser’s Inspector shall in no
way relieve the Manufacturer’s obligation to perform the required inspection
and tests.
7. Hydrotest
All fitting under this specification shall be designed to withstand a field
hydrostatic test pressure with non-corrosive water, after installation , during 24
hours at a following pressure level:
Minimum: P= 1.5 MOP

Where, P= Hydrostatic test pressure, barg
MOP=Maximum operating Pressure, 49 barg

The pressure level will however not exceed MOP 1.5 times the 38Degree C
pressure rating of flanges.
8. TEST CERTIFICATES
Manufacturer shall submit following certificates to Purchaser’s Inspector:
a) Test certificates relevant to the chemical analysis and mechanical
properties of the materials used for construction as per this specification and
relevant standards.
b) Test Reports on radiography, ultrasonic inspection and magnetic
particle examination.
c) Test reports of heat treatment carried out as per the specification.
d) EN 10204 3.1 Certificate stating the quality of relevant Flanges.
9. MARKING
All Flanges shall be marked with:
• PO Number
• Item/ Material Code
• Material Class rating
10. DOCUMENTATION
10.1 Prior to shipment, the Manufacturer shall submit six copies of the test
certificates as listed above.
10.2 All documents shall be in English Language only.
11. PACKING, SHIPPING & HANDLING
After all inspection and tests required have been carried out; all external
surfaces shall be thoroughly cleaned to remove grease, dust and rust and shall
be applied with standard mill paints.

INSPECTION, FLUSHING AND TGPL-TS-STEEL-PTS-008
TESTING OF PIPING SYSTEMS
INSPECTION, FLUSHING AND TESTING OF PIPING SYSTEMS

TABLE OF CONTENTS
1.0 SCOPE .................................................................................................................................... 3

2.0 DEFINITIONS........................................................................................................................... 3
3.0 INSPECTION............................................................................................................................ 3
4.0 FLUSHING............................................................................................................................... 4
5.0 TESTING ................................................................................................................................. 5

1.0 SCOPE
This specification covers the general requirements for inspection, flushing and
testing of piping systems. Flushing and testing of all piping systems shall be
witnessed by the Engineer-In-Charge.
2.0 DEFINITIONS
Shall: This verbal form indicates requirements strictly to be Followed in order to

confirm to the standards and from which no deviation is permitted.
Should: This verbal form indicates that among several possibilities one is
particularly suitable without mentioning or excluding others or that a certain
course of action is preferred but not necessarily required.
May: This verbal form indicates a course of action permissible within the limits of
this standard.
Can: This verbal form used for statements of possibility & capability, whether
material, physical or casual.
ABBREVIATIONS:
PMI - Positive Material Identification
NDT - Non Destructive Testing
P&ID - Process and Instrumentation Diagram
A.S. - Alloy Steel
C.S. - Carbon Steel
C.I. - Cast Iron
S.S. - Stainless Steel
LTCS - Low Temperature Carbon Steel
NACE - National Association of Corrosion Engineers

3.0 INSPECTION
During various stages and after completion of fabrication and erection, the
piping system shall be inspected by the Engineer-In-Charge to ensure that:

Proper piping material has been used.

Piping has been erected as per drawings and instructions of Engineer-
In-Charge. All supports have been installed correctly.
 Test preparations mentioned in this specification have been carried out.
4.0 FLUSHING
Flushing of all lines shall be done before pressure testing.
Flushing shall be done by fresh potable water or dry compressed air, wherever
water flushing is not desirable, to clean the pipe of all dirt, debris or loose foreign
material Required pressure for water flushing shall meet the fire hydrant
pressure or utility water pressure.
For air flushing, the line / system will be pressurized by compressed air at the
required pressure which shall be 50 PSI maximum. The pressure shall then be
released by quick opening of a valve, already in line or installed temporarily for
this purpose. This procedure shall be repeated as many times as required till the
inside of the pipe is fully cleaned.
In line instruments like control valves, orifice plates, Rotary meters, safety valves
and other instruments like thermo-wells which may interfere with flushing shall
not be included in flushing circuit.
The screens / meshes shall be removed from all permanent strainers before
flushing. Screens/meshes shall be reinstalled after flushing but before testing
During flushing temporary strainers shall be retained. These shall be removed,

cleaned and reinstalled after flushing but before testing.
During flushing discharged water/air shall be drained to the place directed by the
Engineer-In-Charge. If Necessary, proper temporary drainage shall be provided
by the contractor.
Care shall be taken during flushing so as not to damage/spoil work of other

agencies. Precautions shall also be taken to prevent entry of water/foreign
matter into equipment, electric motors, instruments, electrical installations etc.
in the vicinity of lines being flushed.
The contractor shall carry out all the activities required before, during and after
the flushing operation, arising because of flushing requirements, such as but not
limited to the following

Dropping of valves, specials, distance pieces, inline instruments and any other
piping part before flushing. The flanges to be disengaged for this purpose shall
be envisaged by the contractor and approved by the Engineer-In-Charge. These
flanges shall be provided with temporary gaskets at the time of flushing.
After flushing is completed and approved, the valve distance pieces, piping
specials etc. shall be reinstalled by the contractor with permanent gaskets.
However, flanges at equipment nozzles and other places where isolation is
required during testing, only temporary gaskets shall be provided.
Records in triplicate shall be prepared and submitted by the contractor for each
piping system for the flushing done in the Performa provided/approved by the
Engineer-in-Charge.
5.0 TESTING
5.1 Extent of Testing
With the exclusion of instrumentation, piping systems fabricated or assembled in

the field shall be tested irrespective of whether or not they have been pressure
tested prior to site welding of fabrication.
To facilitate the testing of piping systems, valves and other equipment may be
included in the system with the prior approval of Engineer-In-Charge if the test
pressure specified is equal to or less than that for the valves and other
equipment.
Lines which are directly open to atmosphere such as vents, drains, safety valves
discharge need not be tested, but all joints shall be visually inspected. Wherever
necessary, such lines shall be tested by continuous flow of fluid to eliminate the
possibility of blockade. However, such lines if provided with block valve shall be
pressure tested up to the first block valve.
Seats of all valves shall not be subjected to a pressure in excess of the maximum
cold working pressure of the valve. Test pressure applied to valves shall not be
greater than the manufacturer’s recommendation nor less than that required by
the applicable code. Where allowable seat pressure is less than test pressure,
test shall be made through an open valve.
Instruments in the system to be tested shall be excluded from the test by

isolation or removals, unless approved otherwise by the Engineer-In-Charge.
Restrictions which interfere with filling, venting and draining such as orifice
plates etc. shall not be installed unless testing is complete.
Control valves shall not be included in the test system. Where bypasses are
provided test shall be performed through the bypass and necessary spool shall
be used in place of the control valve.
Pressure gauges which are part of the finished system, but cannot withstand test
pressure shall not be installed until the system has been tested. Where piping
systems to be tested are directly connected at the battery limits to piping for
which the responsibility rests with other agencies, the piping to be tested shall
be isolated from such piping by physical disconnection such as valve or blinds.
5.2 General Requirements / Test Preparation for Testing
Testing shall be carried out with permanent gaskets installed unless specified
otherwise or instructed by the Engineer-in-Charge.
No pressure test shall be carried out against closed valve unless approved by the
Engineer-in-Charge. The Engineer-in-Charge shall be notified in advance by the
Contractor, of the testing sequence and program, to enable him to be present
for witnessing the test.
Before testing, all piping shall be cleaned by flushing to make it free from dirt,
loose scale, debris and other loose foreign materials by a method approved by
Owner.
All piping systems to be hydrostatically tested shall be vented at the high points
and the systems purged of air before the test pressure is applied.
Wherever in the line any void exists due to any reasons, like absence of control
valves, safety valves, check valves etc. it shall be filled with temporary spools.
All joints welded, screwed or flanged shall be left exposed for examination during
the test. Before pressuring the lines, each weld joint shall be cleaned by wire
brush to free it from rust and any other foreign matter.
Pressure gauges used in testing shall be installed as close as possible to the

lowest point in the piping system to be tested, to avoid overstressing of any of
the lower portions of the system. For longer lines and vertical lines, two or more
pressure gauges shall be installed at locations decided by the Engineer-In-
Charge.
For lines containing check valves any of the following alternatives shall be
adopted for pressure testing: Whenever possible pressurize up-stream side of

valve. Replace the valve by a temporary spool and reinstall the valve after
testing.
Provide blind on valve flanges and test the upstream and downstream of the line
separately and remove the blind after testing. At these flanges, temporary
gaskets shall be provided during testing and shall be replaced by permanent
gaskets subsequently.
Gas lines when hydrostatically tested shall be provided with additional

temporary supports during testing as directed by the Engineer-in-Charge.
When testing any piping system, air or steam of approximately 2 kg/cm 2 may be
used as preliminary test to detect missing gaskets etc. as this avoids the
necessity of draining the line to make repairs.
5.3 Testing Media, Test Pressure and Test Pressure Gauges
5.3.1 Testing Media
In general, all pressure tests shall be hydrostatic using sulphur free water, which
is clean and free of silt. Water shall be tested in approved laboratory and
approval shall be taken from Owner before water filling.
5.3.2 Test Pressure
The hydrostatic/pneumatic test pressure shall be as indicated in the line list or as

per the instruction of Engineer-in-Charge.
The selection of the piping system for one individual test shall be based on the
following:
- Maximum allowable pressure for the material of construction of

piping.
Depending upon the above requirements and based on construction progress,

maximum length of piping shall be included in each test.
5.3.3 Test Pressure Gauge
All gauges used for field testing shall have suitable range so that the test
pressure of the various systems falls in 40% to 80% of gauge scale range. Gauge
shall be of a good quality and in good working condition.

Prior to the start of any test or periodically during the field test program, all test
gauges shall be calibrated using a standard dead weight gauge tester or other
suitable approved testing apparatus. Any gauge showing an incorrect zero
reading or error of more than ± 2% of full scale range shall be discarded. The
Engineer-In-Charge shall check the accuracy of master pressure gauge used for
calibration.
5.4 Testing Procedure
5.4.1 Hydrostatic Test
All vents and other connections used as vents shall be left open while filling the
line with test fluid for complete removal of air. In all lines for pressurizing and
depressurizing the system, temporary isolating valves shall be provided if valves
vents, drains do not exist in the system.
Pressure shall be applied only after the system / line is ready and approved by
the Engineer-in- charge. Pressure shall be applied by means of a suitable test
pump or other pressure source which shall be isolated from the system as soon
as test pressure is reached and stabilized in the system.
A pressure gauge shall be provided at the pump discharge for guidance in

bringing the system to the required pressure.
The pump shall be attended constantly during the test by an authorized person.
The pump shall be isolated from the system whenever the pump is to be left
unattended.
Test pressure shall be maintained for a sufficient length of time to permit

thorough inspection of all joints for leakage or signs of failure. Any joint found
leaking during a pressure test shall be retested to the specified pressure after
repair. Test period shall be maintained for a minimum of three hours.
The pump and the piping system to be tested are to be provided with separate
pressure indicating test gauges. These gauges are to be checked by the standard
test gauge before each pressure test. Care shall be taken to avoid increase in the
pressure due to temperature variation during the test.
5.4.2 Air Test
When testing with air, pressure shall be supplied by means of a compressor. The
compressor shall be portable type with a receiver, after cooler and oil separator.

Piping to be tested by air shall have joints covered with a soap and water
solution so that the joints can be examined for leaks.
All other details shall be same as per hydro testing procedure (specified above)
5.5 Completion of Testing
After the hydrostatic test has been completed, pressure shall be released in a
manner and at a rate so as not to endanger personnel or damage equipment.
All vents and drains shall be opened before the system is to be drained and shall
remain open till all draining is complete, so as to prevent formation of vacuum in
the system. After draining, lines / systems shall be dried by air.
Pressure test shall be considered complete only after approved by the Engineer-
in-Charge. Defects, if any, noticed during testing shall be rectified immediately
and retesting of the system / line shall be done by the contractor at his cost.
5.6 Test Records
Records in triplicate shall be prepared and submitted by the contractor for each
piping system, for the pressure test done in the Performa provided/approved by
the Engineer-in-Charge. Records shall also be submitted for the PMI.

