REALIGNMENT OF 10”NB

NATURAL GAS PIPELINE OF DFPCL

NEAR PANVEL RAILWAY YARD
DFPCL. Tender Doc. No.: 05/51/23NN/DFPCL/001 MECON LIMITED

DFPCL

BID DOCUMENT

FOR

REALIGNMENT OF 10”NB
NATURAL GAS PIPELINE OF DFPCL
NEAR PANVEL RAILWAY YARD
OPEN DOMESTIC COMPETITIVE BIDDING
Vol-II of II

Bid Document No.: 05/51/23NN/DFPCL/001

MECON LIMITED
(A Govt. of India Enterprise)
June, 2013

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 REALIGNMENT OF 10”NB
NATURAL GAS PIPELINE OF DFPCL
NEAR PANVEL RAILWAY YARD
DFPCL. Tender Doc. No.: 05/51/23NN/DFPCL/001 MECON LIMITED

CONTENTS
VOLUME-II OF II

A. LIST OF SPECIFICATION / STANDARDS

1. Specification for Mainline Construction (Onshore) MEC/S/05/21/01

2. Specification for Welding of Onshore Gas MEC/S/05/21/02

Pipelines + Welding Specification Charts

3. Specification for Hydrostatic Testing of Onshore MEC/S/05/21/03

Pipeline

4. Specification for Major Water Crossings MEC/S/05/21/04

(Conventional)

5. Specification for Pipeline Crossing Roads, MEC/S/05/21/05

Railroads, Minor Water and Other Crossings

6. Specification for Repair of Pipeline Corrosion MEC/S/05/21/08

Coating

7. Specification for Pipeline Markers MEC/S/05/21/10

8. Specification for Casing Insulators and End Seals MEC/S/05/62/12

9. Specification for Field Joint Coating (Onshore MEC/S/05/21/13

Pipelines)

10. Specification for Vents, Drains and Wells MEC/S/05/21/15

11. Specification for Blasting MEC/S/05/21/18

12. Specification for Gaskets, Bolts and Nuts MEC/S/05/21/19

13. Specification for Piping Material Specification MEC/23NN/05/28/M/000/1092

14. Technical Specification for Pre-Commissioning and MEC/TS/05/21/62/61 Rev-1

Commissioning

15. Specification for Health, Safety and Environment MEC/S/05/21/65

Management (HSE)

16. Specification for Quality Assurance System MEC/S/05/21/66

Requirements

17. Specification for Documentation for Pipeline MEC/S/05/21/69

Construction

18. Specification for Field Joint Coatings of Pipeline for MEC/S/05/21/74

HDD Crossing

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 REALIGNMENT OF 10”NB
NATURAL GAS PIPELINE OF DFPCL
NEAR PANVEL RAILWAY YARD
DFPCL. Tender Doc. No.: 05/51/23NN/DFPCL/001 MECON LIMITED

19. Specification for Pipeline Crossings Using HDD MEC/S/05/21/75

Method

20. Specification for Long Radius Bends MEC/TS/05/62/015, R-1

21. Specification for Seamless Fittings and Flanges MEC/S/05/21/025

[Size up to DN 400mm (16") NB]

22. Specification for Assorted Pipes MEC/TS/05/62/059A

23. Specification for Ball Valves MEC/TS/05/21/002

24. Technical Notes for Gate & Globe Valves

B. LIST OF DRAWINGS

I. Mechanical Drawings

1. P&I Diagram MEC/23NN/05/28/M/000/0001, R-1

2. Alignment Sheet PROJ/NG-PIPELINE/001, R-0
3. Pipeline Survey Report
i) Detail Survey Report
ii) ii) Water Pipeline Crossing DFPCL/PROJ/NG-PL/CRS/PL/001
iii) Geotechnical Investigation Report
DFPCL/PROJ/NG-
iv) iv) Hydrographical Survey Drg of Kalundre River
PL/TOPO/KALUNDRE RIVER
DFPCL/PROJ/NG-PL/LS/KALUNDRE
v) L Section Drg of Kalundre River
RIVER
DFPCL/PROJ/NG-PL/SOIL-
vi) Sub Soil Profile of Kalundre River
PROFILE/KALUNDRE RIVER
4. Typical Right of use for Pipelines (3 Sheets) MEC/TYP/05/21/01A/001
5. Typical Trench Dimensions for Pipeline MEC/TYP/05/21/01A/002
Typical trench dimensions for two or more
6. MEC/TYP/05/21/01A/003
pipelines in common trench
Trench dimensions and cohesion-less select
7. MEC/TYP/05/21/01A/004
backfill for pipeline in seismic zone
Select Backfill for station approach and Buoyancy
8. MEC/TYP/05/21/01A/005
control measures for pipeline
9. Slope Stabilization in Ghat / Hill Areas MEC/TYP/05/21/01A/006
10. Typical slope breaker details MEC/TYP/05/21/01A/007
11. Min. elastic bend radius for Pipe MEC/TYP/05/21/01A/009
12. Details of Casing Vent and Drain off MEC/TYP/05/21/01A/010
13. Pipeline Symbols MEC/TYP/05/21/01A/011

14. Topographical Symbols MEC/TYP/05/21/01A/012

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 REALIGNMENT OF 10”NB
NATURAL GAS PIPELINE OF DFPCL
NEAR PANVEL RAILWAY YARD
DFPCL. Tender Doc. No.: 05/51/23NN/DFPCL/001 MECON LIMITED

