Volume 2 of 2

(Technical specification)

Section - 2
PIPELINES

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 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
10. Specification for Quality Assurance Plan
11. Specification for HDD
12. Specification for TCP System
13. HSE Specification

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1. Specification for Steel Pipeline Activity
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

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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
 Above ground piping and other above ground installation at CNG station
 Installation of A/G DRS and Odourization system
1.3 It is intended that all the work performed in accordance with this specifications 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 GGL/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 labor, inclusive of supervision and all
materials, excluding the material indicated as GGL 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,

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 including sub-surface conditions, hydrological and climatic conditions, the extent and nature of the
work and materials necessary for the completion of the work and the means of access to the work
area (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 GGL/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 Guideline Technical standard specification including safety standards for
Natural Gas Pipeline
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
OISD 141 Design & Construction requirement for cross-country hydrocarbon pipeline
PFI ES – 24 Recommended Practice for Shop Fabricated Pipeline
SIS – 055900 Pictorial surface preparation standards for painting steel surfaces
SSPC – SP1 Steel structure painting council

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 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. SUBMITTAL BY CONTRACTOR
3.1 The CONTRACTOR shall submit the Procedure for Right of way, Procedure for stringing, Procedure
for Handling & Storage of Line Pipes, Procedure for Trenching, Procedure for Cold Field Bending,
Procedure for Lowering, Procedure for Backfilling, Procedure for Installation of SV and Procedure
for Restoration along with quality records (Activity format, Inspection test plan) at least one week
prior to commencement of the work for approval of GGL/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 GGL/TPIA.
3.3 The CONTRACTOR shall submit Inspection test Plan and GAD where ever applicable for valves,
fittings, Insulating joints, Flanges, Gaskets and other associated material in line with GGL Technical
Specification at least one week prior to commencement of work for approval of GGL/TPIA.
3.4 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.
4.1.2 CONTRACTOR shall notify GGL/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.

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4.1.3 CONTRACTOR shall commence work on such crossing after getting approval from the authorities
and landowners concerned to the satisfaction of GGL/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 GGL’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 GGL/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 center 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
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.
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 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 center of the high voltage system.
If work is done at less than 50m from the center 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.
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.

 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 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.

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5. RIGHT- OF- WAY
The CONTRACTOR is required to perform his construction activities within the width of RoW
provided by GGL 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 GGL/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 GGL 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
GGL/TPIA.
5.2 BARRICADING
CONTRACTOR shall provide proper Barricading of the Work area, whenever working in a Populated
/ Urban / Industrial area, as per GGL 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

 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 centerline. 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 GGL/TPIA, landowner and/or tenant, and
Government Authorities having jurisdiction and as soon as practical after the initial removal. In no

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 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.
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 GGL. Public travel shall not be
inconvenienced nor shall it be wholly obstructed at any point.

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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 GGL/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.
5.5.2 CONTRACTOR shall promptly settle all off RoW damage claims. If CONTRACTOR is fails to do so,
GGL/TPIA shall give written notice to CONTRACTOR. If CONTRACTOR does not settle such claims
within seven days after such notice, GGL 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 GGL/TPIA.

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6.1.2 CONTRACTOR shall reimburse the GGL for the cost of replacement of all GGL 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 GGL.
6.2 TAKING -OVER OF LINE PIPE (As Applicable)
CONTRACTOR shall receive and ` take over ' against requisition line pipe from the GGL’s designated
places. CONTRACTOR shall perform visual inspection of the bare pipe and coating of the corrosion
coated pipes/3LPE coated pipes. In the case of corrosion 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 GGL/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 GGL, 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. Damaged pipe shall be
reported to GGL immediately on receipt and same shall be recorded.
CONTRACTOR shall notify GGL/TPIA well in minimum one week in advance for issue of line pipe
from GGL
In case of delays in takeover of GGL 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 GGL. 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
GGL/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.

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  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 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.

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 avoided damages to the pipe
and coating. CONTRACTOR shall submit to GGL a complete procedure indicating the manner and
arrangement used for handling and staking of coating pipes for GGL 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", 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.

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  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.
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 GGL
and all defective pipe ends repaired. Defective pipe shall be repaired or rejected as directed by the
GGL at no extra cost.
6.6 MATERIALS OTHER THAN LINEPIPE (IF ANY)
6.6.1 CONTRACTOR shall receive and take over against requisition all GGL supplied materials from GGL’s
designated place(s) of delivery as defined in the CONTRACT. CONTRACTOR shall notify GGL/TPIA
well in minimum one week in advance of issue of material from GGL
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 GGL 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 GGL. 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 GGL.
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 appurtenant 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 GGL/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 centerline of the
pipeline taking into account the curves of the pipeline.
Identification of underground utilities shall be carried out and utility authorities shall be informed
before execution of activity.
Excavation operation area shall be barricaded properly.
Suitable trench protection shall be done by CONTRACTOR as guided by GGL/TPIA.
Damage of utilities shall be restored to its original conditions by CONTRACTOR.
No person shall be allowed within close vicinity /radius of operation of equipments.
7.2 EXCAVATION
7.2.1 CONTRACTOR shall, by the method approved by GGL, dig the pipeline trench on the cleared and
graded RoW. In cultivable land and other areas specifically designated by the GGL, 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.

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 Suitable crossings shall be provided and maintained over the open ROW, where necessary, to
permit general public, property owners or his tenants to cross or move stock or equipment from
one side of the trench to the other.
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.
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, the GGL 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.
7.3.2 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 GGL/TPIA.
SR. MIN. DEPTH OF COVER
LOCATION
NO. (MTR)

1 Industrial, Commercial & Residential Areas (Secondary Roads) 1.2

2 Normal / Rocky Terrain 1.0
Minor Water Crossings & Canals / unlined canal / nala 1.5*
3
crossing / tidal areas and other watercourses(1)

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 4 Major River Crossings(1) 2.5*

5 Rivers with Rocky bed 1.5*

6 Lined Canals / drains / nalas etc. 1.5*

7 Drainage ditches at road and railroads 1.0
8 Rocky Areas 1.0

9 Cased / Uncased road Crossings (2) 1.2

10 Cased Railroad Crossings(2) 1.7*

1. For River/Water courses that are prone to scour /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 for minimum 1 meter shall be provided from the existing bed of the river/water course.
2. The cover shall be measured from top of the road or top of the rail, as the case may be.
3. Depth of Cover can be increased / decreased as per the requirement of the Governing Authorities and
GGL instruction as and when required.
4. Whenever the above provision of cover cannot be provided due to site constraints, additional protection
in form of casing/concreting etc. shall be provided. The same shall be as suggested by GGL/TPIA.
5. For All Cases where Depth of Excavation > 1.2 Mtrs, Clause for ‘Confined Space Entry’ as per GGL HSE
Requirements, shall apply.
6. Clause for ‘Confined Space Entry’ as per GGL HSE Requirements, shall apply and GGL Life Saver ‘Confined
Space Entry’ shall be followed.
7. ‘Permit to Work’ shall be required before carrying out any Construction related activity.
8. 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 GGL/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 GGL/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 GGL/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.
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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 GGL.
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:
1. 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 300 mm below from such services.
2. 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 300 mm from existing utility.
3. As far as practical, a minimum separation of 3 meter should be maintained between the steel
pipeline or main and footing of transmission tower.
4. Clear distance between new steel pipeline or main running parallel to existing pipeline should
be 5 meter when heavy conventional construction equipments is expected to be utilized. This
distance may be reduced, after careful assessment of construction methodologies, to 3 meters,
provided it does not result in unsafe conditions during construction.
5. While laying more than one new hydrocarbon pipelines or mains in same trench, clear
separation of minimum 500 mm shall be maintained between adjacent pipelines.
6. No steel pipeline or mains should be located within 3 meter of any habitable dwelling or any
industrial building unless provided with at least 300 mm of cover over and above minimum
cover specified in above table or special protective measures such as concrete slab, steel casing
are provided.
7. 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
GGL.
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. GGL 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. GGL/
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.
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 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 GGL Site engineer. GGL 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 GGL by reason of its caving either before or after pipe is laid. 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.
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

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 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 GGL/ TPIA.

 By applying concrete coating by gunating.

 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 field bends and degree of field bend shall be as per requirements mentioned in
PNGRB technical standard and ASME B 31.8.
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 1.5 m on either side.
8.2.4 The longitudinal welds shall be in the upper quadrants.
8.2.5 The ovalization caused on each pipe by bending shall be less than 2.5% of the nominal diameter at
any point.

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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 disbanding of the coating caused during bending shall be repaired at the CONTRACTOR’s
expenses in accordance with GGL/TPIA approved procedures.
8.2.8 Over bends shall be made in such a manner that the center 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 any way 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.

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 GGL.
9.2 PIPE DEFECTS
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 GGL/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

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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 GGL/TPIA, after submission of section pipe book and
acceptance of the same for the section to be lowered. Entire 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
10.2 Bottom padding shall be done as per GGL 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 300-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 equipments 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.

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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 GGL/TPIA’s, so that it fits in the excavated trench
bed.
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 Post padding work shall start immediately after lowering.
10.10 Pipe cover shall be checked immediately after lowering at every alternate joint.

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.
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 to a height of 300 mm above the top of the pipe.
CONTRACTOR shall select the backfill materials for padding that are acceptable to GGL/TPIA,
whether such padding material would be taken from the adjacent spoil bank or imported from
elsewhere shall be directed by GGL/TPIA. CONTRACTOR shall carry out all these works at no extra
cost to GGL. Loose rock may be returned to the trench after the required selected backfill material

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 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 GGL/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 GGL/TPIA. GGL/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 graveled 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 GGL.
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 GGL. The materials
required may include gravel, special stabilization materials or stabilized mixtures. Moreover, special
processing and/or compacting methods shall require the approval of GGL/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 GGL/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 GGL/ TPIA direction. CONTRACTOR may propose
other methods such as foam dams’ etc. which shall be subject to approval of GGL/TPIA. Such works
shall be done at no extra cost to GGL. 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
GGL/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.

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11.11 CONTRACTOR shall leave the pipe uncovered at certain locations to allow GGL/TPIA to survey the
centerline of the pipe and the level of the pipeline in the backfilled trench. Within 48 hours after
backfilling, GGL/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 GGL/TPIA. CONTRACTOR shall carry out the stabilization to have a consolidated
cover over the pipeline at no extra cost to GGL.
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 atleast 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
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 GGL/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 GGL/TPIA.
Stainless steel tubing will be "swaged" using permanent fittings installed with a hydraulic device.
The bending tool shall be subject to GGL/TPIA approval.

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 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.
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
centerline so the union will not be forced during wake-up. The 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.

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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
GGL/TPIA, a report regarding the method of application and the materials used along with the test
certificates. Only after obtaining written approval from the GGL/TPIA, CONTRACTOR shall
commence of coating work.
Welds shall not be coated until all heat treatment, NDE and inspection activities have been
completed and the item released for coating.
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:
o Socket and seal welds
o Single or multi-pass, pressure retaining fillet welds
o All welds in systems subject to a sensitive leak test (where sensitive leak test is permitted by
GGL)
• Other safety critical welds as designated by GGL.
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.
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 GGL/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 GGL/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 5mm 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.
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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, beveling 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.
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 GGL/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 drawings. CONTRACTOR shall
obtain approval from the GGL/TPIA before installation of the insulating joints.

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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.
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 GGL / TPIA.GGL/ TPIA reverse 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 GGL and
concerned land owner or authority. All surplus and defective materials supplied by GGL 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 GGL.

 All surplus and defective materials supplied by GGL shall be collected by CONTRACTOR and
delivered to designated stockpile areas.
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  All pipe-ends shorter than 1.0 m shall be returned to GGL being scrap, all pipes longer than 6.0 m
shall be reconditioned (bevels, coating, repair, holiday check) provided to GGL’s designated
stockpile materials. All pieces between 1.0 and 6.0 m shall be charged to the CONTRACTOR by GGL.
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 GGL 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 unburnable material shall be disposed off, in an
appropriate manner as per GGL HSE&S 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 GGL/TPIA.
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.

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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 GGL/TPIA shall
be completely indemnified and held harmless by CONTRACTOR from any claims, demands, losses,
expenses etc. that may arise on its behalf or GGL/TPIA may anyway suffer or sustain, relative to,
arising out of, or in connection with same. The GGL/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 geodetric 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 can not be done
according to existing banks because of the absence of it, shall be restored as instructed by
GGL/TPIA. The bed of ditches crossed by the pipeline shall be cleaned over the full width of the
ROW, also outside the ROW if 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 GGL/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 GGL/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
GGL/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 GGL/TPIA, landowner and/or tenant.
14.13 If, in the opinion of GGL/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
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 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 GGL/TPIA.
Subsequently, the entire ROW, which is part of pastureland, shall be prepared for seeding and
fertilized according to the instructions of GGL/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 GGL/TPIA. Ripping
has to be done with rippers with a distance of 50 cm between the ripper blades. The type to be
used shall be approved by GGL/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 GGL/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,
GGL/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 GGL/TPIA.
If site and/or climatic conditions should render this necessary ,GGL/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.

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 In case GGL/TPIA has given prior permission for mixed excavation of the sub-soil as well as in cases
where GGL/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
GGL/TPIA.

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 DOCUMENTATION

 Quality record for each activity

 Procedure, ITP and Progress report of each activities.
 Pipeline route alignment drawing
 No objection certificate from Government / Concern authorities and Land owner.
 Pipe book
 Mechanical clearance of special installation
 As built drawing of pipeline
 As built drawing, plan and Isometric of special Installation
 Batch certificate of all material
 All applicable forms and formats as per GGL approved procedure and guidelines

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2. Specification for Pipeline Welding

1. Scope
2. Reference Code And Standard
3. Submittals By Contractor
4. Base Material
5. Welding Consumables
6. Equipment And Accessories Requirement
7. Welding Processes
8. Bevel Cleaning / Bevel Inspection
9. Alignment And Spacing
10. Weather Conditions
11. Welding
12. Heat Treatment
13. Inspection And Testing
14. Repairs Of Welds
15. Documentation
16. Enclosure

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1. 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.

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 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 examinassions
ASME Section IX Qualification for welding and brazing

3. SUBMITTALS BY CONTRACTOR

3.1 The CONTRACTOR shall submit the Welding Procedure Specification, Procedure Qualification
Record, Welder Qualification Test, and Radiography Procedure along with quality records and
Inspection Test Plan for welding and NDT compatible to this specification at least one week prior
to commencement of the work for the approval of GGL/TPIA.

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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. 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. 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 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.
5.3 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 separately. Cellulose electrodes used
shall however be used as per specific recommendations of manufacturer.
5.4 The electrodes used shall be free from rust, oil, grease, earth and other foreign matter, which
affect the quality of welding.

6. 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.

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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.

7. 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.
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

8. BEVEL CLEANING / BEVEL INSPECTION

Line pipe supplied by GGL 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 beveled 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, satisfactory weld spacing cannot be successfully done, the damaged ends shall
be cut and beveled to the satisfaction of the Engineer – in – charge/TPIA with an approved

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 beveling 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. 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.
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 shall not exceed 1.6
mm. The offset may be checked from outside using dial 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.

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 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. slog., 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. 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. WELDING

11.1 Root Pass

11.1.1 Root pass shall be made with electrodes / filler wires recommended in the welding specification
chart. For fillet welding root welding shall be done with consumable recommended for filler
passes.
11.1.2 The size of the electrodes used shall be as per the approved welding procedure.
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
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
and chiseling.

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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.
11.1.10Fillet 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.
11.1.11Penning shall not be used.
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 1.8 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 speed selected shall enable production of a bead which is sufficiently thick and
which shows no undercutting.
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. 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 penetrate 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. Welding prohibits repair of arc strikes by welding.

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 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. 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. Oxypropane 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.

13. INSPECTION AND TESTING

13.1 General
13.1.1 The CONTRACTOR shall also afford the GGL/TPIA inspector all means and facilities necessary to
carry out inspection. The GGL/TPIA Inspector shall have free access to all concerned areas,
where the actual work is being performed.
13.1.2 The GGL 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:
1) To check the conformance to relevant standards and suitability of various welding
equipment and the welding performance.
2) To witnessed the welding procedure qualification.
3) To witnessed the welders’ performance qualification.
4) 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.

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13.1.4 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, 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 GGL’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 GGL’s and TPIA inspector shall witness the test and certify the qualification of
each welder separately. Only those welders who have been approved by the GGL’s and TPIA
inspector shall be employed for welding.
13.3.2 The welders shall always have in their possession the identification card as per Exhibit-D and
shall produce it on demand by the GGL’s/TPIA Inspector. It shall be the responsibility of the
CONTRACTOR to issue the identity cards after it has been duly certified by the GGL’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

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 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
GGL’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 GGL’s/TPIA will review all the radiographs of welds and inform the CONTRACTOR regarding
unacceptable welds. The decision of the GGL’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.
c) When in the opinion of Engineer-in-charge/TPIA, ultrasonic inspection is required to
confirm or clarify defects indicated by radiography.
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 defective and shall so 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.

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 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 GGL’s/TPIA.
The destructive testing of weld joints shall be made as per Annexure - I.
In addition, welds already cut out for defects for any reason may also be subjected to
destructive testing. 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. 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. 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

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 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.
Welds not meeting the specification after one repair shall be cut out depending upon the extent
of repair. 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.
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- beveled
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 and this
specification, repairs within these limitations are permitted. Defects in the filling and capping
passes shall be repaired preferentially.

15. 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.
15.4 All forms and formats as per GGL approved procedures and Guidelines

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

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  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. 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 Figure 1 of this specification from
areas as free from defects as possible; for this reason it is necessary to take the previous
nondestructive 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 GGL/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 Figure 1. Two ISO type specimens and
two API type specimens shall be taken.
The ISO test specimens are shown in figure 2 of this specification.
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
GGL/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
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).GGL/TPIA may ask for a macrograph with 5 times (5:1) magnification, for
documentation purposes.

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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 to Fig. 5 of 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.
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 Fig. 1 of 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. 3 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 shown
in Fig. 4 of this 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 upto 12 7.5
From 7 upto 9.5 5.0
Less than 7 2.5

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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 00 C & – 100 C.
1.6.3 Requirements (Note 1)
The impact energy shall be
Test Specimen in Average of three specimens Minimum single value
mm Joules(Min) (Joules)
10.0 27.0 22.0
7.5 21.5 17.5
5.0 18.5 15.0
2.5 10.0 8.0
Note 1: Only one value is permitted to be lower than average value upto the value specified.
1.7 Bend test requirements
The Bend test Specimens shall be made and tested as per the requirements of API 1104
Sixteenth edition May 1983 except that the dimensions of the Jig for guided bend test Fig. 5,
para 2.6 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 2.643 and 2.653 of API 1104 Sixteenth
edition May 1983.
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
GGL/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 effect 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.
 Interpret the type of defects detected.
GGL/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
 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 GGL/TPIA. Before inspection begins,
GGL/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

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 production procedure, where there are typical defects the test intends to detect. This test shall
be conducted in the presence of GGL/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 50 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 be 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 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 centimeters 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 GGL/TPIA, are satisfied.
b) Continuous operation:
All the instruments and equipment shall be approved by the GGL/TPIA before being used.
GGL/TPIA has the authority to reject any item, which is considered unsuitable. The decision of
GGL/TPIA is final. The CONTRACTOR appointed to carry out ultrasonic inspections shall also

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 ensure the operational efficiency and maintenance of the instruments and equipment, and shall
immediately substitute any item rejected by GGL/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 a 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.
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

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 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 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, GGL/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 probetube
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 unfavorably oriented cracks, he shall inform
the GGL/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.

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1.12 Other Equipment
The use of rules calibrated in centimeters, 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 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:
1) 100% of all Butt Weld Joints.
2) Full girth welds on the mainline construction including double jointing of pipe, if adopted.
3) Welds for installation of block valves, insulating joints and other appurtenances and tie-ins.
4) Welds at scraper launching and receiving barrels.
5) Terminal Piping.

2. APPLICABLE STANDARDS
This specification shall apply in conjunction with the following (all latest editions):
1) API 1104, Standard for welding Pipelines and related facilities.
2) ASME B 31.8, 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 Nondestructive 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
GGL/TPIA prior to use. It shall include but not be limited to the following requirements:
1) Lead foil intensifying screens, at the rear of the film shall be used for all exposures.
2) Type 2 and 3 films as per ASTM E - 94 shall be used.
3) 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.
4) 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 GGL/TPIA prior to use.

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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 penetra meter 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 GGL/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 GGL/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 GGL. 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 GGL/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 GGL/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, (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 GGL/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 GGL/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
GGL/TPIA.
3.7 GGL/TPIA shall have free access to all the CONTRACTOR’s work facilities in the field.
3.8 Any approval granted by GGL/TPIA shall not relieve the CONTRACTOR of his responsibilities and
guarantees.

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4. RADIATION SOURCE
4.1 Radiographic examination shall be carried out using X-Rays only. Radiographic examination by
Gamma Rays is not allowed,
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. (360oC) 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.

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, four Penetrameters
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.
GGL/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.

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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 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 GGL 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.
GGL/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 GGL/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 GGL/TPIA.
10.2 Certification of all the radiographers, qualified as per clause 10.1 above, shall be furnished by
the CONTRACTOR to GGL/TPIA before a radiographer will be permitted to perform production
radiography. The certificate record shall include
1) Background and Experience Record
2) Training Course Record.
3) Doctor’s report on radiographer’s Oaecuer 0-1 acquity eye test.
4) 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 GGL.

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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 GGL/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 GGL/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 GGL/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.
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 GGL/TPIA prior
to start of work and their telephone No. shall be posted prominently in CONTRACTOR’s field
office

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 All critical industrial injuries shall be reported promptly to GGL/TPIA and a copy of
CONTRACTOR’s report covering each personal injury requiring the attention of physician shall
be furnished to GGL/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 :
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 Temperature :
Post-weld Heat :
Treatment Details
Visual Examination :
Radiographic Examination
Results :
Tensile test results :
Identification
U.T.S Yield Point Elongation Remark
No

C: Impact Test Results

Test Temperature : Notch in :
Type of Specimens : Size of :
(Charpy) Specimens :
————————————————————————————————————
Specimen No Impact Value Average
————————————————————————————————————
1.
2.
D: Chemical Analysis Results:
Electrode Size Used :
Batch No. :

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—————————————————————————
% %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) :
Macro Test results :
Fracture test results :
Remarks :
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

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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./ Electrode negative/ :
D.C. 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 :
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 cooling
Maximum time between commencements and completion or weld:

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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 :
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 :
Radiograph :
Destructive Test :1234
Transverse tensile :
Tensile strength (with units) :
Fracture location :
Test temperature :
Macro examination :
Fillet weld fracture :
Hardness survey :

Type Load Location of hardness measurements (Sketch)

Hardness range :
Parent Metal :
Heat affected zone :
Weld :
Chary V-notch impact tests :
Specimen location and size :
Notch location :
Test temperature :
Results (With units) :
Additional test(s) and results, e.g., chemical analysis, micro-examination, CTOD tests, Bend tests

The statements in this record are correct. The test joints were prepared, welded and tested in
accordance with the requirements of specification.

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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 :
 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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 EXHIBIT – D

WELDER’S IDENTIFICATION CARD

GGL
WELDER’S IDENTITY CARD
Name Welding Position
Welder No. Material
Date of Testing Diameter
Valid upto Wall thickness
Approval of Type of welding
Welding Consumables
W.P.S. Nos.
APPROVED BY

GGL

TPIA

GGL SITE ENGINEER THIRD PARTY AUDITOR

SIGN SIGN
DATE DATE

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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

Approval of the GGL/TPIA Signature of CONTRACTOR with seal

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 TABLE 1 (WELDING SPECIFICATION CHART)

NUMBER OF SPECIMENS
PIPE SIZE, OUTSIDE
TENSILE TENSILE NICK ROOTB FACE SIDE MACRO HARD IMPACT TOTAL
DIAMETER INCHES
API ISO BREAK END BEND BEND NESS
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 2 0 2 0 0 2 2 2 12 22
THAN 12 ¾

12 ¾ AND OVER 2 2 4 0 0 8 2 2 24 44

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SR. WELDING PROCESS FILLER METAL
ITEM MATERIAL PIPE DIA/THK. NDT
NO. ROOT FILLER ROOT FILLER
1 Pipe to Pipe SMAW SMAW

API 5L Gr. X52/X65 OR

ALL SIZE & 100 %
1.1 Pipe ASTM A 333 Gr. 6 OR Uphill Downhill E 6010 E 7010 G
THICKNESS Radiography
ASTM A 106 GR B

2 Pipe to Flange
API 5L Gr. X52/X65 OR
ALL SIZE & UP Hill/ UP Hill/
2.1 Pipe ASTM A 333 Gr. 6 OR E 6013 E 6013 UT/ DPT as
THICKNESS Down Hill Down Hill
ASTM A 106 GR B required by
MSS SP 44 Gr F 52/F65 Engineer-in-
UP Hill/ UP Hill/
2.2 Flange OR ASTM A 105 OR ALL SIZE E 6013 E 6013 Charge
Down Hill Down Hill
ASTM A 350 GR LF2
3 Pipe to Fitting SMAW SMAW

API 5L Gr. X52/X65 OR

3.1 Pipe ASTM A 333 Gr. 6 OR ALL SIZE
ASTM A 106 GR B
100 %
Uphill Downhill E 6010 E 7010 G
MSS SP 75 WPHY Radiography
52/65 OR ASTM A 234
3.2 Fitting ALL SIZE
GR WPB OR ASTM A
420 WPL6

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3. Specification for Field joint coating

1. Scope
2. Reference Code And Standard
3. Submittals By Contractor
4. Material And Equipment Requirements
5. Procedure Of Application
6. Inspection & Testing
7. Marking, Protection, Storage And Handling
8. Repairs
9. 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 GGL 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.

2 REFERENCE CODE AND STANDARD

Following standards and codes of latest edition have been used in this specification

2.1 Governing Standard:

EN 12068 Cathodic protection- External Organic coatings for the corrosion protection of
buried or immersed steel pipeline used in conjunction with cathodic protection-
Tapes and shrinkable materials

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.