PAINTING TGPL-TS-STEEL-PTS-010
PAINTING

TABLE OF CONTENTS
1. GENERAL ...................................................................................................................................... 3
2. 2.0 CODES & STANDARDS .................................................................................................... 4
3. 3.0 CONDITIONS OF DELIVERY .................................................................................................... 5
4. 4.0 IDENTIFICATION..................................................................................................................... 5
5. 5.0 SURFACE PREPARATION STANDARDS ................................................................................... 5
6. PREPARATION OF THE SURFACES................................................................................................ 6
7. CARRYING OUT THE PAINTWORK................................................................................................ 9
Conditions for carrying out paintwork .................................................................................................... 9

1. GENERAL
1.1 These technical specifications shall be applicable for the work covered by the
contract, and without prejudice to the provisions of various codes of practice,
standard specifications etc. It is understood that contractor shall carry out the
work in all respects with the best quality of materials and workmanship and in
accordance with the best engineering practice and instructions of Engineer-In-
Charge.
Wherever it is stated in the specification that a specific material is to be supplied

or a specific work is to be done, it shall be deemed that the same shall be
supplied or carried out by the contractor. Any deviation from this standard
without written deviation permit from appropriate authority will result in
rejection of job.
1.2 SCOPE
1.2.1 Scope of work covered in the specification shall include, without being limited to
the following.
1.2.2 This specification defines the requirements for surface preparation, selection and
application of primers and paints on external surfaces of piping, structures,
Valves etc. The items listed in the heading of tables of paint systems is indicative
only, however, the contractor is fully responsible for carrying out all the
necessary painting, coating and lining on external and internal surfaces as per
the tender requirement.
1.2.3 Extent of Work
1.2.3.1 The following surfaces and materials shall require shop, pre-erection and field
painting:
a. All carbon and low alloy piping, fittings and valves (including painting of
identification marks).
b. All items contained in a package unit as necessary.
c. All structural steel work, pipe, structural steel supports, walkways,
handrails, ladders, platforms etc.

d. Identification lettering/numbering on all painted surfaces of

equipment/piping.
e. Supply of all primers, paints and all other materials required for painting.
f. Over insulation surface of equipment and pipes wherever required.
g. Painting under insulation for carbon steel, alloy steel and stainless steel
as specified.
h. Painting of pre-erection/fabrication and Shop primer.
i. Repair work of damaged pre-erection/fabrication and shop primer and
weld joints in the field/site before and after erection as required
n. All CS Piping, equipment, storage tanks and internal surfaces of RCC
structures.
1.2.4 Unless otherwise instructed, final painting on pre-erection/ shop primed pipes
and equipment shall be painted in the field, only after the mechanical
completion, testing on systems are completed as well as after completion of
steam purging wherever required.
1.2.5 Changes and deviations required for any specific job due to client’s requirement
or otherwise shall be referred to for deviation permit.
2. CODES & STANDARDS
Without prejudice to the specifications of the contract, the following codes and
standards shall be followed for the work covered by this contract.
IS: 5 Colours for ready mixed paints and enamels.
IS: 101 Methods of test for ready mixed paints and enamels,
IS: 161 Heat resistant paints.
IS: 2074 Specifications for ready mixed paint, red oxide zinc chrome priming.
IS: 2339 Aluminium paint for general purposes in dual container.
IS: 2379 Colour code for identification of pipelines.
IS: 2932 Specification for enamel, synthetic, exterior

3. CONDITIONS OF DELIVERY
Packaging
Every recipient will be fitted with a hermetically-sealed lid with an opening that is
sufficiently large to allow the contents to be stirred: the outside and inside are
protected against oxidation, and, the lid, are marked with a strip of colour
identical to the contents.
4. IDENTIFICATION
Every recipient will bear the following information:
 Name of the manufacturer

 Date and number of manufacture
 Name of the product type
 Batch no
 Net weight of the produced or the contents of the recipient
 Date of the expiry.
At the time of delivery, this packaging must bear labels in conformity with the
legal stipulations in force.
Leaving the site after work
After completion of a job a general clean-up shall be carried out by the

Contractor to remove all debris, materials or irregularities that his work has
brought to the site so that it is left tidy:
The restoration work includes among other things:
 The removal of abrasives.

 The removal of the different protective coverings.
 The Contractor will make the required repairs to any damage after
refitting the supports.
The removal of paint and cleaning of the stains from the floor.
5. SURFACE PREPARATION STANDARDS
Following standards shall be followed for surface preparations:
1. Swedish Standard Institution- SIS-05 5900-1967
2. Steel Structures Painting Council, U.S.A. (Surface Preparation

Specifications (SSPC-SP)

3. British Standards Institution (Surface Finish of Blast-cleaned for Painting)

BS-4232.
4. National Association of Corrosion Engineers. U.S.A. (NACE).
5. IS-1477-1971 (Part-1) - Code of Practice for Painting of Ferrous metals in

Buildings. (Part 1, Pre-treatment)
a) The contractor shall arrange, at his own cost to keep a set of latest
edition of above standards and codes at site.
b) The paint manufacturer's instruction shall be followed as far as

practicable at all times. Particular attention shall be paid to the
following:
 Proper storage to avoid exposure as well as extremes of

temperature.
 Surface preparation prior to painting.
 Mixing and thinning.
 Application of paints and the recommended limit on time intervals
between coats.
c) Any painting work (including surface preparation) on piping or

equipment shall be commenced only after the system tests have
been completed and clearance for taking up painting work is given by
the OWNER, who may, however, at his discretion authorize in
writing, the taking up of surface preparation or painting work in any
specific location, even prior to completion of system test.
6. PREPARATION OF THE SURFACES
6.1 General Specifications
The method of preparation of the surface will be implemented in accordance

with the preparation methods described below:
 Mechanical cleaning;
 Manual de-rusting;
 Cleaning (bright blast-cleaning);
The Contractor should have the required material at his disposal to clean the
surfaces to be coated thoroughly in accordance with the preparation methods
regardless of the form or the condition of such surfaces. The cleaning devices

that might be damaged during the surface preparation shall be screened off by
the Contractor.
6.2 Sandblasting
Before beginning cleaning by blasting, the person carrying out the work will take
the following measures:
 Clear the steel surface of oil and/or grease;

 Ensure that each flange collar (section where the sealing is applied) is
properly screened off against the blasting and the subsequent works;
 Check that no blasting grains can act into the pipes during this process.
Any openings not sealed off must be screened off;
 Where there are valves, regulators and other devices, the manufacturer's
identification plate will be dismantled so that all surfaces can be treated.
The plate will then be put back again.
 Screen off all non-metal structures such as rubber where there is a filter;
 With valves, operators and other devices, care should be taken to ensure
that no metal filings or paint get into the apparatus:
 The OWNER reserves the right to carry out part or all of these works
himself.
To prevent rust forming quickly as the result of humidity on the blasted surface,
cleaning by blasting may only be carried out when the temperature of the steel
surface is higher than the dew-point of the ambient air.
Blasting may not be carried out if the relative degree of humidity exceeds 80%.
The choice of the type of blasting medium used depends on local circumstances
such as the possible presence of gas and the material to be blasted.
The abrasive to be used must conform to the local low i.e. it may contain no
carbon and less than 1% free silicon dioxide. Profile surface must at least reach
Sa 2½ during the initial stage of the paintwork. The degree of cleanliness to be
obtained will be inspected in accordance with the Swedish standard SVENSK
STANDARD ISO 8501-1-1988/SS 055900.
Sa 2 1/2: blasted very carefully. Scale, rust and foreign bodies must be removed
in such a way that anything left behind will only be visible as nuances (shading)
or strips.
The blast-cleaning will be carried out by means of compressed air free of water
and oil.

After the blasting and before painting, the surface should be completely cleaned
of blasting material and so forth with a soft brush, a dry cloth or dry compressed
air.
6.3 Mechanical cleaning
If sandblasting is not permitted or if the metal structures are not easily accessible
for blasting or blasting for one reason or another is technically unfeasible,
mechanical de-rusting can be used instead. With mechanical cleaning by means
of chipping, rotating steel brushes and sanding discs, a degree of cleanliness SA.
3 should be reached.
St 3: removal of the old paint layers of which the adhesion leaves something to
be desired and/or of which the paint layer no longer fulfils the requirements.
If parts are present that are so corroded that St 3 is difficult to achieve, this
should be notified to the OWNER representative prior to the start of the works.
N.B:
St. 3: means removal of every old paint layer. Retouching means local polishing
with St. 3 or Sa 3 followed by application of the desired painting system.
After mechanical cleaning, the surface should be made dust-flee with a cloth or a
so brush, washed with an organic solvent and thoroughly dried off with a dry
cloth (e.g. with 1.1.1. Trichoroethane such as Solvethane, Chloroethene).
6.4 Manual De-rusting
Manual de-rusting with the aid of scrapers. steel brushes, sandpaper etc. shall
only be permitted in exceptional cases for local repairs. Any deviation there from
must be requested from the OWNER/ OWNER 's Representative.
Preparation of concrete or cement plaster surfaces
Remove unsound paint layers and loose components with scrapers, blades or
rotating steel brushes. Thoroughly clean the entire surface with water containing
ammonia. Thoroughly remove moss, algae and fungal growths. Where these
growths have been removed, treat the area with a fungicide in accordance with
the instructions for use.
Once the entire area is completely dry, brush off the dead residue of moss, algae
and fungus with a hard brush. In the case of reinforcement steel that has been
laid bare, remove as rust, dust and grease as possible and treat with a printer
coat. When painting concrete surfaces, they must first be checked for cracks.
Cracks larger than 0.3 mm must be repaired with an appropriate system in

accordance with the type and extent of the repairs (e.g. injection with epoxy
mortar). Repair damage such as cracks and bursts to concrete parts with a two-
component mortar or preferably with micro-mortars. Finally check the alkalinity
of the surface with the aid of litmus paper and neutralize it if necessary.
6.5 Removing coating from surface pipelines
The Contractor must have the equipment necessary for the removal of asphalt
from the pipe without damaging the latter (scratching, impact, etc.). The
Contractor undertakes to carry out the work in accordance with an approved
procedure.
7. CARRYING OUT THE PAINTWORK

Conditions for carrying out paintwork
Painting may not be carried out in unsuitable conditions.
All preparatory work and painting may only he carried out in dry weather and at
a minimum temperature of 10° C, except for special eases requested by the
OWNER's Representative.
Unless otherwise stipulated in the specifications of the paint supplier, application

of the paint is forbidden if it is forecast that the temperature will fall to below
0°C before the paint is dry. The temperature of-the surface to be painted must
be at least 3°C higher than the dew point of the ambient air. Application of the
paint is also not permitted if there is a danger that the coat of paint will not be
dry before dew or condensation sets in.
The work must be stopped:
 If the temperature of the surface to be painted is higher than that

described by the supplier.
 In rain, snow, mist or fog or when the relative humidity is higher than 80 %.
Coats that have not yet dried and have been exposed to frost, mist, snow or rain
and might thereby be damaged must be removed after drying and the surfaces
must be repainted at the expense of the Contractor.
The first coat of paint must be applied maximum 3 hours after the preparation of
the surface of the relative humidity of the air is between 50% and 80%. This time
span may be increased to 6 hours if the relative humidity is less than 50%. In all

cases, the preparation of the surface must exhibit degree Sa 3 and at the very
least the appearance of degree Sa 2 ½ at the time of painting.
The coats of paint may only be applied on carefully cleaned surfaces that must be
dry and free of grease and dust.
Special conditions
Painting may be carried out when the Contractor can be sure that the
instructions of the paint supplier have been scrupulously followed with regard to
the parameters in the following (non-exhaustive) list:
 Ambient temperature.
 Surface temperature.
 Relative humidity.
 Dew point.
 Drying times.
The Contractor must in this respect be able to produce the instructions for the
paint on the site. The
Paint Materials
Manufacturers shall furnish the characteristics of all paints indicating the

suitability for the required service conditions. Primer, intermediate and finish
coats shall be of Class-I quality and shall conform to the following:
Primary coat with Zinc rich primer
a. After surface preparation primary coat by Zinc rich primer shall be applied
on the surface.
b. Mixing ratio shall be 3:1 (Base: Accelerator).
c. Primer shall be equally distributed on the surface area using spray gun to
achieve DFT as demonstrated in procedure qualification.
d. After 60 min. DFT (Dry Film thickness) shall be checked by coat gauge and it
should be within 25-40 microns.
Intermediate Coat (Polyamide)
a. Intermediate Coat shall be applied only after drying of the primer coat.
b. Intermediate Coat (Polyamide) shall be applied on surface area using spray
gun.
c. Mixing ratio shall be 4:1 (Base: Accelerator).

d. After 3 hrs. DFT shall be checked and it should be within 75-100 microns.
Top Coat (Polyurethane):
a. Top coat shall be applied only after drying of Intermediate coat.
b. Top coat (Polyurethane) shall be applied on surface area using air less spray
gun.
c. Mixing ration shall be 4:1 (Base: Accelerator)
d. Hand brush / roller shall be used for small areas.
e. After 3 hrs. DFT shall be checked and it should be 30-40 microns.
MANUFACTURERS
The paints shall conform to the specifications given above and Class-I quality in
their products range of any of the-following manufacturers:
i. Asian Paints (India) Ltd,
ii. Bombay Paints
iii. Berger Paints India ltd.
iv. Nerolac Paints Ltd.
v. Jenson & Nicholson
vi. Shalimar Paints
STORAGE
All paints and painting material shall be stored only in rooms to be provided by
contractor and approved by OWNER/ OWNER’s Representative for the purpose.
All necessary precautions shall be taken to prevent fire.
The storage building shall preferably be separate from adjacent, building.
A signboard bearing the words given below shall be clearly displayed outside:
PAINT STORAGE No NAKED LIGHT highly -inflammable
COLOR CODE FOR PIPING:

1) The minimum coating thickness on weld seam shall be as per direction of EIC
and approved procedure.
COLOR CODE:
A) Ball Valve (Above Ground) : Off White
B) Globe Valve (Above Ground) : Oxford Blue-RAL 5005, IS-519941005
C) Check Valve(Above Ground) : Oxford Blue-RAL 5005, IS-519941005
D) Launcher / Receiver : Yellow Golden
E) Handrails : Yellow Golden

F) All underground valves shall have epoxy base coating after surface finish
of SA 2:5
G) Valves and above ground pipes need to be properly blasted to achieve
surface finish of Sa 2:5 before the application of paints.
PRIMER APPLICATION:
The contractor shall provide standard thickness measurement instrument with

appropriate range(s) for measuring.
Dry film thickness of each coat, surface profile gauge for checking of surface
profile in case of sand blasting. Holiday detectors and pinhole detector and
protector whenever required for checking in case of immerse conditions.
i. At the discretion of OWNER/ OWNER's Representative, contractor has to

provide the paint manufacturers expert technical service at site as and
when required. For this service, there should not be any extra cost to the
OWNER.
ii. Final Inspection shall include measurement of paint dry film thickness,
check of finish and workmanship. The thickness should be measured at as
many points/ locations as decided by OWNER/ OWNER's Representative
and shall be within +10% of the dry film thickness.
iii. The contractor shall produce test reports from manufacturer regarding the
quality of the particular batch of paint supplied. The OWNER shall have the
right to test wet samples of paint at random for quality of same. Batch test
reports of the manufacturers for each batch of paints supplied shall be
made available by the contractor.
PAINT SYSTEMS:
The paint system should vary, with type of environment envisaged in and around
the plants. The types of environment are considered for selection of paint
system.