Location of Specimens for WPS for Pipe

15. MEC/TYP/05/21/02/001
Diameter ≤ 12 ¾ “
Location of Specimens for WPS for Pipe
16. MEC/TYP/05/21/02/002
Diameter ≥ 12 ¾ “
17. ISO Tensile Test Specimen MEC/TYP/05/21/02/003

18. Hardness Testing of Welding Joints- Schematic MEC/TYP/05/21/02/004

19. Charpy V-Notch Test Specimen MEC/TYP/05/21/02/005

20. Caliberation Piece of Ultrasonic equipment MEC/TYP/05/21/02/006

Required IQI Sensitivity Source Side

21. MEC/TYP/05/21/02/007
PenetrameteR

22. Typical Stream Crossings MEC/TYP/05/21/04/001

23. Pipeline Road/Highway cased Crossing MEC/TYP/05/21/05/001
24. Typical details of Railway crossings MEC/TYP/05/21/05/002
25. Typical Lined canal crossing (Uncased) MEC/TYP/05/21/05/003
26. Existing pipeline on sleeper crossing MEC/TYP/05/21/05/005
27. Existing Under Ground Pipe Crossing (Type – I) MEC/TYP/05/21/05/006
28. Existing Under Ground Pipe Crossing (Type - II) MEC/TYP/05/21/05/007
29. Under Ground Cable Crossing MEC/TYP/05/21/05/008
30. Over Head Power Line Crossing MEC/TYP/05/21/05/009
31. Typical ROU boundary marker MEC/TYP/05/21/10/001
32. K.M. Post MEC/TYP/05/21/10/002
33. Pipeline Warning Sign MEC/TYP/05/21/10/003
34. Direction marker MEC/TYP/05/21/10/006
35. Tolerances for Fabrication MEC/TYP/05/21/06/001
36. Spectacle Blind MEC/TYP/05/21/06/032
Jack Screw For Spectacle Blind (150#, 300#,
37. MEC/TYP/05/21/06/033
600#)
38. Butt Weld Details MEC/TYP/05/21/06/034
39. Welding of Pipe with Different Thickness MEC/TYP/05/21/06/035
40. Fillet Weld Details MEC/TYP/05/21/06/036
41. Gasket Thickness MEC/TYP/05/21/06/037
42. Stud Bolts RF 300# Dimensions (ASME B16.5) MEC/TYP/05/21/06/039

II. Civil Drawings

Typical Detail of Valve Pit MEC/05/11/STD/TERMINAL/VP-3

III. Cathodic Protection Works - Standard Drawings

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 REALIGNMENT OF 10”NB
NATURAL GAS PIPELINE OF DFPCL
NEAR PANVEL RAILWAY YARD
DFPCL. Tender Doc. No.: 05/51/23NN/DFPCL/001 MECON LIMITED

1. PREPACKAGED ZINC ANODE MEC/SD/05/E9/E/CP/1601

2. PREPACKED MAGNESIUM ANODE MEC/SD/05/E9/E/CP/1602
3. MAGNESIUM RIBBON ANODE FOR MEC/SD/05/E9/E/CP/1603
GROUNDING
4. DETAILS OF TEST STATION FOR TCP MEC/SD/05/E9/E/CP/1604
5. TEST STATION CONNECTION SCHEMES MEC/SD/05/E9/E/CP/1605
6. GALVANIC ANODE INSTALLATION MEC/SD/05/E9/E/CP/1606
7. ZINC RIBBON ANODE FOR CASED MEC/SD/05/E9/E/CP/1607
CROSSINGS WITH COATED CASINGS
8. PIPELINE GROUNDING THROUGH MEC/SD/05/E9/E/CP/1608
POLARISATION CELL AND GALVANIC
ANODES
9. DETAILS OF TEST STATION FOR MEC/SD/05/E9/E/CP/1614
POLARIZATION CELL
10. CONNECTION SCHEME FOR HOOKING MEC/SD/05/E9/E/CP/1616
THROUGH CJB/TEST STATION
11. DETAILS OF THERMIT WELD FOR CABLE TO MEC/SD/05/E9/E/CP/1618
PIPE JOINT

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 Rev. : 0
Edition : 1

SPECIFICATION
FOR
MAINLINE CONSTRUCTION (ONSHORE)

SPECIFICATION NO.: MEC/S/05/21/01

(OIL & GAS SBU)

MECON LIMITED
DELHI 110 092
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 1

TITLE MAINLINE CONSTRUCTION MEC/S/05/21/01 REVISION : 0

(ONSHORE)
EDITION : 1

CONTENTS
SL.NO. DESCRIPTION

1.0 SCOPE

2.0 REFERENCE CODES, STANDARDS AND SPECIFICATIONS

3.0 REQUIREMENTS OF R.O.U. AND ACCESS THERETO

4.0 RIGHT-OF-WAY

5.0 HANDLING, HAULING, STRINGING AND STORING OF MATERIALS

6.0 TRENCHING

7.0 BENDING

8.0 LINING UP

9.0 LAYING OF PIPE

10.0 BACK-FILLING

11.0 TIEING-IN

12.0 SPECIAL INSTALLATIONS ON THE PIPELINE

13.0 WORKING SPREAD LIMITATIONS

14.0 CLEAN-UP AND RESTORATION OF RIGHT-OF-WAY

15.0 MAINTENANCE DURING DEFECTS LIABILITY PERIOD

PREPARED BY: CHECKED BY: APPROVED BY: ISSUE DATE :

(Shalini Singh) (Sunil Kumar) (A.K. Johri) Jan. 2009

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 41

TITLE MAINLINE CONSTRUCTION MEC/S/05/21/01 REVISION : 0

(ONSHORE)
EDITION : 1

1.0 SCOPE

1.1 This specification covers the minimum requirements fo r t he v arious act ivities t o b e
carried out by CONTRACTOR for or about the construction of cross-country pipelines.