3 SUBMITTALS BY CONTRACTOR

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.

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 a. Complete descriptive technical catalogues or data sheet describing the materials offered
along with samples of anti-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 GGL/TPIA approval has been given, any change in material or manufacturer shall be
notified to GGL/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 (Refer to Annexure II) at least one week
prior to commencement the work for approval of GGL/TPIA.

4 MATERIAL AND EQUIPMENT REQUIREMENTS

4.1 General
4.1.1 The CONTRACTOR shall be responsible to provide the coating material at site in compliance
with the requirement of this specification.
4.1.2 Test Certificates shall be available to GGL/TPIA for review before commencement of work.
4.1.3 The material and equipment like joint coating material, material for blasting, primer, blasting
hopper, air compressor, burners etc. shall be approved by GGL/TPIA. Sand blasting shall not
be allowed. Garnet will be the preferable blasting media.
4.1.4 CONTRACTOR shall be responsible for arranging all manpower required for application,
testing and inspection of coating in the filed in accordance with this specification
4.1.5 Coating material shall be capable to withstand a maximum service temperature of 60°C. The
material shall possess high dielectric strength, good tensile strength, and good resistance to
thermal ageing as mentioned in Table-1 & Table-2 of this specification.

4.2 Field joint corrosion coating material

4.2.1 Heat shrinkable wraparound sleeve

 Heat shrinkable sleeve shall consist of radiation cross-linked thermally stabilized, ultraviolet
resistance, semi-rigid backing, with a uniform thickness of high shear strength and
thermoplastic / copolymer hot melt adhesive.
 The joint coating system shall utilize 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.
 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.
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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 GGL/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 2.0
mm.
4.2.4 Cut Back length of pipe coating for coating sleeved shall be 150 mm (+0, -10 mm).
4.2.5 The field joint coating material shall be supplied with minimum following physical, chemical
& electrical properties.
4.2.5.1 Properties of Backing

Table – 1: Properties of Backing

A. Physical Properties

Specified
Sr. No. Properties Unit Test Condition Test Method
Requirement

1 Tensile Strength MPa > 15 25° C DIN EN 12068

2 Elongation % > 400 25° C DIN EN 12068

3 Impact Resistance N-m > 15 25° C DIN EN 12068

B. Chemical Properties

1 Water Absorption % < 0.05 24 hours at 25°C ASTM D 570

Resistance to Thermal Change Elongation,

2 % 100 °C DIN EN 12068
Ageing-100 days < 25%

C. Electrical Properties

1 Volume Resistivity Ohm-cm > 1016 25 °C ASTM D 257

2 Dielectric Strength kV > 30 1000 volt / sec ASTM D 149

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 Table – 2: Properties of Coating System (As Applied)

A. Physical Properties

Sr. Specified
Properties Unit Test Condition Test Method
No. Requirement

1 Impact Resistance>15J N-m No Holidays 23°C & 30 Blows DIN EN 12068

2 Resistance to peel

 With metal surface > 3.5

2.1  With mill coating > 3.5 23 °C DIN EN 12068

 At layers overlap > 1.5

N/mm
2.2  With metal surface >1 60 °C

 With mill coating >1 DIN EN 12068

 At layers overlap > 0.3

> 0.6
Resistance to
3 mm Remaining 60 °C DIN EN 12068
indentation
thickness

Lap shear strength

4
between

 Wrapping & metal

surface
4.1 N/mm2 > 0.05 60 °C DIN EN 12068
 Wrapping & Mill
Coating

Cathodic Disbondment 30 days, test

5 (Radius of mm < 15 method A at DIN EN 12068
Disbondment) 60°C

6 Dielectric Strength kV > 30 1000volt /sec ASTM D 149

NOTE: CONTRACTOR shall obtain prior approval from GGL/TPIA regarding the
manufacturer of the joint coating, complete technical details along with tests certificates

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 complying the requirements shall be submitted to GGL for the purpose. Only GGL/TPIA
approved manufactures shall supply the materials.

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 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 GGL
5.2 The CONTRACTOR shall submit and demonstrate to GGL/TPIA, the proposed materials and
work procedures. The proposed procedures, materials and equipment shall be approved by
GGL/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 a neptha 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 GGL/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 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. Minimum DFT of applied
epoxy shall be 200 microns.
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

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 area shall be cleaned and re-primed. The wet film thickness shall be 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 100 mm is
ensured prior to shrinking (after shrinking the minimum overlap will be 50mm) 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. 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
centering 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 thermocrayons 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 100 mm.
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 and weld profile 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 pealed 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.

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6 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).
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 GGL/TPIA. The test voltage shall be 5 kV
+ 5 kV/mm of total thickness, subject to a maximum of 25 kV. Inspection of the sleeves shall
be conducted only after the joint has cooled below 50 0C (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 GGL/TPIA.
6.3 Testing
6.3.1 GGL/TPIA reserves the right to remove and test, one of every 50 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 GGL/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.

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6.3.5 If the adjacent two sleeves are acceptable the test rate shall be increased to one sleeve
every twenty-five until GGL/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 GGL/TPIA reserves the right of 100% removal of sleeves if they are not convinced that the
requirements of clause 6.3.3 are achieved.
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 2.00 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 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 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. Mobilize 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 GGL/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 GGL/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 DOCUMENTATION
CONTRACTOR shall provide the following as minimum.
 Test certificates/results as per Manufacturer’s Quality Control Procedure for each batch of
materials.
 Calibration certificates of measuring Instrument, testing Equipment.
 Insulator qualification record certified by manufacturers.
 Process qualification records.
 Quality records.
 Procedure for field joint coating
 ITP
 Progress Report
 All Forms and Formats as per GGL approved procedures and Guidelines

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4. Specification for Pipeline Crossing
1. Scope
2. Reference Codes And Standards
3. Submittal By Contractor
4. General
5. Road & Rail Road Crossing
6. Crossing Of Buried Services
7. Minor Water Course Crossings
8. Documentation

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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 GGL /
TPIA for review & approval.
This specification shall be read in conjunction with the conditions of all specifications and
documents included in the CONTRACT between GGL/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.
2.1 Governing Standard
ASME B 31.8 -Gas Transmission and Distribution Piping Systems
API RP 1102 -Recommended Practice for Liquid Petroleum Pipelines
Crossing Railroads and Highways.
2.2 Reference Standard
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
GGL HS&E - GGL HS&E Management System Manual and -GGL
Security Manual

3. SUBMITTAL BY CONTRACTOR
1.1 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 GGL/TPIA.
1.2 The CONTRACTOR shall submit construction drawing and Inspection test plans for all the
activities compatible to this specification (Refer Annexure II) at least one week prior to
commencement of the work for approval of GGL/TPIA.

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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 GIDC etc., shall be obtained by GGL principally and CONTRACTOR shall
co-ordinate & obtain necessary approval from such authority to cross the highway/ Railway
& Canal by Push jack boring method approved by GGL / 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 GGL/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 GGL/TPIA reserves the right to demand for individual crossings from the CONTRACTOR a
separate detailed report for approval, containing:
 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 GGL.
4.3 Pipeline crossings for road, railroad, canals and rivers etc., shall be hydrostatically 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 )

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  Whenever, in GGL/TPIA’s opinion, the repair of pipeline at crossing, in case of a leak
during final hydrostatic testing, would require inordinate amount of efforts and / or time
 Whenever 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. 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 GGL/TPIA and to the satisfaction of GGL/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 GGL/TPIA for safety of traffic. Adequate traffic warning signals and/or
traffic lights and suitable diversions shall be provided as directed by GGL/TPIA/Authority
having jurisdiction over these areas. Such diversions shall not cross the pipeline where it has
already been installed, unless proper safeguarding at GGL/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 carrier or casing pipe. If excessive void or too large
hole results, or if it is necessary, in the opinion of GGL/TPIA, to abandon the bored hole,
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 prompt remedial measures such as filling the hole with suitable material shall be taken to
the entire satisfaction of the GGL/TPIA and Authorities having jurisdiction there of at no
extra cost to GGL/TPIA. Equipment used for installation of casing pipe shall be of the type
approved by GGL/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. GGL/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. 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 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 GGL/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 GGL/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 meters center (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 GGL/TPIA shall
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 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 GGL/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).

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 GGL/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
GGL/TPIA. Procedure and other applicable documents as per CONTRACT, and as directed by
GGL/TPIA., shall be prepared and submitted to GGL/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
favorable 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.

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 Whenever required by GGL/TPIA, CONTRACTOR shall execute a soil investigation before
start of construction. Based on this soil investigation, he shall prepare a construction
drawing, work method and time schedule for approval by GGL/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 GGL/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 GGL/TPIA.
7.11 Banks and trenches of minor water crossings shall be back filled with soil which is to be
approved by GGL/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 GGL/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 30
centimeters 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 cleanup 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
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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.
 All forms and Formats as per GGL approved procedures and Guidelines
8.2 Detail drawings of Crossing (Typical drawings attached with this document)
1) GGL-TS/STEEL-TYPICAL-001 – Existing under-ground pipe crossing (Type-1)
2) GGL-TS/STEEL-TYPICAL-002 – Existing under-ground pipe crossing (Type-2)
3) GGL-TS/STEEL-TYPICAL-003 – Overhead power line crossing
4) GGL-TS/STEEL-TYPICAL-004 – Under Ground cable crossing
5) GGL-TS/STEEL-TYPICAL-005 – Major Canal crossing (Cased)
6) GGL-TS/STEEL-TYPICAL-006 – Major canal crossing (Open Cut)
7) GGL-TS/STEEL-TYPICAL-007 – Minor Canal/khadi/nala crossing
8) GGL-TS/STEEL-TYPICAL-008 – Road/Highway pipeline crossing (Cased)
9) GGL-TS/STEEL-TYPICAL-009 – Road Crossing (Open Cut)
10) GGL-TS/STEEL-TYPICAL-010 – Railway Crossing
11) GGL-TS/STEEL-TYPICAL-011 – Casing pipe detail
12) GGL-TS/STEEL-TYPICAL-012 – Detail of Vent and Drain off arrangement
13) GGL-TS/STEEL-TYPICAL-013 – Right of Way (ROW) for pipelines
14) GGL-TS/STEEL-TYPICAL-014 – Slab protection on pipeline
15) GGL-TS/STEEL-TYPICAL-015 – River crossing with over & Sag bend
16) GGL-TS/STEEL-TYPICAL-016 – Support to SV Vent pipe

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5. Specification for Pipeline Hydro test

1. Scope
2. Reference Codes And Standards
3. Submittal By Contractor
4. General
5. Hydrostatic Test Procedure
6. Test Duration And Pressure
7. Equipment And Instrumentation
8. Procedures
9. Acceptance
10. Termination
11. Measurements
12. Calculations
13. Precautions During The Test
14. Preservation Of Pipeline
15. 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 GGL /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 standards and codes of latest edition have been used in this specification.
2.1 Governing Standard
ASME B 31.8 : Gas Transmission and Distribution Piping Systems.
API RP 1110 : Pressure Testing of Liquid Petroleum Pipelines.
2.2 Reference Standard
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.

3. SUBMITTAL BY CONTRACTOR
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 GGL/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 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:

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 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 GGL and TPIA.
Pre-testing
Pipe and fittings shall be pre-tested prior to the pull-back 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 GGL/TPIA.
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 GGL /TPIA.

5. HYDROSTATIC TEST PROCEDURE

The procedure shall strictly comply with the requirements of these specifications and shall be
submitted to GGL / 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.
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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.

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, leveling, 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 and gauging:
 Cleaning pigs with spring loaded steel wire brushes except for internal coated pipe.
 In this case pigs to be provided with nylon / polyurethane brushes, four cup batching pigs.
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  Gauge pigs with gauge plate diameter equal to 95 % of the heavy wall pipe in the
pipe sections, (gauge plate shall be 95 % of nominal pipe diameter)
 Caliper Pig Unit - Aluminum gauge plate of 6.5 mm thick shall be used for gauging
The CONTRACTOR shall provide a sufficient number of pigs, including spares.
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. 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.
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 Temporary scraper traps 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.

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 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 shall be repaired as per coating specification and GGL/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.

8. PROCEDURES
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 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 GGL /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.
8.4 Air Pigging:
Before filling operation, CONTRACTOR shall clean the pipeline by air driven pigs. Air pigging
shall be preferable in sections. Each section shall be cleaned by following the sequence of pigs
as below:
 Cleaning pigs provided with spring loaded brushes & polycups.
 Pigs provided with air jet nozzles to keep the internal dust in turbulence ahead of the
pigs.
 Batching pigs with four polycups shall be passed to remove mud, dirt, debris and any
other materials inside the pipe.
 Gauging pigs with four polycups and with aluminum plate of 6.35 mm thick, diameter
of gauge plate shall be 95% of thickest pipe internal diameter.
Note: -
Cleaning of line shall be evaluated by GGL/TPIA.
In case of damage to gauging plate, the cause shall be justified by CONTRACTOR and shall
satisfy GGL/TPIA. If the gauge plate is buckled or stuck-up in the line. CONTRACTOR shall
locate the pig / identify the cause and should rectify the damage of pipe without any
additional cost to GGL.
8.5 WATER FILLING
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 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 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 4 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 GGL / TPIA.
8.7 PRESSURIZATION
The pressurization shall be performed in the presence of GGL /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:
 Line shall be pressurized at 30% of test pressure.
 Plot PV graph as explained below for air-volume acceptance.
 Pressurize to 50% of test pressure, hold pressure for 1 hour.
 Drop pressure to static head of test section at test head.
 Pressurize to 75% of test pressure, hold pressure for 1 hour.
 Drop pressure to static head of test section at the test head.
 Pressurize to test pressure.
In case, during the hold periods indicated above, a decrease in pressure is observed, the above
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 PLOTTING [PV Graph]
In order to check the presence of air in the pipeline, during the pressurization to full test
pressure, CONTRACTOR shall take pressure and added volume reading and
 Plot volume Vs pressure, the air content in the test shall then be established.
 In case, the air content exceeds 0.2% of the volume of the test section at 30% of test pressure,
further pressurization shall be stopped.

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 If after successive trails of venting, the air content still remains at more than 0.2% of the
volume of the test section, the CONTRACTOR shall repeat the pigging activities to remove the
air pockets.
 The procedure shall be repeated till the air content in the test section does not exceed the
allowable limit of 0.2% of the test section at 30% of test pressure.
 In case the air content is within 0.2% of the test section then pressurizing can continue.
8.9 MECHANICAL STRENGTH TESTING
After successful air-volume testing, pressurize the pipeline to test pressure, the pressure shall
be held for 24 hrs. Any drop in pressure more than 0.3 kg/cm2 (irrespective of temperature
drop), additional measured amount of water shall be added to compensate the pressure drop
i.e. to reach test pressure. PV plot shall be maintained for all such water added i.e. all relevant
records for pressure drop / water volume added / pressure raised etc. shall be maintained.
This shall be maintained for 24 hrs and the records shall be submitted to TPIA in writing.

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 GGL / TPIA.
CONTRACTOR shall comply with instructions of the GGL /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 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 GGL furnished materials, CONTRACTOR shall be reimbursed for
furnishing all labor, equipment, materials, except those materials furnished by the GGL 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.

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9.4 CONTRACTOR shall haul and stockpile all damaged and defective pipes to storage locations
designated by the GGL / 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 GGL / TPIA.
10.1 DEPRESSURIZATION AND DEWATERING
The pipeline shall be slowly depressurized at a moderate and constant rate as instructed by
GGL /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.
 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 GGL /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 foam pigs each in different colors / numbered for this
purpose.
The line shall be considered de-watered when a negligible amount of water is flushed out by
the last foam pig and approval is given by the GGL / TPIA.
10.2 During de watering, 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 25% of initial weight.

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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 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, 7.5o/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 4 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
Scale : -10oC to + 40oC
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:
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 Accuracy : + 1% of the scale range
Scale : 0oC to + 60oC
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: ri

Vp = (0.884 ----- A) X 10-6 XVt X P X K

ti
Where:
Vp = Computed water amount required to raise by Pressure in the section

to be tested (m3).

Vt = Geometrical volume of the section (m3).

P = Pressure rise (bar).

ri = Nominal inner radius of the pipe (mm).
ti = Nominal pipe thickness (mm).
A = Isothermal compressibility value for water at The Pressurization
temperature in the P range (bar-1)x 106.(Refer water compressibility factor Vs
pressure and Temperature chart).
K = A dimension less coefficient that is equal to
A value of 1.02 for longitudinally welded Pipe.
12.2 The pressure change due to a water temperature change shall be calculated through the
following
Formula:
BX ΔT
ΔP = ——————-
0.884 ri + A
ti
Where,
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 ΔP = Pressure change resulting from a temperature change (bar)
ΔT = algebraically 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 the test and that of steel
(oC-1) x 106.
A = Isothermal compressibility value of water as estimated at the pressure and
temperature values obtained at the end of test (bar-1) x 106.
ri = Nominal inner radius of the pipe (mm).
ti = 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 thermocouples installed in the
pipeline shall be removed and damaged corrosion coating shall be repaired usingGGL / 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 barg as per the direction of EIC

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15. DOCUMENTATION
CONTRACTOR shall provide following as minimum
 Schematic layout of cleaning, filling and testing facilities.
 Calibration certificate of measuring instrument and testing equipment.
 A profile of the pipeline that shows the test sites, all instrument and injection connection.
 Pipe filling logs and records.
 Additive specification, required concentration and additive injection records.
 Pig inspection records including photographs of the damages.
 Records of gauging pig, caliper pigging (intelligent pigging) and photograph.
 Quality records.
 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.
 Air-volume calculation
 Pressure change due to temperature change calculation.
 Records and photograph of all leaks.
 All forms and formats as per GGL approved procedures and Guidelines

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6. Specification for Swabbing & Drying

1. Scope
2. Reference Codes & Standards
3. Submittal By Contractor
4. General
5. Swabbing
6. Drying
7. Documentation

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1. SCOPE
This Specification covers the Swabbing & drying of Pipeline after completion of hydro
testing.

2. REFERENCE CODES & STANDARDS

2.1 Governing Standard
ASME B 31.8 - Gas Transmission and Distribution piping system
2.2 Reference Standard Nil

3. SUBMITTAL BY CONTRACTOR
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 GGL/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 meet minimum of 400 cfm.
4.2 A digital dew point meter (with self-calibration) shall only be used for checking the reading.
4.3 Dryer shall achieve a dew point of 8 to 150C 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,
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.

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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 hours 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 Hydrotest 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.
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.
1) Calibration certificates of measuring instrument
2) Quality records
3) Drawing indicating swabbing & drying operation connection
4) All forms and formats as per GGL approved procedures and Guidelines

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7. Specification for Casing Insulator & End seals

1. Scope
2. Submittals By Contractor
3. Functional Requirement
4. Design Requirement
5. Material Requirement
6. Inspection And Testing
7. Documentation

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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
0.1 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
1) 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.
2) Test certificates and results of previously conducted tests, for all properties of this
specification
3) 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 GGL/TPIA approval has been given, any change in material or manufacturer shall
be notified to GGL/TPIA, whose approval in writing of all changes shall be obtained before
the materials are used.
0.2 The CONTRACTOR shall submit the Installation procedure and Inspection test plan
compatible to this specification (Annexure I) at least one week prior to commencement of
the work for approval of GGL/TPIA.

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.

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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 GGL Drawing. 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 GGL/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 GGL/TPIA on casing insulators drawing /
design.
Bolting used in casing insulation 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 GGL/TPIA on casing end seals drawings /
designs.

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5. MATERIAL REQUIREMENT
5.1 Casing insulators shall be made of injection molded high density Polyethylene or other
material equivalent or superior as approved by GGL/TPIA and shall meet the following
specification:
Sr.N Property Acceptance Test Test Method
o. Criteria Condition
1 Dielectric strength 450 – 500 - ASTM D – 149
Volts/mil
2 Compressive strength 3200 psi - ASTM D – 695
3 Tensile strength 3100- 5000 psi - ASTM D – 638,651
4 Impact strength 4.0ft.lb/inch - ASTM D – 256 of notch
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 Rey Chem and equivalent made.
Service provider shall conform the same prior to purchase
Insulators shall be of Heavy duty HDPE materials

Sr.N Acceptance Test

Property Test Method
o. Criteria Condition

Backing (sleeves and

1
closures Path)

1.1 Tensile strength 2200 psi min. - ASTM D – 638

1.2 Ultimate Elongation 400 % min. - ASTM D – 638

Heat Shock No visual At 225 0C, 4

1.3 D – 2671 drips
cracks flow hours

2 Adhesive

Ring and ball

2.1 2200 psi min. - ASTM E - 28
softening point

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 Lap Shear 60 0C – 25 psi
& 23 0C – 250
2.2 ASTM D - 1002
psi (2
inch/min)

System
3
(as applicable)

Peel strength (To

5 psi (10
3.1 casing and carrier pipe ASTM D –1000
inch/min)
and closure patch)

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.
 Test certificates/results as per Manufacturer’s Quality Control Procedure for each batch of
materials.
 Calibration certificates of measuring Instrument, testing Equipment.
 Quality records.
 Installation Procedure
 Inspection & Test Plan
 Inspection Report
 All forms and formats as per GGL approved procedures and Guidelines

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8. Specification for Pipeline Marker

1. Scope
2. Reference Codes And Standard
3. Submittal By Contractor
4. General Requirements
5. Aerial Markers
6. Route Markers
7. Kilometer Markers
8. Row Boundary Markers (Rcc)
9. Pipeline Warning Signs
10. Direction Markers (Rcc)
11. Navigation Waterway Pipeline Crossing Warning Sign
12. Documentation

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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 GGL / TPIA and CONTRACTOR.

2. REFERENCE CODES AND STANDARD

Following standards of latest edition have been referred in this specification:
2.1 Governing Standard
API RP 1109 Recommended Practice for Marking Liquid Petroleum Pipeline Facilities
2.2 Reference Standard
Nil
3. SUBMITTAL BY CONTRACTOR
The CONTRACTOR shall submit the Installation procedure of markers along with activity
report / record and inspection test plan compatible to this specification (Refer to Annexure
II) prior to commencement of the work for approval of GGL / 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 GGL
/ 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 GGL/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. AERIAL MARKERS
5.1 Aerial markers shall be installed along the pipeline route at every 5 Km intervals and or at
places specified by GGL/TPIA.
5.2 Aerial markers shall be installed at 1000 mm to the left of the pipe centerline viewing
towards the direction of flow.
6. ROUTE MARKERS
Pipeline Route Markers shall be positioned along entire length of the Pipeline at a maximum
spacing of 100 meters in urban area and 200 meters within industrial parks for steel mains,
throughout the network.

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 A Steel marker shall be marked in bold and legible local language and Hindi / English with at
least the following:
 Company Logo
 Warning
 Name of Company : GUJARAT GAS LIMITED
 Chainage in Mtr.
 Emergency phone number
 Warning - “High Pressure Gas Line, Dial before Digging” etc.
 Arrow marking indicating pipeline distance from Marker and the Depth of pipeline
A RCC marker shall be marked in bold and legible local language English with at least the
following:
 Company Logo
 GAS
 Pipe Diameter
 Arrow marking indicating pipeline distance from Marker and the Depth of pipeline

7. KILOMETER MARKERS
These shall in general be installed along the pipeline between the aerial markers at every
one-kilometer interval. These shall indicate cumulative distance in km for the reference base
station or as desired by GGL / TPIA.
KILOMETER post shall be 1000 mm to the left of the pipe centerline viewing towards the
direction of flow and as directed by GGL/TPIA as per

8. ROW BOUNDARY MARKERS (RCC)

Right-of-way boundary markers shall be fabricated and installed as per the drawings at every
250 meters interval along the entire pipeline route. These shall be installed on either side of
the pipeline alignment to define the ROW boundary limits. These shall also be installed at
pipeline turning points to maintain the continuity of the ROW limits.

9. PIPELINE WARNING SIGNS

Pipeline warning signs shall be installed at:
 National and state highway crossing s - 2 No.
 Other road crossings (Metaled 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
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 And any other location as shown in the approved drawings and as directed by the GGL /
TPIA.
Pipeline warning signs shall identify the existence of the pipeline and display the name of the
COMPANY with an emergency telephone, and a Warning - “High Pressure Gas Line, Dial
before Digging” etc.

Warning sign shall be installed to the left of the pipeline center viewing in the direction of
flow at 1000 mm from pipeline

10. DIRECTION MARKERS (RCC)

Direction markers as shall be installed to identify the significant Turning Points of the
Pipeline during aerial traverse. One direction marker shall be installed along the pipeline
alignment, one on either side of the Turning Point at 100 M from the Turning Point.

11. NAVIGATION WATERWAY PIPELINE CROSSING WARNING SIGN

Navigable Waterway pipeline crossing warning sign shall be installed at both banks of
navigable watercourses where pipeline is crossing, in lieu of the pipeline warning signs.
Painting and stenciling for all the aforesaid shall be done as indicated in respective
standards.

12. TYPICAL DRAWINGS FOR MARKERS

1. GGL/TS/STEEL-MARKER/KM POST-001: Typical drawing for pipeline construction –
KILOMETER POST
2. GGL/TS/STEEL-MARKER/AERIAL-002: Typical drawing for pipeline construction –
DIRECTION AERIAL MARKER
3. GGL/TS/STEEL-MARKER/WARNING-003: Typical drawing for pipeline construction –
PIPELINE WARNING SIGN
4. GGL/TS/STEEL-MARKER/ROW-004: Typical drawing for pipeline construction – ROW
BOUNDARY MARKER
5. GGL/TS/STEEL-MARKER/WATERWAY-005: Typical drawing for pipeline construction –
NAVIGABLE WATERWAY PIPELINE CROSSING WARNING SIGN
6. GGL/TS/STEEL-MARKER/PIPELINE-006: Typical drawing for pipeline construction -
PIPELINE MARKER (RCC)

13. DOCUMENTATION
 Quality records
 Marker Installation Reports
 Inspection & Test Plan
 All forms and formats as per GGL approved Procedures and Guidelines

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9. Specification for Concrete Coating

1. Scope
2. Reference Codes And Standards
3. Submittal By Contractor
4. Materials & Equipment Requirements
5. Application Procedure
6. Inspection And Tests
7. Coating Of Field Welds
8. Repairs
9. Marking, Protection, Storage, Transportation, Unloading, Hauling And Handling
10. Documentation

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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 GGL 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.