Primers and finish coats for any particular paint systems shall be from same
manufacturer in order to ensure compatibility.
Table – 1
Colour Coding Scheme for Pipes and Equipment
SI. No. Content Ground Colour First Colour Band Second Colour
Band
1 COMPRESSED AIR
a) Plant Air Sky Blue Silver Grey -
b) Instrument Air Sky Blue French Blue -
2 GASES
a) Charge Gas Golden Yellow Signal Red Smoke Grey
Precautions to be taken
Neither the environment of the site nor the marking labels of devices may be
covered with paint and they must be kept free of paint splashes. To this end, it is
advisable to use removable masking tape.
Paint splashes, leaks, etc. on any adjacent installations such as measuring

apparatus, valves, pipes. sources of light, insulation, heat insulators, walls,
concrete, etc, must immediately be wiped up and the damage repaired before
the paint is dry.
Otherwise, the OWNER will be obliged to have the cleaning carried out at the
expense of the Contractor. The paint recipient will only be opened at the time of
use (unless otherwise specified by the manufacturer).
Method of application
Normally, three methods of application will be used on the construction site for
the paint products. i.e. with a brush, with a roller or with a spray gun.
 The brush method makes it possible to obtain good penetration of the

paint over irregularities in the metal.
 Only this method will be used for application of the base coats, for
retouching and for protrusions, welded areas, riveted joints or bolted
joints:
 The roller method may be used on large flat surfaces for the intermediate
and topcoats.
 The spray gun method must be used in accordance with the instructions
of the manufacturer and carried out by qualified personnel.
The Contractor must guarantee that all safety measures have been taken for
such work. The spray gun method may only he used on site for places that are
difficult to reach with the brush. In this case, a request must be made to the
OWNER/ OWNER's Representative for a deviation.
All paintwork will be carried out with good brushes or rollers that are suitable for
the type of paint being used and for the form of the material to be painted and
fitted with short handles.
Application of the Painting
Application of the paint will be carried out in accordance with best practice in
order to obtain a homogeneous and continuous layer. The OWNER or the TPIA
may demand that painting of a layer will only be started after acceptance by
them of the surface preparation or of the previous layer of paint.
The layers of paint must have a uniform thickness. They must he spread in such a
way that all concave parts are dried out and that the surface is completely
covered and has a glossy appearance without leaving brush marks and without
exhibiting bubbles, foam, wrinkles, drips, craters, skins or gums that arise from
weathered paint,
Each layer must have the colour stipulated in the tables of the present
specifications, which clearly differs from the previous layer, taking account of the
Colour of the top layer, all of which for the purpose of being able to identify the
number of coats and their order of sequence
The dry coating thickness indicated in the description of the paint systems are
minimum thickness. In this connection, the Contractor is obliged to contact the
paint manufacturer and conform to his guidelines. The Contractor must respect
the thickness specified by the supplier.
QUALITY CONTROLS AND GUARANTEE
The Contractor is responsible for checking the weather conditions to ascertain

whether the paintwork can be carried out within the technical specifications.
The Contractor should have the required calibrated monitoring apparatus for this
purpose on site (with calibration certificates). The personnel who will have to use
this apparatus should have the training for this purpose.
The OWNER or his representative and possibly the approved supervisory body
indicated by the OWNER will maintain supervision during the works and inspect

the works with random checks. A daily report will be drawn up in relation to the
department that maintains supervision of these works.
The supplementary inspection and the supervision by the OWNER or the

approved supervisory body do not diminish in any way the liability of the
Contractor. The proper execution of the work and the materials used may be
checked at any time.

TECHNICAL SPECIFICATIONS BUTT
WELDED, SOCKET WELDED AND TGPL-TS-STEEL-PTS-003
SCREWED FITTINGS
BUTT WELDED, SOCKET WELDED AND SCREWED FITTINGS

SCREWED FITTINGS
TABLE OF CONTENTS
1. GENERAL ................................................................................................................................ 3
2. MARKING AND DISPATCH ....................................................................................................... 4

SCREWED FITTINGS
1. GENERAL
Chemical composition, physical properties, tests, dimensions and tolerances,
heat treatment and marking shall conform to the applicable latest
codes/standards/specifications. Any deviation shall be highlighted on a separate
sheet by the vendor in the quotation itself.
Test reports shall be supplied for all mandatory tests as per the material
specifications. Test reports shall also be furnished for any supplementary tests as
when required will be informed. Material test certificates (physical properties,
chemical composition & heat treatment report) shall also be furnished for
fittings supplied.
All fittings shall be seamless in construction unless otherwise specified. Seamless
fittings shall be with no negative tolerance on wall thickness. Welded fittings
shall not be acceptable.
Outside diameters and wall thickness (unless otherwise mentioned) of butt
welded fittings shall be in accordance with ASME B36.10 and ASME B36.19 as
applicable.
For reducing butt weld fittings having different wall thicknesses at each end, the
greater wall thickness of the fitting shall be employed and inside bore at each
end shall be matched with the specified inside diameter.
Bevelled ends for all fittings shall conform to ASME B16.25.
Fittings under “NACE” category shall meet the requirements of MR-01-75.
Thickness/schedule lower than specified shall not be accepted.
The gasket contact surfaces of stub ends shall be flat with face finish as specified
below:
• Serrated Finish Serrations with 250 to 500µ in AARH
• Smooth Finish: Serrations with 125 to 250 µ in AARH
Seamless stub ends shall not have any welds on the body.
Threaded ends shall have NPT taper threads in accordance with ASME/ANSI.
All socket welded and screwed fittings shall be in accordance with ASME B16. 11
to the extent covered in the specification except for unions which shall be in
accordance with MSS-SP-83.
SCREWED FITTINGS
Special fittings like weld-o-let, sock-o-let, sweep-o-let etc. which are not covered
in ASME, MSS-SP & Standards shall be as per manufacturer’s std. Contours of
these fittings shall meet the requirements of ASME B31.3. Manufacturer shall
submit drawings / catalogues of these items along with the offer.
Length of all long half couplings shall be 100 mm unless otherwise specified.
All seamless fittings shall be required to have undergone hydro test at a test
pressure of 90% SMYS of the material.
The bevel ends of all butt weld fittings shall undergo 100% MP/DP test.
Swage nipples (concentric/eccentric) if specified as pipe materials are acceptable
in forging materials (up to 1½”) and wrought fitting materials (above 1½”) also in
the corresponding material grades.
Abbreviations for ends of swages and nipples shall be as follows:
PBE : Plain Both Ends
TBE : Threaded Both Ends
2. MARKING AND DISPATCH
Each fitting shall be legibly and conspicuously stamped in accordance with the
requirements of applicable standards.
Steel die marking with round bottom punch may be permitted on body of butt
weld CS & lower alloy steel fittings.
Paint or ink for marking shall not contain any harmful metals or metal salts such
as Zinc, Lead or Copper which causes corrosive attack on heating.
Fittings shall be dry, clean and free of moisture, dirt and loose foreign materials
of any kind.
Fittings shall be protected from rust, corrosion and mechanical damage during
transportation, shipment and storage.
Rust preventive used on machined surfaces to be welded shall be easily
removable with a petroleum solvent and the same shall not be harmful to
welding.
Each end of fitting shall be protected with a wood, metal or plastic cover.

SCREWED FITTINGS
Each size of fitting shall be supplied in separate packaging marked with the
purchase order number, item code number, material specification, size and
schedule/thickness / rating.

SEAMLESS FITTINGS TGPL-TS-STEEL-PTS-009
SEAMLESS FITTINGS

TABLE OF CONTENTS
1. SCOPE .................................................................................................................................... 3
3. MANUFACTURE’S QUALIFICATION .......................................................................................... 4
4. MATERIAL .............................................................................................................................. 4
5. DESIGN AND MANUFACTURE ................................................................................................. 4
8. PAINTING, MARKING AND SHIPMENT ..................................................................................... 6
9. WARRANTY ............................................................................................................................ 6
10. DOCUMENTATION.................................................................................................................. 7

1. SCOPE
1.1 This specification covers the minimum requirements for the design, manufacture
and supply of following fittings in size NB 300mm and smaller to be installed in
natural gas piping system.
1.1.1 Fittings such as tees, elbows, caps etc. shall conform to the requirements of
MSSSP-75, latest edition. Dimensions standard for Screwed/SW fittings shall be
as per ANSI B16.11.
1.2 All requirements contained in the above standards shall be fully valid unless
cancelled, replaced or amended by more requirements as stated in this
specification.
2.1 Reference has also been made in this specification to the latest edition of the
following codes, standards and specifications:
ASME B 31.8: Gas Transmission and Distribution Piping System
ASME B 31.4: Liquid transportation system for hydrocarbon liquid petroleum gas,
anhydrous ammonia and alcohols
MSS-SP-97: Forged carbon steel branch outlet fittings – socket welding, threaded
and butt welding ends.
ANSI B 16.25: Butt – Welding Ends
ASME B 16.9: Factory made wrought steel butt welding fittings
ASME B 16.11: Forged Steel Fittings, Socket Welding and Threaded
ASTM A 370: Mechanical Testing of Steel Products
ASTM Part-1: Steel Piping, Tubing, Fittings
MSS-SP-25: Standard marking system for valves, fittings, flanges and unions.
MSS-SP-75: Specification for High Test Wrought Welding Fittings
2.2 In case of conflict between the requirement of MSS-SP-75, & above reference
documents and this specification, the requirements of this specification shall
govern.

3. MANUFACTURE’S QUALIFICATION
Manufacturer for fittings must possess the records of a successful proof test in
accordance with the provisions of relevant MSS-SP-75 and/or ANSI B16.9/ANSI
B16.11 as applicable. These records shall be submitted at the time of bidding.
4. MATERIAL
4.1 The basic material for fittings shall be as indicated in the Purchase Requisition
Additionally; the material shall also meet the requirements specified hereinafter.
4.2 Steel used shall be fully killed.
This specification and the relevant codes, prior to shipment, at his works. Such
inspection and tests shall be, but not limited to the following:
4.3 Each heat of steel used for the manufacture of fittings shall have carbon
equivalent (CE) not greater than 0.45 calculated from check analysis in
accordance with the following formula:
Mn Cr + Mo + V NI + Cu
CE = C + ------- + ------------------- + ------------
6 5 15
Carbon contents on check analysis shall not exceed 0.22%.
4.4 Unless specified otherwise, Charpy V-notch test shall be conducted for each heat
of steel, in accordance with the impact test provisions of ASTM A370 at
temperature of 0ºC. The average absorbed impact energy values of three full-
sized specimens shall be 30 joules.
The minimum impact energy value of any one specimen of the three specimens
analysed as above, shall not be less than 80% of the above mentioned average
value.
4.5 Hardness testing shall be carried out by Manufacturer in accordance with

applicable ASTM code.
5. DESIGN AND MANUFACTURE
5.1 Fittings such as tees, elbows and reducers shall be seamless type and shall
conform to ASME B16.9 for sizes 50mm (2”) NB and above ASME B16.11 for sizes
below 50mm (2”) NB.

5.2 Fittings such as weldolets, sockolets, etc. shall be manufactured in accordance

with MSS-SP-75.
5.3 Stub-in or pipe-to-pipe connection shall not be used in the manufacture of tees.
Tees shall be manufactured by forging or extrusion methods. Fittings shall not
have any circumferential joints.
5.4 All butt weld ends shall be bevelled as per ASME B16.25.
5.5 Repair by welding on parent metal of the fittings is not allowed.