1.2 The various a ctivities c overed in th is specification include th e following works of

pipeline construction :

„ Clearing, grubbing and grading of Right-of-way

„ Construction of all temporary facilities required in connection with the WORKS

„ Staking of the pipeline route

„ Handling, hauling, stringing and storing of all materials

„ Tre nching

„ Field-bending of line pipe

„L ining-up

„ Pipeline laying

„ Backfilling

„T ieing-in

„ Installation of aux iliary facilities and appurtenances forming a part of pipeline

installation

„ Clean-up and restoration of Right-of-way;

„ Maintenance during defects liability period.

1.3 This specification shall be read in conjunction with the conditions of all specifications
and documents included in the CONTRACT between COMPANY and CONTRACTOR.

1.4 CONTRACTOR shall, with due care and vigilance, execute the work in compliance with
all laws, by- laws, ordinances, regulations etc. and provide all se rvices and labour,
inclusive of supervision thereof, all materi als, e xcluding th e m aterials in dicated a s
"COMPANY Supplied materials" in the CONT RACT, e quipment, applianc es or othe r
things of whatsoever nature required in or about the execution of the work, whether of
a temporary or permanent nature.

1.5 CONTRACTOR shall take full responsibility fo r the stability and safety of all operations
and methods involved in the WORK.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 2 of 41

TITLE MAINLINE CONSTRUCTION MEC/S/05/21/01 REVISION : 0

(ONSHORE)
EDITION : 1

1.6 CONTRACTOR shall be deened to have inspected and examined the work area(s) and
its surroundings and t o have satisfied himself so far as pract icable as t o the form and
nature thereof, includ ing sub -surface co nditions, 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).

1.7 CONTRACTOR shall be deemed to have ob tained all necessary in formation subject as
above ment ioned as t o risk s, cont ingencies and all other circumstances, which may
influence the WORK.

1.8 CONTRACTOR shall, in connection with the WORK, provide and maintain at his own
costs, all lights, guards, fencing, watching etc., when and where necessary or required
by COMPAN Y or by any duly c onstituted auth ority and/ or by the authoritie s having
jurisdiction thereof for the protection of the WORK and properties or for the safety and
the convenience of public and/ or others.

2.0 REFERENCE CODES, STANDARDS AND SPECIFICATIONS

2.1 Reference has b een mad e in this specification to the latest edition of the following
codes, standards and specifications :

a) ANSI B 31.8 - Gas Transmission and Distribution Piping

Systems

b) ANSI B 31.4 - Liquid Petroleum Transportation Piping Systems

c) API 1104 - Standard for Welding P ipelines and Related

Facilities

d) API 1105 - Bulletin on Construction P ractices for Oil and

Products Pipelines

e) Part 1992 - Transportation of Natural and Other Gas

Title 49 by Pipe line (U S D epartment of Transportation -
Pipeline Safety Standards)

f) Part 195 - Transportation of Liquids by P ipeline (US

Department of Transportation - Pipeline Safety
Standards).

In case o f d ifferences b etween t he req uirements o f t his sp ecification and that of the
above referred codes, st andards and spec ifications, the requirements of this
specification shall govern.

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

„ the words "Shall" and "Must" are mandatory.

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 3 of 41

TITLE MAINLINE CONSTRUCTION MEC/S/05/21/01 REVISION : 0

(ONSHORE)
EDITION : 1

„ the works "Should, "May" and "Will" are non-mandatory, advisory or

recommended.

3.0 REQUIREMENTS OF R.O.U. AND ACCESS THERETO

CONTRACTOR shall, before st arting any clearing operations , familiarise himself with all
the requirements of the Authorities having jurisdiction over the Right of Way for work
along the pipeline route or in connection wi th the use of ot her lands or roads for
construction purpose.

CONTRACTOR shall not ify COMP ANY well in advance during work progress, the
method of c onstruction for c rossing roa d, pipe line, c able, railway, rive r and othe r
existing obstacles.

CONTRACTOR shall not commence work on such crossings before having obtained
approval from t he aut horities and land owners c oncerned to th e sa tisfaction of
COMPANY. The crossings shall be installed to meet at a ll times the requirements and
conditions of the p ermit issued b y t he aut horities co ncerned. In t he ab sence o f any
specific requirements by authorities, CONTRACTOR shall comply with COMPANY'S
instructions.

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 specifications shall also apply.

Where the ROW comes within 30 metres of an ex isting line or facility, CONTRACTOR
shall propose and provide me thods to saf e-guard the existing line or fac ility (e .g. a
demarcation fence). No work is allowed in su ch a rea w ithout C OMPANY's prior
approval.

3.1 Safety measures during construction of pipelines inside the area influenced
by high voltage lines

3.1.1 General

Pipelines which are constructed inside the area of high voltage lines may be electrically
influenced by the high voltage lines. The voltage caused by the influence may at times
be high e nough to pose danger to personnel working on the pipeline. It is imperative
therefore, that the instructions given below should be strictly observed.

3.1.1.1 It is a necessity that all personnel working on the pipeline which is being laid in the
area influenced by the high voltage systems, be given clear inst ructions on measures
to be taken.