2. REFERENCE CODES AND STANDARDS

2.1 Governing Standard
IS-269 : Indian Standard Specification for ordinary & 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.
2.2 Reference Standard
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.

3. SUBMITTAL BY CONTRACTOR
The CONTRACTOR shall submit the Concrete Coating procedure along with quality records
and inspection test plan compatible to this specification prior to commencement of work for
approval of GGL / TPIA.

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4. MATERIALS & EQUIPMENT REQUIREMENTS
The CONTRACTOR shall supply all the materials and equipment’s 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 /GGL, 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) OR Sulphate Resistance Cement (SRC) 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 /GGL 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/GGL approval. Instead of coarse
aggregates, iron ore shall be used, upon approval of TPIA/GGL.
 Aggregates shall be clean and free from injurious amounts of salt, alkali, deterious
substances or organic impurities.
4.3 WATER
The water shall preferably be 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/GGL 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 confirm ASTM A-185. Wires shall conform to ASTM A-82.
 Steel wires shall be galvanized at finished size. 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
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 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/cm3 (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.
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, 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.

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  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
3
Upto 25 m 03
3
26 to 50 m 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/GGL 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 GGL, 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/GGL 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 coating of girth weld joints
shall be required. The reinforcement shall protrude a minimum 5 cm 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.

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  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, one mesh while the special lap shall be three meshes.
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.
 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 beveled to a slope of approximately two-to-one
(2:1). It shall terminate about 100 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 /GGL 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/GGL” 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.

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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.
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/GGL. CONTRACTOR shall submit a detailed procedure for field
joint concrete coating for TPIA/GGL 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 molds 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 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).

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8.1 Spalling due to compression or shearing caused by impact against other object. Spalling 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 spalling 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 spalling 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 spalled 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.

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/GGL 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.
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  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/GGL, from the site of receipt to the coating yard
and after concrete coating completion and acceptance, to 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
beveled 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
 All forms and formats as per GGL approved procedures and guidelines

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10. Specification for Quality Assurance Plan

1. Introduction
2. Quality Goals, Objectives And Critical Success Factors
3. Quality Management Organization And Responsibilities
4. Submital By Contractor
5. Quality Assurance System Requirements:
6. Annexure – I
7. Quality Assurance / Departmental Activity Control Manual
8. Quality Plan:
9. 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 CONTRACTOR 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 CONTRACTOR’s 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 sub-CONTRACTORs, and conducting QC surveillance of
CONTRACTOR’s 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
 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.

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3. Quality Management Organization and Responsibilities

A. Project Quality Plan.

Material Supplied by CONTRACTOR

1. QAP approvals : QA QC IN Charge/TPI and

GGL
2. In process inspection : CONTRACTOR /GGL/ TPI
3. Review Material test certificate : CONTRACTOR/GGL/TPI
4. Material test certificates review & Accept : GGL/ TPI
5. Recording of Material identification number : CONTRACTOR – TPI
6. Acceptance of test result of Material : GGL/TPI

Construction

1. QAP approvals : QA QC In charge and GGL

2. Preparing of standards operating procedure : CONTRACTOR
3. Review and approvals of SOP : TPI – GGL
4. Procedure Qualification : CONTRACTOR
5. In process inspection : CONTRACTOR – TPI
6. Monitoring Quality of in process inspection : GGL/TPI
7. Corrective and preventive action for Non-conformance : CONTRACTOR
8. Pipeline Strength testing approvals : CONTRACTOR
9. Installation of special equipments as per P&ID : CONTRACTOR
10. Ensuring functional test of all the installed equipment : GGL

B. CONTRACTOR’s key quality and verification personnel;

1. Project /Construction Manager
2. Site supervisors
3. QA / QC Manager / Egg. :
4. ASNT level II technicians

C. Sharing quality related information:

1. Electrode qualification test result : TPI to GGL
2. Welding Qualification test result : TPI to GGL
3. Field joint coating procedure qualification records : TPI to GGL
4. Welder performance reports : CONTRACTOR to TPI to
GGL
5. Repetitive quality non-conformance and corrective actions : TPI to GGL
6. Measuring instruments calibration requirements : TPI to CONTRACTOR
7. Line pipe coating damage / holiday report : TPI to GGL

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 8. In adequacy in activity reports : 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/GGL.
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:
 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.
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.

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5.4 Nonconformance Handling (Internal Sources):
Non conformances brought out by CONTRACTOR’s / Sub-CONTRACTOR’s own review / audit
shall be resolved by CONTRACTOR’s / 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 Nonconformance Handling (External Sources):
Nonconformance 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.
5.7 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.
5.8 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.
5.9 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 and certified for
compliance by the CONTRACTOR before submitting to TPIA for information.
5.10 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.
5.11 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:
 CONTRACTOR’s 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.
 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.
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  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 hydrotesting
 Hydrotesting 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
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 like 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:

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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
 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 The CONTRACTOR is not obliged to provide any advance written notification of these points.
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 GGL/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 :
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
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  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

Refer GGL Specification for Horizontal Direction Drilling Method

Document Number: GGL/TS/SP-HDD/03, REV-00

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12. Specification for Cathodic Protection

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1. Introduction
This document summarizes the Technical requirements and the Specifications for
installation of Temporary Cathodic Protection System. This scope includes Design for
Temporary Cathodic Protection system, Supply of materials, Installation, Commissioning,
Surveys (pre and post commissioning) and Interference mitigation new steel pipeline
construction, as per the requirement of GGL.
The Purpose of this document is to provide the basic criteria and input parameters to be
adopted for the detailed design of the Temporary Cathodic Protection System for 3 LPE/FBE
coatedsteel pipeline.

The CONTRACTOR shall visit the pipeline ROWs and related sites and familiarize about the
site conditions. Non familiarity with site conditions will not be accepted as a reason either
for extra claims or for not carrying out the work in total conformity with these document.

2. Codes & Standards

 PNGRB-T4S : Technical standard & specification including safety

standards for petroleum & petroleum product pipeline regulations
 NACE standard SPO169-2013 : Control of external Corrosion on underground or
submerged metallic piping system (21001-SG)
 RP0286-97 : Electrical isolation of CP pipeline
 SP0200-2014 : Steel- cased pipeline practices (21091-SG)
 SP0177-2014 formerly RP0177 : Mitigation of alternating current & lightning effect
on metallic structures and corrosion (21021-SG)
 NACE standard TM0497 2012 : Measurement of technique related to criteria for
cathodic protection on buried or submerged metallic piping system
 NACE SP0572-2007 : Design installation, operation and maintenance of
impressed current deep anode beds
 IS 8062 : Code of practice for cathodic protection of buried
pipeline/structures for transportation of oil, NG & liquids.
 IS 3043 : Code of practice for earthing
 ISO 15589 (Part-1) : Petroleum & natural gas industries – Cathodic
Protection of pipeline transportation system- part-1: On shore pipeline Petroleum &
natural gas industries external coating for buried or submerged metallic piping system
used in transportation system
 ISO21809
 DIN 30670-2012 : PE coating for steel pipeline & fittings-
requirement & testing
 BS 7361, part-1 : Cathodic protection, code of practice of land &
marine applications
 ASTM A518 M : Corrosion Resistance High Silicon Iron castings
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  ASTM B418 : Cast and wrought galvanic zinc anodes
 ASTM B338 : Specification for seamless and welded Titanium
and Titanium alloy tubes for condenser and heat exchangers.
 ASTM B843 : Magnesium alloy anodes for cathodic Protection
 IS 1554, part-1 : PVC insulated (heavy duty) cables
 IS 8502 Grade A : Applicable IS standard for Supply of Calcined
Petroleum Coke
 VDE 0150 : Protection against corrosion due to stray current
from DC installations.

3. Detail Scope of Work

Contractor’s detailed scope of work includes:
3.1 Corrosion survey for site data generation and interpretation report and design -basis for CP
system.

 Pre-design surveys
 Soil resistivity survey.
 Soil Ionic and microbial analysis.
3.2 Design, detailed engineering of TCP including the following:

 Corrosion survey and Additional data collection

 Design Basis
 Basis & Assumptions
 Protection Criteria and Parameters
 Design Formulae and List of Code and Standard used
 Design and all the Calculations
 System Details
 Detailed Engineering for BOM preparation
 Specifications for all Equipment / instrument and Material
 Data Sheets for all Equipment and Material
 All Reporting Formats for various Activities
 QA/QC Plan
 Attenuation Calculation
 Drain Potential calculation
 Drawings
 Commissioning
 Interference and Mitigation
 All Material test certificates
3.3 Contractor has to submit the execution procedures and QA/QC plans before
commencement of work to Owner / Owner’s representative in line with the GGL issued
Technical specifications for approval.

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3.4 Procurement which includes supply, factory inspection, transportation, loading and
unloading of Cathodic Protection transformer rectifier units, sacrificial and impressed
current anodes, cables, test stations, junction boxes, permanent reference cells,
polarization coupons, solid state de-coupler devices, spark gap arrestors, zinc grounding cells
and all other material required for complete TCP & PCP work . Materials shall be procured as
per specification/material data sheet – Annexure - 2
3.5 Installation, testing, pre-commissioning and commissioning of TCP works as defined in this
tender including approved job procedures for field testing, pre-commissioning and
commissioning.
3.6 Barricading, Caution Boards, and Barricading Tape will be made available as per GGL
drawing, specifications.
3.7 Supply, installation, testing & commissioning of additional test lead points as per GGL
requirement besides of the planned test lead points along the pipeline route.
3.8 Supply, installation, testing and commissioning of each CP unit (CPTR/CPPSM).
3.9 CONTRACTOR shall carry out permanent Earthing arrangement for TR unit
installation/shifting/replacement.
3.10 Supply, installation, testing and commissioning of permanent reference cells-Cu-CuSO4.
3.11 Supply, testing, laying and termination of CP cables in various junction boxes, etc. and
repair/replace when necessary.
3.12 Supply, installation, testing & commissioning of distribution board ACDB /DCDB at CP
locations.
3.13 Identification of anode bed locations for each CP station along with
suitability/adequacy/current drainage survey test.
3.14 Supply, installation, testing & commissioning of shallow (horizontal / vertical) / deep well
type anode beds at CP locations and integration with CP units.
3.15 Complete civil works including material and services required for TCP system are in the
scope of contractor.
3.16 Co-ordination and Conducting AC interference survey and mitigation including supply,
installation, testing and commissioning of solid state De-coupler and polarization cell
devices& zinc anodes.
3.17 Co-ordination and Conducting DC (Mutual) interference survey with other pipelines/
Railways/DC/AC system in mainline and mitigation thereof.
3.18 Protection of insulating joints through supply, installation, testing & commissioning of
grounding cell & surge diverter.
3.19 Measuring, recording and submitting PSP values & CP station data to assess the status of
protection in the stretches of pipeline.
3.20 Supply, installation & testing of Bond stations wherever required for maintaining the
pipelines at equipotential level to avoid any mutual interference and co-ordination with

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 other pipeline owner for the same. Any damage to owner/ foreign pipeline/
installation/utility/ property shall be rectified by contactor at no extra cost to the GGL.
3.21 Protection of Hot Spot areas along the pipeline stretches. Repair of all coating damages
occurred during connection of cables to the piping intended to be cathodically protected.
3.22 Retesting, measuring, recording data of all the stretches after mitigation of interference and
extending protection at Hot spots for full protection of the pipeline stretches.
3.23 Submission of complete documentation, consisting of design guidelines, drawings,
procedures and other relevant data for owner's approval & record.
3.24 CONTRACTOR shall depute assessed & trained competent manpower to carry out the jobs
as per GGL's requirement and ensure that they carry out the roles and responsibilities
effectively.
3.25 CONTRACTOR shall carry out all work as per applicable codes & standards as mentioned in
this tender document.
3.26 CONTRACTOR shall carry out the following surveys after installation & commissioning of PCP
system, and carry out necessary mitigation action if required. The report shall be submitted
to OWNER in relevant format
- CIPL survey
- DCVG survey
- Coating Conductance/CAT survey
- AC/DC interference survey.
3.27 CP system monitoring for three months from the date of commissioning with monthly
progress reports & mitigation of any anomaly required to tune up the functioning of PCP
system.
3.28 All civil works associated with complete cathodic protection work – TCP which includes
providing cable trenches, foundation for equipment etc. In case transformer rectifier unit
have to be located outside, proper kiosk to prevent direct sunlight shall have to be supplied
by CP contractor.
3.29 As-Built documents along with drawings shall be submitted at the time of handing over the
entire system.
3.30 Document / Drawing and the design it covers are property of GGL. They are merely loaned
and on the borrower’s express agreement that they will not be reproduced, copied, loaned,
exhibited, not used except in the limited way and private use permitted by any written
consent given by the lender to the Borrower.
3.31 The CONTRACTOR will have to accordingly mobilize work and deploy adequate skilled &
trained manpower conversant with work procedure, adequate number of tools, tackles,
testing and Construction Equipments requisite for smooth work progress so that CP work
could also be completed within Schedule specified for the project.

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4. Submittals by CONTRACTOR

4.1.1 General
Within two weeks from the date of commissioning, CONTRACTOR shall submit four copies of
the list of all as- built drawings, construction documents, design & detail engineering copy
etc.
All drawings and documents shall be in English and shall follow metric system. Number of
copies of each submission shall be as follows unless otherwise specified.
Submission No. of copies
a. For review / approval design basis, procedures, Formats, data sheets 2 copies + 1 Soft copy
b. Drawings issued for execution/ construction 2 copies + AutoCAD [CD]
c. Final/ As built drawings execution/ construction 2 copies + 2 set of AutoCAD[CD]
d. Operation/ Maintenance manual, vendor data, OEM Certificates 2 copies +[CD]
e. Supplied materials TC.

4.1.2 Drawings and Documents

As a part of the contract, drawings and documents shall be furnished which shall include but
not limited to the following:
a. Report on corrosion survey
b. Basis of system design and design calculations, equipment selection criteria and sizing
calculations
c. Bill of material, material requisitions, and purchase requisitions
d. Quality assurance / Quality control procedures
e. Detailed construction drawings (including as built status)
f. Sacrificial anode fabrication drawings
g. Typical layout drawing for anode ground bed installation and connection
h. Equipment layout, cable layout and schedules.
i. TLP & Junction Box Erection / Installation Details Drawing
J. Permanent Cu-CuSO4 reference electrode installation Drawing
k. Fabrication, installation details of surge diverter, grounding cell and polarization cell with its
enclosure and housing
l. Cable- to-pipe joint details for charged and non-charged pipelines
m. Incorporation of anode beds, polarization cell, Surge diverters, test stations, etc. and other
relevant features of CP system-design in Pipeline alignment sheet and other related
drawings
n. Identification of section of pipeline affected by interference, source of interference and
details of interference mitigation arrangements provided. Various measurement data at all
relevant test stations with and without mitigation measures provided
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 o. Detailed commissioning report including various measurement data at all test stations etc.
p. Vendor drawings and catalogues, test certificates
q. Operation and maintenance manuals
r. Miscellaneous
- Equipment inspection and testing procedure - construction, installation procedures
- Field testing and commissioning procedures
- Procedure for monitoring of cathodic protection after commissioning - Quality control
procedures.
- Post Commissioning Testing/Monitoring Periodicity and Methodology

5. CONTRACTOR’S SCOPE OF SUPPLY

The CONTRACTOR scope of supply includes as a minimum, but not limited to the
following resources:
5.1 MATERIALS,EQUIPMENT, INSTRUMENTS, TOOL, TACKLES:
 All the materials required for TCP shall be as per Material Specification/Data she ets
mentioned in Annexure – 2
 CONTRACTOR shall obtain necessary approval from GGL, in case of any deviation from
Material Specification/Data sheets mentioned in Annexure – 2
 CONTRACTOR shall provide test certificates provided by OEM for all the materials to GGL
before starting of work at site and shall produce the same on demand by EIC. If the
material is of foreign make, contractor shall provide import documents. CONTRACTOR
shall get it verified through GGL/TPIA as and when requested at his own expense and no
extra cost to GGL.
 CONTRACTOR shall advise GGL promptly, if any correspondence / warranty claim may be
taken up with the supplier of the equipment / spares installed in the Plant or a claim may
be made under any insurance policy.
 CONTRACTOR shall provide calibration certificates of all measuring instruments to be
used for the execution of work. CONTRACTOR shall rectify, repair or replace the
instruments at his own cost
 CONTRACTOR shall provide all consumables required for completion of any CP related
Job timely. In case any item is not covered in SOR, vendor shall notify GGL and take
permission in written for purchase.
 CONTRACTOR shall provide all resources, instruments, equipment; tools tackles required
for timely completion of any CP related Job as per Annexure-B
 CONTRACTOR shall raise invoices against consumed spares along with services report, test
certificates and delivery acceptance

5.2 MANPOWER:
 CONTRACTOR shall mobilize adequate number of Manpower (as given in Annexure-A) in
accordance with the allocated job orders to complete each job within agreed timeline.

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  The trained and competent manpower deputed at site should not move to other job without
permission of GGL.
 CONTRACTOR shall provide organization chart with role and responsibility to GGL. In case of
any change in manpower allocation, contractor shall seek prior approval from GGL.

5.3 MATERIAL RECONCILIATION (For any material issued by GGL):

 Material shall be free from dust, mud, and other foreign particles.
 CONTRACTOR shall inspect, notify and return the defective material within 15 days of receipt
of material from GGL.
 If any shortage or damage is found in material/instruments returned against total issued then
necessary deduction will be made from payment due to CONTRACTOR.

6. GGL’S SCOPE OF SUPPLY & WORK

 GGL will issue necessary approval and Work Permits to carry out the job as required.

7. SLA AND PENALTY

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.

8. ENCLOSURES
ANNEXURE-1 - Details of Manpower requirement
ANNEXURE-2 - List of measuring instruments, tools & tackles
ANNEXURE-3 – Cathodic Protection Design Criteria, Installation & Commissioning
Procedure including Post Commissioning Surveys
ANNEXURE -4 - Technical Data Sheets
ANNEXURE -5 - ITP Plan and Report Formats
ANNEXURE -6 - Reference Drawing for Installation/ Construction
ANNEXURE -7 - Monitoring Formats

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 ANNEXURE-1

Details of Manpower requirement

Category Qualification Experience Knowledge, Skills
For Graduate engineer –2
years Work experience in
Design, installation, 1. Understanding of overall knowledge of
Graduate
commissioning & CP system like basic of CP system,
Engineer /
equipment & Instruments required for
Diploma Engineer Maintenance of ICCP
system. monitoring the performance of CP
in Electrical
CP engineer For Diploma engineer – 5 system, various surveys, data analysis
engineering +
years work experience in and corrective actions requirements
( NACE CP
Design, installation, and implementations.
Certified )
commissioning & 2. Skills – Resource management,
(Refer Note)
Maintenance of ICCP Analytical & Communication
system.
Minimum 5 years work
experience in installation,
commissioning & 1. Basic of CP system & procedures of
Supervisor Diploma
Maintenance of ICCP Monitoring & Maintenance
system.
1. Understanding of Quality &HSE
Requirements in job / activity including
use of any Personal Protective
2 years of
Equipment & relevant Work Procedure
work experience in
/ Work Permit System.
installation,
Field 2. Knowledge of Half-cell, TR Units, various
Diploma Engineer commissioning &
Technician TLP's, Instrument like Multimeter,
maintenance of ICCP
ammeter, Min. Criteria of CP readings,
system.
Surge Diverters etc. Various surveys like
CIPL, DCVG, ON-Off & CAT and
calibration of all kinds of meters

Note: NACE CP certified Engineer for following jobs but not limited to:
 Design, installation and commissioning of ICCP system.
 Review and certification of monitoring report.
 Review of TCP system for adequacy against the commissioned network.
 Review of CIPL, DCVG, CAT, CAT-A frame, Coating conductance, ON-Off Potential, Pearson survey documents.
 CP survey Data analysis, recommendation along with mitigation action to provide adequate protection of pipeline
through CP system.

 Bidder shall nominate a dedicated person for co-ordination with the EIC who is as
qualified as the CP Engineer.

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 ANNEXURE-2
List of measuring instruments, tools & tackles

Sr.No. Name of Equipments

1. CAT Survey with 'A' Frame Equipment
2. Pipeline Current Mapper
3. DCVG Survey Equipment
4. Close Potential Loggers - SINCORDERs or superior version with all accessories
5. Pearson Survey Equipment
6. Pipe and Cable Locator
7. Soil Resistivity Meters (Wenner’s 4-Pin rugged null band indicator type and Direct Reading
digital type)
8. Fully Automatic, Programmable Current Interrupters
9. Holiday Detector
10. Micro Ohm Meter
11. Multi-combination Meters / Multimeter/Analog meter (Imported and Indigenous make,
portable type ± For C.P. applications)
12. Meggers (Imported and Indigenous makes, 500 V and 1000 V ± For measurement of insulation
resistance.)
13. Portable Cu/CuSO4 Reference Electrode
14. DC Clamp on Ammeter
15. Coating Thickness Gauge Meter
16. Pipe Thickness Tester
17. GPS Navigator
18. Data Logger
19. Pin Brazing Instruments
20. Insulator tester model number CE-IT, RF-IT- 1 No.
21. LC-4 Corrosion Voltmeter for PSP measurement-2 Nos.
22. Clamp meter of various diameter size for pipe current measurement - 1 no.
23. Crimping Device

NOTE: Vendor shall provide the duly calibrated equipment, instruments, and tools/tackles at the start
of project and calibration shall be carried out as per approved frequency. Contractor shall provide
calibration certificate on demand by TPI/ GGL EIC.

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 ANNEXURE – 3
Cathodic Protection Design Criteria, Installation & Commissioning Procedure including Post
Commissioning Surveys

1. CATHODIC PROTECTION DESIGN CRITERIA

Unless expressly varied and otherwise specified in the project specifications, following
parameters shall be used for design of temporary cathodic protection [TCP] system.
Those parts of sacrificial anode cathodic protection [TCP] system which will be integrated with
permanent cathodic protection system [PCP] such as Reference Cu-CuSO4 electrodes, Test
Lead Points, Junction Boxes, Pin Brazing, Epoxy Encapsulation, Markers, Polarization Coupons
etc. shall be designed based on permanent CP parameters.

1.1 Temporary Cathodic Protection System

Pipe to soil potential (PSP) measurements shall be between (-) 0.85 V (ON) and (-) 1.5 V (ON)
for 3 layer polyethylene/FBE coated pipe lines, with respect to a Cu/CuSO4 reference
electrode.
At the locations of polarization coupons, the coupon to soil potential measurement shall be
between (-) 0.85V (OFF) to (-) 1.2V (OFF) with respect to Cu/CuSO4 reference electrode.

1.2 Protective Current Requirements

The total current requirements for the pipeline requiring cathodic protection shall be
calculated from the area of the pipeline, the current density requirements and the estimated
coating breakdown factor.
Data for current density requirements at ambient temperature for design purpose of 3LPE
coated pipeline is as per table -1 below:

Table-1

Minimum Protection* Current Density(µ

Soil resistivity
A/m2)
Soil resistivity < 10 ohm-m 35
Soil resistivity ≥ 10 ohm-m and < 100 ohm-m 15
Soil resistivity ≥ 100 ohm-m 10

*Note:
- The current densities given in Table-1 already include the current requirements due to the
expected coating breakdown during the design life of the pipeline.
- The current density values stated above shall be applicable where the temperature of the
medium transported by pipeline / the surface temperature of the buried pipeline do not

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 exceed 300 C. The conditions where the temperature exceeds 300 C, the current density
shall be increased by 25 % per 100 C rise in temperature above 300 C.
- Actual current density to be adopted shall be decided based upon soil & other
environment condition, current drainage survey data, proximity of foreign pipeline and
other interference areas affecting the installations. Where necessary for satisfactory
protection of pipeline current density shall be suitably increased by CONTRACTOR.
1.3 Interference Criteria
A positive potential swing of 50 mili-volts or more shall be considered sufficient to indicate the
presence of an interaction / interference situation requiring investigation and incorporation of
mitigation measures by the CP contractor.

1.4 Other Parameters for Design

Other parameters to be considered for [TCP] and [PCP] design:
 Safety Factor for Current Density : 1.3
 Anode Utilization Factor : 0.85 for centre connected Anode
: 0.5 for Ribbon Anode
 Pipeline natural potential (-) 0.45V [as measured from existing /upcoming structure in the
same soil matrix].
 Unless otherwise specified in project specification the design life of [TCP] temporary CP shall
be two (2) years or till commissioning of PCP whichever is earlier and that of [PCP] permanent
CP shall be forty (40) years.
 Along the ROW where soil resistivity is higher than 100 Ω-m temporary CP for the pipeline may
not be necessary subject to Owner’s Approval.
 Steel Resistivity =2.2 X 10-7Ω M
 Maximum Loop Resistance =1 Ω

2. SYSTEM DETAILS-TEMPORARY CATHODIC PROTECTION

The temporary cathodic protection system shall include the following materials to be supplied:
- Sacrificial anode [Zn or Mg as applicable based on the soil resistivity survey report] ground
beds in special back-fill
- Test stations [TLP] of all types including AJB,CJB, Bond boxes and its accessories like shunts
and resistors
- Permanent reference cells Cu-CuSO4 Electrodes [CSE]
- Pin Brazing epoxy encapsulated
- Surge diverter and Grounding cell at IJ
- Solid state polarization cell/DC decoupling device at AC Interference locations
- Polarization coupons for corrosion monitoring
- CP cables
- Cables to pipe connections
- Markers for Cables, Anode beds etc.
- CP System at Cased Railway Crossings
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 - Earthing of Motor Operated Valve [MOV] and other Electrical equipments without disturbing
CP System through Sacrificial anodes
Where it is essential to install the equipment in hazardous area, such equipment shall be
flame proof type and shall meet the requirement of IS: 2148 shall be suitable for gas group
IIB, temperature class T3 (200°C). Indigenous equipment shall be certified by CMRI or any
other recognized testing body and shall be approved by the concerned statutory authority.
All flameproof equipment shall carry the BIS license marking as per the requirement of
statutory authorities.