6.1 The Manufacturer shall perform all inspection and tests as per the requirements
of this specification and the relevant codes, prior to shipment, at his works. Such
inspection and tests shall be, but not limited to the following:
6.1.1 Visual inspection.
6.1.2 Dimensional checks as per MSS-SP-75 for fittings/applicable standards.
6.1.3 Chemical composition, mechanical properties and hardness examination.
6.1.4 All finished wrought weld ends shall be 100% ultrasonically tested for lamination
type defects. Any lamination larger than 6.35 mm shall not be acceptable.
6.1.5 All other tests not specifically listed but are required as per applicable standard/
specification.
6.2 Purchaser’s Inspector may also perform stage wise inspection and witness tests
as indicated in Para 6.1 at manufacturer’s works prior to shipment. Manufacturer
shall give reasonable notice of time and shall provide without charges reasonable
access and facilities required for inspection to the Purchaser’s Inspector
Inspection and tests performed/witnessed by Purchaser’s Inspector shall in no
and test.
Manufacturer shall produce the certificates (in original) for all, including, but not
limited, the following tests:
a) Certificates of chemical analysis and mechanical properties of the

material used for construction as per this specification and relevant
standards.

b) Certificates of required non-destructive tests inspections.
c) Certificates of all other tests as required in this specification.
d) In case any of the said certificates is not available during the final test, the
supply shall be considered incomplete.
8. PAINTING, MARKING AND SHIPMENT
All fittings shall be marked as per MSS-SP-25.
All loose material and foreign material i.e. rust, grease, etc. shall be removed
from the inside and outside of the fittings.
Ends of all fittings shall be suitably protected to avoid any damage during transit.
Metallic bevel protectors shall be used for fittings of size 18” and larger each item
shall be marked with indelible paint with the following data:
a) Manufacturer marking
b) Material Specification
c) Size & Sch.
d) Heat No.
Package shall be marked legibly with suitable marking ink to indicate the
following:
a) Order Number
b) Package Number
c) Manufacturer’s Name
d) Type of Fitting
e) Size (inches) and Wall Thickness (mm)

9. WARRANTY
Manufacturer will reimburse purchaser for any fitting furnished on this order
that fails under field hydrostatic test if such failure is caused by a defect in the
fitting, which is outside the acceptance limits of this specification. The
reimbursement cost shall include fitting, labour and equipment rental for finding,
excavation, cutting out and installation of replaced fitting in position. The field
hydrostatic test pressure will not exceed that value which will cause a calculated

hoop stress equivalent to 100% of specified minimum yield strength for the pipe
with which the fitting is to be attached without impairing its serviceability.
10. DOCUMENTATION
10.1 All documents shall be in English Language.
10.2 At the time of bidding bidder shall submit the following documents:
a) Reference list of previous supplies of similar fittings of similar

specification.
b) Clause wise list of deviation from this specification, if any.
c) Brief description of the manufacturing and quality control facilities of the

Manufacturer’s work.
d) Manufacturer’s qualification requirement as per section 3.0 of this

specification.
e) Quality Assurance Plan (QAP).
10.3 Within two weeks of placement of order, the manufacturer shall submit four
copies of method of manufacture and quality control procedure for raw material
and finished product.
Once the approval has been given by Purchaser, any change in material, method
of manufacture and quality control procedure shall be notified to Purchaser
whose approval in writing of all changes shall be obtained before the fittings are
manufactured

WELDING OF STATION PIPING TGPL-TS-STEEL-PTS-006
WELDING OF STATION PIPING

TABLE OF CONTENTS
1. GENERAL ...................................................................................................................................... 3
2. WELDING PROCEDURES .............................................................................................................. 4
3. NON DESTRUCTIVE EXAMINATION ........................................................................................... 18
4. REPAIRS OF WELDS .................................................................................................................... 26
5. INSPECTION ............................................................................................................................... 27
6. DOCUMENTS TO BE SUBMITTED BY THE CONTRACTOR ........................................................... 28

1. GENERAL
1.1 Scope
This specification shall be followed for the fabrication of all types to welding
joints of piping system within the battery limits of all pressure piping of station.
This specification shall apply to all suppliers, vendors, manufacturers, and
fabricators. The CONTRACTOR is responsible for all and shall ensure that all
components to be incorporated into the work meeting this specification.
No supplier, vendor, manufacturer or fabricator shall subcontract the welding
fabrication of any item without written approval from the OWNER and the
OWNER will not issue such an approval unless the proposed welding fabricator
has received prior OWNER approval for the type of welding to be carried out.
The welded pipe joints shall include the following and shall not relieve the
contractor of his responsibilities and guarantee.
a) All pipe joints, longitudinal butt welds, circumferential butt welds and
socket welds.
b) Attachments of forging, flanges and other supports to pipes.
c) Welded manifold headers and other sub-assemblies.
d) Welded branch connections with or without reinforcing pads.
e) Joints in welded / fabricated piping components.
f) The attachments of smaller connection for vents drain drips and other
instrument tapings.
1.2 Codes, Standards and Regulations
All welding performed under this Specification shall meet or exceed the
requirements specified by the latest revisions of the following applicable Codes
and Regulations
Indian Provincial regulations governing the welding of piping systems,
augmented with the following:
1. PNGRB NOTIFICATION: Technical Standards and specifications including safety

standards for city or local natural gas distribution Schedule-1 network.

2. AWS (American Welding Society).

a) A3.0 (Standard Welding Terms and their Definitions).
b) A5.1 (Specification for Mild Steel Covered Arc Welding Electrodes).
c) A 5.17(Specification for Bare Carbon Steel Covered Electrodes).
d) A 5.18 (Specification for Carbon Steel Filler Metals for Gas Shielded Arc
Welding).
e) A 5.20 (Specification for Mild Steel Electrodes for Flux Cored Arc
Welding Electrodes).
3. Applicable Local Boilers and Pressure Vessels Act and Regulations.

4. ASME B 31.3 Chemical Plant and Petroleum Refinery and Process Piping.
5. ASME Sec. VIII Div. 1 - Pressure Vessels.
6. ASME Sec. IX - Welding.
7. ASME/ANSI B31.8 - Gas Transmission and Distribution Systems.
8. ASME Sec V - Non-destructive examination.
9. API Std 1104 – Standard for Welding Pipelines and Related Facilities.
10. AWS D 1.1
All welding procedures used by fabricators and CONTRACTORS shall have been
established and qualified in accordance with the appropriate sections of one or
more of the codes and standards listed above, and approved by the OWNER.
Where a conflict occurs between these specifications and / or any of the above
codes or standards the more stringent shall apply.
2. WELDING PROCEDURES
2.1 CONSUMABLES
All the welding consumables necessary for the execution of the job such as
electrodes, filler wires, argon etc., the CONTRACTOR shall provide at his own
expenses, and these should bear the approval of the OWNER before starting the
work.
The welding electrodes and filler wires supplied by the contractor shall confirm
to this specification and standard codes and shall be of the make approved by

the OWNER and shall submit all test certificates to the Owner for review and
approval.
The contractor shall submit batch test certificates from the electrodes
manufacturers, giving details of physical and chemical tests carried out by them,
for each batch of the electrodes to be used.
Electrode qualification test records for each batch shall be carried by contractor
and test records submitted, for obtaining the approval of the ENGINEER
INCHARGE.
The electrodes, filler wires and flux used shall be free from rust, oil, grease, earth
and other foreign matter, which affect the quality of the welding.
All coated metal arc-welding electrodes shall comply with AWS specification A
5.5, A5.1 type unless approved otherwise by the OWNER.
All welding consumables including fluxes shall be supplied in sealed containers
and stored in a dry location at a minimum temperature of 68°F/20 o C and a
maximum relative humidity of 70%. Low-hydrogen electrodes, after removal
from factory seal containers, shall be stored at a minimum temperature of
150°F/66o C and suitably dried prior to use.
The welding filler metals shall have a chemical composition as near as possible to
the parent metals to be welded. The finished weld as deposited, or after post
weld heat treatment (PWHT) when required, shall be at least equal to the parent
metal as to unit strength, ductile, and other physical properties and in resistance
to corrosion, hydrogen attack, or other operating environment factors as
required. Permission to change filler metals to those other than the ones
qualified in accordance with this specification must be obtained in writing, from
the OWNER.
Electrode and rod diameters shall conform to the parameters of the weld
procedure.
The CONTRACTOR shall provide adequate drying ovens and take proper
precautions in the storage and handling of low-hydrogen electrodes.

Electrodes and filler rods shall be protected from mechanical damage or

deterioration. All unidentified damaged or deteriorated electrodes or filler wires
shall be removed from the working area and rejected.
Any low hydrogen type SMAW electrodes not contained in heated quivers shall
be removed from the site. Electrodes shall not be exposed to wet or high humid
conditions.
Care of welding consumables is the responsibility of the CONTRACTOR.
CONTRACTOR should follow the manufacturer’s recommendations for handling
and storage of welding electrodes however, the following are the minimum
requirements:
Low-hydrogen SMAW electrodes shall be kept in commercial electrode ovens
after the factory container has been opened. The electrode holding oven
temperature shall be maintained between 175°F (79°C) and 250°F (121°C). Any
low-hydrogen SMAW electrodes that have been exposed for more than 4 hours
prior to restocking into the holding oven or any SMAW low-hydrogen electrodes
that have become wet or have damaged coatings shall not be used rejected and
removed from site.
Baking oven shall be used for the low hydrogen electrode and welding flux.
Other (non-low-hydrogen) SMAW electrodes shall be kept in a dry and dust-free
enclosure after opening of the factory container. These non-low-hydrogen
electrodes shall be held at a temperature below 150°F (66°C).
Bare wire and bare filler rod (GTAW) shall be stored in a dry and free from dust,
grease etc.
The Contractor shall carry batch wise testing of electrodes.
Different grades of electrodes shall be stored separately.
SHIELDING GAS
The composition and the purity of the shielding gas, when required by the
welding processes other than Shielded Metal Arc Welding (SMAW) process,
Contractor shall bear the approval of the Owner / Owner’s representative.
An appropriate gases or gas mixture of the following quality shall be used.
 Argon gas complying with BS 4365.

 Carbon dioxide gas complying with type 1 specified in BS-4105
 Gas mixtures that have been proved to be satisfactory as a result of
procedure approval tests.
When a gas mixture is used, which has specified additions viz. 2% O2, 5% CO2,
the variation of such addition shall not exceed +10% of that stated. Moisture
content shall correspond to a dew point of -300 C or lower. All shielding gas
containers shall have clear identification labels which include the gas type.
Pipe (Station/terminal piping)
 Shielded Metal Arc Welding (SMAW) and Gas Tungsten Arc Welding
(GTAW) shall be used for welding of station/terminal piping.
 For pipe sizes 2” and below, the entire joint shall be carried out by
GTAW.
 For pipe sizes above 2”, root pass shall be carried out by GTAW and
the filler passes by GTAW/SMAW.
 GTAW process shall be used for fillet/socket joints.
2.2 WELDING PROCESS

Welding of various materials under this specification shall be carried out using
one or more welding process as given below with the approval of the ENGINEER
IN CHARGE.
- Shielded Metal Arc Welding Process (SMAW)

- Gas Tungsten Arc welding process (GTAW)
The CONTRACTOR shall have a separate welding procedure for each method of
welding be intends to employ.

Automatic and semiautomatic welding processes shall be employed only with

the approval of the ENGINEER IN CHARGE. The welding procedure shall be
adopted and consumables used shall be specifically approved.
A procedure qualification record (PQR) shall be included for each WPS. The PQT
shall be witnessed by the OWNER/ OWNER’s Representative and shall be
supported with the lab report from the testing laboratory.
A combination of different welding process could be employed for a particular
joint only after duly qualifying the welding procedure to be adopted and
obtaining the approval of ENGINEER IN CHARGE.
All testing shall be performed and certified by OWNER approved testing
laboratory, agency or equivalent. The minimum acceptable written procedure
shall detail information on the following parameters.
1. The scope of work performed under the procedures.

2. The base metals and applicable specifications.
3. The welding process.
4. Type, size, classification and composition of filler metals. (The specific
brand name(s) of the flux-wire shall become an essential variable of
the procedure qualification)
5. Type of current and voltage range as per range
6. Width of electrode weave or oscillation
7. Joint preparation and cleaning procedures.
8. Tack welding procedures. Method of marking the location of tack
welds to facilitate post weld inspection shall also be included
9. Electrode polarity.
10. Applicable welding positions.
11. Preheat and inter pass temperatures. (Control method)
12. Welding travel speed.
13. Root preparation prior to welding from second side, (where
applicable).
14. Removal methods for weld defects and stray arc strikes.
15. Inter pass-cleaning method.
16. Repair welding.

17. Post welding heat treatments (if required).
18. Shielding gas, and flow rates
19. Type of (GTAW) electrode, size and tip angle.
20. Welders qualified and deployed in production welds shall always bear
an identity card in the manner so approved by OWNER/OWNER’s
representative.
The CONTRACTOR shall only employ welders who have a valid welding certificate
for the procedures being used.
The CONTRACTOR shall have all welders tested in accordance with the applicable
code or standard. Testing shall be at the Contractor's expense including test
pieces. Irrespective of pre-qualification all welders proposed to be deployed in
the work shall be tested and qualified a fresh. No welder shall be allowed to
make any weld for which he is not qualified.
Welding with larger-size electrodes for specific applications may be allowed only
if each welder qualifies with the largest-size electrode to be used in production.
This option is strictly at the OWNER discretion.
OWNER shall specify the details of the welder qualification tests.
For carbon steel, filler wire combinations shall be chosen such that the deposited
hardness of the cap pass shall not exceed 240 BHN. For low-temperature
materials and other materials heat input shall be minimized and comply with the
WPS parameters.
The CONTRACTOR may propose alternate process in addition to those listed. Any
proposed process shall require written OWNER approval and qualification prior
to implement. CONTRACTOR and OWNER shall agree on tests, results, and other
criteria before OWNER approval is granted.
All butt welds in pipe smaller than 60.3 mm O/D ("NPS 2" inch) Schedule 80 shall
be made by GTAW. Root pass by gas metal arc is acceptable for pipe larger than
60.3 mm O/D (NP (2'') inch).
All welds in pressure equipment must be qualified for Charpy V impact testing at
0°C.
When impact tests are required, tests shall be taken from the weld metal, fusion
line, 2mm from fusion line, and 5mm from fusion line.
Permanently installed backing rings shall not be used.
All butt welds in pressure equipment shall have the same chemical and
mechanical properties as the parent metal.
All welding procedures must be qualified for Charpy-V impact testing.
Extreme care shall be taken to ensure that electrode separation by classification
is maintained in the CONTRACTOR's inventory. All storage bins and ovens for
welding consumables shall be clearly labelled. In addition, all GTAW bare rod
filler metals shall be tagged with the AWS designation of the filler metal. Any
welding consumables not readily identifiable shall not be used.
All pressure containing welds shall be of a minimum of two passes with overlap
of starts and stops. This shall include socket welds and seal welds of threaded
connections.
Weld stops and starts shall he staggered so that adjacent weld passes do not
contain stops/starts within 25mm (1 "inch) of each other.
The electrodes shall be purchased from the list of approved manufacturer's and
the same shall be supplied with proper certificates and batch certificates.
The width of weave during production welding shall be within the acceptable
limit of the OWNER approved and qualified welding procedure, qualification
certificates, and production welding operating sheets. As a norm this will be
limited to a maximum of 3 times the core diameter of SMAW electrodes,
whichever is the lesser.
Each weld pass layer shall be completed in one full cycle/ circumference before
proceeding with the next. Blocking out or segmental welding is not permitted.
All tools and equipment used in the welding operations shall be in good
operating condition and shall be of sufficient capacity to ensure welds of the
specified quality are achieved throughout the work. It shall be the right of the
OWNER to request at any times the re-calibration of gauges and meters etc. to
ensure compliance with welding procedure-operating sheets/ WPS.