3.1.1.2 Vehicles and equipment must be earth-connected. This may be effected by attac hing
an uninsulated cable or chain (which t ouches th e grou nd) of a dequate le ngth to th e
underside of the vehicle.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 4 of 41

TITLE MAINLINE CONSTRUCTION MEC/S/05/21/01 REVISION : 0

(ONSHORE)
EDITION : 1

3.1.1.3 If its not impossible for plant and/ or materials to come within 50m of the centre of the
high v oltage sy stems, sp ecial measures must b e t aken t o p revent any approach
beyond that distance, unless article 3.1.2 is complied with.

3.1.1.4 DURING THUNDERSTORMS OR WHEN DISCHARGES ARE OBSERVED ON INSULATORS

ALL PERSONNEL MUST LEAVE THE AREA OF THE HI GH VOLTAG E LI NE AN D
PIPELINE.

3.1.1.5 To p revent elect rical v oltage in a no n-buried sect ion of the pipeline from rising to
dangerous levels, the length of t he p ipeline sect ion which has b een weld ed together
before burial must not exceed the length at which the max. admissible voltage may be
induced. This length may be calculated using an approved calculation method.

3.1.1.6 Before a p ipeline sect ion is lo wered int o the trench the structure's earth electrodes
indicated in the drawings or determined with calculatio n met hod must have been
installed and c onnected both to the pipeline section already buried and t o the section
which is ab out t o b e b uried. T he elect rical co nnections which serv e t he p urpose o f
preventing dangerous voltages must have a min. area of 35mm2.

Said connect ions must not be int errupted unt il aft er t he permanent safet y earth
connections have been installed and connected to the entire uninterrupted pipeline.

3.1.1.7 The weld ed co nnection b etween t he p ipeline sect ion and t he section already buried
must be installed at a distance of at least 50m from the nearest point of a pylon base.

3.1.1.8 Personnel d oing wo rk insid e t he area o f influence o f t he hig h v oltage sy stem must
wear e lectrically insulating foot-wear (e.g. rubbe r kne eboots) and we ar insulating
rubber or plastic gloves.

3.1.2 Additional measures for work at less than 50m from the centre of the high
voltage system.

If work is done at less t han 50m fro m t he cent re o f t he hig h v oltage sy stem, t he
regulations be low must be c omplied w ith in a ddition to th e rules specified in clause
3.1.1.

3.1.2.1 The work must not be started until agreement has b een reached with the authorities
which co ntrols t he hig h v oltage sy stem, ab out t he imp lementation o f t he safet y
measures specified in this section.

3.1.2.2 Measures must be taken to prevent ex cavating and hoist ing equipment s from
approaching high voltage lines to within any of the following distances.

This distance depends on the voltage carried. For individual c onnections the distance
must be :
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 5 of 41

TITLE MAINLINE CONSTRUCTION MEC/S/05/21/01 REVISION : 0

(ONSHORE)
EDITION : 1

0 - 50 KV 3m
40 - 200 KV 5m
200 - 380 KV 8m

The measures taken may be as follows :

1. Special selection of equipment, or limiting or blocking certain directions of

movement, or limiting the operational ar ea, t hereby mak ing it imp ossible fo r
any work to tbe done at a dist ance from t he high v oltage line of less than the
accepted minimum.

2. In case the measures recommended in 1. 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 re d and whit e must prevent any work
being done inside the dange r are a. Furt her, an insp ector must b e p revent all
the time.

3.1.2.3 In the event that a v ehicle, crane et c. should accidently come into contact with a live
cable of a high voltage system or flash-over of electrical charge occurs, the driver must
not leave his vehicle because this will pose a serious threat to his life.

The vehicle or crane must break the contact WITHOUT ANY HELP FROM OUTSIDE.

The driv er must not leav e his v ehicle unit l be has managed to leave "the dangerous
area, or a lternatively, w hen th e Ele ctricity Au thorities h ave given notice that the
cable(s) have been put out of circuit. In case a serious fire starts in the vehicle, he is
permitted to jump from the vehicle, clearing it as far as p ossible, while t he j ump
should possible be to a dry spot.

4.0 RIGHT-OF-WAY

The CONTRACTOR is required to perform his construction activities within the width of
Right-of-way set a side f or c onstruction of pipe line, unle ss he has made ot her
arrangements with the land owner and/ or t enant for using extra land. Variation in this
width caused by local condit ions or installation of a ssociated pipeline facilities or
existing pipelines will be identified in th e field or instructed to the CONTRACTOR by
COMPANY.

The ROW boundary lines shall be staked by the CONTRACTOR, so as t o prepare the
strip for laying the pipeline. CONTRACTOR shall also establish all required lines and
grades n ecessary to c omplete th e w ork and shall be responsible for the accuracy of
such lines and grades.

4.1 Staking

Prior to cleaning operations CONTRACTOR shall :

1) Install Bench Marks, Intersection Points and other required survey movements.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 6 of 41

TITLE MAINLINE CONSTRUCTION MEC/S/05/21/01 REVISION : 0

(ONSHORE)
EDITION : 1

2) Stake markers in the centreline of the pipeline at distance of max imum 100
metres for straight line se ctions and max imum 10 met res for horizontal bends.
Wherever ROW centreline has b een st aked o n g round, CONT RACTOR shall
exercise care in accurat ely staking the pipeline centreline, in consultation with
COMPANY.

3) Stake two ROW markers at least at every 100 metres.

4) Set ou t a re ference lin e w ith re spect in pipeline centrelin e at a conv enient

location. Markers on reference line shall be at a distance of maximum 100m for
straight line sections and maximum 10m for horizontal bends.

5) Install distance markers locating and indicating special poin ts, such as but not
limited to :

„ Contract limits, obstacle crossings, change of wall thickness, including

corresponding chainage, etc.