2.1 Sacrificial Anodes

The sacrificial anodes for temporary cathodic protection shall be selected based on the soil
resistivity along ROW as specified below:
Soil Resistivity Type of Anode
0-10 ohm-m Zinc Anodes type-II
10 to 30 ohm-m Low potential magnesium anodes(- 1.55V)
30 to 50 ohm-m High potential magnesium anodes(- 1.75V)
> 50 ohm-m Zinc /Magnesium Ribbon Anodes

Note: Where magnesium anodes are used for protection of 3LPE/FBE coated pipeline, the
anodes shall preferably be of low potential (1.55 V) type.
Anodes shall be installed along the pipeline at suitable intervals as per pipeline protection
voltage, attenuation calculations and ground bed resistance/current output of anode
installations. At high resistivity area the zinc/magnesium ribbon anodes shall be installed all
along the pipeline by the side of the pipeline in the pipeline trench.
Suitability of the selected sacrificial anodes for soil conditions with particular attention to
carbonates, bicarbonates, phosphates and nitrates, shall be checked for proper operation by
the CP contractor. The anodes shall be laid in proper type of back fill, such that the effect of
soil is minimal on the anode effectiveness and life. Suitable safe guards against anode
passivation in soil shall be taken by the contractor.
Each electrically continuous section of pipeline shall be protected totally by single type of
anode to avoid inter-anode circulation currents.
The anodes shall be installed at sufficient depth to reach moist soil and shall be separated
from the pipeline by at least 5 m and 2 m for magnesium and zinc anodes respectively. The
magnesium ribbon anode shall be separated from the pipeline by at least half a meter. The
anode connections to pipe line shall be routed through test stations.
However, environment suitability [such as pH, excessive carbonate, bi-carbonates,
sulphates, chlorides, nitrates etc. which could result in anode passivation] should be checked
prior to lowering of sacrificial anodes suitability in the anode beds. Zn should not be used if
soil/water pH is over 9.
At the temporary CP anode ground bed, the leads of all the anodes shall be connected
individually through Shunt and Resistor [for controlling each anode output individually] in
the TLP/ junction box.
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For sacrificial anode CP system the anodes shall be supplied with tail cable 10 mm2 XLPE
insulated / PVC sheathed copper conductor single core cable of sufficient length so as to
reach junction box, for termination, without difficulty. No joints are permissible on the cable
run from anode tail to junction box.
The tail cable connection with the iron insert of anode shall be tightly done followed by
epoxy encapsulation so as to ensure that no necking takes place which could result in
snapping of cable connection.
For the consumption rate and chemical composition of sacrificial anodes refer Annexure -2
Note: Contractor shall furnish spectrographic analysis from each heat both for Zinc (Zn) and
Magnesium (Mg) anodes along with electrochemical test results .CP Contractor shall
mention specifically the method of Spectrography (Atomic Absorption/Emission
Spectrometry/Photometry) for Owner’s Approval.
Tolerance in Fabrication of Sacrificial Anodes
Visual Inspection shall be carried out on all the Anodes regarding surface finish, excessive
shrinkage, cracks, cable joint to anode core etc.
 The anode surface shall be free from cracks (which may reduce the performance of the
anode).
 Any cracks which follow the longitudinal direction of elongated anodes shall not be
acceptable.
 Small cracks in the transverse direction of elongated anodes and in anodes of other
shapes may be accepted provided the cracks would not cause any mechanical failure
during service of the anode considering that the combination of cracks and lack of bond
to the anode core is detrimental.
 For transverse cracks the acceptable limits shall be furnished by the bidders along with
the offer.
 The anode shall be free from excessive shrinkages. The following limits shall be used.
Maximum 10% of the depth of anode or 50% of the depth of the anode core whichever
is less. The depression may be measured from the edges of one side.
 The surface of the anodes shall be free from coatings and slag/ dross, inclusions etc.
 The maximum deviation from straightness shall not exceed 2%.
 The weight tolerance on individual anodes may be taken as ± 5%. The total weight of the
anodes shall not have negative tolerance.
 Recommended dimensional tolerance shall be as follows:
Length ± 2.5%
Width/ thickness ± 5%
 One anode per heat shall be radio graphed to evaluate slags, voids, inclusion etc.
 At least 10% number of anodes from each heat to be checked for conformity to
dimensions &weight.
 One anode, at least shall be tested destructively to check bond between Anode material
and steel insert, slag, inclusion etc. Failure of one anode during the test shall make the
entire anode lot liable for rejection.

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2.2 Anodes for Grounding
The anodes for grounding of catholically protected above ground pipelines at intermediate
SV stations, pigging stations, city gate stations etc, grounding of motor operated valves on
catholically protected portion of the pipeline, grounding of pipeline through solid state
polarization cell device at EHV/HV line crossings or running in parallel, etc, shall be
minimum 20 kg net weight . The anode and cable terminations shall be suitable for the
anticipated fault current at the location of installation. For pipelines protected by sacrificial
anodes, the anodes for directly grounding the pipeline shall be of the same type as the one
provided for the protection of the pipeline.

2.3 Special Backfill

The composition of special back fill for anodes shall be as below:
- Gypsum 75%
- Bentonite 20%
- Sodium Sulphate 5%

2.4 Test Stations

Test stations shall be provided along the pipeline ROW for monitoring the performance of
the cathodic protection system at the following locations. Test stations shall be provided at
additional locations, if required, so that distance between any two adjacent test stations
does not exceed 1 km in inhabited areas and 2 km in uninhabited areas like forest/deserts:
- At all insulating joints and Sectionalizing Valve (SV) stations.
- At both sides of major road crossings.
- At vulnerable locations with drastic changes in soil resistivity.
- At connections of surge diverters, grounding cells and polarization cells.
- At HT AC/DC overhead line crossings and selected locations where HT overhead line is in the
close vicinity of the pipeline.
- At railway line crossings and running parallel to the pipeline.
- At both sides of major river crossings.
- At high voltage cable crossings or along routes where HV cables are running in parallel.
- In the vicinity of DC networks or grounding system where interference problems are
suspected.
- At crossings/parallel running of other pipelines/ structures.
- At both sides of cased crossings.
- At any other locations considered vulnerable/locations where interference is expected.
- At any other locations considered necessary by owner/ owner’s representative.
Test stations shall have weatherproof enclosure having degree of protection IP 55 and
hinged lockable shutter. The test stations shall be hot dip galvanized to a thickness of 125
microns followed by 10-15 microns of EICH primer and 300 microns of grey shade epoxy
paint. 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 both temporary [TCP] and
permanent CP system [PCP] and shall be suitable for total life of permanent CP system.
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 A nameplate of anodized aluminium with black back ground and white letters shall be fixed
to the inner side of the test station. The nameplate shall carry the following minimum
information:
 Manufacturer’s name
 Test station type
 Test station number
 Chainage in km
 Test station cable connection scheme
 Distance from pipeline in meters
 Direction of product flow
At the locations of solid state polarization device, the test station size shall be suitable for
mounting the solid state polarization device inside the test station and shall be vandal proof.
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 and anode-
disconnecting link.
Test stations used for bonding shall be provided with shunt and resistor as a means to
monitor and control current flow between the pipeline and foreign pipelines or structures
that may exist in common ROW.
Test station with current measuring facility shall be provided at interference prone areas, on
both sides of major river crossings, near marshy areas and minimum one for every 10 km
max. along the pipeline.
Terminals and different schemes of wiring shall be provided as per the test station
connection scheme shown in drawing GGL-TS-TSC-DRG. Minimum twenty percent spare
terminals shall be provided in each test station. The location of all the test stations shall be
marked with their connection schemes and other relevant information on alignment sheets.
Terminal blocks and different scheme of wiring as required shall be provided in the test
station as per the test station connection scheme sketch.
The location of all the test stations shall be marked with their connection schemes and other
relevant information on alignment sheets. A detailed test station schedule shall be prepared.

2.5 Permanent Reference Cell

High purity Cu/CuSO4 reference cells with proven high reliability shall be provided for stable
coupon to soil potential measurement at the locations of polarization coupons.
Permanent Copper /Copper Sulphate reference electrodes three (3) numbers at each CP
Station and one at middle of two consecutive CP Stations are to be installed for [P-S-P]
Monitoring.
The reference cell should be suitable for installation in dry desert conditions and high
temperature environments. The life of reference cells shall be minimum 20 years under
burial conditions.
Reference cell access points shall be provided near insulating joint locations and at SV
stations, where the ground is paved, for measurement of pipe to soil potentials.

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 A perforated PVC pipe filled with native soil and buried at the location shall be provided for
the purpose. The length of the PVC pipe shall be adequate to reach the native soil below the
paving.

2.6 Isolating Spark Gap Arrestor

Explosion proof type spark gap arrestor shall be connected across each isolating joint to
protect it from high voltage surges.
The spark gap arrestor shall be suitable for lightning impulse current (8/20µs) 100 kA at
rated power frequency to withstand voltage 300V AC, 50 Hz. The spark over voltage shall be
as follows:
100% lightning impulse spark over voltage (1.2/50 µs) : 2.2 kV
Power frequency spark over voltage (50 Hz) : 1.0 Kv

2.7 DC Decoupling Device (Solid State Polarization Cell)

At each crossing or parallel run of pipeline and overhead EHV line of 66KV and above, the
pipeline shall be grounded through DC decoupling device with zinc galvanic anodes of min.
20 kg net each as shown in drawing GGL-TS-ZNG-DRG. The grounding shall be done at
regular intervals of maximum 1 km where power transmission lines run parallel within 25m
of the pipeline, to ground any surges in the pipeline potential that may appear in case of
power transmission line faults.
Locations along pipeline where continuous induced over-voltage due to EHV/HV line etc. is
expected or observed during commissioning, the pipeline shall be earthed through DC
decoupling device to the earth system of the EHV/HV tower causing the voltage induction or
to a separate earthing system of zinc anodes through DC decoupling device. The DC
decoupling device shall be installed inside a vandal proof test station.
The total system including cable, cable termination and DC decoupling device/grounding cell
shall be suitable for the anticipated fault current at the location of its installation
The grounding system shall have minimum resistance to earth to restrict the pipeline voltage
as per NACE/VDE criteria but shall not exceed 5 ohms. The zinc grounding anodes shall be
pre packed with special backfill adequately so that the performance of the zinc grounding
anode is not affected by carbonates, bicarbonates, nitrates, etc., present in the soil. In any
case, the thickness of back fill shall not be less than 50mm on all the sides of the zinc
grounding anode.
Motor operated valves where located on the cathodically protected portion of the pipeline
shall be grounded by a zinc or magnesium anode of 20 kg net where the type of anode
provided for the CP system of the pipeline is zinc or magnesium respectively. The MOV
power supply cable armour shall be insulated (by cutting and taping with insulation tape) at
MOV end to avoid armour carrying CP current.

2.8 Polarization Coupons

The steel coupons of pipeline material shall be provided along the pipeline to monitor the
adequacy of the CP system to polarize/protect coating holidays. Coupon shall be installed at
CP station drain points, mid points along the pipeline, at locations where pipeline is bonded
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 to foreign pipeline/structures, interference prone areas, and marshy areas and at other
locations such that minimum one coupon is installed maximum every 10 km approximate or
the maximum interval specified in the project specification/data sheet, along the pipe line.
Coupons shall be installed at bottom 1/3rd portion of the pipeline and 250mm approx. away
from the pipe surface.
Coupons shall be constructed from the pipeline material and shall have uncoated surface of
100 mm x 100 mm exposed to soil. Two cables one for connection to pipeline for protection
and other for potential measurement shall be provided for each coupon. The protection
cable shall be connected through a magnetic reed switch inside the test station to enable
measurement of coupon 'OFF' potential.
A permanent reference electrode shall be installed adjacent to the coupon in a manner so as
to measure the representative potential of the coupon.

2.9 Cables
Cables shall be of annealed high conductivity stranded copper conductor, 1100V grade PVC
or XLPE insulated, armoured, PVC sheathed conforming to IS-1554 part-I, except for
reference cell, potential measurement and impressed current CP anode tail cables. The size
of the copper conductor of the cables shall be as below:
Anode Tail cables: The size of the copper conductor shall be 10 mm2 for zinc / magnesium
anode to test station. The length of anode tail cable shall be sufficient for routing from
anode to test station for anodes meant for temporary CP. The anode tail cable shall be un-
armoured.
Potential measurement cable: The potential measurement cable shall be of size 6 mm2 and
shall be armoured.
Current measurement cable: The current measurement cable shall be of size 10 mm2 and
shall be armoured.
Reference Electrode Cables / Polarization Coupon Cable:
The cables for reference cells shall be of size 10 mm2and for coupon 6 mm2& 10 mm2
respectively. Cable shall be of PVC aluminium backed by mylar/polyester tape shielded PVC
sheathed and shall be armoured.

Polarization/Grounding Cell Cable/ Surge Diverter / Earthing Cable/IJ: The size of cable for
polarization cell, DC decoupling device, grounding anodes and, isolating spark gap arrestor, IJ
connections shall be suitable for the maximum fault current subject to minimum size of
25mm2. The cable shall be armoured.
Bonding / Hook-up, Header Cable-CJB/AJB: The size of cable for bonding, header (AJB, CJB)
shall be minimum size of 35mm2. The cable shall be armoured.

2.10 Cable to Pipe connections

All cable connections to the pipeline shall be made by pin brazing. The resistance of the
cable to pipe at the connection point shall not exceed 0.1 ohm. 3 LPE /FBE coating shall be
repaired after connection of cable conductor to pipeline. The coating repair material shall be

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 compatible with the original coating and shall prevent ingress of water along the cable
surface and at the interface of coating repair with the original pipe coating.

3. INSTALLATION-TEMPORARY CATHODIC PROTECTION

3.1 Sacrificial Anodes

Magnesium/ Zinc anodes are installed as stated below:
1) Measure the distance from pipe line as per approved drawing and mark anode location.
The anodes shall be installed at sufficient depth to reach moist soil and shall be separated
from the pipeline by at least 5 m and 2 m for magnesium and zinc anodes respectively.
2) The anode shall be soaked in clean water for 24 hour before installation.
3) Auger an 8” dia. hole with 3 M depth for vertical installation of anode or excavate 3 M
depth trench for horizontal installation. But vertical installation shall be preferable.
4) Install the pre-packaged anode in vertically/horizontal configuration in drilled hole or
excavated pit. The top of the anode should be at the same level as bottom (6 o’clock)
position of the pipeline.
5) Lay the cable up to test station box as per cable laying procedure.
6) Connect anode tail cable(s) to one terminal or more terminals of test station by using lugs
and brass nut bolt and tighten it as per connection scheme.
7) Backfill the excavated soil and pour water up to saturation.
8) Measure open circuit potential of anode after installation.
9) Measure Pipe to Soil Potential (PSP) w.r.t Cu/CuSO4 reference cell before & after
connecting the anode to pipe line.
10) At any location if rock is found then anode shall be installed in lesser depth or in
horizontal configuration, this is to avoid current shielding because of rock, however it
shall be ensured that pipeline is protected.
11) Depth of magnesium anode installation in rock shall be decided based on trench
condition for pipeline laying.

3.2 Test Stations

The location of the test stations shall be marked on row as per approved design with their
connection scheme and other related information on alignment sheet.
1) Make a pit of dimension 1 m x 1 m x 1m. The distance of P/ L center to Foundation pit
center shall be 2mtr.
2) Foundation should be cast either at site location or at a convenient storage yard. The
overall dimensions of foundations shall be 600 mm x 600 mm x 800 mm with 100mm of
FGL above ground. The concrete mix should be M 15 Grade. The steel reinforcement
shall be as shown in the enclosed drawing. The foundation cast should be properly
watered and cured sufficiently.
3) Care should be taken about the mainline pipe and its insulation to ensure that no damage
is caused to them during excavation on the pipeline for cable to pipe connections. A
reference should be made to approve test station schedule for the type of connection

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 scheme designed for the respective test station. Make required number of cable to pipe
connections of appropriate cable size and length.
4) Place a PVC ring / bushing on the rim of the M.S. pipe protruding out of the foundation
block. This is to avoid damage to cable insulation while pulling the cables into the
enclosure.
5) Pull the cables up to the top of foundation and then dress them through the support pipe
into the enclosure
6) The cable entry shall be sealed with bitumen compound after laying of cable to avoid
entry of water /insect into test station.
7) The M.S. support pipe along with enclosure should be erected on top of foundation block
by matching the base plate bolt welded with base plate during fabrication.
8) Care should be taken so that the top of the foundation and the top of the enclosure
remain in the horizontal plane. The enclosure shall be weather proof, with hinged
lockable shutter. Enclosure shall be made of at least 3 mm thick steel sheet and it should
be suitable for M.S. Post mounting with terminals required for both temporary and
permanent CP system height of test Station shall be 1.0 m from ground level.
9) The orientation of the enclosure (box) should be such that its door faces the pipeline.
10) Mount the necessary hard ware within the enclosures and terminate the cable on to the
respective terminals. Number of terminal and different scheme of wiring shall be as per
the Test Station connection scheme GGL-TS-TSC-DRG.
11) Top Foundation bolt shall be covered with PCC
12) Measure pipe to soil potential with portable multi meter and Cu/CuSO4 reference
electrode at all cables terminals inside the box.
13) The name plate of test station shall in minimum carry following information:
- TLP & Type
- Chainage in KM
- Test Station Connection Scheme Type
- Distance from Pipeline in Mtr.
- Direction of flow

3.3 Cable Laying

1) Cables shall be laid in accordance with approved layout drawings. No joint shall be
permitted in a single run. Cable route shall be carefully measured and cables shall be cut to
required lengths including required loops. Minimum ½ meter cable loop shall be provided
near anodes, pipeline & test station for any adjustment.
2) All cable will be required to be laid at a depth of 0.75 m inside station / plant area and 1.5 m
depth outside plant / station area in sand under brick cover backfilled with normal soil. The
route shall be marked with polythene cable warning mats placed at the depth of 0.5/0.8 m.
From finished ground level for inside station and outside plant area respectively. All
dimensions shall be as per approved cable laying drawing GGL-TS-CLD-DRG.
3) In case of above ground cables installation, all unarmored cables forming part of permanent
C.P. System shall be laid in G.I. conduit of sufficient size, with all fittings, fixtures and
accessories.

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 4) Cables shall be neatly arranged in trenches in such a manner that crisscrossing is avoided
and final take off to equipment is facilitated.
5) All underground unarmored cables forming part of TCP/PCP system shall run through PE /
PVC sleeves.
6) All underground cables shall be enclosed by RCC or G.I. conduit of proper size while passing
through road/rail crossings.
7) Cable termination shall be by means of correctly sized crimped lugs & appropriate ferrule.
8) Crimping shall be by means of proper Crimping tools only.
9) The cables for reference cells and pipeline potential measurement shall be routed in a
separate trench other than the trench provided for the rest of the CP system cables, AC
cables for CP TRU etc.

3.4 Cable to Pipe Connection

1) Mark the location required for making pit for pipe to cable connection.
2) Ensure the necessary work permit issued by GGL if required.
3) Make the Site Safety Risk Assessment (SSRA) and ensure mitigation action prior to going for
execution.
4) Conduct the Tool Box talk and share the necessary information and hazard involved.
5) Identify the underground utilities by cable locator/trial hole/information from other agency
if required.
6) Pipe to cable connection shall be laid in accordance with approved drawing GGL-TS-PB-DRG.
7) Qualification of pin brazing procedure to be carried out before taking up field work / field
joint.
8) The cable to pipe connection will be made by using pin brazing method. The following
procedure to be followed:
- Excavate a pit over the pipeline to expose the pipeline top surface at pin brazing location
where cable to pipe connection is to be carried out as per design document (or) opposite to
the test station /CP station location. Care should be taken not to damage the coating of
buried pipeline during excavation. Only manual excavation shall be carried out over the
pipeline.
- Make a trench of dimension as per site requirement and distance between two pipes to
cable joints.
- Ensure pit with V shape/shoring/ shuttering as per GGL HSE requirement.
- Make marking on to the pipeline for making the cable to pipe connection. The number of
marking for connection will be as per the connection scheme type at that particular location.
The location for pin Brazing of cable shall be selected such a way that the pipe joints and
field- coated areas are avoided.
- Care shall be taken that cable to pipe joint is not made upon the seam on circumferential
weld of pipe.
- Distance between 2nos of cable to pipe connection shall be minimum 300mm.
- Cut and remove the coating on the pipe line with care without damaging the pipe of
approximate size (50 mm*50 mm) gently, to suit the size for pin brazing using a sharp chisel.
- Use a flat rough file (or) emery paper to remove coating residue.
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 - Clean the surface of the pipeline materials to white metal finish. All the cables shall be
tested before installation to ascertain the healthiness of the cable.
- Remove the protective sheathing and insulation form the cable to expose the bare copper
conductor minimum 5 mm (or) as required for crimping lug on wire stands, properly. Care
should be taken that cable cutters used do not cause deformation of conductor or damage
to sheathing and insulation.
- Ensure that the bare conductor is clean, bright and dry.
- If the conductor is corroded, then cut it back until bright, clean conductor is to be found.
- If the conductor is wet then dry it with a clean dry cloth, ensuring that the cable insulation
and sheathing are not damaged.
- Take proper pin for brazing gun and secure it properly inside the gun.
- Place the gun on bright metal surface and pull the trigger so that current passes through the
pin and pin melts and gets connected to the surface. During the entire operation keep the
gun pressed on the surface for proper bonding.
- Wait for approx. 10 seconds and then lift the gun.
- Ensure that the stud bullet is firmly connected to the pipe. Check the connection by striking
hand.
- Connect a suitable lug to the cable with suitable nut & washers and crimp it properly.
- Connect the cable to the stud bullet connected to the pipe and tighten it properly as per
given in drawing.
- Remove the debris if any, using brush.
- Visually examine the cable to pipe connection that the entire conductors are incorporated in
the lug.
- Place a required size of plastic funnel around the exposed area such that about 5 mm wide
coating remains inside the plastic funnel .Place M- seal around the plastic funnel to prevent
leakage of encapsulation materials.
- Fill up the plastic funnel from the top by pouring epoxy & hardener in the proportion of 1:10
to achieve electrical insulation.
- The resulting surface shall be clean, bright and slightly rough.

4. FIELD TESTING AND COMMISIONING-TEMPORARY CATHODIC PROTECTION

4.1 Testing at Site-Temporary Cathodic Protection System

GGL’s representative shall visit the works during manufacture of various equipment [Anodes,
Cables, Junction Boxes, Test Lead Points etc.] to assess the progress of work as well as to
ascertain that only quality raw material and fabrication technology is used for the same. All
necessary assistance during such inspections shall be provided by the CONTRACTOR to
owner’s representative.
The minimum testing, inspection requirements for all components/ equipment shall conform
to the requirements as defined in the relevant codes and standards. Detailed inspection and
testing procedures along with the acceptance criteria, including various stages where hold
points, review etc shall be for owners inspection, shall be prepared by CONTRACTOR for GGL
approval.
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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, company name and purchase order details
etc.
GGL 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. CONTRACTOR shall notify the GGL at least 20 days in advance giving exact details
of tests, dates and addresses of locations where the tests would be carried out.
CONTRACTOR shall furnish the detailed field testing and commissioning procedure for
approval. Field tests as per the approved procedures shall be carried out on the equipment/
systems before being put into service. The acceptance of the complete installation shall be
contingent upon inspection and field test results being satisfactory.
Before the CP facilities are placed in operation all necessary tests shall be carried out to
establish that all equipment, devices, wiring and connection, etc. have been correctly installed,
connected and are in good working condition as required for intended operation.
GGL representative may witness all the tests. At least one week’s notice shall be given before
commencing the tests.
All tools, equipment and instruments required for testing shall be provided by CONTRACTOR
Field tests as per the reviewed field testing and commissioning procedures prepared by the
CONTRACTOR shall be carried out. All tools, equipment and instruments required for testing
shall be provided by CP contractor. Generally, the following minimum tests must be carried
out and recorded.
Cables
- Cable No.
- Voltage grade.
- Conductor cross-section.
- Continuity check.
Isolation joint / Isolating Spool
- Location.
- Pipe to soil potential of both protected and non-protected sides of the isolation joint
before and after energization of CP system.
Isolating Spark gap Arrestor
- Location/identification number.
- Rating / Type
- Explosion proof enclosure.
- Check for proper connection& healthiness.
DC Decoupling device
- Location/Identification number.
- Type / Ratings.
- Check standby current drain after CP system energization. (Current drain with respect to
voltage across the cell shall be recorded).
- Details of grounding provided for the DC decoupling device.
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 Zinc or Magnesium Anode Ground Bed
- Location
- Vertical/horizontal
- Check for actual layout and compliance with drawings.
- Current output of anode
Polarization Coupons
- Location
- Exposed area/size of coupon.
- Coupon to soil 'ON' and 'OFF' potentials.
- Type of reference cell.
- Magnetic reeds switch rating.
- Operation of magnetic reed switch with magnet.
Reference Cell
- Location
- Type of cell
- Potential reading
- Installed on top/bottom level of pipeline

4.2 Commissioning-Temporary Cathodic Protection System

Natural potential of pipe to soil for the constructed pipeline shall be measured at all the test
station locations, coupon to soil natural potentials shall be measured at the locations of
polarization coupon installations.
The anode shall be connected to pipeline in the test station and the pipe to soil potential
observation shall be made after allowing sufficient time for polarization. The current output of
each anode at temporary CP anode ground bed shall also be measured to ensure that it does
not exceed the output current capacity of the anodes. In case the anode output current
exceeds the rated capacity, it shall be controlled by insertion of resistance element in the
anode circuit inside test station and the pipe to
Soil potential shall be rechecked for adequacy of protection. At locations of polarization
coupons the coupon 'OFF' potential shall be measured by switching off the reed switch. The
coupon potential shall be between (-) 0.85V (OFF) to (-) 1.2V (OFF). At other test locations
“ON” potential shall be measured and the “ON” Potential shall be between (-)0.95V to (-)1.2V
Additional anodes shall be provided where required, to achieve desired level of protection and
to keep the anode output current within the rated value. In case pipe to soil potential exceeds
the specified value, suitable resistance shall be inserted in the anode circuit to limit the
potential. Anode installation shall become individually operational as above.
After connecting all the sacrificial anode to pipe line, measurement of pipe to soil potentials
shall be taken at each test station to ensure conformity to protection criteria.
Coupon to soil 'OFF' potential shall be measured at all locations of coupon installations by
operation of magnetic reed switch in the test station to ensure conformity of pipe protection
to 'OFF' potential criteria.