2.3 Joint Preparation

The surface of the pipe at the weld area shall be free from dust, grease, scale,
paint, grit or any other foreign material, which may adversely affect the final
weld quality.
Bevels shall be 35° and all field cuts shall be normal to the axis, of the pipe, Miter
welds are prohibited.
All pipes shall be bevelled for welding with an approved mechanical bevelling
machine.
Damage to bevels, which could possibly affect the quality of the weld, shall be
removed prior to welding. If the pipe shall be cut and the pipe end re-bevelled,
Lamination check by UT method shall be done prior to welding of gas cutting end
pipe. Pipe cutting by means of grinding is prohibited.
Where welding pipe both to a flange or another pipe or component, there must
be a band of at least 25M mm (1" inch) wide around the internal / external joint
weld preparation that is ground to bright metal, and is free of all foreign matter,
To assure proper spacing and alignment in accordance with the applicable Code,
an approved line-up clamp shall be used.
All Weldments shall conform to the straightness and alignment specified herein.
Correction of improperly fitted parts shall be accomplished by disassembly and
refitting. Reworking by hammering or flame straightening shall not be permitted.
The ends of piping components to be joined shall be aligned as accurately as is
practicable within existing commercial tolerance on diameters, wall thickness,
and out of roundness. Maximum bore mismatch shall not exceed 1/16” inch (1.6
mm), Alignment shall be preserved during welding.
When joints of unequal thickness are joined, the internal offset shall not exceed
1.6 mm (1/16"). If this value is exceeded, the excess thickness of the heavier end
shall be machined or ground back from the bevel on a one-to-four (1:4) taper.
Maximum bore mismatch shall not exceed 0.8mm (1/32 inch), Where ends are
to be Joined and the internal misalignment due to difference in wall thickness,
etc. exceeds 1.6 min (1/16 inch), the wall extending internally shall be internally

trimmed, Internal machining shall be performed so that the inside diameters of

the components coincide.
When cutting pipe to length, it should be cut by mechanical means. if practical.
Ends that are to have flanges attached either in the shop or field must be cut
true and square.
2.4 Preheating
Preheat for pressure piping and furnace tubs shall be in accordance with ASME
B31.3 and B31.8 or as per approved WPS.
All pipe joints having a wall thickness greater than 9.5 mm (0.375") shall he
preheated to 100°C prior to welding.
Preheating shall he carried out with an approved torch system which will provide
uniform heating.
The preheating area shall be at least 100 mm (4") wide cantered about the weld
and shall extend around the entire circumference of the pipe.
Preheat temperatures shall be checked with temperature sensitive crayons or by
other approved methods. If a joint requires preheating, the same temperature
requirements shall be maintained for each succeeding pass.
2.5 WELDING DETAILS

2.5.1 All pressure welding shall be performed in accordance with approved and
qualified welding procedures as required per code.
2.5.2 Each weld shall be uniform in width and size throughout its full length.
2.5.3 Each layer or welding shall be smooth and free of slag, cracks, pinholes, undercut
(Internal and external), porosity and excessive bead shall be completely fused to
the adjacent weld beads and base metal.
2.5.4 The cover pass shall be free of coarse ripples, irregular surface, non-uniform
pattern, high crown, deep ridges or valleys undercut, arc strikes, porosity,
undercut, slag, or shatter.
2.5.5 Butt welds shall be slightly convex, of uniform height, and have full penetration,
unless otherwise approved.
2.5.6 For piping, limitations on weld reinforcement shall apply to the internal surfaces
as well as to the external.
2.5.7 Fillet welds shall be of a specified size with full throat and the legs of uniform
length.
2.5.8 Arcs shall only be struck in the weld groove. A controlled arc must be maintained
while welding. Should an arc strike occur, it shall be removed by grinding and the
area shall be etched (10% Nital) to confirm heat affected area removal, and MT
examined to ensure absence of any surface cracking.
Repair of arc strikes by welding is prohibited.
2.5.9 After each pass the layer of weld metal must be cleaned to remove all slag, scale
dirt etc. wire brushes, grinder, or chipping hammer shall be used as needed to
prepare proper surface for each succeeding weld pass.
2.5.10 Repair, chipping or grinding of welds shall be done in such a manner as not to
gouge, groove or reduce the base metal thickness.
2.5.11 No welding shall be done if the temperature of the base metal is below 50°F. Nor
shall there be any wedding done if there is moisture, grease, or any foreign
material on the joint to be welded.
2.5.12 A qualified welder shall make tack welds. Cracked tack welds shall be completely
ground out and NDE by MT/PT prior to re-weld.
2.5.13 The CONTRACTORS shall make no substitution of materials or modifications to
details without the prior written approval of the OWNER.
2.5.14 Welders and welding operators shall not be qualified on production welds.
2.5.15 The CONTRACTOR shall ensure that welders and welding operators are only
employed on those parts of the work for which they are qualified.
2.5.16 Each welder and welding operator shall possess an appropriate temperature
measuring device. All supervisors shall possess a copy of the approved welding
procedures.
2.5.17 Alternatively, welding procedures may he clearly display at each welding
location. Welders shall be familiar with the requirements of the appropriate
approved welding procedures. Any welder found not complying with the
approved welding procedures during production welding shall be removed from
the work and the non-conforming weld(s) may be completely rejected, at the
discretion of the OWNER.

2.5.18 No welding should be undertaken without approved WPS.

2.5.19 The OWNER will not provide any WPS to the CONTRACTOR.
Pipe 2” and below shall have minimum wall thickness equivalent to sch 80
Pipe above 2” shall have minimum thickness equivalent to Sch 160 for 600# and
Sch 80 for 300#
2.6 Welding Techniques

2.6.1 General
a) All welding shall be performed in accordance with an approved and qualified
welding procedure.
2.6.2 Cleaning
a) All weld impurities shall be removed between passes. Cleaning may
be done with either hand or power tools.
b) All rough irregularities in the cover pass and weld spatter shall be
removed.
2.6.3 Weld Identification

Each finished weld shall be clearly marked to identify the portion made by each
welder.
2.7 Defects and Repairs

Welds containing defects not exceeding an aggregate of five (5) percent of the
length of the root bead may be removed by grinding, chipping or arc gouging and
re-welded in accordance with an approved procedure. Welds containing defects
exceeding that amount shall be cut out and replaced.
When defects are ground out the entire weld shall be preheated to a
temperature of 150 °C (300 °F) prior to welding.
All repaired welds shall be radio graphed or by the same method of original
defect detention.
2.8 Post Weld Heat Treatment (PWHT)

2.8.1 CONTRACTOR is responsible for all PWHT requirements. Which shall be
performed as specified by the OWNER and in accordance with ANSI/ASME B31.3
or approved WPS.

2.8.2 PWHT of pressure piping and furnace tubes shall be in accordance with ASME
B31.3, B31.8 and the specification for Post Weld - Heat Treating.
2.8.3 Controlled atmosphere furnaces are preferred for heat treatment. Procedures
using electric resistance, induction, or flame burner rings are acceptable for
shop or field heat treatment. OWNER prior to heat treatment must approve
these procedures.
2.8.4 CONTRACTOR must notify the OWNER prior to starting PWHT operations.
2.8.5 CONTRACTOR shall furnish a PWHT record chart. The chart must be dated,
numbered and labelled with job identification. CONTRACTOR name and person
Responsible for the PWHT. Heat-treated lane, welds and spool numbers shall be
identified on the chart.
2.8.6 The completed PM/HT record chart shall be submitted for OWNER approval
following completion of heat treatment.
2.8.7 Stress relieving of piping shall be performed as per ASME B31.3 ASME B31.8. as
applicable.
2.8.8 Stress relieving may he performed by electrical induction or by electric resistance
heating devices, or by furnace that has a large enough capacity to accommodate
the entire piece being heat-treated.
2.8.9 The stress relieving temperature to be attained shall be 1100°F/593oC minimum
1150°F/621oC maximum. The soak period of this temperature shall be one hour
per 25.0 mm (1 inch) of pipe wall thickness and in no case shall the soak period
be less than one hour.
2.8.10 Rate of heating and cooling shall be in accordance with the requirements for
thermal stress relief presented in Section VIII of the ASME Boiler and Pressure
Vessel Code. In any event, the rate of heating above 600°F/315 o C may not be
more than 400°F/205oC per hour, nor the rate of cooling more than
500°F/260oC per hour when above 600°F/315o C.
2.8.11 For field stress relieving, a continuous temperature record Log shall be
furnished of the program from heating, soaking and cooling to 600°F. A
minimum of two thermocouples shall be installed at each weld so that
continuous readings can be assured in the event of thermocouple failure.

2.8.12 Local heat treatment of welds shall consist of heating ID pipe length completely
around the circumference of the pipe welds or pipes as required to eliminate
thermally induced stresses. A continuous record of time and temperature shall
be maintained for at least two points on each weld during the course of heat
treatment with methods other than exothermic kits.
2.8.13 During heat treatment, the ends of the pipe shall be temporarily plugged to
minimize air-cooling. Sufficient insulation shall be applied to maintain the
required heat treatment temperature. The full thickness of 75mm (3"-inch)
insulation shall be continued for a minimum distance of 610 mm (2 feet) on
each side of the heating elements, and shall be in place until the weld has
cooled to below 100°F/37
2.8.14 When local heat treatment is used, care shall be exercised with restrained piping
so that no upsetting will be caused by thermal expansion.
2.8.15 A minimum 10% of all locally (field) heat-treated welds shall require Brinell
hardness testing.
2.8.16 Unless otherwise indicated by OWNER, Brinell hardness limits apply to welds
after PWHT. The hardness of the weld shall be determined by the average value
of three tests (of 3 indentations) taken per 120 degrees’ quadrant around the
weld.
2.8.17 The test areas of the weld shall be ground or filled to provide a suitable surface
for testing. If a Tele brineller is used to measure the hardness the bar shall be as
close as practical to the anticipated weld hardness. If a poor indention is
obtained on an individual test, a retest shall be made on an adjacent area.
2.8.18 Hardness tests other than Brinell may be used if the values obtained can be
equated to the Brinell hardness numbers, and the proposed equipment and
procedures have received prior OWNER approval.
2.8.19 Flange facing and threaded connections must be adequately protected against
oxidation during stress relieving and must be cleaned and freed of defects after
stress relieving.
2.8.20 No heating or welding may be applied to any piping or weld joint after stress
relieving is complete.

2.8.21 All stress relieving equipment and execution shall be supplied at Contractor’s
expense.
2.9 WELDING PROCEDURE QUALIFICATION
Welding procedure qualification shall be in accordance with the relevant
requirement of API 1104/ ASME Sec. IX latest edition or other applicable codes
and the job requirements. The Contractor shall submit the welding procedure
specification in format as per PQR. Format immediately after the receipt of the
order. Owner’s representative will review, check and approve the welding
procedure submitted and shall release the procedure for qualification test. The
complete set of test result as per API 1104 / ASME sec. IX shall be submitted to
the OWNER/ OWNER’s representative for approval immediately after completing
the procedure qualification test and at least 2 weeks before the commencement
of actual work. Standard test specified in the code shall be carried out in all
cases.
All materials to be welded shall be subjected to visual examination as per the
code.
In addition to these test the following test shall be carried out.
 Radiography testing
 Macro/ Micro Examination.
 Hardness test.
 Dye Penetrate examination.
 Chemical Examination
 Bend Test
 Charpy V-notch Impact test at Weld and HAZ at 0 °C & -20 °C .
These tests shall be carried out on specimens depending upon the type of base
material, operating conditions and requirements laid down in the detailed
drawing and specification. It shall be the responsibility of the Contractor to carry
out all the tests required to the satisfaction of the OWNER/ OWNER’s
representative.
The procedure qualification test shall be carried out by the Contractor under
field conditions at his own expense.