ROW mark ers shall b e st aked o ut at the boundary limits of Right-of-way wherever
possible. ROW marke rs shall be painte d re d with numbe rs painte d in white . N umber
shall be identical to centreline marker numbe r with letters A (le ft side ) a nd B (righ t
side) added, (looking, in flow dire ction). Reference markers shall also carry the same
information as its corresponding centreline markers.

Markers shall be of suitable material so as to serve their purpose and shall be coloured
distinctly for easy identification. CONTRACTOR shall be responsible for the
maintenance and rep lacement o f t he reference line markers until the permanent
pipeline markers are placed and the as-built drawings are submitted and approved.

Any deviation from the approved alignment shall b e executed by CONTRACTOR after
seeking COMPANY approval in writing prior to clearing operations.

4.2 Monuments

All shrines, monument, border stones, stone walls and the like shall be protected and
shall be subjected to no harm during c onstruction. Any violation of the above by the
CONTRACTOR shall be brought to th e n otice of th e C OMPANY a nd oth er c oncerned
authorities. Restoration of the above shall wholly be the responsibility of the
CONTRACTOR.

4.3 Fencing

Prior to clearing or grading of the Right-of-way or stringing of pipe, CONTRACTOR shall

open fences on or crossing the construction Right-of-way and install temporary gate of
sound construction made of similar mat erials and suitable quality to serve purpose of
original fence. Ad jacent p ost shall b e ad equately b raced t o p revent slackening of the
remainder o f t he fence. Befo re such fences are cut and o pened, CONT RACTOR shall
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 7 of 41

TITLE MAINLINE CONSTRUCTION MEC/S/05/21/01 REVISION : 0

(ONSHORE)
EDITION : 1

notify the land owner or tenant, and where practicable, the opening of the fences shall
be in acco rdance wit h t he wishes o f sa id owner and t enant. In all cases where
CONTRACTOR removes fences to obtain wo rk route, CONTRACT OR shall provide and
install temporary fencing, and on completion of construction shall restore such fencing
to its original condition.

CONTRACTOR shall install temporary fenc ing on either side o f ROW where in
COMPANY's opinion, it is cons idered essent ial t o ensure safet y and no n-interference,
especially in areas like grasing lands, villages etc.

Fencing shall be remov able type wherever necessary, to permit crossing of t raffic. The
type of fe ncing must be suitable for the situation in accordance with user. The pole
distance shall not be gre ater than 6m. Th e minimum height of t he fencing shall be
1.2m above grade. Fencing can consist of one or more rows of smooth wire and/ or of
barbed wire.

Fencing shall be cont inuously maintained and the thorough-ways inspected to be shut
during the execution of the work.

4.4 Row Clearing and Grading

4.4.1 All stumps shall be grubbed for a c ontinuous strip, wit h a widt h equal t o trench top
width plu s tw o m etres on e ither side c entred on the pipe line c entreline. Further, all
stumps will be grubbed from areas of the construction Ri ght-of-way, where Right-of-
way grading will be re quired. 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 lev el. Any stump cut off must be left in a conditio n suitable for rubber-
tyred pipeline equipment traffic.

4.4.2 All grubbe d stumps, timbe r, bush undergrowth and root c ut or re moved from the
Right-of-way shall be disposed of in a ma nner and method satisfactory to C OMPANY,
land-owner and/ or t enant, and Gov ernment Authorities having jurisdication and as
soon as practical after the initial removal. In no case, it shall be left to in terfere with
the grading and laying operations. Whenever stumps are grubbed and a hole is left in
the ground, CONTRACTOR shall back-fill the ho le and compact it to prevent water
from gathering in it and creating a big hole.

4.4.3 CONTRACTOR shall grade the pipeline Right-of-way as required for proper inst allation
of the pipe line, for providing ac cess to the pipeline during c onstruction, and for
ensuring that the pipeline is co nstructed in acco rdance with the good engineering and
construction practices.

4.4.4 CONTRACTOR shall grade sharp points or low points, without prejudice to se ction 6.0
of this specification, to allo w the pipe to be bent and laid within the limits set forth in
these specifications and drawings as regards the minimum elastic curvature permitted,
and shall drill, blast or ex cavate any rock or other material which cannot be graded off
with ordinary grading equipment in orde r to mak e an adequat e work ing space along
the pipeline.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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(ONSHORE)
EDITION : 1

4.4.5 No temporary or permanent deposit of any kind of material resulting from clearing and
grading shall be pe rmitted in th e a pproach to roa ds, ra ilways, streams, ditches,
drainage ditches and any othe r position which may hinder t he passage and/or t he
natural water drainage.

4.4.6 The Right-of-Way clearing and grading operations shall in no case involve embankment
structures of a ny type a nd c lass w ithout prior approval of the authoritie s having
jurisdiction over the same.

4.4.7 In the case of natural or artificial deposi ts of loose soil, sand, he aps of earth, or other
fill materials, these shall be re moved till stable natural ground level is reached so as to
ensure the construction of the pipeline ditch is in stable ground.

4.4.8 In the case of Right-of-Way clearing and grading on h illside or in steep slope areas,
proper barriers or other structures shall b e provided to prevent the removed materials
from rolling downhill. The Right-of-Way crossfall shall not exceed 10%.

4.4.9 Wherever the pipeline Right-of-Way runs across plantations, alongside farmyards, built
up areas, groups of tre es, horticultural spreads, gardens, grass-fi elds, ditches, roads,
paths, railways or any other area with restrictions of some kind, CONTRACTOR shall
grade only the minimum area required for digging and constructing the pipeline. In the
said places, CONTRACTOR shall carry out th e works in such a way that damage done
from the pipeline construction is kept to a minimum.