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 In case of insufficient protection as per the CP design criteria, on any portion of the pipeline/
any coupon, the CP team shall carry out necessary additions/modifications to the provided
protection.

4.3 Monitoring-Temporary Cathodic Protection System

Where the CP system provided is temporary, the C.P. system shall be monitored at all test
stations once in a month for healthiness/adequacy of protection till commissioning of
permanent CP or for design life of temporary CP specified whichever is less. At the locations of
polarization coupons, the coupon 'ON' and 'OFF' potentials shall be measured by switching off
the magnetic reed switch. The coupon 'OFF' potentials shall be within (-) 0.85V to (-) 1.2V
(OFF). During this period if any deficiency/ interference in protection system are noticed, the
same shall be rectified / augmented by providing additional anodes as required. The
monitoring report shall be submitted regularly to GGL for review/information.

4.4 Cathodic Protection System at Cased Crossings

Coated casing shall be protected additionally by independent [from carrier pipe protection
system] 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 CP design
parameters specified for the main pipeline.
At cased crossing where casing is uncoated or unpainted, additional protection for casing pipe
may not be provided. In this case additional protection of carrier pipe through zinc ribbon
anode may not be provided.

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 ANNEXURE – 4

TECHNICAL DATASHEETS
1. Cables & Pin Brazing For Cathodic Protection System

1. SCOPE
This specification covers the minimum technical requirements for the Supply of Cables for
TCP/ICCP System and Pin Brazing on steel pipelines for connecting the cables.
The Cables should be a standard product of a manufacturer regularly engaged in production.
The cables shall be supplied in accordance with the following specifications and data sheets.

2. DATA SHEET

Distributed Anode Tail Cable:

 Conductor Size - 10 Sq mm
 No of Cores - Single
 Conductor – Stranded Copper
 Insulation – XLPE
 Sheathing - PVC
 Protection - Unarmoured
 Insulation Voltage Grade - 1100V
Deep Anode bed Tail Cable:
 Conductor Size –10 Sq mm
 No of Cores - Single
 Conductor – Stranded Copper
 Insulation – ETCFE
 Sheathing - HMWPE
 Protection - Unarmoured
 Insulation Voltage Grade – 1100V
Bonding / Hook-up / Header Cable-CJB/AJB
 Conductor Size – 35 Sq mm
 Conductor – Stranded Copper
 No of Cores - Single
 Insulation - XLPE
 Sheathing PVC
 Protection – GI Armoured
 Insulation Voltage Grade – 1100V
Polarization/Grounding Cell Cable/ Surge Diverter / Earthing Cable
 Conductor Size – 25 Sq mm
 Conductor – Stranded Copper
 No of Cores - Single
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  Insulation - XLPE
 Sheathing PVC
 Protection – GI Armoured
 Insulation Voltage Grade – 1100V
Reference Electrode and Potential Measurement Cable
 Conductor Size – 10 Sq mm and 6 Sq mm respectively
 Conductor – Stranded Copper
 No of Cores - Single
 Insulation - XLPE
 Sheathing PVC
 Protection – GI Armoured
 Insulation Voltage Grade – 1100V
Power Supply Cable:
 Conductor Size – 16 Sq mm
 Conductor – Stranded copper
 No of Cores – Three
 Insulation - XLPE
 Sheathing - FRLS
 Protection – GI Armoured
 Insulation Voltage Grade – 1100V
3. CABLE IDENTIFICATION:
The overall sheath of the cables shall be marked with “CP SYSTEM CABLE” at every one
meter interval and the colour of outer sheath shall be Yellow.
4. PIN BRAZING REQUIREMENTS:
The Pin Brazing connection shall have
 Extremely low Contact Resistance ≤ 0.1 Ω.
 Low transition resistance 7.5 to 14 μ Ω per brazed joint
 High mechanical strength Binding strength 490 N/mm2
 Shear Strength 245 N/mm2
 Brazing Temperature 6500 C
 Time per Braze 2 Seconds
 Weather Effect Suitable for all weather operation
 Life 40 Years +
Cable connection through Pin Brazing to be field tested for contact resistance &
temperature, etc.

5. TESTING& INSPECTION:
Cables shall be tested by contractor and inspected by Owner before dispatch, testing shall
be conducted in accordance with codes and standards enclosed in this document, as per
routine tests done by manufacturer and additional tests done by manufacturer. Test
Certificate shall be furnished by manufacture.
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6. LIST OF MANUFACTURERS:
 M/s Netco Cables, New Delhi
 M/s Fort Gloster Cables
 M/s Cables Corporation of India Ltd.
 GGL Approved Vendor list

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2. REFERENCE ELECTRODE – Cu/CuSO4
1. SCOPE
This specification covers the minimum technical requirements for Supply of Permanent
Reference Electrode for Cathodic Protection System.
The Permanent Reference Electrode shall be a standard product of a manufacturer regularly
engaged in production. The Reference Electrode shall be supplied in accordance with the
following specifications and data sheets.

2. DATA SHEET:
Type : Cu-CuSO4
Application : Direct Buried
Sensing Membrane : Ceramic
Stability : +10mV with 3micro Amp Load
Design Life : More than 40 years
Moisture Retention : Twin layer Membrane
Ion Trap layer : Chloride Iron Trap
Dimensions : 40mm Diameter x 180mm Long
3. TESTING CERTIFICATES
The testing shall be conducted in accordance with codes and standards enclosed in this
document, as per routine tests done by manufacturer. Test Certificate shall be furnished by
manufacturer.

4. LIST OF MANUFACTURERS / VENDORS

 M/s MC Miller USA
 M/s Electrochemical Device USA
 M/s Fontana
 M/s Tinker & Rasor
 GGL Approved Vendor list

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3. SURGE DIVERTER
1. SCOPE
This specification covers the minimum technical requirements for Supply of Surge Diverter
for Cathodic Protection System.
The Surge Diverter shall be a standard product of a manufacturer regularly engaged in
production. The Surge Diverter shall be supplied in accordance with the following
specifications and data sheets.

2. DATA SHEET:
Type : Spark Gap Type – Explosion proof
Current, 8/20 micro Second wave : 100 Kilo Amp
Spark over AC Voltage – 50 Hz : 1 kV
Impulse (1.2/50 micro second) : 2.2 kV
Rated Discharge Surge Current (8/20usec) : 100kA
Continues Operation
Voltage : 10 V
Surge Diverter Housing : In Test Station Box
Enclosure : 3 MM thick MS Sheet Steel epoxy
painted with door lock Weather
Proof type - IP 55 rating.

3. TEST CERTIFICATES
The testing shall be conducted in accordance with codes and standards enclosed in this
document, as per routine tests done by manufacturer. Test Certificate shall be furnished by
manufacturer.
4. LIST OF MANUFACTURERS:
 M/s Dehn Germany
 M/s Dairyland Electrical Industries – USA
 M/s MC Miller
 M/s Raychem
 M/s Interprovincial Corrosion Control Company ltd.

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4. TEST STATION

1. SCOPE
This specification covers the minimum technical requirements for the Design, Manufacture
and supply of Test Stations.
The Test Station should be a standard product of the manufacturer regularly used for
impressed current cathodic protection system. This specification confers requirement for
type, rating, manufacture and testing of different types of Test Stations. The Test Stations
shall be supplied in accordance with the following specifications and data sheet.

2. DATA SHEET
Enclosure : 3 MM thick MS Sheet Steel Fabricated, Weather Proof
having degree of protection IP-55.
Size : 250MM (H) x 250mm (W) x 200mm (D)
Cable entries in : Through Support pipes-100 mm dia, 1000 mm long & 4.5
mm
Test Station WT
Door : Hinged Lockable Door.
Door Gasket : Neoprene Rubber.
Terminal board : 06 MM Epoxy Bakelite Sheet with 20% spares.
Terminals : SS – 304/Brass Nut & Bolts.
Surface painting : Sand Blasting SA 2 -1/2
Hot Dip Galvanizing to 80µm
One Coat of Zinc Chromate Primer, one coat of Phosphate &
\ Two Coats of Epoxy Paint - Light Grey 631
Total Paint Thickness : – 120µm DFT
Terminal board marking : Screened with Permanent Ink
/ Identification
 Test Station Identification No.
 Connection Scheme - TYPE
 Chainage and direction of Flow.
 Distance from Pipeline in meters.
Terminal Plate : Fibre Reinforced Epoxy Bakelite.
Name Plate : Stainless Steel
Foundation : Pre cast Reinforced Cement Concrete Base with Base Plate
with Pipe for cable entry from bottom
600mm x 600mm x 800mm
Test Station : Type - A, B, C, D, E, H, I
Connection Scheme : Drawing no. GGL-TS-TSC-DRG
 TYPE - A - For Potential Measurement- For every 1 KM
 TYPE - B - For Current Measurement- Every 10 KM and at Major river crossings
 TYPE - C - For Foreign pipeline Crossing- At every CP protected pipeline crossing
 TYPE - D -For Cased Crossing-NH, Railways crossings
 TYPE - E -For Insulating joint
 TYPE - H - For HT Electric Line Crossing For Insulating joint

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  TYPE - I - For Galvanic Anode installation
3. TESTING & INSPECTION
Test Station shall be inspected by Owner before dispatch, testing shall be conducted in
accordance with codes and standards enclosed in this document, as per routine tests done
by manufacturer and additional tests done by manufacturer. Test Certificate shall be
furnished by manufacturer.
4. LIST OF MANUFACTURERS
 M/s Advance Electronic Systems, Baroda
 M/s Corrpro Systems, Baroda.
 M/s Underground pipeline & NDT services, Noida
 M/s Control Plus Oil and Gas Solutions Pvt. Ltd., Ahmedabad
 GGL approved vendor list
Flame Proof:
 M/s Ex Protecta, Mumbai
 M/s FCG Limited, Mumbai
 M/s Baliga Lighting Equipments, Chennai

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5. MAGNESIUM ANODE

1. SCOPE

This specification covers the minimum technical requirements for Supply of Mg Anodes for
Cathodic Protection System.
The Mg Anode shall be a standard product of a manufacturer regularly engaged in
production. The Anode shall be supplied in accordance with the following specifications and
data sheets.

2. DATA SHEET:
Galvanic Material : Mg
Applicable Standard : ASTM B 843
Net Weight of Active Mg Metal : 10 Kg.

Composition of Mg Anode:

Element Weight Weight

(Low Potential type) (High Potential type)
Manganese : 0.15 – 0.7 % 0.5 – 1.3 %
Copper : 0.02 % max. 0.02 % max.
Silicon : 0.1 % max 0.05% max.
Zinc : 2.5 % - 3.5 % -
Aluminium : 5.3 % - 6.7 % 0.01% max.
Iron : 0.003 % max. 0.03% max.
Nickel : 0.002 % max 0.001% max.
Magnesium : Remainder Remainder
Active anode Cross Section Dimensions: 76MM x 76 MM
Length of Active Anode : 1000 MM
Backfill Mixture for Mg Anodes : Gypsum 75% + Bentonite 20% + Sodium Sulphate
5%
Anode Insert core : 10mm TOR Rod – Electro galvanized
Anode Cable Connection : Silver Soldered connection to TOR
Anode tail Cable Conductor Size : Copper 1C X 10 sq mm – Sufficient length
Voltage class : 1100 Volt
Anode tail cable make : Netco/Suyog/Finolex/Asian/CCI
Cable Insulation and Sheathing : Armored XLPE/PVC insulated
Anode Cable Joint Insulation : Epoxy Sealed
Pre-packed Anode Dimensions : 200 mm Dia x 1250 mm Length
Pre-packed Anode Gross Weight : 20 Kg (Min)
Open circuit potential : 1.55 V (-) wrt Cu-CuSO4 Ref Cell

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 Anode Consumption : 7.9 Kg/AY

3. TESTING CERTIFICATES

The testing shall be conducted in accordance with codes and standards enclosed in this
document, as per routine tests done by manufacturer. Test Certificate shall be furnished by
manufacturer. The following minimum test shall be performed by vendor:

 Anode Composition per Lot

 Anode Weight – Net / Gross
 Anode Surface Finish Check
 Anode to Cable Joint Resistance
 Anode Backfill Composition by Weight
 Anode dimension
 Anode potential wrt Cu-CuSO4 Ref Cell

4. LIST OF MANUFACTURERS:

 M/s Scientific Metal Engineers Karaikudi

 M/s Shakti Enterprises Ahmedabad
 M/s Protech Alloy Anodes Karaikudi
 M/s Electro-Protection
 GGL approved Vendor list

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6. ZINC ANODE
1. SCOPE
This specification covers the minimum technical requirements for Supply of Zinc Anodes for
Cathodic Protection System.
The Zinc Anode shall be a standard product of a manufacturer regularly engaged in
production. The Anode shall be supplied in accordance with the following specifications and
data sheets.

2. DATA SHEET:
Galvanic Material : Zinc
Applicable Standard : ASTM B 418-67
Net Weight of Active Zinc Metal : 10 Kg.
Composition of Zinc Anode:
 Aluminium : 0.005%
 Cadmium : 0.003%
 Copper : 0.002%max.
 Iron : 0.0014%max.
 Lead : 0.003%max.
 Others : 0.01%max
 Zinc : Remainder
 Active anode Cross Section Dimensions : 45 MM x45 MM
 Length of Active Anode : 1400 MM
 Backfill Mixture for Zinc Anodes : Gypsum 75% + Bentonite 20%+ Sodium
Sulphate 5%
 Anode Insert core : 10mm TOR Rod – Electro galvanized
 Anode Cable Connection : Silver Soldered connection to TOR
 Anode tail Cable Conductor Size : Copper 1C X 10 sq. mm – Sufficient
Length
 Voltage class : 1100 Volt
 Anode tail cable make : Netco/Suyog/Finolex/Asian/CCI
 Cable Insulation and Sheathing : Armored XLPE/PVC insulated
 Anode Cable Joint Insulation : Epoxy Sealed
 Pre-packed Anode Dimensions : 150 mm Dia. x 1600 mm Length
 Pre-packed Anode Gross Weight : 20 Kg (Min)
 Open circuit potential : 1.10 V (-)
 Anode Consumption : 11.24 Kg/AY

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3. TESTING CERTIFICATES
The testing shall be conducted in accordance with codes and standards enclosed in this
document, as per routine tests done by manufacturer. Test Certificate shall be furnished by
manufacturer. The following minimum test shall be performed by vendor:
 Anode Composition per Lot
 Anode Weight – Net / Gross
 Anode Surface Finish Check
 Anode to Cable Joint Resistance
 Anode Backfill Composition by Weight
 Anode dimension
4. LIST OF MANUFACTURERS:
 M/s Scientific Metal Engineers Karaikudi
 M/s Shakti Enterprises Ahmedabad
 M/s Metal Founders Mumbai
 M/s Protech Alloy Anodes Karaikudi
 M/s Corpen
 M/s Electro-Protection
 GGL approved Vendor list

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7. SOLID STATE DC DECOUPLER/POLARIZATION CELL

1. SCOPE
This specification covers the minimum technical requirements for Supply of Solid State
Decoupler /Polarization Cell for Cathodic Protection System.
The Solid State decoupler/ Polarization Cell shall be a standard product of a manufacturer
regularly engaged in production. It shall be supplied in accordance with the following
specifications and data sheets.

2. DATA SHEET
Type : Solid State Type
Rating : As below
Description Rating
Steady state current (RMS symmetrical) : 35 A min at 65 0 C and min 2 V DC

AC fault current (RMS symmetrical for 50 Hz) : 6.1 kA min for 1 cycle, 3.5 kA min
for 30 cycles
AC fault current (RMS symmetrical for 60 Hz) : 6.5 kA min for 1 cycle, 3.7 kA min
for 30 cycles
AC voltage under maximum : Less than 10 V peak to peak
Rated AC fault current
DC Blocking voltage ± 2 V (Standard)
DC leakage current at 1.2 V shall not be more than 0.5 mA
Model No. : PCR 5 kA, 5000 Amperes @ 30 Cycles.
Lightning Surge Current : 50,000 Amperes crest for 8 x 20 µ seconds.
Ambient Temperature : -45˚ C to 65˚ C
Solid State Polarization : The device provides DC Blocking when absolute
Cell Replacement voltage across the terminals is
3.0 volts Negative to 1.0 volt Positive.
The device further provides a grounding (or coupling) path for steady state AC current of a
magnitude of 35 Amperes.
Solid State Design eliminates the maintenance requirements and the potentially hazardous
electrolytes associated with polarization cells and have a higher DC blocking voltage.
The device is made of solid state components which have an instantaneous response with
respect to voltage, thereby initiating voltage clamping immediately when the voltage attempts
to exceed the blocking level selected.
Number of Repeated Operations: Virtually unlimited under maximum ratings, provided the
operations are not immediately repetitive.
Enclosure : IP 55 Enclosures for Non Hazardous Applications

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 Mounting : The cell is made to mount on a flat surface provided with
appropriate holes in the back plane.
3. TESTING CERTIFICATE
The testing shall be conducted in accordance with codes and standards enclosed in this
document, as per routine tests done by manufacturer. Test Certificate shall be furnished by
manufacturer.
4. LIST OF MANUFACTURERS
 M/s Dairyland Electrical Industries - USA
 M/s Kirk Engineering
 M/s Interprovincial Corrosion Control Company ltd.
 M/s ELK Engg
 M/s Rustrol
 GGL approved Vendor list

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8. ZINC GROUNDING CELL
1. SCOPE
This specification covers the minimum technical requirements for Supply of Zinc Grounding
Cell for Cathodic Protection System.
The Zinc Grounding Cell shall be a standard product of a manufacturer regularly engaged in
production. The Cell shall be supplied in accordance with the following specifications and
data sheets.

2. DATA SHEET:
Galvanic Material : Zinc
Applicable standard : ASTM B 418-67
Net Weight of Active Zinc Metal : 10 Kg. + 10 Kg.
Number of Cell Plates : 2 Nos.
Insulating Spacer : Bakelite
Insulating Spacer Thickness : 25mm
Rating : Greater than 10 kA surge
Composition of Zinc Anode:
 Aluminium : 0.005%
 Cadmium : 0.003%
 Copper : 0.002%max.
 Iron : 0.0014%max.
 Lead : 0.003%max.
 Others : 0.01%max
 Zinc : Remainder
Active Anode Cross Section Dimensions : 36 MM x 36 MM
Length of Active Anode : 1450MM
Backfill Mixture : Gypsum 75% + Bentonite 20% + Sodium
Sulphate 5%
Anode Insert core : 10mm TOR Rod – Electro galvanized
Anode Cable Connection : Silver Soldered connection to TOR
Anode tail Cable Conductor Size : Copper 1C X 25 sq mm – Sufficient length
Voltage Class : 1100 Volt
Cable Insulation and Sheathing : Armored PVC/PVC insulated
Anode Cable Joint Insulation : Epoxy Sealed
Pre-packed Anode Dimensions : 200mm Dia x 1900mm Approximate Length
Pre-packed Anode Gross Weight : 60 Kg (Min)
Open Circuit Potential : 1.1 V (-)
Anode Consumption rate : 11.24 Kg/AY

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3. TESTING CERTIFICATES
The testing shall be conducted in accordance with codes and standards enclosed in this
document, as per routine tests done by manufacturer. Test Certificate shall be furnished by
manufacturer. The following minimum test shall be performed by vendor:
 Anode Composition per Lot
 Anode Weight – Net / Gross
 Anode Surface Finish Check
 Anode to Cable Joint Resistance
 Anode Backfill Composition by Weight

4. LIST OF MANUFACTURERS / VENDORS

 M/s Scientific Metal Engineers Karaikudi
 M/s Shakti Enterprises Ahmedabad
 M/s Protech Alloy Anodes Karaikudi
 M/s Electro-Protection
 GGL approved Vendor list

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9. CORROSION COUPON
1. SCOPE
This specification covers the minimum technical requirements for Supply of Corrosion
Coupon for Cathodic Protection System.
The corrosion coupon shall be a standard product of a manufacturer regularly engaged in
production. The Anode shall be supplied in accordance with the following specifications and
data sheets.

2. DATA SHEET:
Material : Pipeline materials
Size : 100 mm x 100 mm area unless otherwise specified
Cable connection : Cable connection of 10 sq mm &6 sq mm provided
to the coupon for connecting it to pipeline for
cathodic protection and potential measurement
respectively.
Associated item : Vacuum sealed magnetic reed switch: Connection of
coupon in test station shall be through it.
Reed switch rating : To carry & break minimum 50mA at 50 V DC
Magnet for operation : As per system requirement.

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 ANNEXURE-5

ITP

&

REPORT FORMATS
 TABLE OF CONTENTS
1. INSTALLATION PROCEDURE FOR DEEP WELL ANODE GROUND BED………………………1
2. INSTALLATION PROCEDURE FOR PCP HORIZONTAL ANODE GROUND BED……………3
3. CIVIL CONSTRUCTION & INSTALLATION /ERECTION PROCEDURES FOR
TRANSFORMER RECTIFIER UNIT…………………………………………………………………….………5
4. TEST STATIONINSTALLATION……………………………..………………………………………………….7
5. CJB/AJB INSTALLATION……..………………………………………………………………………..………..9
6. PROCEDURE FOR CABLE LAYING…..…………………………………………………………………..…11
7. CABLE TO PIPE CONNECTION BY PIN BRAZING……………..……………………………………..13
8. PROCEDURE FOR PERMANENT REFERENCE CELL/ELECTRODE INSTALLATION……..15
9. PROCEDURE FOR SURGE DIVERTER INSTALLATION……………………………………..……….17
10. INSTALLATION PROCEDURE FOR GALVANIC ANODES (Mg/Zn)………..…………………..19
11. INSTALLATION PROCEDURE FOR POLARIZATION CELL………………………………………….21
12. INSTALLATION PROCEDURE FOR POLARIZATION COUPON…………………………………..23
13. TR UNIT TESTING & COMMISSIONING………………………………………………………..………..25
14. CP SYSTEM COMMISSIONING……………………………………………………………………………….27
15. CLOSE INTERVAL POTENTIAL SURVEY……………………………………..…………………………….28
16. DCVG SURVEY REPORT………………………………………………………………..………………………..29

Note: These are sample formats. Bidder shall submit the formats for all activities including
which are not mentioned above for the approval of GGL prior to carrying out any activity.
 1. INSPECTION & TEST PLAN
INSTALLATION PROCEDURE FOR DEEP WELL ANODE GROUND BED

PROJECT

OWNER GUJARAT GAS LIMITED

MAIN CONTRACTOR

REFERENCE DOCUMENT

REFERENCE DRAWING

SR. ACTIVITY CONTRACTOR TPI GGL REMARK

APPROVAL OF ANODE GROUND BED

1 S R A
INSTALLATION PROCEDURE

LOCATION CHECK &DIMENSIONAL CHECK FOR

2 DEPTH, DISTANCE, LENGTH AND DIAMETER OF P W RM
ANODE GROUND BED.

CHECK THE ALIGNMENT AND LOWERING OF

3 P W RM
ANODE

4 CHECK COKE BREEZE FILLING P W RM

CABLE LAYING, BACKFILLING AND CABLE

5 P W RM
TERMINATION AT AJB

ANODE TO GROUND RESISTANCE

6 P W RM
MEASUREMENT

7 GROUND BED RESISTANCE MEASUREMENT P W RM

LEGEND
A – APPROVAL P- PERFORM BY
R - REVIEW RM - RANDOM CHECK
W - WITNESS ALL S – SUBMIT BY

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 SITE INSPECTION AND TEST REPORT

1 WORK/ACTIVITY INSTALLATION OF DEEP WELL ANODE GROUND BED

2 REF. BID/PO CONTRACTOR

3 REF. DRAWING

4 REF. DOCUMENT

DEEP WELL ANODE GROUND BED LOCATION : DATE:

CP STATION LOCATION CHAINAGE KM

NO. OF ANODES RATING AMPS

ANODE DIMENSION AND

OK / NOT OK ANODE TAIL CABLE SIZE
SPACING AS PER DESIGN

CASING PIPE DIA PVC SHROUDING PIPE DIA

ANODE BED DEPTH MTR.

ANODEBED WELL HEAD CHAMBER/PIT OK / NOT OK

CABLE LAYING,BACKFILLING AND CABLE TERMINATION OK / NOT OK

LENGTH OF MS CASING PIPE WELDED AND LOWERED REMARKS

ACTIVE LENGTH MTR.

PASSIVE LENGTH MTR.