2.10 Welder’s Qualification

Welders shall be qualified in accordance with the API 1104 / ASME sec. IX or
other applicable codes. It shall be the responsibility of the Contractor to carry
out qualification tests of welders. No welder shall be permitted to work without
the possession of identity card.
If a welder is found to perform a type of welding or in a position for which he is
not qualified, he shall be debarred from doing any further work. All welds
performed by an unqualified welder shall be cut and redone by a qualified
welder at the expenses of the contractor.
2.11 Destructive Testing
OWNER has the authority to order the cutting of up to 0.1% of the total numbers
of welds completed for subjecting to destructive test at no extra cost to OWNER.
The destructive testing of joints shall be as per API 1104 / ASME- Sec IX welding
procedure qualification.
In addition, welds already cut out for defects for any reason may also be
subjected to destructive testing. The sampling and the re-execution of welds
shall be carried out by the contractor at his own expenses. If the results are
unsatisfactory, welding operations shall be suspended and may not be restarted
until the causes have been identified and the contractors have adopted
measures which guarantee acceptable results. If it is necessary in OWNER
opinion the procedure shall be re-qualified. The weld joint represented by
unsatisfactory welds shall stand rejected unless investigation proves otherwise.
3. NON DESTRUCTIVE EXAMINATION
3.1 GENERAL
a) This specification shall govern the basic requirements for Non
Destructive Examination (NDE) as it applies to the fabrication, testing and
inspection of all Pressure Piping, and Transmission Piping.
b) No supplier, vendor, manufacturer or fabricator shall subcontract the
non-destructive examination of any such equipment without written approval
from the OWNER, and the OWNER will not issue such an approval unless the

proposed NDE SUBCONTRACTOR has received prior OWNER approval for the
type of NDE work proposed.
The non-destructive examination of 100% girth welds shall be carried out.
3.2 CODES AND STANDARDS

a) Work performed under this section shall confirm to the latest edition of
following codes and standards:
i) ASME B31.3 Process Piping.

ii) ASME. Section V - Non-destructive Examination.
iii) ANSI/ASIA. B31.8 Gas Transmission and Distribution System.
iv) ASNT/PCN/CGSB Standards for certification of Non-
Destructive Testing Personnel.
v) API 1104
b) Work shall also be carried out in compliance with all general
specification dealing with welding and fabrication of various
equipment.
3.2.1 CONFLICT
Where a conflict occurs between this Specification and any of the above Codes
or Standards the more stringent shall apply. The contractor shall inform the
OWNER in writing and receive written certification form the OWNER. The
contractor shall have readily available for use at the request of the OWNER latest
editions of all codes, specification and standards necessary for execution of the
work at work site.
3.3 ABBREVIATIONS
ASME- American Society of Mechanical Engineers
ANST- American Society for Non-Destructive Testing
ASTM- American Society for Testing and Materials
AWS- American Welding Society
DPI- Dye Penetrant Inspection
HS&E- Health Safety and Environment
MPI- Magnetic Particle Inspection
NDT- Non-Destructive Testing

PCN- Personnel Certification in Non-Destructive Testing
PWHT- Post Weld Heat Treatment
UT- Ultrasonic Testing
3.4 NDE CERTIFICATION
All Non Destructive Examination (NDE) CONTRACTORs contracted by the OWNER
or working for fabricators or CONTRACTORs carrying out work on the OWNER
behalf shall have in place an up-to-date Quality Control Manual and Code of
Practice which shall cover the following:
i) All aspects of NDE of which the CONTRACTOR SUB-CONTRACTOR is
qualified.
ii) Current resumes of all presently employed personnel including their
certifications (PCN, ASNT, CGSB or equivalent).
iii) All proposed specific NDE procedure,
A registered copy of QC manual shall be made available to OWNER and shall be
reviewed and approved by the OWNER quality assurance personnel prior to
services being used. Updates to the Manual shall be forwarded to the registered
holder as they become available.
The OWNER will review and approve element's i), ii) & iii) above: prior to start on
any said TGPL work. Any approval given by the OWNER does not relieve the
CONTRACTOR of his obligations under governing, codes, rules and specifications.
All equipment shall be certified and current, to recognized calibration standard
and in first class working condition.
Full compliance with all governmental and local regulatory requirements of
HS&E, which shall be fully complied with.
3.5 VISUAL INSPECTION

a) Visual examination shall be carried out before, during and after
fabrication in accordance with ASME Sec. V article 9 and ASME B31.3.
b) Cracks, (regardless of size and location) and under cutting or any
evidence of poor workmanship, materials, etc., if not repairable shall
be cause for rejection.
c) Welds shall be visually inspected wherever accessible in accordance

with the following requirements:
1 Internal misalignment 1.5 MM or Less
2 Cracks or lack of fusion None permitted.
3 Incomplete penetration (for None permitted.

other than 100% Radiography
butt-weld)
4 Surface porosity and exposed not permitted

slag inclusions (4.7mm
Nominal Wall thickness and
less)
5 Concave root surface (SLICK For single sided welded joints concavity of the
UP) root surface shall not reduce the total
thickness of joint including reinforcement to
less than the thickness of the thinner of the
components being joined.
6 Weld ripples irregularities 2.5 MM or Less
7 Lack of uniformity in bead 2.5 MM or Less

width
8 Lack of uniformity of leg 2.5 MM or Less

length
9 Unevenness of bead 2.0 MM or Less
10 Weld undercutting 0.8 MM or 'A thickness of thinner

components joined by butt weld,
whichever is less. (shall be smooth
finished)
11 Overlap 1.5 MM or Less
12 Bead deflection 2.5 MM or Less

13 External weld reinforcement and internal weld protrusion (when backing

rings are not used) shall be fused with and shall merge smoothly into the
component surfaces. The height of the lesser projection of external weld
reinforcement or internal weld protrusion from the adjacent base material
surface shall not exceed the following limits
Wall thickness of thinner Weld reinforcement or internal weld

component joined by butt protrusion (MM) Max
weld (MM)
6.4 and under 1.6
Over 6.4 – 12.7 3.2
14 Throat thickness of fillet welds: Nominal thickness of the thinner component x

0.7 or more.
15 FLATTENING: Flattening of a bend, as measured by difference between the

nominal outside diameter and minimum or maximum diameter at any cross
section shall not exceed 5% of the nominal outside diameter of pipe.
16 REDUCTION OF WALLTHICKNESS: Reduction of wall thickness of a bend, as

measured by difference between the nominal thickness and minimum
thickness shall not exceed 10% of the nominal wall thickness of pipe. Welds
having any imperfections which exceed the limitations specified in various
clauses shall be repaired by welding, grinding or overlaying etc.
However, number of times of repair welding for the same weld shall be as
follows:
MATERIAL NO. OF TIMES OF REPAIR WELDING
1.0 CS UPTO 300# 1 OR LESS
2.0 CS ABOVE 300# 1 OR LESS
3.6 NON-DESTRUCTIVE TESTING

3.6.1 GENERAL
a) All NDT shall be performed in accordance with ASME B31.3 /ASME
8.31.8/ ASME code Section V except as modified by this specification.

b) The CONTRACTOR shall prepare NDT procedure covering all aspects of

the work. The NDT procedure shall be submitted to OWNER for review
and approval. Approval of the NDT procedure shall be required before
any NDT can be performed.
c) The CONTRACTOR shall prepare and maintain documentation to track
percentage of welds tested and the weld repair rate. The proposed
documentation shall be made available for review and approval.
d) All welds, regardless of pipe class shall be examined by 100% visual,
radiography and MPI, DPI, as applicable.
e) CONTRACTOR shall not deviate from any requirement of this specification
without written approval to do so from OWNER.
f) No exemption permitted in regards to full HS&E compliance.
3.6.2 RADIOGRAPHIC EXAMINATION

3.6.2.1 General
a) The quality of radiographs shall meet or exceed all requirements of the
appropriate International standards and applicable general specifications.
b) X - Ray is the preferred radiographic method. Use of Gamma ray can be
done prior approval.
c) Particular attention shall be paid to using radiographic ultra-fine grain
film suitable for the application, maintaining correct radiographic
geometry during exposure, obtaining correct density also required by the
appropriate standard and the correct placement and exposure of image
quality indicators (IQI's or penetrameters).
d) ASTM wire type IQI's are preferred. The OWNER may permit the use of
other type IQI's on a preapproved basis, provided the NDT CONTRACTOR
can demonstrate satisfactory results.
e) Radiographic technique shall produce maximum contrast and good
definition of IQI wires and shall obtain minimum radiographic density of
10 in the weld image. Fluorescent intensifying screens shall not be used.
f) Max radiographic density shall be 2.0 - 4.0 in all areas of the weld and
parent metal.
g) The inability to view the appropriate wire or hole on any radiograph shall
be cause for automatic rejection of that radiograph which shall be re-
radiographed at no expense to the OWNER.
Type 2 and 3 films as per ASTM E94-04(2010) shall be used.

3.6.2.2 Operator Certification

a) Radiographers supplied by the CONTRACTOR shall be certified to ASNT
Level II, AWS QC] and as per AWS B1.10 (guide for non-destructive
inspection of welds).
b) An operator qualified to ASNT Level I may assist the Level II operator but
all film and sentencing interpretation shall be carried out by a Level ll or
higher operator who shall sign off all report sheets.
c) Visual welding inspection shall be conducted only by a qualified welding
inspector, who shall have a minimum AWS (QC. I) CWI or CSWIP 3.1
certification.
d) The OWNER shall review and approve all QA/QC personnel prior to
deployment on the project.
3.7 MAGNETIC PARTICLE INSPECTION (MPI)

a) MPT shall be carried out in accordance with the requirements of ASME.
Section V. Article 7, & Section VIII DIV 1, Appendix 6. And as modified by
this specification.
b) AC electromagnetic yokes shall be used. A background of white contrast
paint shall be used in conjunction with a black magnetic ink (wet particle).
The technique shall be carried out in the continuous mode and two
examinations shall be carried out at right angles to cover for both
transverse and longitudinal defects. There shall be sufficient overlap to
allow 100% coverage.
c) All unacceptable or spurious indications found by this method shall be
investigated and removed by grinding followed by thickness check.
3.8 DYE PENETRATE INSPECTION (DPI)

a) DPI shall be carried out accordance with the requirements of ASME BPV,
Section V, Article 6, & ASME Section VIII DIV 1, Appendix 8, and as
modified by this specification.
b) Unless requested otherwise, DPI shall be carried out using the solvent
removable method.
c) If necessary welds may be lightly dressed to facilitate DPI testing or to
assist in the interpretation of any indications.
d) All unacceptable or spurious indications found by this method shall be
investigated and removed by grinding followed by thickness check.

3.9 ULTRASONIC WELD EXAMINATION (UT)

Ultrasonic operators supplied by the NDE CONTRACTOR shall be certified to a
General Standards Board (ASNT/PCN) approved by the OWNER.
3.10 EXTENT OF INSPECTION AND TESTING

3.10.1 Piping systems which are designed and constructed in accordance with ASME
B31.8 Standard for gas pipeline systems shall have all welds radiographically
inspected.
3.10.2 Ultrasonic Testing
a) UT testing shall be carried out as per ASME B31.3 and ASME Sec. V article
5.
b) All welds which are not being radiographed and all other welds
configuration, which does not permit to be radio graphed, shall be
ultrasonic tested.
c) All tie-in welds where pressure testing is not possible.
Notes:
1) Ultrasonic testing, in lieu of radiography, is acceptable only where
radiography is not practicable e.g. branch connections.
2) UPI or DPI of branch welds to be performed prior to and lifter
attachment of compensating plate if applicable.
3) Open drains vents or other open ended line shall be leak tested only.
4) For piping within skid packages, the CONTRACTOR shall use this table as
a guide only and prepared NDE plan for review and approval by OWNER
as required in the respective package specification.
5) Vat required where wall thickness of scanning surfaces is less than
10mm and where branch size is less than NPS 4". Non-ferrite materials
shall not be examined with UT methods.

4. REPAIRS OF WELDS
4.1 With the prior permission of ENGINEER IN CHARGE welds that do not comply
with the standards of acceptability shall be repaired or the joint cut out and re-
welded.
A separate welding procedure specification sheet shall be formulated and
qualified by CONTRACTOR for repair welds simulating the proposed repair to be
carried out. Separate procedures are required to be qualified for (a) through
thickness repair (b) partial repair and (c) capping repair. Welders shall be
qualified in advance for repairs. The root pass, for repairs opening the root, shall
be replaced by the vertical uphill technique. The procedure shall be proven by
satisfactory procedure tests to API 1104 including the special requirements of
the specification, and shall also be subjected to metallographic examination,
hardness surveys and Charpy test to determine the effects of repair welding on
the associated structure.
Root sealing or single pass repair deposit shall not be allowed. Internal root
defects shall be ground thoroughly and welded with a minimum of two passes.
However, while grinding for repairs, care shall be taken to ensure that no
grinding marks are made on the pipe surface anywhere.
The repair shall be subjected, as a minimum requirement, to the same testing
and inspection requirements as the original weld. Re-radiography of the repaired
area shall be carried out. In addition, a minimum of 6” weld length on the either
side of the repaired area shall be re-radiographed. A 100% ultrasonic test shall
be done at the repaired area externally. Any repaired area that is wide, irregular
or rough shall be rejected and a full cut out shall be done.
Repairs are limited to a maximum of 30% of the weld length. Welds containing
cracks shall be cut out and re-bevelled to make a joint. TGPL shall authorize all
repairs.
4.2 Weld Rejected by Accumulation of Defects
Where a weld is rejected by accumulation of defect clause, as defined by API
1104 and this specification, repairs within these limitations are permitted.
Defects in the filling and capping passes shall be repaired preferentially.