4.5 Provision of Detours

CONTRACTOR shall do all necessary gradin g and bridging at road, wate r and other
crossings and at other locations where need ed, to pe rmit the passage of its me n and
equipment. It is und erstood t hat t he CONT RACTOR has recognised such restricctive
features of the Right-of-Way and shall p rovide the necessary detoors and execute the
works without any e xtra c ost to C OMPANY. Pu blic tra vel sh all n ot be in convenienced
nor shall be wholly obstructed at any point.

CONTRACTOR at his own cost shall furnish and maint ain watchman detours, lanterns,
traffic lights, barricades, signs, wherever necessary to fully protect the public.

CONTRACTOR shall be responsible for moving its equipment and men across or around
watercourses. Th is m ay re quire th e c onstruction of te mporary bridge s or culverts.
Temporary bridging or ac cess to fording re quired for Right- of-Way c rossing wate r
courses shall be constructed. CONTRACTOR sh all ensure that such temporary works
shall no t int erfere wit h no rmal wat er flo w, av oid o verflows, k eep the existing
morphology unchanged and shall not unduly damage the banks or wate r courses. No
public ditches or drains sh all 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 COMPANY a copy of such approval.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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(ONSHORE)
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4.6 Steep and Rocky Terrain

Grading operations could normally be carried ou t a long th e Righ t-of-way with

mechanical excavators or manually. In certain areas, grading may have to be resorted
to exclusively by blasting.

In rough or steep terrain, CONTRACT OR may hav e t o grade access roads and
temporary bypass roads for its own use. Wh ere such access roads do not fall on the
Right-of-Way, CONTRACTOR shall obtain necessary written permission from land
owners and tenants and be responsible for all damages caused by the construction and
use of such ro ads, and at no ex tra co st t o COM PANY, Wherev er ro cky t errain is
encountered, grading shall be c arried out in all types of solid rocks which cannot be
removed until loosened by blasting, drilling, we dging or by other recognised means of
quarrying solid rocks.

Where use o f ex plosives is req uired in co nnection with Right-of-Way grading and
trenching, CONTRACTOR shall comply fully with requirements of the use o f explosives
as provided under clause 6.3 of this Specification.

4.7 Off Right-of-Way Damages

CONTRACTOR shall confine all its operations within limit s of th e Righ t-of-Way. An y
damage to prope rty ou tside ROW sh all be re stored or se ttled to the CONTRACTOR's
account.

CONTRACTOR shall promptly settle all o ff Right- of-Way damage c laims. Should
CONTRACTOR fail to do so, COMPANY shall give written notice to CONTRACTOR that if
CONTRACTOR does not settle su ch c laims w ithin se ven da ys a fter su ch n otice,
COMPANY sh all h ave th e a uthority to se ttle c laims f rom th e a ccount of the
CONTRACTOR.

5.0 HANDLING, HAULING, STRINGING AND STORING OF MATERIALS.

5.1 General

The CONTRACTOR shall ex ercise utmost care in handling in pipe and othe r materials.
CONTRACTOR shall be fully responsible for a ll m aterials a nd their identification until
such tim e th at th e pipe s a nd oth er m aterials are installed in pe rmanent installation.
CONTRACTOR shall be fully responsible for materials, howe ver, me thod of storage
shall be approved by COMPANY.

CONTRACTOR shall reimb urse t he COM PANY fo r t he co st o f replacement of all

COMPANY supplied materials damaged during the period in which such materials are in
the custody of the CONTRACT OR. It shall be CONTRACTOR' s responsibility to unpack
any packing for the materials supplied by COMPANY.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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(ONSHORE)
EDITION : 1

5.1.2 "Taking Over" of Line Pipe

The following stipulations shall apply in c ase CON TRACT provide s for supply of line
pipe, bare and/or corrosion coated, by COMPANY.

CONTRACTOR shall receiv e and 't ake o ver' against requisition, line pipe from the
COMPANY's designated place(s) of de livery as de fined in the CON TRACT.
CONTRACTOR shall perform visual inspection of the bare pipe s and c oating of the
corrosion co ated p ipes, as t he case may be, in the presence of COMPAN Y and all
damages shall be recorded. In the case of corrosion coated pipes CONTRACTOR at his
option may c arry out holiday de tection at a p rescribed set v oltage and reco rd such
holidays, in t he p resence o f COM PANY, at t he t ime o f 't aking o ver'. However, if
CONTRACTOR proposes to pe rform only visual inspection of coating, then repair of all
holidays found at t he t ime of lay ing t he pipe line shall be c arried out by the
CONTRACTOR at no ex tra cost t o COMP ANY. T he CONT RACTOR shall be ent itled t o
extra compensation for repair and rectification of defects recorded at the time of taking
over as per the rate set forth in the "CONTRACT". Repair of all damage s after taking
over the delivery of the materials shall be to the CONTRACTOR'S cost. In case of delay
in handing ov er of COMPANY supplie d mate rial, CO NTRACTOR shall be fully
responsible for stopping and rearranging mean s of transportation at no extra cost to
the COMPANY.