STATUS OF BACKFILL IN BORE WELL OK/NOT OK

ANODE CABLE LAYING /TERMINATION OK/NOT OK

RESTORATION WORK OK/NOT OK

ANODE BED CURRENT OUTPUT AMPS

ANODE BED RESISTANCE OHM

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 2. INSPECTION & TEST PLAN

INSTALLATION PROCEDURE FOR PCP HORIZONTAL ANODE GROUND BED

PROJECT

OWNER GUJARAT GAS LIMITED

MAIN CONTRACTOR

REFERENCE DOCUMENT

REFERENCE DRAWING

SR. ACTIVITY CONTRACTOR TPI GGL REMARK

APPROVAL OF ANODE GROUND BED

1 S R A
INSTALLATION PROCEDURE

LOCATION CHECK &DIMENSIONAL CHECK FOR

2 DEPTH, DISTANCE, LENGTH OF ANODE P W RM
GROUND BED.

CHECK THE ALIGNMENT AND LOWERING OF

3 P W RM
ANODE

4 CHECK COKE BREEZE FILLING P W RM

CABLE LAYING, BACKFILLING AND CABLE

5 P W RM
TERMINATION AT AJB

INDIVIDUAL ANODE TO GROUND RESISTANCE

6 P W RM
MEASUREMENT

7 GROUND BED RESISTANCE MEASUREMENT P W RM

LEGEND
A – APPROVAL P- PERFORM BY
R - REVIEW RM - RANDOM CHECK
W - WITNESS ALL S – SUBMIT BY

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 SITE INSPECTION AND TEST REPORT
1 WORK/ACTIVITY INSTALLATION OF PCP HORIZONTAL ANODE GROUND BED
2 REF. BID/PO CONTRACTOR

3 REF. DRAWING

4 REF. DOCUMENT

HORIZONTAL ANODE GROUND BED LOCATION : DATE:

CP STATION LOCATION CHAINAGE KM

ANODE DIMENSION AS PER

OK / NOT OK ANODE TAIL CABLE SIZE
DESIGN
ANODE BED LENGTH MTR. BACKFILL MATERIAL

SPACING BETWEEN ANODES OK / NOT OK RATING AMPS

CABLE LAYING,BACKFILLING AND CABLE TERMINATION OK / NOT OK

RESTORATION WORK OK/NOT OK

INSTALLED
DISTANCE
CABLE ANODE CABLE PE/PVC TERMINATION ANODE
BETWEEN
ANODE NO. LENGTH INSTALLATION TAG SLEEVE AT AJB CURRENT
ANODE
(MTR.) DEPTH (MTR.) NO. (YES/NO) (OK/NOT OK) OUTPUT
(MTR.)
(AMPS)
A1

A2

A3

A4

A5

A6

A7

A8

A9

A10

Etc.

ANODE BED RESISTANCE OHM

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 3. INSPECTION & TEST PLAN

CIVIL CONSTRUCTION & INSTALLATION /ERECTION PROCEDURES FOR TRANSFORMER RECTIFIER UNIT

PROJECT

OWNER GUJARAT GAS LIMITED

MAIN CONTRACTOR

REFERENCE DOCUMENT

REFERENCE DRAWING

SR. ACTIVITY CONTRACTOR TPI GGL REMARK

1 APPROVAL OF PROCEDURE S R A

2 VISUAL INSPECTION OF TR UNIT P W RM

3 VERIFICATION OF LOCATION P R A

4 MATERIALS INSPECTION FOR CIVIL WORK P R RM

5 TR PLATFORM WORK P W RM

6 CP UNIT INSTALLATION P W RM

7 CABLE TERMINATION P W RM

8 TR PLATFORM MATERIAL & FENCING P W RM

9 REPORTS P R A
LEGEND
A – APPROVAL P- PERFORMED BY
R - REVIEW OF RECORD RM - RANDOM CHECK
W - WITNESS ALL S – SUBMITTED BY

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 SITE INSPECTION AND TEST REPORT

CIVIL CONSTRUCTION & INSTALLATION /ERECTION PROCEDURES

1 WORK/ACTIVITY
FOR TRANSFORMER RECTIFIER UNIT
2 REF. BID/PO CONTRACTOR
3 REF. DRAWING
4 REF. DOCUMENT
CP STATION LOCATION CHAINAGE KM
CONSTRUCTION OF TR PLATFORM/FOUNDATION
DESCRIPTION/CHECK STATUS REMARKS
MATERIAL USED FOR CIVIL WORK OK / NOT OK
CONSTRUCTION WORK AS PER DRAWING OK / NOT OK
CURING OF CIVIL CONSTRUCTION OK / NOT OK
EARTHING OF EQUIPMENT OK / NOT OK
ERECTION/INSTALLATION OF TR UNIT/OTHERS
DESCRIPTION/CHECK STATUS REMARKS
INSTALLATION OF UNIT OK / NOT OK
MOUNTING OF UNIT OK / NOT OK
CABLE TERMINATION/ TAGGING OK / NOT OK
EARTH PIT OK / NOT OK
EARTHING OF EQUIPMENT OK / NOT OK
PDB INSTALLTION WITH ACCESSORIES OK / NOT OK
ERECTION/INSTALLATION OF FENCING WITH GATE
DESCRIPTION/CHECK STATUS REMARKS
MATERIAL USED FOR FENCING/GATE WORK OK / NOT OK
CONSTRUCTION WORK AS PER
OK / NOT OK
DRAWING/INSTRUCTION
APPLYING OF PRIMER/PAINT OK / NOT OK
GATE & LOCKING ARRANGEMENT OK / NOT OK

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 4. INSPECTION AND TEST PLAN
TEST STATION INSTALLATION

PROJECT

OWNER GUJARAT GAS LIMITED

MAIN CONTRACTOR

REFERENCE BID/PO

REFERENCE DRAWING

SR. ACTIVITY CONTRACTOR TPI GGL REMARK

1 APPROVAL PROCEDURE S R A

2 CHECK PIT DIMENSION & LOCATION P W RM

CHECK CONCRETE FOUNDATION SIZE, GRADE,
3 P W RM
REINFORCEMENT, PCC MIXURE & CURING.
CHECK INSTALLATION OF TLP POST MOUNTING
4 P W RM
ABOVE FOUNDATION

CHECK PROPER SEALING OF CABLE ENTRY AT

5 P W RM
FOUNDATION

CHECK FOUNDATION LEVEL & HEIGHT ABOVE

6 P W RM
GROUND
CHECK TERMINATION OF CABLE INSIDE TLP AS
7 P W RM
PER CABLE CONNECTION SCHEME
CHECK CABLE CONNECTION SCHEME & NAME
8 P W RM
PLATE OF TLP
9 CONTINUITY TEST OF CABLES P W RM

10 TLP PAINTING IF REQUIRED P W RM

LEGEND
A – APPROVAL P- PERFORMED BY
R - REVIEW OF RECORD RM - RANDOM CHECK
W - WITNESS ALL S – SUBMITTED BY

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 SITE INSPECTION AND TEST REPORT

1 WORK/ACTIVITY INSTALLATION OF TEST STATION

2 REF. BID

3 REF. DRAWING

4 REF. DOCUMENT

SR. ACTIVITY SITE DETAILS REMARKS

1 TEST STATION LOCATION CH. IN KM

2 TEST STATION TYPE

3 DISTANCE FROM PIPELINE IN MTR.

4 PIT DIMENSION AS PER DRAWING OK / NOT OK

CONCRETE MIX, CONCRETE FOUNDATION

5 OK / NOT OK
& SIZE AS PER APPROVED DRG. & CURING

6 MOUNTING OF JUNCTION BOX OK / NOT OK

7 FOUNDATION LEVEL OK / NOT OK

HEIGHT OF FOUNDATION ABOVE GROUND

8 OK / NOT OK
LEVEL

9 TEST STATION DOOR/LOCK/GASKET OK / NOT OK

CABLE ENTRY & CABLE ENTRY HOLE

10 OK / NOT OK
SEALING

CABLE TERMINATION INSIDE TLP AS PER

11 OK / NOT OK
CABLE CONNECTION SCHEME

12 CABLE IDENTIFICATION TAGS /FERRULES OK / NOT OK

CABLE CONNECTION SCHEME & NAME

13 OK / NOT OK
PLATE OF TLP FIXATION
PSP MEASUREMENT & FINAL
14 OK / NOT OK
ACCEPTANCE

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 5. INSPECTION AND TEST PLAN
CATHODE JUNCTION BOX/ANODE JUNCTION BOX INSTALLATION

PROJECT

OWNER GUJARAT GAS LIMITED

MAIN CONTRACTOR

REFERENCE BID/PO

REFERENCE DRAWING

SR. ACTIVITY CONTRACTOR TPI GGL REMARK

1 APPROVAL PROCEDURE S R A

2 CHECK PIT DIMENSION & LOCATION P W RM

CHECK CONCRETE FOUNDATION SIZE, GRADE,
3 P W RM
REINFORCEMENT, PCC MIXURE & CURING.
CHECK INSTALLATION OF CJB/AJB POST
4 P W RM
MOUNTING ABOVE FOUNDATION

CHECK PROPER SEALING OF CABLE ENTRY AT

5 P W RM
FOUNDATION

CHECK FOUNDATION LEVEL & HEIGHT ABOVE

6 P W RM
GROUND

7 CHECK TERMINATION OF CABLE INSIDE CJB/AJB P W RM

8 CHECK NAME PLATE OF CJB/AJB P W RM

9 CONTINUITY TEST OF CABLES P W RM

10 CJB/AJB PAINTING IF REQUIRED P W RM

LEGEND
A – APPROVAL P- PERFORMED BY
R - REVIEW OF RECORD RM - RANDOM CHECK
W - WITNESS ALL S – SUBMITTED BY

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 SITE INSPECTION AND TEST REPORT

1 WORK/ACTIVITY INSTALLATION OF CJB/AJB

2 REF. BID

3 REF. DRAWING

4 REF. DOCUMENT

SR. ACTIVITY SITE DETAILS REMARKS

1 CJB/AJB LOCATION

2 PIT DIMENSIONAS PER DRAWING OK / NOT OK

CONCRETE MIX, CONCRETE FOUNDATION

3 OK / NOT OK
& SIZE AS PER APPROVED DRG. & CURING

4 MOUNTING OF JUNCTION BOX OK / NOT OK

5 FOUNDATION LEVEL OK / NOT OK

HEIGHT OF FOUNDATION ABOVE GROUND

6 OK / NOT OK
LEVEL

7 CJB/AJB STATION DOOR/LOCK/GASKET OK / NOT OK

8 CABLE ENTRY OK / NOT OK

9 CABLE TERMINATION INSIDE CJB/AJB OK / NOT OK

10 CABLE IDENTIFICATION TAGS /FERRULES OK / NOT OK

11 NAME PLATE OF CJB/AJB FIXATION OK / NOT OK

12 FINAL ACCEPTANCE OK / NOT OK

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 6. INSPECTION AND TEST PLAN
CABLE LAYING

PROJECT

OWNER GUJARAT GAS LIMITED

MAIN CONTRACTOR

REFERENCE BID

REFERENCE DRAWING

SR. ACTIVITY CONTRACTOR TPI GGL REMARK

1 APPROVAL PROCEDURE S R A

2 CHECK CABLE TRENCH ROUTE MARKING P W RM

3 CHECK DEPTH OF CABLE TRENCH P W RM

CHECK SAND SPREADING AND BRICK COVER
4 P W RM
LAYING

5 CHECK WARNING TAPE/MAT PLACEMENT P W RM

CHECK BACKFILLING OF TRENCH &

6 P W RM
RESTORATION OF SITE

CHECK CABLE TERMINATION INSIDE JUNCTION

7 P W RM
BOX
CHECK CABLE IDENTIFICATION TAG/FERRULE
8 P W RM
AS PER CABLE CONNECTION SCHEME
CHECK CABLE ROUTE MARKER AT REGULAR
9 P W RM
INTERVAL
LEGEND
A – APPROVAL P- PERFORMED BY
R - REVIEW OF RECORD RM - RANDOM CHECK
W - WITNESS ALL S – SUBMITTED BY

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 SITE INSPECTION & TEST REPORT

1. WORK /ACTIVITY PROCEDURE FOR CABLE LAYING

2. REF. BID NO./PO

3. REF. PROCEDURE

4. REF. DRAWING

SR. ACTIVITY SITE DETAILS REMARKS

1 LOCATION

2 CABLE SIZE AND LENGTH

OK / NOT OK
3 CABLE TRENCH

OK / NOT OK
4 DEPTH

OK / NOT OK
5 SAND/BRICK COVER

OK / NOT OK
6 WARNING MAT

OK / NOT OK
7 CABLE TERMINATION

CABLE IDENTIFICATION TAGS /FERRULES AS OK / NOT OK

8
PER CABLE CONNECTION SCHEME
OK / NOT OK
9 TRENCH BACKFILLING

OK / NOT OK
10 SITE RESTORATION

11 CABLE ROUTE MARKER OK / NOT OK

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 7. INSPECTION AND TEST PLAN
CABLE TO PIPE CONNECTION BY PIN BRAZING

PROJECT

OWNER GUJARAT GAS LIMITED

MAIN CONTRACTOR

REFERENCE BID

REFERENCE PROCEDURE

REFERENCE DRAWING

SR. ACTIVITY CONTRACTOR TPI GGL REMARK

1 APPROVAL PROCEDURE S R A

2 CHECK LOCATION FOR CONNECTION P W W

3 CHECK EXPOSED PIPE SURFACE P W RM

CABLE TO PIPE CONNECTION BY PIN

4 P W RM
BRAZING METHOD

CHECK SPACING BETWEEN TWO PIN

5 P W RM
BRAZING POINTS

6 TIGHTNESS TEST OF CABLE P W RM

7 CONTINUITY TEST OF CABLE P W RM

CHECK RESORATION AND

8 P W RM
ENCAPSULATION

9 CHECK HOLIDAY P W RM

LEGEND

A – APPROVAL P- PERFORMED BY

R - REVIEW OF RECORD RM - RANDOM CHECK

W - WITNESS ALL S – SUBMITTED BY

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 SITE INSPECTION & TEST REPORT

1 WORK/ACTIVITY PROCEDURE FOR CABLE TO PIPE CONNECTION BY PIN BRAZING

2 REF. BID

3 REF. DRAWING

4 REF. PROCEDURE

SR. ACTIVITY SITE DETAILS REMARKS

1 TEST STATION LOCATION CH. IN KM

2 TEST STATION TYPE

3 NUMBER OF CONNECTIONS & CABLE SIZE(S)

CABLE TO PIPE CONTACT RESISTANCE

4 OK / NOT OK
(shall be ≤0.1Ω)
OK / NOT OK
5 SPACING BETWEEN CONNECTIONS

OK / NOT OK
6 LENGTH of CABLE(S)

OK / NOT OK
7 EPOXY & HARDNER FILLING

OK / NOT OK
8 CONNECTION STRENGTH & CONTINUITY

OK / NOT OK
9 HOLIDAY TEST

OK / NOT OK
10 BACKFILLING OF PIT

OK / NOT OK
11 RESTORATION WORK

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 8. INSPECTION AND TEST PLAN

PROCEDURE FOR PERMANENT REFERENCE CELL/ELECTRODE INSTALLATION

PROJECT

OWNER GUJARAT GAS LIMITED

MAIN CONTRACTOR

REFERENCE BID

REFERENCE PROCEDURE

SR. ACTIVITY CONTRACTOR TPI GGL REMARK

1 APPROVAL PROCEDURE FOR REF.CELL S R A

CHECK MATERIAL TEST CERTIFICATE NUMBER &

2 P W W
DATE

3 VISUAL INSPECTION OF REF. CELL P R RM

4 SOAK IN FRESH WATER FOR 24 HOURS P W RM

COMPARATIVE READING MEASUREMENT WITH

5 P W RM
PORTABLE REFERENCE CELL

6 CHECK DIMENSION AND TAIL CABLE LENGTH P W RM

7 VERIFICATION OF LOCATION P W RM

REFERENCE CELL INSTALLATION DEPTH,

8 P W RM
POSITION & BACKFILLING

9 CABLE TERMINATION & TAGGING P W RM

MEASURE PIPE TO SOIL POTENTIAL AFTER

10 P W RM
INSTALLATION OF REF. CELL.
LEGEND
A – APPROVAL P- PERFORMED BY
R - REVIEW OF RECORD RM - RANDOM CHECK
W - WITNESS ALL S – SUBMITTED BY

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 SITE INSPECTION & TEST REPORT

WORK/ACTIVITY
1 INSTALLATION OF PERMANENT REFERENCE CELL/ELECTRODE

2 REF. BID

3 REF. DRAWING

4 REF. PROCEDURE

SR. ACTIVITY SITE DETAILS REMARKS

1 CP STATION /TEST STATION LOCATION

2 CHAINAGE IN KM

3 TYPE OF REFERENCE CELL

OK / NOT OK
4 DEPTH OF REF. CELL

OK / NOT OK
5 DISTANCE FROM PIPELINE

OK / NOT OK
6 SPACING BETWEEN REF. CELLS

OK / NOT OK
7 CABLE TERMINATION INTO CJB/TLP

a) PSP WITH REF. CELL NO. 1

8
b) PSP WITH PORTABLE REF. CELL
a) PSP WITH REF. CELL NO. 2
9
b) PSP WITH PORTABLE REF. CELL
a) PSP WITH REF. CELL NO. 3
10
b) PSP WITH PORTABLE REF. CELL

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 9. INSPECTION AND TEST PLAN

PROCEDURE FOR SURGE DIVERTER INSTALLATION

PROJECT

OWNER GUJARAT GAS LIMITED

MAIN CONTRACTOR

REFERENCE BID

REFERENCE PROCEDURE

SR. ACTIVITY CONTRACTOR TPI GGL REMARK

1 APPROVAL PROCEDURE FOR SURGE DIVERTER S R A

CHECK MATERIAL TEST CERTIFICATE NUMBER &

2 P W W
DATE

3 VISUAL INSPECTION OF SURGE DIVERTER P R RM

4 VERIFICATION OF LOCATION P W RM

5 INSTALLATION OF SURGE DIVERTER P W RM

6 CABLE CONNECTION AND LAYING P W RM

7 INSULATION OF IJ/SURGE DIVERTER P W RM

LEGEND
A – APPROVAL P- PERFORMED BY
R - REVIEW OF RECORD RM - RANDOM CHECK
W - WITNESS ALL S – SUBMITTED BY

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 SITE INSPECTION & TEST REPORT

1 WORK/ACTIVITY INSTALLATION OF SURGE DIVERTER

2 REF. BID

3 REF. DRAWING

4 REF. PROCEDURE

SR. ACTIVITY SITE DETAILS REMARKS

1 LOCATION

2 CHAINAGE IN KM

3 SR. NO. OF SURGE DIVERTER

4 INSTALLATION OF SURGE DIVERTER OK / NOT OK

OK / NOT OK
5 CABLE CONNECTION

6 PSP READING OF PROTECTED SECTION

7 PSP READING OF OTHER SECTION

OK / NOT OK
8 CABLE TERMINATION

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 10. INSPECTION & TEST PLAN

INSTALLATION PROCEDURE FOR GALVANIC ANODES (Mg/Zn)

PROJECT

OWNER GUJARAT GAS LIMITED

MAIN CONTRACTOR

REFERENCE DOCUMENT

REFERENCE DRAWING

SR. ACTIVITY CONTRACTOR TPI GGL REMARK

APPROVAL OF ANODE INSTALLATION

1 S R A
PROCEDURE

2 CHECK LOCATION & DEPTH P W RM

3 ANODE CONDITION (BACKFILL,BAG,CABLE) P W RM

4 OPEN CIRCUIT POTENTIAL MEASUREMENT P W RM

CHECK THE ALIGNMENT AND LOWERING OF

5 P W RM
ANODE

6 SPACING BETWEEN ANODES P W RM

7 NATURAL PSP MEASUREMENT P W RM

PSP MEASUREMENT (AFTER CONNECTING

8 P W RM
WITH ANODE)

CABLE CONNECTION AND CONNECTOR

9 P W RM
ASSEMBLE WITH ANODE CONTINUITY CHECK

10 CHECK CABLE TERMINATION AND TAGGING P W RM

LEGEND
A – APPROVAL P- PERFORM BY
R - REVIEW RM - RANDOM CHECK
W - WITNESS ALL S – SUBMIT BY

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 SITE INSPECTION AND TEST REPORT

1 WORK/ACTIVITY INSTALLATION PROCEDURE FOR GALVANIC ANODES(Mg/Zn)

2 REF. BID/PO CONTRACTOR

3 REF. DRAWING

4 REF. DOCUMENT

ANODE LOCATION CHAINAGE IN KM

TYPE OF GALVANIC ANODE
TEST STATION TYPE
(Mg/Zn)
ANODE DIMENSION AS PER
OK / NOT OK DISTANCE FROM PIPELINE MTR.
DESIGN

NO. OF ANODES BACKFILL MATERIAL

SPACING BETWEEN ANODES CURRENT OUTPUT OF ANODE mA

ANODE CONDITION AND LOWERING OK/NOT OK

CABLE LAYING,BACKFILLING,CABLE TERMINATION AND

OK / NOT OK
TAGGING

RESTORATION WORK OK/NOT OK

ANODE OPEN CIRCUIT POTENTIAL w.r.t. Cu/CuSO4

ANODE NO. TAIL CABLE LENGTH (MTR.)
REF.CELL

A1

A2

A3

A4

A5

Etc.
PSP w.r.t. Cu/CuSO4 REF.CELL BEFORE CONNECTING ANODE

PSP w.r.t. Cu/CuSO4 REF.CELL AFTER CONNECTING ANODE

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 11. INSPECTION & TEST PLAN

INSTALLATION PROCEDURE FOR POLARIZATION CELL

PROJECT

OWNER GUJARAT GAS LIMITED

MAIN CONTRACTOR

REFERENCE DOCUMENT

REFERENCE DRAWING

SR. ACTIVITY CONTRACTOR TPI GGL REMARK

APPROVAL OF POLARIZATION CELL

1 S R A
INSTALLATION PROCEDURE

2 CHECK LOCATION P W RM

3 INSTALLATION OF POLARIZATION CELL P W RM

4 CABLE CONNECTION AND LAYING P W RM

5 MEASUREMENT OF STANDBY VOLTAGE P W RM

LEGEND
A – APPROVAL P- PERFORM BY
R - REVIEW RM - RANDOM CHECK
W - WITNESS ALL S – SUBMIT BY

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 SITE INSPECTION AND TEST REPORT

1 WORK/ACTIVITY INSTALLATION OF POLARIZATION CELL

2 REF. BID/PO CONTRACTOR

3 REF. DRAWING

4 REF. DOCUMENT

LOCATION CHAINAGE IN KM TEST STATION TYPE

INSTALLATION OF POLARIZATION
OK / NOT OK CABLE TERMINATION OK / NOT OK
CELL

STANDBY CURRENT mA STANDBY VOLTAGE mV

FINAL RESTORATION WORK OK/NOT OK

GROUNDING ANODE EARTH RESISTANCE

Notes:

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 12. INSPECTION & TEST PLAN

INSTALLATION PROCEDURE FOR POLARIZATION COUPON

PROJECT

OWNER GUJARAT GAS LIMITED

MAIN CONTRACTOR

REFERENCE DOCUMENT

REFERENCE DRAWING

SR. ACTIVITY CONTRACTOR TPI GGL REMARK

APPROVAL OF POLARIZATION COUPON

1 S R A
INSTALLATION PROCEDURE

2 CHECK LOCATION P W RM

3 INSTALLATION OF POLARIZATION COUPON P W RM

4 BACKFILLING AND RESTORATION P W RM

5 CABLE TERMINATION AND TAGGINGS P W RM

6 PSP MEASUREMENT OF PIPE AND COUPON P W RM

LEGEND
A – APPROVAL P- PERFORM BY
R - REVIEW RM - RANDOM CHECK
W - WITNESS ALL S – SUBMIT BY

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 SITE INSPECTION AND TEST REPORT

1 WORK/ACTIVITY INSTALLATION OF POLARIZATION COUPON

2 REF. BID/PO CONTRACTOR

3 REF. DRAWING

4 REF. DOCUMENT

LOCATION CHAINAGE IN KM TEST STATION TYPE

POLARIZATION COUPON CABLE TERMINATION AND

OK / NOT OK OK / NOT OK
CONDITION TAGGING AT TEST STATION
INSTALLATION OF POLARIZATION
COUPON WITH BACKFILLING AND OK / NOT OK DISTANCE FROM PIPELINE MM
RESTORATION

PSP MEASUREMENT WITH PERMANENT REFERENCE CELL

POLARIZATION COUPON “OFF” POTENTIAL

Notes:

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:
SIGN:
DATE
 13. SITE INSPECTION & TEST REPORT
TR unit Testing & Commissioning

DATE REF. NO. BY

Pipeline Network :

CP Station Location :

System Condition : As Under

Sr.
Test / Operation conditions Measure / Observe Data / Observation
No.
Observe Mains ON LED
1 Switch on AC input circuit and meters / Lamps Record AC
Volts

Observe switch
operation
Switch ON Corrosion Voltmeter
Record target PSP
Put Volt Selector switch to Ext. position
2 Record Natural PSP
Volts
Ref. Position 1
Put Volt Selector switch to Ext. position Volts
Ref. Position 2
Volts
Ref. Position 3

Observe switch
operation
Observe Operation of
MAN switch
Record Coarse switch
position
Switch ON DC output Circuit Record Fine switch
Set Mode selector switch to MAN position position
3
Vary DC output by coarse & Fine Voltage Record Natural PSP for
Control switch operation Ref. Position 1 Volts
Ref. Position 2 Volts
Ref. Position 3 Volts
Record Output DC Volts
Volts
Record Output DC Amps
Amps
Sr.
Test / Operation conditions Measure / Observe Data / Observation
No.
Observe switch
Set Mode Selector switch to AUTO operation
position by set AVCC / AUTO ref switch to
AVCC position Vary DC output Volts / Observe switch
Amps by output voltage setter up to operation
optimum values set by coarse / fine volt Record max DC output
control switch Volt Volts
4 Record max DC output
Adjust coarse / fine volt control switch to amps Amps
higher position and set the over current Record over current
limit limit Amps
Record max PSP Volts
Try to increase output current above the Observe over current
set over current limit value led and circuit
operation
Observe Switch
Set AVCC / AUTO ref switch to AUTO REF
Operation
position

Observe under
5 Set target potential to (-) 0.85 Volts
protection LED

Set target potential to (-) 2.50 Volts

Observe over
protection LED

Record PSP
Internal/set
Ref. Position 1 Volts
Ref. Position 2 Volts
6 Set Target potential to optimum value
Ref. Position 3 Volts
Record
DC output volt Volts
DC output amps Amps

7 Remarks:

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 14. SITE INSPECTION & TEST REPORT

CP System Commissioning

DATE REF. NO. BY

Pipeline Network :
CP Station Location/Nos. : 1. 2. 3.
CP Station Reading : As Under
Natural
System AC Input DC Input PSP w.r.t. CuCuSO4 in Volt
/Set PSP Remarks
Location
ACV ACA DCV DCA Ref-1 Ref-2 Ref-3

Test Station Reading : As Under

Test Station Details PSP Measured w.r.t. CuCuSO4 Ref Cell in (-) Volt

Instant After 24 hours After 72 hours Remarks

Location
Sr. TS No. TS Type Natural
/chainage On Off On Off On Off

Special Remarks:

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 15. SITE INSPECTION & TEST REPORT
CLOSE INTERVAL POTENTIAL SURVEY

Daily Progress Report for Close Interval Potential Survey (CIPS)

Owner Gujarat Gas Ltd
Contractor

Report No. Date:

Spread
Soil strata Marshy/Silty/Dry/Sandy/Rocky
Name of TRU

Instruments
Details

Location Distance
Sr. Chainage Topographical
(Test Station No.) surveyed (Km) Remarks
No. (Km) Details
Start End Today

Distance Covered Previous :-

Distance Covered Cumulative :

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 16. SITE INSPECTION & TEST REPORT

DCVG SURVEY REPORT

PROJECT
CLIENT Gujarat Gas Ltd.
CONTRACTOR
LOCATION OF TEST CP STATION DATE:
DC Output Voltage DC Output Drain point Signal in
in Volts Current in mVolts
Amps
As found
(in case of CP Station )
Set Value for Survey
Fault Signal Distance Distance of Distance of Signal Calculated
Chainage Upstream between downstream Upstream at pipe to
in Km Test Post upstream test post Test Post Down remote Fault
Nature
“S1” Test post “D2” “D1” stream earth signal %IR
of fault
and Test potential “OL/RE”
defect Post “P/RE”
“dx” “S2”

FOR CONTRACTOR FOR TPI FOR GUJARAT GAS

NAME:

SIGN:

DATE
 ANNEXURE-6

REFERENCE DRAWING
FOR
INSTALLATION/CONSTRUCTION
 REFERENCE SAMPLE DRAWING FOR

1. PIN BRAZING
2. CABLE LAYING OUTSIDE/INSIDE STATION/PLANT AREA
3. CONSTRUCTION DETAILS OF SACRIFICIAL MAGNESUIM ANODE
4. CONSTRUCTION DETAILS OF SACRIFICIAL ZINC ANODE
5. SACRIFICIAL ANODE INSTALLATION
6. ZINC GROUNDING CELL
7. TEST STATION FABRICATION & INSTALLATION
8. TEST STATION CONNECTION SCHEME
9. FABRICATION & INSTALLATION OF CATHODE JUNCTION BOX
10. FABRICATION & INSTALLATION OF ANODE JUNCTION BOX
11. DEEP ANODE BED
12. SHALLOW ANODE BED PCP
13. POLARIZATION / CORROSION COUPON
14. ZINC RIBBON ANODE FOR CASED CROSSING WITH COATED/PAINTED CASING
 ANNEXURE-7

MONITORING FORMATS
 TABLE OF CONTENTS
1. Soil Resistivity Survey ....................................................................................................... 1
2. Pipe to Soil Potential Monitoring – ON POTENTIAL ............................................................ 2
3. Pipe to Soil Potential Monitoring – ON/OFF POTENTIAL .................................................... 3
4. Availability of CPPSM / CPTRU / CPVSM............................................................................ 4
5. Inspection, Functional Check for Transformer / Rectifier Unit & CP System: ....................... 5
6. Monitoring of Polarisation Coupon ................................................................................... 9
7. Monitoring of B – Type Test Station ................................................................................ 10
8. Calculation of Current Density to Check healthiness of pipeline coating ........................... 11
9. Monitoring of Polarisation Cell ....................................................................................... 12
10. Monitoring of Surge Diverter ......................................................................................... 13
11. Monitoring of Grounding Resistance of Anode / Earthing of Polarization Cell .................. 14
12. Foreign Pipeline Crossing .............................................................................................. 15
13. Foreign Pipeline Crossing- Interference Study ................................................................ 16
14. Anode Ground Bed & Anode/ Cathode Junction Box Monitoring .................................... 17
15. Integrity of the Isolating Joints ...................................................................................... 21
16. Cased Crossings Monitoring (Rail / Road) ...................................................................... 22
17. Monitoring of Sacrificial Anode ..................................................................................... 23
18. High Tension Line Crossing ............................................................................................ 24
19. Minor/ River Crossing ................................................................................................... 26
20. CIPL Survey Report........................................................................................................ 27
21. Direct Current Voltage Gradient Survey ......................................................................... 28
22. CAT Survey Report ........................................................................................................ 29
 1. Soil Resistivity Survey
Year/ Month:

Sr.No. Loc. GPS Electrode Spacing (m) Resistivity (ohm-m) Date

Chainage Coordinates and
Time
1 1 2 3 … … 1 2 3 … …
2

4
5
6
7
8
9
10

Reported by: Reviewed by:

 2. Pipe to Soil Potential Monitoring – ON POTENTIAL

Frequency -
Pipeline Section:
Tag numbers of C.P. station / stations feeding the pipeline section:
Year / month:

TLP Last PSP Current PSP

TLP Type Location Chainage Remarks
No. ON ON
1
2
3
4
5
6

Acceptance Criteria: ON PSP: -0.85 V< PSP < -1.5 V w.r.t. Cu / CuSO4 reference electrode.

Note:
 Additional data of PSP monitoring at cased crossings / HT crossings / foreign pipeline
crossings / major & minor river crossings shall be as per respective monitoring
formats.
 In case PSP reading at TLP cannot be taken, reason has to be assigned in the remarks
column and mitigation measure to be adopted to ensure reading is taken in the
subsequent monitoring cycle.

Reported by: Reviewed by:

 3. Pipe to Soil Potential Monitoring – ON/OFF POTENTIAL

Frequency -
Pipeline Section:
Tag numbers of C.P. station / stations feeding the pipeline section:
For PSP – OFF survey
- Tag numbers of C.P. station / stations interrupted:
- All zinc / magnesium anodes directly connected to the pipe section / casing pipes
disconnected. Tag number of these test stations:
Year / month:
Last ON / OFF Current ON /
TLP PSP OFF PSP
TLP Type Location Chainage Remarks
No.
ON OFF ON OFF
1
2
3
4
5
6
Acceptance Criteria: ON PSP: -0.85 V< PSP < -1.5 V w.r.t. Cu / CuSO4 reference electrode.
OFF PSP: -0.85 V < PSP < -1.2 V w.r.t. Cu / CuSO4 reference electrode.
Note:
 Additional data of PSP monitoring at cased crossings / HT crossings / foreign pipeline
crossings / major & minor river crossings shall be as per respective monitoring
formats.
 In case PSP reading at TLP cannot be taken, reason has to be assigned in the remarks
column and mitigation measure to be adopted to ensure reading is taken in the
subsequent monitoring cycle.

Reported by: Reviewed by:

 4. Availability of CPPSM / CPTRU / CPVSM
Date:
Month / Period
Location % of
Name of Pipeline Section Running Breakdown
Sr. No. of CP Availability of Remarks
Pipeline (IJ to IJ) Hrs Hrs
Unit CP Unit
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Reported by: Reviewed by:

 5. Inspection, Functional Check for Transformer / Rectifier Unit & CP System:
• Date of Inspection :
• Station :
Name of the station /location
Make
Unit Sr. No.
Unit rating
Operating Voltage
I. Initial status:
A. Switches positions:

a) Unit in
b) Electrode selector in
c) Ref. voltmeter position
d) Coarse switch position
e) Auto/ Manual position
f) Fine & course switch position
respectively
B. CP Parameter readings:
AC I/P Voltage =
AC I/P Current =
DC O/P Voltage =
DC O/P Current =
Select Ext. Ref. =
Internal .Ref =
Ref.1 =
Ref.2 =
Ref.3 =
Under protecting setting =
Over protection setting =
Ref. Fail Setting =
Lowest Ref. =
C. Indication status
Unit in Auto/AVCC Ref. mode led glowing :
Ref/1/2 /3 lowest glowing :
Ref/1/2 /3 fail led indication :
Mains ON Indication :
 II. Meter calibrations:

Panel Meters Panel Meter Reading Reading taken through Multi- Remarks
Description Meter
AC Input
Voltmeter
AC Input
Ammeter
DC output
Voltmeter
DC Output
Ammeter
PSP meter

III. Unit Operation in Auto Operation Check:

Ref.Voltage O/P Voltage O/P Current
Int.Ref. –
Ext.Ref. –
Output Voltage
Out Current
Remarks

IV. Alarm indication Test:-

Unit in auto:
Unit in AVCC:
U/P led :
O/P led:
All Ref Fail:
Ref. 1 Fail
Ref. 2 Fail
Ref. 3 Fail
Ref. 1 Lowest
Ref. 2 Lowest
Ref. 3 Lowest
Over current
V. No load and load test:-

Parameters No load Test: readings Load Test: reading Remarks

Partial Full
AC I/P Voltage
AC I/P Current
DC O/P Voltage
DC O/P Current
 VI. Circuit resistance Test (Anode/Ground bed Resistance):
Pipe current driving voltage :
Back emf :
Pipe current (output current) :
Resistance across Anode and Pipe :
VII. Interference Checking/Inspection:
A. AC Pickup across Anode & Pipe :-
B. AC Pickup across Reference Ref Cell :-
VIII. Current Interrupter circuit healthiness testing/Inspection:-
IX. Permanent Reference Cell Test:

Ref. cell Open circuit voltage ref. Loaded ref cell Remarks
voltages
Ref.1
Ref.2
Ref.3

X. RMU Panel Inspection:

Initial Status

Parameter reading on RMU display

CP Station: PSP: Signal Strength:

Voltage: Current: Registration:

Menu –
a) Set up configuration :
b) Scaling parameter :
c) Alarm configuration :
a) Set up configuration:

RMU Address/CP station

Set time
Set date
Start time
Log rate
CuCuSO4 Ref. Electrode
 Dis Scroll
Limit
ICP-1000

b) Scaling parameter:
Shunt mV
Amp.
Run hour reset
Data reset
Under protection
Over Protection
Ref. Fail
Off set
AC signal
AC display
Ical

c) Alarm Configuration:
A1:
A2:
A3:
I cp-1000 SR #
PC number

1. Battery cell V with RMU supply (AC supply OFF) :

2. Converter module I/P PSP signal :
3. Converter module O/P PSP signal :
4. Voltage across ground & 5V (DC) :
5. Voltage across ground & 12V DC :
6. Voltage across ground + Ve B &-Ve B DC :
7. 6 V AC Voltage terminal :
XI. Observations:

XII. Recommendation:

Reported By: Reviewed By:

 6. Monitoring of Polarisation Coupon
Date:
Month / Period

Sl. Name Pipeline Location of Chainage Date of PSP Polarization Remarks

No. of Section Polarization Reading Coupon (-) Volt
Pipeline (IJ to IJ) Coupon
ON OFF

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Reported by:

Reviewed by:
7. Monitoring of B – Type Test Station
 8. Calculation of Current Density to Check healthiness of pipeline coating

Frequency -
Pipeline Section:
Tag numbers of C.P. station / stations feeding the pipeline section:
Year / month:

Surface
Area of Total Current
Type Pipeline Length Dia
Sl. Name of P/L Current Density
to Section Remarks
No. Pipeline Section
coating (IJ to IJ)
Sq.
meter mm Amp. µA / m2
meter
1
2
3
4
5

Acceptable Criteria:
- 3 Layer Polyethylene Coating- Current Density ≤ 50 µA / m2
- Single layer Fusion Bonded epoxy coating- 50 µA / m2 ≤Current Density ≤ 150 µA / m2
- Coal tar Enamel wrapping and coating -150 µA / m2 ≤Current Density ≤ 300 µA / m2

Reported by: Reviewed by:

9. Monitoring of Polarisation Cell
10. Monitoring of Surge Diverter
 11. Monitoring of Grounding Resistance of Anode / Earthing of Polarization Cell
Date:
Month/ Period:
Grounding
Sl. Name of Pipeline Section Location of Date of
Chainage resistance in Remarks
No. Pipeline (IJ to IJ) Polarization Cell Reading
Ohms
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Reported By:

Reviewed By:
 12. Foreign Pipeline Crossing

Frequency -
Pipeline Section:
Name of foreign pipeline:
Tag numbers of C.P. station / stations feeding the pipeline section:
Year / month:
PSP at
PSP at
foreign
GGL Bonding of GGL / foreign pipeline
pipeline
TLP
TLP
TLP TLP Location/
Direction of current Remarks
No. Type Chainage Current
flow from GGL to
Yes / flow
ON ON foreign pipeline or
No through
foreign pipeline to
bond
GGL
1
2
3
4
5
6

Acceptable criteria:
ON PSP: -0.85 V< PSP < -1.5 V w.r.t. Cu / CuSO4 reference electrode.
If the ON PSP at GGL pipeline crossing TLP is substantially different from the upstream /
downstream TLP, then the same has to be investigated by conducting ON/OFF testing by
cyclically switching ON /OFF TR GGL TR unit and foreign pipeline TR units.

Reported by: Reviewed by:

 13. Foreign Pipeline Crossing- Interference Study

Frequency –
Pipeline Section:
Name of foreign pipeline:
Tag numbers of C.P. station / stations feeding the pipeline section:
Tag numbers of C.P. station / stations interrupted GGL:
Tag numbers of C.P. station / stations interrupted foreign pipeline:
All zinc / magnesium anodes directly connected to the pipe section / casing pipes
disconnected. Tag number of these test stations:
Year / month:
GGL TRU interrupted* Foreign pipeline TRU interrupted*
PSP at
PSP at GGL PSP at foreign
PSP at GGL TLP foreign
TLP TLP Location/ TLP pipeline TLP
pipeline TLP
No. Type Chainage
ON (GGL ON
ON OFF ON TRU ON (Foreign ON OFF
OFF) TRU OFF)

* Note: A positive swing of 50 mV and more when TRU is switched ON from OFF indicates
interference.

Acceptable criteria:
ON PSP: -0.85 V< PSP < -1.5 V w.r.t. Cu / CuSO4 reference electrode.
OFF PSP: -0.85 V < PSP < -1.2 V w.r.t. Cu / CuSO4 reference electrode.

Reported by: Reviewed by:

 14. Anode Ground Bed & Anode/ Cathode Junction Box Monitoring

Frequency -
Pipeline Section:
Tag numbers of C.P. station feeding the anode ground bed:
Year / month:
Date of last inspection:
Anode Groundbed details:
Sr. No. Description Details
1 Date of Installation of anode bed
2 Anode bed configuration Shallow (H or V) / Deep
3 Anode material
4 Nos. of anode / anode strings
5 Rated current output of each anode / anode string
6 Current output of the anode bed
7 Distance between anode bed and pipeline (meters)
8 Design Ground bed resistance Ω

Visual Inspection:
Deep anode ground bed:
Sr. No. Description Details
1 Casing cover intact
2 Vent pipe intact
3 Anode cable route marker intact

Shallow anode ground bed:

Sr. No. Description Details
1 Anode cables route marker intact

Anode junction box:

Sr. No. Description Details
1 Painting – external / internal
2 Operation of lock
3 Sealing of cable entry in the junction box
4 All terminals are tight
Cathode junction box:
Sr. No. Description Details
1 Painting – external / internal
2 Operation of lock
3 Sealing of cable entry in the junction box
4 All terminals are tight
Functional Checks:

Shallow anode bed (Horizontal / Vertical) – Current measurement at anode junction box

Anode ground bed current (current flowing in the anode header cable):

Shunt Rating Shunt Current

Remarks
(A/mV) (mV) (Amp)

Individual anode current (current flowing in individual anode tail cables):

Anode Shunt Rating Shunt Variable Current
resistance Remarks
No (A/mV) (mV) (Amp)
rating
1
2
3
4
5
6
7
8
9
10
11
12
13
Total current

Acceptance criteria:

- All individual anodes should deliver almost equal current.

- Sum of current of individual anodes should be equal to the current measured in the anode
header cable
Deep ground bed – Current measurement at anode junction box
Anode ground bed current (current flowing in the anode header cable):

Shunt Rating Shunt Current

Remarks
(A/mV) (mV) (Amp)

Individual anode strings:

Anode Anode string
Shunt Rating Shunt
String current Remarks
(A/mV) (mV)
No (Amp)
1
2
3
4
5

All anodes on the same string:

Single feed / Dual feed

Anode Anode string
Shunt Rating Shunt
String current Remarks
(A/mV) (mV)
No (Amp)
1
2

Acceptance criteria
- Sum of current of individual anodes should be equal to the current measured in the anode
header cable
Anode ground bed resistance:
The ground bed resistance shall be measured using a three point method of earth resistance
(62% method) using a Earth resistance tester

Deep Ground Bed – All anodes in one string:

Anode Distance of Distance of Anode Bed
Ground Electrode (P2) Electrode (C2) Resistance Remarks
bed Meters Meters Ω
18.6 30

Note C1& P1 terminal of the 4 point earth tester to be shorted and connected to Anode
ground bed header cable

Acceptance criteria:
For soil resistivity < 10,000 ohm-cm: < 1 ohm
For soil resistivity >10,000 ohm-cm: < 1.5 ohm

Shallow Ground Bed – Individual Anode to ground resistance:

Distance of Distance of Anode
Individual
Electrode (P2) Electrode (C2) Resistance Remarks
Anodes
Meters Meters Ω
1 18.6 30
2 18.6 30
3 18.6 30
4….. n 18.6 30

Shallow Groundbed resistance: (All anodes connected through tail cables in AJB)
Anode Distance of Distance of Anode Bed
Ground Electrode (P2) Electrode (C2) Resistance Remarks
bed Meters Meters Ω
18.6 30

Acceptance criteria:
For soil resistivity < 10,000 ohm-cm: < 1 ohm
For soil resistivity >10,000 ohm-cm: < 1.5 ohm

Reported By: Reviewed By:

 15. Integrity of the Isolating Joints
Frequency -
Pipeline Section:
Tag numbers of C.P. station / stations feeding the pipeline section:
Year / month:

PSP
TLP Location/ IJ
TLP Type Below ground / Remarks
No. Chainage Un-Protected
Protected Side
Above ground Side

1
2
3
4
5
6

Acceptable criteria:
Protected side: ON PSP: -0.85 V< PSP < -1.5 V w.r.t. Cu / CuSO4 reference electrode.
Un-protected side: ON PSP: < -0.6V w.r.t. Cu / CuSO4 reference electrode. (This reading could be more electro-
negative if zinc grounding cells are connected on the un-protected side for earthing of SV station equipment. The
healthiness of IJ then to be tested by interrupting the TR units during the yearly ON OFF PSP measurements. IJ is
healthy if the PSP on the un-protected side remains the same or becomes more electro-negative when the TR
units is switched from ON to OFF.)

Reported by: Reviewed by:

Integrity of the Isolating Joints
Frequency -
Pipeline Section:
Tag numbers of C.P. station / stations feeding the pipeline section:
Year / month:
PSP
TLP TLP Location/ IJ
Protected Side Un-Protected Side
No. Type Chainage Below ground / Remarks
Above ground
ON OFF ON OFF

1
2
3
4
5
6
Acceptable criteria:
Protected side: ON PSP: -0.85 V< PSP < -1.5 V w.r.t. Cu / CuSO4 reference electrode.
OFF PSP: -0.85 V< PSP < -1.2 V w.r.t. Cu / CuSO4 reference electrode.
Un-protected side: ON PSP: < -0.6V w.r.t. Cu / CuSO4 reference electrode. (This reading could be more electro-
negative if zinc grounding cells are connected on the un-protected side for earthing of SV station equipment. The
healthiness of IJ then to be tested by interrupting the TR units during the yearly ON OFF PSP measurements. IJ is
healthy if the PSP on the un-protected side remains the same or becomes more electro-negative when the TR
units is switched from ON to OFF.)

Reported by: Reviewed by:

 16. Cased Crossings Monitoring (Rail / Road)
Frequency -
Pipeline Section:
Tag numbers of C.P. station / stations feeding the pipeline section:
Year / month:

Potential of No. & Wt

Condition Casing pipe Zn / Mg of Zn / Mg PSP Reading
TLP TLP Location/
of Drain & Bare / anodes anodes Remarks
No. Type Chainage
Vent Pipe Coated (if connected to Carrier Casing
casing pipe *) PSP ON C/S*
1
2
3
4
5
(*) Casing pipe to soil measurement (C/S) has to be taken be disconnecting Zn or Mg anodes connected to the
casing pipe.
Acceptance Criteria: Casing to carrier pipe electrically clear: Pipe to electrolyte ON potentials are > -1V w.r.t.
Cu/ CuSO4 and the difference PSP & C/S potentials is greater than 100 mV.
Indication of shorting: Minor Indication: Pipe to electrolyte ON potentials are > -0.85V w.r.t. Cu / CuSO4 and the
difference in the PSP & C/S potentials is greater than 10 mV and less than or equal to 100 mV.
Moderate Indication: Pipe to electrolyte ON potentials are borderline -0.85V w.r.t.
Cu / CuSO4 and the difference in the PSP & C/S potentials is greater than 10 mV and less than or equal to 100 mV.
Severe Indication: Pipe to electrolyte ON potentials are < -0.85V w.r.t. Cu / CuSO4 and the
difference in the PSP & C/S potentials is less than 10 mV.
Reported by: Reviewed by:
Cased Crossings Monitoring (Rail / Road)
Frequency –
Pipeline Section:
Tag numbers of C.P. station / stations feeding the pipeline section:
Year / month:

Potential No. & Wt

of Zn / of Zn / Mg PSP Reading- OFF
Casing PSP Reading- ON
Condition Mg anodes
TLP TLP Location/ pipe
of Drain & anodes Remarks
No. Type Chainage Bare /
Vent Pipe Carrier
Coated (if connected to Carrier Casing Casing
PSP
casing pipe *) PSP ON C/S* C/S*
OFF
1
2
3
4
5
(*) Casing pipe to soil measurement (C/S) has to be taken be disconnecting Zn or Mg anodes connected to the
casing pipe.
Acceptance Criteria: Casing to carrier pipe electrically clear: Pipe to electrolyte ON potentials are > -1V w.r.t.
Cu / CuSO4 and the difference PSP & C/S potentials is greater than 100 mV.
Indication of shorting: Minor Indication: Pipe to electrolyte ON potentials are > -0.85V w.r.t. Cu / CuSO4 and the
difference in the PSP & C/S potentials is greater than 10 mV and less than or equal to 100 mV.
Moderate Indication: Pipe to electrolyte ON potentials are borderline -0.85V w.r.t.
Cu / CuSO4 and the difference in the PSP & C/S potentials is greater than 10 mV and less than or equal to 100 mV.
Severe Indication: Pipe to electrolyte ON potentials are < -0.85V w.r.t. Cu / CuSO4 and the
difference in the PSP & C/S potentials is less than 10 mV.
Reported by: Reviewed by:
 17. Monitoring of Sacrificial Anode

Frequency:

Date:

Month/Period:

ANODE LOCATION CHAINAGE IN KM

TEST STATION TYPE TYPE OF GALVANIC ANODE (Mg/Zn)

PSP w.r.t. Cu/CuSO4

REF.CELL PSP w.r.t. Cu/CuSO4 REF.CELL AFTER
Sl. No. Anode No.
DISCONNECTING ANODE CONNECTING ANODE

1 A1

2 A2

3 A3

4 A4

5 A5

6
7
8
9
10

Reported by: Reviewed by:

 18. High Tension Line Crossing

Frequency -
Pipeline Section:
Tag numbers of C.P. station / stations feeding the pipeline section:
Year / month:

Location / Induce Type of DC- Details of Total

Chainage/ PSP d AC Decoupler Grounding bed resistance of
TLP TLP HT Voltage ON potenti grounding
Wt
No. Type (33/66/132 al Solid Mg / bed
KIRK* No.
/ State Zn
DC V AC V Kg Ω
220/440kV)
1
2
3
4
5
6

Acceptable criteria:
ON PSP: -0.85 V< PSP < -1.5 V w.r.t. Cu / CuSO4 reference electrode.
Induced AC Potential: For personnel protection < 15V AC
Total grounding resistance < 5Ω
(*) In case of KIRK cell check KOH solution up to green mark indicated on the cell.