5. INSPECTION
5.1 The CONTRACTOR shall extend all facilities, assistance and co-operate fully with
the OWNER in all aspects of inspection and NDE and shall give adequate notice
of any required fabrication inspection stages, together with sufficient time for
thorough inspection by the OWNER. OWNER shall have the right to establish
hold points at any point in the fabrication sequence.
5.2 Although is the Contractor’s primary responsibility to perform weld examination,
OWNER shall have the right to observe the examination of all welds by non-
destructive means. The inspection may be at any time before, during and after
fabrication. The CONTRACTOR shall conduct daily NDE of welds to assess weld
quality. Up-to-date examinations are required to identify and prevent the
reoccurrence of weld defects on subsequent welds. Records and evidence of all
weld examinations shall be available at all times for OWNER to review and
approve.
5.3 OWNER may use any method of inspection necessary to establish quality control
and ensure adherence to welding procedures. OWNER shall have the right to
accept or reject any weld not meeting the requirements of this specification.
5.4 OWNER reserves the right to perform inspection at shop / field where fabrication
and erection of piping is in progress for (but not limited) for the following
objective:
a) To check conformance to relevant stands and suitability of various

welding equipment and welding performance.
b) To witness the welding procedure qualification.
c) To witness the welder performance qualification.
d) To witness the Electrode Qualification Test.
5.5 Contractor shall intimate sufficiently in advance the commencement of
qualification test, welding works and acceptance tests to enable the owner/
owner’s representative to be present to supervise them.
5.6 Any discrepancies between the approved WPS and the production welds noted
by OWNER, any or all of the work made under these conditions is subject to
rejection.

6. DOCUMENTS TO BE SUBMITTED BY THE CONTRACTOR

a) Electrode and welding consumables qualification records for the welding
consumables tested and approved for the work.
b) Batch test certificate, for the electrodes used, obtained from the
Electrode Manufacturers.
c) Proposed heat treatment chart procedure.
d) Heat treatment chart.
e) Weld joint tensile, hardness test, Impact test result.
f) Welding procedure specification immediately after receipt of order.
g) Welding procedure qualification records.
h) Welder performance qualification records immediately after conducting
welder Qualification tests.
i) Radiography procedure and the NDT procedure.

FOR STUDS - BOLTS, NUTS & TGPL-TS-STEEL-PTS-004
GASKETS
STUDS - BOLTS, NUTS & GASKETS

GASKETS
TABLE OF CONTENTS
1. SCOPE .................................................................................................................................... 3
2. STANDARDS & CODES............................................................................................................. 3
PNGRB – Petroleum and Natural Gas Regulatory Board.................................................................................................... 3
3. ABBREVIATIONS ..................................................................................................................... 3
4. TECHNICAL NOTES FOR BOLTS AND NUTS............................................................................... 3
5. TECHNICAL NOTES FOR GASKETS ............................................................................................ 5

GASKETS
1. SCOPE
This specification provides minimum requirement for design, manufacturing,
Inspection, Testing and supply of Nuts, Studs, Bolts and Gaskets covering sizes ½”
NB through 12” NB (300mm) for ANSI pressure classes # 150 through # 800 to be
used in City Gas distribution for handling Natural Gas.
2. STANDARDS & CODES
PNGRB – Petroleum and Natural Gas Regulatory Board

3. ABBREVIATIONS
AARH : Average Arithmetic Root Height
BHN : Brinnel Hardness Number
CS : Carbon Steel
MR : Material Requisition
PMI : Positive Material Identification
RTJ : Ring Type Joint
4. TECHNICAL NOTES FOR BOLTS AND NUTS
4.1 The process of manufacture, heat treatment, chemical & mechanical
requirements and marking for all stud, bolts, jack screws & nuts shall be in
accordance with the codes/standards and specifications. The applicable
identification symbol in accordance with the material specification shall be
stamped on each bolt and nut. Vendor shall strictly comply with codes/standards
and specifications stipulations and no deviations shall be permitted.
4.2 Testing
4.2.1 Test reports shall be supplied for all mandatory tests as per the relevant material
specifications.
4.2.2 Material test certificate shall also be furnished. (Heat Analysis, Product Analysis
and Mechanical Requirement.
4.2.3 PMI shall be performed as per the scope and procedures defined in the
Specification for PMI at Vendor’s Works.

GASKETS
4.2.4 Stress Rupture Test as detailed in ASTM A453 shall be carried out for all ASTM
A453 bolting material irrespective of the temperature.
4.3 All bolting shall be as per ANSI B 18.2.1 for studs, M/c bolts and jackscrews and
ANSI B18.2.2 for nuts.
4.4 Threads shall be unified (UNC for 1” dia and 8UN for > 1” dia) as per ANSI B.1.1
with class 2A fit for studs, M/c bolts and jackscrews and class 2B fit for nuts.
4.5 Stud bolts shall be threaded full length with two heavy hexagonal nuts. Length
tolerance shall be in accordance with the requirement of ANSI B 16.5.
4.6 The nuts shall be double chamfered, semi-finished, heavy hexagonal type and
shall be made by the hot forged process and stamped as per respective material
specification.
4.7 Heads of jackscrews and m/c bolts shall be heavy hexagonal type. Jackscrew end
shall be rounded.
4.8 Each size of studs & m/c bolts with nuts and jackscrews shall be supplied in
separate containers marked with size and material specifications. ‘CRYO’ shall be
marked additionally in case ‘CRYO’ is specified in the requisition. Inner rings
shall be provided for the following:
4.9 The heat treatment for stud bolts & nuts shall be as per code unless mentioned
otherwise.
4.10 For S.S. nuts and bolts minimum impact energy absorption shall be 35 Joules and
test temperature shall be - 196°C unless mentioned otherwise. For other
materials impact energy and test shall be as per respective code.
4.11 Bolts/nuts of material of construction B7M/ 2HM shall be 100% Hardness tested
as per supplementary requirement S3 of ASTM A 193.
4.12 When specified as galvanized, the studs, M/C bolts and nuts shall be ‘hot dip zinc
coated’ in accordance with requirements of ‘class C’ of ‘ASTM A 153’. As an
alternative, electro galvanizing as per IS 1573, ‘Service Grade Number 2’ is also
acceptable.

GASKETS
5. TECHNICAL NOTES FOR GASKETS

5.1 All gaskets shall conform to the codes/standards and technical specifications as
given. Vendor shall strictly comply with technical specification and no deviations
shall be permitted.
5.2 Process of manufacture, dimensions and tolerances not specified in specification
and it shall be in accordance with the requirements of the codes/standards.
5.3 Testing
5.3.1 Test reports shall be supplied for all mandatory tests for gaskets as per the codes
& standards specified in this technical specification.
5.3.2 For Spiral wound material following shall be furnished:
a) Manufacturer’s test certificate for filler material and spiral material as per the
relevant material specifications.
b) Manufacturer’s test certificate for raw materials and tests for compressibility/
seal-ability & recovery as per the relevant material specifications.
5.4 Full face gaskets shall have bolt holes punched out.
5.5 Filler material for spiral wound gaskets shall not have any colour or dye.
5.6 All spiral wound gaskets shall be supplied with Outer ring. Material of the outer
ring shall be CS unless otherwise specified.
5.7 For spiral wound gaskets, material of Inner Compression ring shall be same as
Spiral Strip material.
5.8 Face finish of metallic RTJ gaskets shall be 32 to 63 AARH.

5.9 Gaskets of different types and sizes shall be placed in separate shipping
containers and each container clearly marked with the size, rating, material
specification and item code.
5.10 Any additional requirements specified in this technical specification, shall be fully
complied with.
5.11 Spiral wound gasket as per ASME B16.20 shall match flanges to ASME B16.5 up
to 12” unless specifically mentioned otherwise.

FOR VALVE (Size – Below 4”) TGPL-TS-STEEL-PTS-002
FOR VALVE (Size – Below 4”)

TABLE OF CONTENTS
1. SCOPE .................................................................................................................................... 3
3. Abbreviations ......................................................................................................................... 4
4. MATERIALS............................................................................................................................. 4
5. DESIGN AND CONSTRUCTION REQUIREMENTS ....................................................................... 6
8. PAINTING, MARKING AND SHIPMENT ..................................................................................... 9
9. SPARES AND ACCESSORIES ................................................................................................... 10
10. DOCUMENTATION................................................................................................................ 10

1. SCOPE
This specification covers the minimum requirements for design, manufacture, testing
and supply of low temperature carbon steel ball, plug and globe valves designed and
manufactured to BS EN ISO 17292/API 6D standard for size DN 100 mm (4”) and
below and ANSI pressure rating Class 150, 300, 600, 800 (Socket weld end and Flange
connection) for use in pipeline systems handling Natural Gas.
All valves shall be manufactured and supplied in accordance with the BS EN ISO
17292/API 6D Latest edition, Petroleum and Natural Gas Regulatory Board – Pipeline
Transportation Systems – Pipeline valves, with additions and modifications as
indicated in the following sections of this specification.
Reference has also been made in this specification to the latest edition (edition
enforce at the time of issue of enquiry) of the following Codes, Standards and
Specifications.
PNGRB- Petroleum and Natural Gas Regulatory Board

ASME B31.3 Process Piping.
ASME B31.8 Gas Transmission and Distribution Piping Systems.
ASME B16.5 Steel Pipe Flanges and Flanged Fittings.
ASME B 16.10 Face-To-Face and End-To-End Dimensions of Valves.
ASME B 16.25 Butt-welding Ends.
ASME B16.34 Valves Flanged, Threaded and Welding Ends.
ASME B16.47 Large Diameter Steel Flanges.
API 1104 Welding Pipelines and Related Facilities.
ASME Sec VIII Boiler and Pressure Vessel Code - Rules for Construction of
Pressure Vessels
ASME Sec IX Boiler and Pressure Vessel Code – Welding and Brazing
ASTMA-370 Standard Test Methods and Definitions for Mechanical Testing
of Steel Products.
ASTM B 733 Auto Catalytic Nickel Phosphorous Coating on Metals.
ISO17292:2015 Metal ball valves for petroleum, petrochemical and allied
industries

ISO 5208:2015 Industrial valves -- Pressure testing of metallic valves

API 598 Valve Inspection and Testing
MSS-SP-6 Standard Finishes for Contact Faces of Pipe Flanges and
connecting-end Flanges of Valves and Fittings.
MSS-SP-44 Steel Pipeline Flanges.
SSPC-VIS-1 Steel Structures Painting Council Visual Standard.
SIS 055900 Pictorial Surface Preparation Standards for Painting Steel
Surface (Swedish standard)
In case of conflict between the requirements of this specification, BS EN ISO
17292/API 6D Latest edition and the Codes, Standards referred in clause 2.2
above, the requirements of this specification shall govern.
3. Abbreviations
API American Petroleum Institute

ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
BM Base Metal
DN Nominal Size
EPC Engineering, Procurement and Construction
HAZ Heat Affected Zone
MSS-SP Manufacturers Standardization Society – Standard Practice
NDT Non Destructive Testing
NPS Nominal Pipe Size
SSPC Steel Structures Painting Council
WM Weld Metal
4. MATERIALS
Materials for major components of valves shall be as indicated in Valve Data Sheet.
Other components shall be as per Manufacturer's standard (suitable for the service
conditions indicated in Data Sheet) and shall be subject to approval by TGPL. In
addition, the material shall also meet the requirements specified hereinafter.
Carbon steel used for the manufacture of valves shall be fully killed.

The ratio of body yield strength and body ultimate tensile strength of each test valve
on which body yield strength and body ultimate tensile strength are determined,
shall not exceed 0.90.
The carbon equivalent (CE) of valve end connections which are subject to further
field welding by TGPL shall not exceed 0.43 on check analysis for each heat of steel
used, as calculated by the following formula:
Mn Cr + Mo +V Ni + Cu
CE = C + + +
6 5 15
Impact Test Requirement -:

For Carbon Steel material-:
Charpy V-notch test shall be conducted at 0 C. the average absorbed energy
value of full sized specimens shall be 32 J. The minimum impact energy value of
specimen shall not be less than 28 J.
For LTCS Material:
Charpy v-notch standard shall be conducted as per the applicable Material
Standard, however the test temperature shall be no case more than (-) 45o C
(i.e test temperature shall be as per material standard or (-) 45o C whichever is
less)
Apart from above to (for LTCS material) additional charpy v-notch test shall be
conducted at -20o C. the average absorbed energy value of full sized specimens
shall be 35J. The minimum impact energy value of specimen shall not be less
than 28J.
Hardness test shall be carried out as per ASTM A370 for each method of
manufacture and each heat of steel used in the manufacture of valves. A full
thickness cross section shall be taken for this purpose and the maximum
hardness of the materials of valve components shall not exceed 248 HV10.
In case of LTCS, Ball material the ball shall have 75 micrometers thick
electroless nickel plating (ENP) as per ASTM B733 with SC 2, Type II, and Class
2. The hardness of plating shall be min. 50 RC.

For all forge material the fine grained perlitic structure of the steel shall be
verified by at least one micrographic examination per lot according to ASTM E
112. The grain size shall be as per ASTM Standards.
5. DESIGN AND CONSTRUCTION REQUIREMENTS
Valve design shall meet the requirements of BS EN ISO 17292/API 6D and shall
be suitable for the service conditions indicated in the Valve Data Sheet. The
ASME Boiler & Pressure Vessel Code, Section VIII, Division 1 shall be used to
design the valve body. Valve shall be manufacturing as per QSL-3 (Quality
Specification Level) requirements of Annexure-J of API 6D Allowable stress
requirements shall comply the provisions of above code. In addition, corrosion
allowance indicated in Valve Data Sheet shall be considered in valve design.
The ball valves shall be bi-directional.
For above ground valves, body design shall be either fully welded or bolted
type. Valve end connection shall be socket weld and flanged ends, as per
requirement. Valve body joints with threads are not permitted. In the valve
body outlets also, threading is not permitted.
Ball shall be of single piece, solid type construction. And non -lubricating type.
All ball valve shall be Full bore (FB). Reduced Bore (RB) valves shall not be
permitted.
Ball mounting shall be floating type only for all valves of size below 2”.
All valves shall be wrench operated valve. Direction of operation of wrench
shall be in clock-wise direction while closing the valve
Valves shall be designed to withstand a sustained internal vacuum of at least 1
(one) milli-bar (a) in both open and closed positions.
Valve shall be provided with indicator to show position of ball port
Valve shall be provided with stops for both fully open and fully closed position.
Bolted valve shall be used.
Valve ends shall be as indicated in the Valve Data Sheet. End-to-end
dimensions for valve shall be in accordance with ASME B 16.11 shall be as per
Manufacturer Standard and shall be subject to approval by TGPL.