5.2 Handling and Hauling of Line Pipe

5.2.1 Bare Pipe

CONTRACTOR shall unload, load, stockpile an d transport the bare pipes using suitable
means and in a manner t o avoid denting, flattening, or othe r damage to pipe s. Pipe
shall not be allowed to drop or strike objects which will da mage the pipe but shall be
lifted or lowered from one leve l to another by suitable eq uipment. Lifting hooks when
used, shall be equipped with a plate curved to fit the curvature of the pipe. In loading
pipe on truc ks each length shall be lowe red to position without dropping and e ach
succeeding length shall rest on special supports on the tr uck and shall be se parated
from the adjacent pipes. After loading, suitable chains and padding shall be used to tie
the load securely to each bols ter. Pipes, when stock piled, shall be placed on suitable
skids t o k eep t hem clear o f t he g round and flo od wat er. T he CONT RACTOR shall
provide all necessary timber or other materials required for th e stock-piling. While
stacking, the number of allowable layers of bare pipes shall be calculated as pe r API
RP5L1 and shall be agreed with COMPANY. The stacks must be prope rly se cured
against sliding and shall consist of pipes of t he same d iameter and wall thickness.
Adjacent st acks of pipes hav ing different dimensional charact eristics shall be clearly
separated.

Pipes which are damage d at the time of delivery or "taking-over " (when line pipe is
supplied by COMPAN Y), partic ularly those which are dented, buc kled, or othe rwise
permanently de formed, must be stac ked se parately a nd m ay be tra nsported to th e
sites only when these defects have been repaired or eliminated.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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(ONSHORE)
EDITION : 1

5.2.2 Corrosion Coated Pipes

The CON TRACTOR shall load, unload, transp ort and stockpile the coated pipes using
approved suitable means and in a manner t o avoid damage to the pipe and c oating.
CONTRACTOR sh all su bmit to th e C OMPANY, a c omplete proc edure indicating the
manner and arrangement used for handling and stacking of coated pipes for COMPANY
approval prior to commencement of handling operations.

Use of vaccum lifting equipments are p referred. Hooks may also be used for handling
the pipes provided they have sufficient width and depth to fit the inside of the pipe and
covered with soft material like rubber, teflon or equivalent, so as not to cause damages
to be vel or pipe e nds. During hoisting, c ables/wire rope s shall have suffic ient
inclination compared to pipe axis so th at they do n ot come into contact with external
coating.

Coated pipes may be handled by means of slings and belts of proper width (minimum
60mm) made of non-metallic/non - abrasive materials. In this case, pipes to be
stacked shall be separated row by row to avoid damage by rubbing the coated surface
in the process of taking off the slings. Use of round sectional slings are prohibited.

During handling, suit able handling equipmen t with prope r le ngth of booms shall be
used. Fork lifts may b e used p rovided t hat t he arms o f t he fo rk lift are co vered b y
suitable pads pre ferably rubber. Before lifting operations it is esse ntial to ensure that
the pipe surface is free from foreign mat erial with sharp edges. Belts/slings when used
shall b e cleaned t o remo ve hard mat erials such as stone, gravel etc. Coated pipes
shall not be bumped against any other pipe or any other objects. Rolling, skiding or
dragging shall be strictly forbidden.

Coated pipes at all times sh all be stacked completely clear from the ground so that the
bottom row of pipe s remain free from any surface water. The pipes shall st acked at a
slope so that driving rain does not collect inside the pipe.

The coated pipes at all times shall be st acked by plac ing them on ridge s of sand free
from stones and covered wit h a plast ic f ilm or on woode n supports provide d with
suitable cover. This cover can, for ex ample, co nsist o f d ry, g erm free st raw wit h a
plastic film, otherwise foam rubber may be used. The supports shall be spaced in such
a manner so as t o avoid permanent bending of the pipes, particularly in case of small
diameter pipes with low wa ll thickness. The pipes sha ll be stac ked so that the
uncoated bevelled ends are in line at one end thus making differences in length clearly
noticeable.

Stacks shall consist of limited number of la yers so that the pressure exercised by the
pipe's own we ight does not c ause damages to the coating. Each pipe section shall be
separated by me ans of spac ers suit ably spaced for t his purpose. Stacks shall be
suitably secured against falling down and shall consist of pipe sections having the same
diameter and wall t hickness. T he weld b ead of pipe s shall be positione d in suc h a
manner so as not to touch the adjacent pipes.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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(ONSHORE)
EDITION : 1

Coated Pipes stacked in open storage yard s/dump yards shall be suitably covered on
top to decrease direct exposure to sunlight.

The e nds of the pipe s during handling an d stac king shall always be prote cted with
bevel protecters.

The lorries/rail wagons shall be equipped with adequate pipe supports having as many
round hollow beds as the number of pipes to be placed on the bottom of the lorry bed.
Supports shall be provided for at least 10% of the pipe length. These supports shall be
lined with a rubbe r prote ction and shall be spaced in a manner as t o support equal
load from the pipe s. The rubbe r prote ction shall be free from all nails and staples
where pipes are in co ntact. T he seco nd la yer and all subse quent layers shall be
separated from other layers wi th adequate number of separating layers of protective
material such as straw in plastic covers or otherwise to avoid direct touch between the
coated pipes.

All stachions of lorries/rail wagons used for tra nsportation sh all be c overed by non-
abrasive material like rubber belts or equivalent. Care sha ll be e xerclsed to prope rly
cover the top of the st anchions and co nvex p ortions such as reinfo rcement o f t he
truck/rail wagon only, rivets etc. to prevent damage to the coated surface.

5.3 Stringing of Pipe

Pipes shall be unloaded from the stringing trucks and lowered to the ground by means
of by means of boom trac tor or swinging crane o r o ther suit able eq uipment using
lifting devices as ment ioned earlier. Dragging or sliding of pipe shall not be permitted.
Special precaution shall be taken during stringing of corrosion corrosion coated pipe as
per t he sp ecial req uirements o f p revious p ara. Stringing of pipe shall only be carried
out in day light and aft er clearing and grading operations have been completed. Pipes
shall not be strung along the ROW in rocky areas where blasting may be required, until
all blasting is completed and the area cleared of all debris.