Reported by: Reviewed by:

 High Tension Line Crossing

Frequency -
Pipeline Section:
Tag numbers of C.P. station / stations feeding the pipeline section:
Year / month:

Induced AC Total
Potential of
potential Resistance of resistance
Type of DC- Details of each
Location / (72 hours) each of
PSP Decoupler Grounding bed grounding
Chainage/ grounding cell grounding
TLP TLP ON/ cell
HT Voltage bed
No. Type OFF
(33/66/132/ AC V Mg
Solid
220/400kV) KIRK* / Wt No. 1 2 3 4 1 2 3 4
State
Zn
DC V Min Max Kg V V V V Ω Ω Ω Ω Ω
1
2
3
4
5
6
Acceptable criteria:
ON PSP: -0.85 V< PSP < -1.5 V w.r.t. Cu / CuSO4 reference electrode.
OFF PSP: -0.85 V < PSP < -1.2 V w.r.t. Cu / CuSO4 reference electrode.
Induced AC Potential – 72 hours data logging, data logger report to be attached: For
personnel protection < 15V AC
Individual grounding cell potential: Type zinc (-) 1.05 V to (-) 1.1 V // Type magnesium (-) 1.50
V to (-) 1.55 V
Total grounding resistance < 5Ω

Reported by: Reviewed by:

 19. Minor/ River Crossing

Frequency -
Pipeline Section:
Tag numbers of C.P. station / stations feeding the pipeline section:
Year / month:
Sacrificial anode PSP Reading –
Location/ Open Potential Mg / Zn ON Remarks
TLP No. TLP Type
Chainage Cut/HDD U/S D/S U/S D/S
TLP TLP TLP TLP
1
2
3
4
5
6

Note: U/S is upstream and D/S is downstream

Acceptable criteria:
ON PSP: -0.85 V< PSP < -1.5 V w.r.t. Cu / CuSO4 reference electrode.
Potential of Zinc / Magnesium Anode: Type zinc (-) 1.05 V to (-) 1.1 V // Type magnesium (-)
1.50 V to (-) 1.55 V

Reported by: Reviewed by:

 20. CIPL Survey Report

Frequency - Date of
Survey
Pipeline Section:
Tag numbers of C.P. station /
stations feeding the pipeline section:
Year / month

Chainage ON PSP OFF PSP Details of location Min Remarks

Reported by: Reviewed by:

 21. Direct Current Voltage Gradient Survey

Date of the Survey :

Pipeline ID :
Route : From : XXXX To : XXXX
Chainage : From : KM To : KM

Calibration Certificate No. :

DCVG Survey
Equipment Required for Inspection 1)
Equipment
2) Multimeter

Defect GPS
Srl. S1 D1 S2 D2 Dx OL/RE P/RE % Acceptance
Location Chainage Coordinates I
No. / Remarks
(KP) E0 N0 (mV) (Km) (mV) (Km) (Km) (mV) (mV) R
1
2
3
4
LEGENDS
S1 Signal strength at upstream test post
S2 Signal strength at down stream test post
D1 Distance of upstream test post
D2 Distance of downstream test post
Dx Distance between upstream test post and defect
OL/RE Over the line to remote earth potential
PRE Pipe to remote earth potential

Remarks:

Reported by: Reviewed by:

 22. CAT Survey Report
Frequency - Date of
Survey
Pipeline
Section:
Tag numbers of C.P. station / stations feeding the pipeline section:
Year /
month

Signal
Section Rate
Signal dB Loss
Signal Depth Interval of Loss Coating
Location Date Chainage Distance m mA S(n) = dB L(n)
mA m Km I(n) = dB/km Classification
20log10l(n) = S(n)-
d(n) - d(n-1) L(n)/l(n)
S(n-1)

<10dB/Km -
Good
Coating
10dB~25dB/
Km-Fair
Coating
25dB~70dB/
Km-Poor
Coating
>70dB/Km -
Massive
defects

Reported by: Reviewed by:

13. HSE Specifications

1. Steel Laying Safety

2. Machine Boring Safety
3. Shot blasting, field joint, coating, holiday testing, charged pipeline buffing, painting
4. Non-Destructive Test by Gama Rays & X-Rays
5. Hydro Testing of Steel Pipeline
6. Pneumatic Testing of Steel Pipeline by Air or Nitrogen
7. Sequence of pressure testing of the installation
8. Commissioning of Steel Pipeline With Odorized Gas
9. Commissioning of Steel Pipeline/DRS with Un-Odorized Gas
10. Hot Tapping in Steel Pipeline
11. Lifting, Loading & Unloading of Heavy Equipments
12. Annexures

Page 175 of 206

CONTRACTOR SEAL & SIGN

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 GGL WPI or Life Saver as per permit to work requirement to be followed.
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
6 Rescue arrangements ensured in case of an emergency.
If required, lanterns, traffic lights & watchman, barricades, warning signs shall be provided for
7
protection of public & vehicular traffic.
Precautions against over-head electrical lines to be taken so as to ensure that booms of the crane does
8
not touch the pipelines 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 when the pipeline is
13 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 staking of
15
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.
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 that they
22
don`t roll back on road and harm the public.
If blasting is required at some hard rocky area, the work shall be carried out as per approved procedure
23
and check the nearby utility should not effected and be sure that in this area stringing shall be done
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 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 required,
24
from concerned authorities shall be obtained
At the crossing like road and railway, before start of trenching, trench and nearby area use for heavy
equipment, area shall be checked with cable locator and pipe locator and also identify the all
underground exiting utility and obstacle. The areas to be identify and mark them with the temporary
25
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 GGL
and concerned GGL 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.
28 Crossover plates provided for pedestrian safety.
Flow of any Channel/Drain/Nala/river etc. shall not be obstructed for movement of construction
29
machinery without obtaining necessary permission from concerned authorities
Trenching planning shall be done according to lowering in spools, & shall be done near by time of
30
lowering.
31 For lowering proper lifting plan to be in place.
Standard pipe cradle can be used and a demonstration shall be carried out that pipe coating is not
damaged. Alternatively non-abrasive pipe belts shall be used and care must be taken while removing
32
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) and for
33 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
34 laid. Following such inspection the presence of water is permitted provided 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.
Hydra/Cranes as required minimum numbers shall be used for holding the pipeline in gentle S curve
35 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 interval of
36
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 / soft soil
37
bedding shall be done
Immediately after lowering level of pipe to be checked with level machine, same to be recorded for as
38
–built
39 Whenever the pipe sections are left open at intervals to be tied in at a later date under road, marshy

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 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.
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 to the top
41 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
42 temperature, damaging actions of adverse weather conditions, sliding down of trench 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 could damage
43
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
44 trench, sheet piling or other effective water breakers across the trench shall be 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 / backfilling
45 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.
2 Proper supervision as per PTW matrix for execution & safety to be ensured.
3 GGL WPI or Life Saver as per permit to work requirement to be implemented.
4 Tool Box talk to be performed prior to start job.
Ensure to protect employees from falling into the entrance or exit pit by the placement of a guardrail
5
or fence at ground level around the pits.
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. Before
9
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.

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16 Never leave operator station while machine is in operation.
17 Avoid loose fitting clothing, loose or uncovered jewellery.
Remove all loose objects stored in or on the machine. Remove all objects which do not belong in
18
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.
Know and use the hand signals required for particular jobs and know who has the responsibility for
31
signaling.
It is the operator’s responsibility to know that all underground utilities have been located before the
32
bore is started, and to avoid them by using proper boring techniques.
It is the responsibility of the operator to read and understand the Operator’s Manual and other
33 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 ensure the
34
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 not possible
36
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 & values in tracker
37
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 be sure that
40
the exhaust fumes have been properly vented.
41 Do not modify this machine.

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3 Shot blasting, field joint, coating, holiday testing, charged pipeline buffing, painting

3.1 Grinding
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 GGL WPI or Life Saver as per permit to work requirement to be followed.
4 Tool Box talk to be performed prior to start job.
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
Special care to be taken while overhead grinding, proper space to be ensured for sitting and doing
7
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. Machine
9
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
1 As per PTW Matrix, Permit to be obtained.
2 Proper supervision as per PTW matrix for execution & safety to be ensured.
GGL WPI or Life Saver as per permit to work requirement to be followed. Cordoning of site as per site
3
condition.
4 Tool Box talk to be performed prior to start job.
5 All Hazards to be identified through site specific risk assessment.
6 Rescue arrangements ensured in case of an emergency.
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 work needs to be ensured.
12 Welding huts to be ensured for welding purpose.
13 Quality of welding rods ensured.
For tie in proper holding arrangements to be in place. It should be ensured that pipes don`t get
14
dislocated and injure the nearby working crew members.
15 Adequate space needs to be ensured for welder to perform welding work.
Precautions for gas escape (if project is on existing gas network) and monitoring to be ensured before
16
any hot work on the pipelines construction.
17 Inspection of hose connection, flash back arrestor of gas cutting set.

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 All air/ gas pipe lines and air/ gas hoses are frequently inspected. Air/gas hoses shall not be used for
18
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 other
20
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 heat. The
23
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 not with
24
matches. Flash back arrester must be used.
Gas cylinders should be placed in locations where sparks or flame from welding or cutting work cannot
25
contact them.
26 All dissolved Acetylene cylinders should be kept in upright position whenever in use.
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 another.
27
Adequate arrangement should be made to prevent cylinders falling from the vehicles.
 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 chained and
28
should be in upright position.
Application of oil, grease or any other lubricating materials to regulators, valves or fittings of gas
29 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 cylinders should be
30
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.
The colored lenses used for welding or gas cutting must be of proper shade for the work being done.
32

Before any heavy structural member is gas cut, it should be ensured that it is cleared and supported by
33
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 operations, if there is
34
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, leather apron
35
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 or other
37
persons connected with arc -welding job should wear colored 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.
Suitable fire extinguishers in working condition should be kept closed to all welding and gas cutting
40
operations.

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 In confined spaces, where the means of exit is a manhole other small opening, means should be
41 provided, such as life belt and lift-line for quickly removing the workers in case of an emergency. An
attendant should be stationed outside the exit at all times while the work is in progress.
In case of electrical extension is required, only ELCB/RCCB electrical extension board with proper wire
42
length is to be use.
Welding procedure qualification shall be carried out in accordance with the relevant requirements
43 Section 5 QUALIFICATION OF WELDING PROCEDURES CONTAINING FILLER METAL ADDITIVES of API-
1104, 2005 edition and GGL Specification.
All welding procedure specification shall be submitted to GGL for review & release and for releasing
44
the procedure for procedure qualification test.
Once welded specimens cleared visually it shall be subjected to radiographic testing and subsequently
45 to destructive testing. Destructive testing shall be done as per GGL Specification and Section 5.6 for
manual welding of API 1104, 2005 edition.
A complete set of test results shall be submitted to GGL for approval immediately after completing the
46
procedure qualification tests.
Prior to start of fit-up bevel cleaning shall be carried out using power brush for a width of 25 mm from
47 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 which
48
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 them to avoid damage to the PE
49
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 root pass
50 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 with complete
51 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 least 50% of the pipe thickness.
52
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.
Only one welder shall be used for main line welding work up to the 8”φ pipeline & two welders shall
53
be used for main line welding work above the 8”φ pipeline.
54 In case of two welders to be used, Welder No. 1 shall start from 12'O' clock position and proceed

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 towards 6'O' clock, In respect to Anti-clock wise direction Welder No.2 shall start from 3`O`clock
position and proceed towards 6`O`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 welds,
55 shrinkage, cracks, undercuts, dimensions of weld surface porosity and other surface defects. If any
such defects are noticed they shall be rectified
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 circumference and both
56
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 of any other weld.
57
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. Preheating shall extend to 3
58 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
1 As per PTW Matrix, Permit to be obtained.
2 Proper supervision as per PTW matrix for execution & safety to be ensured.
GGL WPI or Life Saver as per permit to work requirement to be followed. Cordoning as per site
3
condition to be performed.
4 Tool Box talk to be performed prior to start job.
5 All Hazards to be identified through site specific risk assessment.
6 Rescue arrangements ensured in case of an emergency.
7 Trained and experience person shall do this work.
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.
Holiday detector can be used to detect for cracks in the coating generated due to corrosion on Cold
10
bent pipes
It is carried out before lowering in a complete check by a circle holiday detector for pipe coating (PE
11 Coating) 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.
The holiday detector used shall be checked and calibrated daily before the commencement of work
12 with an accurate D.C. voltmeter. The detector electrode shall be in direct contact with the surface of
coating to be inspected.
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 The entire surface of the coated field joint shall be inspected by means of a full circle holiday detector
with a visual & audible signal. The test voltage shall be 5 KV + 5 KV/mm of total thickness of coating,
13
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
1 As per PtW Matrix, Permit to be obtained.
2 Proper supervision as per PtW matrix for execution & safety to be ensured.
GGL WPI or Life Saver as per permit to work requirement to be followed. Cordoning as per site
3
condition to be performed.
4 Tool Box talk to be performed prior to start job.
5 All Hazards to be identified through site specific risk assessment.
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 process
11
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 ensured, no grinders to be used
12
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
3.5 Shot Blasting
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.
GGL WPI or Life Saver as per permit to work requirement to be followed. Areas to be cordoned off &
3
barricaded if called for.
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4 Tool Box talk to be performed prior to start job.
5 All Hazards to be identified through site specific risk assessment.
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
7 inspected for robustness (no wear tear or cracks etc in hoses or air carrying arrangements) before start
of the procedure. Air to be free from moisture, oil etc contaminants.
Any chemical use to be used for surface cleaning should be done by proper care in respect of
8
applicable PPEs.
There could be exposure to noise, vapors, fumes, dust etc in the operation and hence proper
9
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
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.
GGL WPI or Life Saver as per permit to work requirement to be followed. Cordoning/barricading of
3
area is must with warning signs.
4 Tool Box talk to be performed prior to start job.
5 All Hazards to be identified through site specific risk assessment.
6 Rescue arrangements ensured in case of an emergency.
Non-destructive testing of welds must be performed by Radiography (X-ray or Gama Rays), other than
7
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 deadlines are
8
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).
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 test of a weld to
11
ensure the acceptability of the weld.

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 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
12
Lack of fusion at the root Not acceptable
Burn through Un-repaired burn through are not acceptable
Excess weld penetration (1ntcnial) > 2mm Not acceptable
Excess weld reinforcement > 3mm Not acceptable
(External)
Except for a welder whose work is isolated from the principal welding activity, a sample of each
13 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
14 record showing by milepost, engineering station, or by geographic feature, the 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
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.
GGL WPI or Life Saver as per permit to work requirement to be followed. Cordoning/barricading of
3
area is must with warning signs.
4 Tool Box talk to be performed prior to start job.
5 All Hazards to be identified through site specific risk assessment.
6 Rescue arrangements ensured in case of an emergency.
Reduce Exposure. Minimizing short-term exposure to radiation sources such as X-ray devices and
7 gamma-emitting materials is one of the most effective ways to avoid long-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 source but to be
8
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 regard to
9 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 radiography
10
work Injuries.
11 Working Crew informed about Hazards due to Radiation.
12 Radiography team shall have a personal TLD for determining the personal dose.

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 If the TLD badge evaluation shows exposure to be in excess of the allowable limits of a member, then
13 non-radiation work shall be given to him until return to active radiographic work as per BARC
guidelines.
Use of Calibrated Radiation Survey meter for marking/cordoning of radiation exposure zone shall be
14
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 around in a
17
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 single direction
18
and angle for maximum effectiveness in usage.
In gamma ray situations, distance is an important factor when operating in the field; Proper signage
19 around the testing area will alert personnel and third parties of radiation 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 can be
20 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 radiation
21
exposure to workers and the public.
The intensely penetrating nature of gamma rays forces scrutiny on not only shielding and protection
22
methods, but also distance from the source.
An “exclusion” zone is roped off around the location of the radioactive material, and personnel are
23 forbidden to enter the zone while the source is exposed. Proper signage should be placed liberally near
the testing site to warn third parties.
The radiographer and agency must be approved by BARC and we must check the documents related to
24
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 radiographer whose
25
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 respective Source
27
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-radiations
28 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 and to the full
29
satisfaction of GGL 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
30
PENETRAMETER. The reference table is as follow:
Pipe Wall Thickness or Essential Wire Dia ASTM SET DIN SET

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 Weld Thickness(mm) (mm)
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
Lead screen of thickness 0.005”/0.1 to 0.15 mm and 0.2 to 0.25 mm front & back respectively shall be
32
used.
Surface Penetration:
33 As far as possible all irregularities from the surface (to the extent of 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 no. B on the
34
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.
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 GGL.
 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 source side. In
35
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 carefully without
36
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 when
37 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.

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 Film Processing:
38 Film shall be process in a dark room under safe light. The temperature of the chemical shall be 20°C ±
1°C or as specified. The film shall be unloaded in hangers/ spools care fully to avoid any marks.
Film Viewing:
The films shall be viewed under a high intensity Film Viewer capable of reading Radiographs of Density
39
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:
40 Contrast of the film shall be adequate to manifest on the Radiograph even the smallest 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 / rejection
42 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 this procedure
ACCEPTANCE OR REJECTION CRITERIA:
Acceptance or rejection criteria shall be in accordance with API 1104. Radiographic examination of all
43
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 &GGL 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.

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 Table A: Common Methods for Reducing Harmful Exposure
Sr Particulars Common Method
.
N
o.
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
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.
GGL WPI or Life Saver as per permit to work requirement to be followed. Cordoning as per site
3
requirement to be done
4 Tool Box talk to be performed prior to start job.
5 All Hazards to be identified through site specific risk assessment.
6 Rescue arrangements ensured in case of an emergency.
Put information of each valve that pipeline under hydrostatic tested for preventing unauthorized
7
personnel operates it.
Suitable precautions in the event of piping system rupture shall be taken to eliminate hazards to
8
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 person to enter
10
the area, a site engineer together with a safety man if required will be guard during testing.
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 be less than
16 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.

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 Equipment that is not to be subjected to pressure test shall be either disconnected from the piping
21
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 fittings spiral
22
wound gasket shall be used.
All equipment that is removed from lines during hydrostatic testing (particularly control valves) must
23
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
25 shall apply for piping systems with pressure rating class 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.
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
26 Pressure at which to be Tested:
ASME B31.8 specifies the test pressure factors for pipeline operation at hoop stress of ≥ 30% of SMYS.
This 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:
Pressurization shall be done in the presence of the TPIA/CONTRACTOR /GGL at a moderate and
constant rate not 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
27 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 observed through
28 the test duration, except for a change due to temperature effects as per the applicable specifications. It
should also be observed that there is no evidence of sweating before, during and after the ‘hold period’
on all the weld joints.
De-Pressuring Method:
29
The line and equipment shall be completely drained by suitable means after completion of hydrostatic

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 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
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.
GGL WPI or Life Saver as per permit to work requirement to be followed. Cordoning as per site
3
requirement to be done
4 Tool Box talk to be performed prior to start job.
All Hazards to be identified through site specific risk assessment. Proper exclusion zones to be
5
identified and cordoned off
6 Rescue arrangements ensured in case of an emergency.
Pneumatic pressure testing of piping and systems at moderate-to-high test pressures or at low test
7 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 overpressure
8
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 system failure
9 can be dramatically reduced by testing at night or on weekends when fewer personnel are on (and
possibly off) site.
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
10 pressures. As per availability exclusion zone to be decided if possible at least 5 meter 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 adhere to suitable,
11
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 effectively
13
ensures proper materials in the fabricated piping.
Pressure design calculations for both operating and test pressures must be documented and checked
14
for all piping.
For pneumatic testing, the test media shall be oil free, dry air or any inert gas (N2 - nitrogen). The use
15
of air for testing shall be limited to a maximum pressure of 7.0 barg. Above this pressure nitrogen shall
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 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 must be checked to ensure
16
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 pressure
18
instruments shall be included in the test.
Piping containing check valves shall have the source of test pressure on the upstream side. If this is not
19
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 in the fully
20
open position.
Where the test pressure to be applied to the piping is greater than the maximum allowable test
21 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.
A list shall be prepared for sensitive equipment that shall be removed, blocked off or isolated during
23 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 positioned at
25
the lowest point.
Accuracy of pressure gauge shall be at least 1-2% at full scale and 1-2% for the recorder. The test
26
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 shall be
27
stopped and the equipment recalibrated.
Pressure gauges and recorders used to indicate and record test pressure shall be dead weight tested
28
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 of all welded
29
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) to join sections
30
of pre-tested piping must be carefully reviewed to ensure guaranteed quality of the weld joint.
The following are excluded from pressure tests:
31  All small bore instrument control piping downstream of the first piping block valve.
 Open drains and vents to atmosphere (leak test only).
Piping joints and welds shall not be insulated or physically covered until satisfactory completion of
33
testing in accordance with this specification, except for painting of prefabricated welds.
7. Sequence of pressure testing of the installation
Sr.
Work Instructions
No

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 The project or concerned engineer(s) has cleared all NDT/Traceability records and the Test Pack has
1
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 pressure shall
6 gradually be increased to 50% of the specified test pressure and kept for minimum 10 minutes to
equalize strain.
The pressure shall then be increased in steps of 10% of the specified test pressure, until the specified
7 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 to the design
8
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 regulation requires
10 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
Sr.
Work Instructions
No
As per PTW Matrix, Permit to be obtained. Ensure GGL Venting, Purging and Commissioning Procedure
1
is followed.
2 Proper supervision as per PTW matrix for execution & safety to be ensured.
3 GGL WPI or Life Saver as per PTW requirement to be followed. Cordoning of the site is must.
4 Tool Box talk to be performed prior to start job.
5 All Hazards to be identified through site specific risk assessment.
6 Rescue arrangements ensured in case of an emergency.
7 Ensure adequate fire extinguisher & firefighting 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 advance before
14
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 team/HSE officer.
16
It shall be reviewed from point of required isolation valves before commissioning of any network.

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 Required isolation shall be identified and readiness for isolation in case of any incident shall be ensured
17
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.
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, commissioning of gas
24
in to steel pipelines without odorant.

9. Commissioning of Steel Pipeline/DRS with Un-Odorized Gas

Sr.
Work Instructions
No
All attempts needs to be done to ensure that Pipelines/ DRS/ Skids etc are not Commissioned with un-
odorized gas, but if at all it is to be done then for un-odorized gas entry following precautions must be taken;
 A 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
GGL 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 GGL.
The other compliances need to be as follows which should be followed step by step before starting the
commissioning job.
1 As per PTW Matrix, Permit to be obtained.
2 Proper supervision as per PTW matrix for execution & safety to be ensured.
3 GGL WPI or Life Saver as per PTW requirement to be followed. Cordoning to be done.
4 Tool Box talk to be performed prior to start job.
5 All Hazards to be identified through site specific risk assessment.
6 Rescue arrangements ensured in case of an emergency.
It is to be ensured that all pre-commissioning work is completed and test certificates available,
7
excavations are properly back filled.
All the material required for pre-commissioning and commissioning process are staked on site properly
8
with cordoning and warning signs displayed.
In case of line is pigable following to be ensured for pigging, swabbing, drying and flushing adequate
9
precautions are taken i.e. launcher, receiver ends are cordoned and un-authorized entry/exit restricted.

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 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 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 conveyed or with the materials in the pipeline
10
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
11 ascertain that the pipeline system has been mechanically completed in all 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 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
12
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 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/equipments, the field instruments like actuated valves, control
valves, shut down valves, transmitters, solenoid valves, shut down switches, alarms, etc, shall

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 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 equipments, 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 been
13
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 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
14 tie in. The operation shall be carried out using 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
15
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.

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  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 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:
 The pipeline system including the underground pipelines and the above ground piping at dispatch
and receipt stations, sectionalizing valve station, intermediate 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
16 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 status for underground pipeline and
17
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.

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 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.
 Inertisation 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 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
18
underground pipeline. The amount of nitrogen shall depend on the length of the pipeline portion 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 hook-up/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
the-pig-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 intervals during the course
19 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.
20 The system shall be considered to have been commissioned successfully when the pipeline system
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 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 minimum period of 72 h 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.
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).
21  Pre-commissioning checks; Residual dewatering and swabbing; Low pressure leak 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
1 As per PTW Matrix, Permit to be obtained.
2 Proper supervision as per PTW matrix for execution & safety to be ensured.
3 GGL WPI or Life Saver as per Permit to Work requirement to be followed, cordoning done.
4 Tool Box talk to be performed prior to start job.
5 All Hazards to be identified through site specific risk assessment.
6 Rescue arrangements ensured in case of an emergency.
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;
7  Hot tap fittings should be tested to 1.1 of the 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) depends on
8
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. During hot
10 tapping, consideration must be given to the possibility of operational upsets which may alter the
process temperature or pressure.
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
11 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.
The metallurgy of weld materials, the hot tap fitting, and the weld rod must be compatible with the
12
metallurgy of the equipment to be welded or hot tapped. For metal thickness less than 1/4th inch

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 (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 the weld
13 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 rates and
14
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?
 Has the location of hot tap been identified and marked on the line?
1
 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?
 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?

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  Has a fire watch been assigned and appropriate firefighting equipment provided?
 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?
1  Is the fitting properly positioned so that misalignment of the hot tapping machine will 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 obstructed?
1
 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?
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
1
before closing the hot tap valve?
 Has the hot tap valve closed?
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  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
The hot tap machine should be cleaned, removing the hydrocarbons/chemicals from the line
1
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 GGL WPI or Life Saver as per Permit to Work requirement to be followed, cordoning done.
4 Tool Box talk to be performed prior to start job.
5 All Hazards to be identified through site specific risk assessment.
6 Rescue arrangements ensured in case of an emergency.
Many accidents occurred due to unsecured loads or loads that slipped off during lifting, so ensure those
7
are secured properly.
Many accidents occurred due to either structural failure of the load bearing part of the crane or
8
toppling or collapsing of cranes when they became unstable.
The duties and responsibilities of a lifting supervisor include:
 Coordinating 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 signalmen
9 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):
10  Defective or damaged lifting gears such as slings, hooks, inserts, eyes, shackles;
 Improper rigging of loads;
 Lack of proper receptacles for loose loads such as bricks; or under capacity of lifting gears
11 The following are some common hazards associated with lifting operations involving mobile cranes.
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  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:
1) Poor ground conditions (e.g., unstable ground);
2) Failure to use or fully extend outriggers or stabilizers;
3) Failure to level the crane;
4) Rapid derricking, slewing or maneuvering;
5) Overloading of cranes;
6) Bypassing of safety devices; or
7) 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.
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 Lifting Plan that
13
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.
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 Lifting gears must also be inspected to ensure that they are free of any faults or defects before any
17
lifting operation can begin.
Lifting supervisor must not allow the lifting operation to be carried out if any defects are spotted during
18 the pre-use checks by the crane operator until all the faults of the cranes are 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)
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, water content,
21 decomposition, irregular shapes and residues in system, cylinders etc can affect the accuracy of load
weight to be estimated).
10. HSE Procedure, Guidelines, Forms and Formats
CONTRACTOR to follow GGL approved HSE procedures and guidelines as and when applicable for various
activities/stages during project execution. The list of same is given below and will be issued to
CONTRACTOR by EIC as and when applicable/required. Below list is indicative only and hence
CONTRACTOR to refer the latest list / version of same as and when applicable.
10.1 HSE Procedures
1 Procedure for Permit to Work
2 Procedure for Safety and technical competency Training
3 Procedure for waste management
4 Procedure for Contractor performance Assessment
10.2 HSE Guidelines
1 Guidelines for Medical Fitness
2 Guideline for GGL life savers
3 Guidelines for Trenching and Excavation
4 Guidelines for PPEs
5 Guidelines for Lifting operations
6 Guidelines for Site Specific Risk Assessment (SSRA)
7 Guidelines for Safe Natural Gas Venting
8 Guidelines for First Aid and Medical Treatment
9 Guidelines for Tool Box Talk (TBT)
10.3 Forms and Formats
1 Memo Format
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2 First Aid Box contents
3 First Aid box Content Usage Format
4 PPE Applicability Matrix
5 Training applicability Matrix
6 Training Frequency and Trainer Matrix
7 Waste Management Matrix
8 Contractor Performance Assessment Report (CPAR)
9 GGL Life Saver
10 SSRA Format

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 Aluminum 2,700
7 Earth 1,600
8 Paper 1,120
9 Copper 8,800
10 Lead 11,200
11 Wood 800

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