Valves shall be suitable for above ground installation as indicated in Valve Data
Sheet.
Valve design shall ensure repair of stem seals/packing under full line pressure.
Valve shall be fire tested design.
Valve shall be long pattern with anti-static features.
Repair by welding is not permitted for cast body and forged body valves.
No casting is permitted for stem material of all valves. Valve stem shall be
capable of withstanding the maximum operating torque required to operate
the valve against the maximum differential pressure corresponding to
applicable class rating for a minimum of 500 open-close-open cycles for a
design life of 40 years. The combined stress shall not exceed the maximum
allowable stresses specified in ASME section VIII, Division 1.
The Manufacturer shall perform all inspection and tests as per the
requirements of this specification, approved quality assurance plan (QAP) and
the relevant codes, prior to shipment, at his Works. Such inspection and tests
shall be, but not limited to, the following:
All valves shall be visually inspected. The internal and external surfaces of the
valves shall be free from any strikes, gouges and other detrimental defects. The
surfaces shall be thoroughly cleaned and free from dirt, rust and scales.
Dimensional check on all valves shall be carried out as per the TGPL approved
drawings.
Chemical composition and mechanical properties shall be checked as per this
specification and relevant material standards, for each heat of steel used. All
testing frequency shall be as per Inspection & Test Plan/ QAP. Heat treatment
chart for forging material shall be witness & start/stop time signed by TPIA.
Valve body and seat shall be hydro-test as per ISO 5208/ API 598 latest
edition/applicable codes and standard.
In addition to above, pneumatic testing and functional testing shall be carried
out at 7 bar (g) for 800# pressure rating valves, using nitrogen for 15 minutes.
High pressure shell and seat pneumatic testing shall be submerged in water.
A supplementary air seat test as per API 6D (Annexure H) shall be carried out
for all valves. A bubble tight seal is required without the use of any sealant. No
leakage is allowed. Test pressure shall be held for at least 15 minutes.
Valves shall be subjected to Operational Torque Test as per API 6D (Annexure
H) under hydraulic pressure equal to maximum differential pressure
corresponding to the applicable ANSI class rating of valve. It shall be
established that the force required to operate the valve does not exceed the
requirements stated in this specification.
Non-destructive examination of individual valve material and component
consisting of but not limited to castings, forgings, plates and assembly welds
shall be carried out by the Manufacturer.
 All valves made by forgings shall be radiographically and ultrasonically

examined in accordance with the procedure and acceptance standard
of Annexure E of ASME B16.34. Body fabricated from plates is not
acceptable.
 External surfaces of all forgings shall be 100% wet magnetic particle
inspected. Method and acceptance shall comply with ASME B16.34.
All body tests to be done before painting.

TGPL reserves the right to perform stage wise inspection and witness tests in
QAP above at Manufacturer's works prior to shipment. Manufacturer shall give
reasonable access and facilities required for inspection to the TGPL's Inspector.
TGPL reserves the right to require additional testing at any time to confirm or
further investigate a suspected fault. The cost incurred shall be to
Manufacturer’s account.
In no case shall any action of TGPL or his inspector shall relieve the
Manufacturer of his responsibility for material, design, quality or operation of
valves.
Inspection and tests performed/witnessed by the TGPL’s Inspector shall in no
and tests.

Manufacturer shall submit the following certificates:
a. Mill test certificates relevant to the chemical analysis and mechanical
properties of the materials used for the valve construction as per the
relevant standards.
b. Test certificates of hydrostatic and pneumatic tests, helium test
complete with records of timing and pressure of each test.
c. Test reports of ultrasonic inspection, if applicable.
d. Test report on operation of valves conforming.
e. All other test reports and certificates as required by Standard – BS EN
ISO 17292/API 6D latest edition and this specification.
The certificates shall be considered valid only when signed by TGPL's Inspector.
Only those valves which have been certified by TGPL's Inspector shall be
dispatched from Manufacturer's works. TPIA shall issue 3.1 certificates as per
EN 10204.
8. PAINTING, MARKING AND SHIPMENT
Valve surface shall be thoroughly cleaned, freed from rust and grease and
applied with sufficient coats of corrosion resistant paint. Surface preparation
shall be carried out by shot blasting to SP-6 in accordance with "Steel
Structures Painting Council - Visual Standard SSPC-VIS-1"/ Sa 2 ½ in accordance
with "Swedish standard - SIS- 055900" as per Painting specification.
The external surfaces of all valves shall be provided with high build epoxy
coating with a min. thickness of 300 microns DFT (dry film thickness).
All above ground valves shall be painted as per Painting specifications suitable
for highly/normal corrosive environment as applicable.
All valves shall be marked as per API 6D. The units of marking shall be metric
except nominal diameter, which shall be in inches.
Valve ends shall be suitably protected to avoid any damage during transit. All
threaded and machined surfaces subject to corrosion shall be well protected by

Moly coat type grease or other suitable material. Socket Weld Ends shall be
protected with metallic or high impact plastic protectors.
Packaging and shipping shall be as per Specification/ as per Applicable
Standards.
On packages, following shall be marked legibly with suitable marking ink:

a) Order Number
b) Manufacturer's Name
c) Valve size and rating
d) Tag Number
e) Serial Number
9. SPARES AND ACCESSORIES
All spares required for start-up and commissioning of the valve shall be supplied
along with the valve.
Manufacturer shall furnish list of recommended spares and accessories
required for two years of normal operation and maintenance of valves and
price for such spares shall be quoted separately.
10. DOCUMENTATION
Documentation to be submitted by Manufacturer to TGPL is summarized
below. Number of Copies (Hard copies / soft copies etc.) shall be as indicated
in CONTRACT document.
TGPL shall approve the following documents from manufacturer/supplier and
verify before placement of order:
a) General arrangement/ Sectional drawing & blow-up drawing of seat
assembly shall be submitted. Number of turns for Gear Operated
valves shall be indicated in the GA or shall be furnished separately.
b) Reference list of similar ball valves manufactured and supplied in last
ten years indicating all relevant details including project, year, client,
location, size, rating, service etc.

g) In case of soft seated valves, copy of Fire Safe Test certificate of

qualifying valve as per API 607/API 6FA carried out in last 10 years shall
be furnished.
After placement of order, the Manufacturer shall submit the following
drawings, documents and specifications for TGPL's approval:
a) Detailed sectional drawings showing all parts with reference numbers
and material specifications.
b) Assembly drawings with overall dimensions and features. Drawing
shall also indicate the number of turns of hand wheel (in case of gear
operators) required for operating the valve from full open to full close
position and the painting scheme. Complete dimensional details of
support foot (where applicable) shall be indicated in these drawings.
Manufacture of valves shall commence only after approval of the
above documents. Once the approval has been given by TGPL, any
changes in design, material and method of manufacture shall be
notified to TGPL whose approval in writing of all changes shall be
obtained before the valve is manufactured.
c) Quality Assurance Plan (QAP) for approval.
d) Inspection Test Plan for approval.
Prior to shipment, Manufacturer shall submit to TGPL following:
a) Test certificates as per this specification.
b) Manual for installation, erection, maintenance and operation
instructions including a list of recommended spares for the valves.

Personnel Protective Equipments Matrix (PPE Matrix)
Safety Safety Hi Visibility Ear Welding Grinding Safety Safety Leather Gas
Employees Handgloves
Shoes Helmet Jacket plug/muff Screen Screen belt googles apron Mask
Engineers, (Area Incharge/ Zone
Incharge Contractors,Engineers,   
       
Executives, GET)
Supervisors   
       
Project Managers   
       
TPE   
       
Contractor Labours (Depending on
HIRA, he may have to use other PPE   
       
also as per requirements)
Welders           
Grinders           
PE technician           
GI/Cu technician           
O&M technician/Those engaged at
CGS/Odourant filling
          
Dispenser/Compressor operators           
Crane Operator           
Plumber/Those who will work at
heights more than 2 m
          
Breaker Operator           
Note: Based on HIRA and Line Managers requirements, additional PPE may be required to be used
MEDICAL FITNESS REQUIREMENTS
All the employees deputed for Torrent Gas Pvt. Limited (TGPL) work should undergo
pre employment medical examination covering the basic height, Weight, Eye Vision
Basic Requirement test , Chest X ray & Blood Test , Urine Routine and produce a physical fitness
certificate from a MBBS doctor and shall submit a copy of the entire medical fitness
certificate to an authorized representative of TGPL
Sr. No. Employee MEDICAL TEST AND FITNESS REQUIREMENTS

Engineers (AIC/ZIC/ Contractor
1 Physical fitness certificate from MBBS Doctor
Engineers/Executives/GET etc.)
2 Supervisors Physical fitness certificate from MBBS Doctor
3 Project Managers Physical fitness certificate from MBBS Doctor
4 TPE Physical fitness certificate from MBBS Doctor
5 Contractor Labours Physical fitness certificate from MBBS Doctor
6 Welders Physical fitness certificate from MBBS Doctor
7 Grinders Physical fitness certificate from MBBS Doctor
8 PE Technicians Physical fitness certificate from MBBS Doctor
9 GI/Cu technicians Physical fitness certificate from MBBS Doctor
10 O&M-Technicians Physical fitness certificate from MBBS Doctor + Audiometry
11 Dispenser Operators Physical fitness certificate from MBBS Doctor + Audiometry
12 Compressor Operators Physical fitness certificate from MBBS Doctor + Audiometry
13 Plumbers Physical fitness certificate from MBBS Doctor + Vertigo Checks
14 Crane Operators Physical fitness certificate from MBBS Doctor + Colour Blindness tests + Audiometry
15 Breaker operator Physical fitness certificate from MBBS Doctor + Audiometry

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TECHNICAL SPECIFICATION FOR LAYING,

TESTING AND COMMISSIONING OF CGD –

STEEL PIPELINE NETWORK

Sr. No Document Page No.

Total no. of Pages: 420

Vendor Evaluation Criteria

Sr. No Criteria Supporting Document

3 List of competent and experience manpower List of employees and its

2. GENERAL TERMS & CONDITIONS

3. SPECIAL CONDITION OF CONTRACT

3.2 JOB SPECIFIC REQUIREMENT

3.2.1 Quality Assurance / Quality Control Program

3.2.2 Third Party Inspection

3.2.3 Work Execution

3.2.4 Emergency Response Plan

Torrent Pharmaceuticals Limited, the flagship Company of Torrent Group, having a

Sr. No. Geographical Area’s Name

This scope covers the combination of various activities required to execute

ii) The OWNER means M/s. Torrent Gas Pvt. Ltd.

xvii) SPECIFICATIONS shall mean and include schedules, details, description,

xxvi) “STORES” shall mean the company stores located in GA.

xxix) “APPROVED” shall mean approved in writing including subsequent written

xxx) “CONSTRUCTION EQUIPMENT” means all appliances / equipment and things of

xxxi) "MOBILIZATION” shall mean establishment of sufficiently adequate

agreed schedule of work implementation to the satisfaction of owner/ engineer

xxxiv) “MECHANICAL COMPLETION” means completion of the pipeline laying and

xl) “HSE” means Health, Safety & Environment.

2. GENERAL TERMS & CONDITIONS

o Pipeline laying through horizontal directional drilling (HDD) method

labour inclusive of supervision thereof. All materials, equipment, appliances, or

2.1.7 CONTRACTOR shall be deemed to have obtained all necessary information on

2.2 TECHNICAL REQUIREMENTS FOR PIPELINE CONSTRUCTION

2.2.1 PIPELINE CONSTRUCTION

2.2.1.1 Requirement of Right of Way (R.O.W.)

The Right-of-way boundary lines shall be staked by the CONTRACTOR so as to

2.2.1.2 Restricted Right-of-Way

2.2.1.3 RoW Markers

2.2.1.4 Protection of Underground and Overhead Structures

2.2.1.5 Protection of Trench (Wherever Required)

2.2.1.6 Protection of Working Site

2.2.1.7 Identification of Pipe

2.2.1.8 Night Caps

CONTRACTOR is not allowed to close or divert roads or watercourses without

2.2.1.10 Horizontal Directional Drilling

2.2.1.11 Pipeline Markers

2.2.1.12 Installation of Fittings, Valves, Insulating Joints, Skid Assemblies

2.2.1.13 Pipeline Hydrostatic testing

2.2.1.14 Pneumatic Testing-as applicable, Drying and Commissioning

2.2.1.15 Valve Station & Hook-Up

2.2.1.16 Domestic/Common Pressure Reduction Station & Hook-Up

2.2.1.17 Tar cutting and Soil handling/Shifting (Wherever Required)

2.2.1.18 Soil Shortage (Wherever Required)

2.2.1.19 Rocky Terrain:

/ drill or sledge hammer and chisel or removal of the same by additional

2.2.2 MATERIAL MANAGMENT

MATERIALS TO BE SUPPLIED BY CONTRACTOR

2.2.2.1 Loading, Unloading, Handling, Hauling & Storing of Materials

2.2.2.2 Materials to Be Supplied by CONTRACTOR

2.2.2.3 Material Reconciliation

/ instruments, equipment (issued by TGPL) shortage / damage then cost of

bevelling, shall be treated as serviceable materials. All cut pieces of pipe

2.2.3 WORK MANAGEMENT

2.2.3.1 Location of Site