The stringing of the pipe on the ROW sha ll be done in such a manner so as to cause
the least interference with the normal use of the land crossed and to avoid damage to
and interference with the pipes. The sequence of pipes must be interrupted at suitable
intervals, spaced to coincide with passages, roads, railwys , water crossings as well as
at other places if requested by landowner / tenants to permit use of land.

In case line pipe supply is by diffe rent manufacturers s, CONTRA CTOR shall string all
line pipe s of one manufac turer be fore c ommencing the stringing of line pipes of
another manufacturer.

When parallel pipelines ar e being constructed, bumping against and c ontact with the
strung se ctions of pipe shall be avoide d, whether t he st ringing o f t he p ipes fo r the
individual lines is carried separately or simultaneously.

The pipe lengths shall be properly spaced in order to make easier t he handling during
the welding phase.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 13 of 41

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(ONSHORE)
EDITION : 1

It shall be the responsibilit y of the CONTRACTOR to see that pipe is strung as per the
approved drawings for the prope r placement of pipe by size , thic kness, grade and
other specifications. Any additi onal handling of pipe s due to failure to comply with the
requirements shall be at the CONTRACTOR's expense.

5.4 Repair of Damaged pipes

After the pipe s have be en strung along the ROW, th ey sh all be inspe cted by the
CONTRACTOR and by t he COMPANY. All defect ive pipe ends shall have to be repaired
as per the directions of the COMPANY or as per the requirements of this specification.

5.5 Materials other than linepipe

CONTRACTOR shall receive and take over against requisition all COMPANY supplied
materials from COMPANY's designated place(s) of deliv ery as defined in t he
CONTRACT. CONT RACTOR shall perform visual inspection and de fects, if any noted,
shall be recorded sep arately. T he CONT RACTOR shall b e ent itled t o ex tra
compensation for repair and re ctification of such defects at the rates set forth in the
"CONTRACT".

The CONTRACTOR shall perform the necessary loading, unloading, hauling from points
designated by the COMPAN Y and storing, if ne cessary, of all mate rials. The
CONTRACTOR shall ex ercise care in handling, storing and distributi on of mate rials in
order to avoid damage and de terioration of these materials and prevent their theft or
loss.

Materials excluding line pipe shall be stored in sheltered storages . Such materials shall
not be stru ng on th e Righ t-of-Way bu t sh all be tra nsported in covered conveyances
for use only at the time of installation.

CONTRACTOR shall ensure that all valves and whenever applicable, other materials are
fitted with suitable end covers of th e type a pproved by C OMPANY. Ma terials w ith
worked surfaces such as flanges, pipe fit tings, etc. must be stacked and handled so as
to avoid contact with the ground or with substances that could damage them.

The manufacturer's instructions regarding t emperature and p rocedure fo r st oring

materials which are subject to a lteration of the original properties and cnaracteristics
did to unsuitable storage must be strictly complied with and, if re quired, an ade quate
heat conditioning shall be provided for these materials.

When supplied in c ontainers and packages they must not be thrown or droppe d, not
handled using hooks which could damage t he container or the materials, either during
loading/unloading or during successive handling, until their final use.

Storage of coat ing mat erials which are susceptible to de terioration or damages
especially due to humidity, ex posure to hi gh thermal cconditions or other diverse
weather conditions, shall be suitably stored and protecte d. The se mate rials shall be
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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(ONSHORE)
EDITION : 1

kept pe rmanently in store , supporte d abov e the ground in a dry plac e, prote cted
against t he weat her and t ransported for use only at t he t ime and in quantities
necessary for immediat e application. Deteriorated mat erials shall not be used and
replaced with no extra cost to COMPANY.

5.6 Identification

CONTRACTOR shall provide all pipes, bends, etc. greater than 2" with serial numbers
as soon as possible and measure their length and state is on the pipes, etc. Pipes to be
bent shall be measured prior to be nding. Identification (i.e. letter, number and length)
shall be indelible.

All serial numbers shall be recorded in a list, which shall also state appurtenant pipe
numbers.

Beside recording the stamped - in pipe numbers, length of pipe and painte d-on serial
numbers, the stampe d-in numbe rs of T- pieces, be nds, valve s, e tc. and the batch
numbers of be nds, T- pieces, valve s, e tc. and the make of valve s, shall also be
recorded in said list.

Before a pipe length, pipe end, etc. is cut the painted serial number and stamped-in
pipe numbe r shall be transferred by CONTRACTOR in t he p resence o f COM PANY t o
either side of th e join t w hich is to be made by c utting, and the changes shall be
recorded in t he ab ove ment ioned list stating the (new) length. The results shall be
such that all pipes, pups, etc. of diameter greater than 2" bear clear marks painted on.

CONTRACTOR shall ex plicitly inst ruct his st aff t hat part s which cannot be identified
must not be removed, except after permission by COMPANY.

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.

6.0 TRENCHING

6.1 Location

CONTRACTOR shall, ex cavate and maint ain t he p ipeline t rench o n t he st aked cent er
line of the pipeline taking into account the curves of the pipeline.

6.2 Excavation

6.2.1 CONTRACTOR shall, by any method approv ed by COMPANY, dig the pipeline trench on
the c leared and grade d Right- of-Way. I n c ultivable land and othe r areas specifically
designated by the COMPANY, top 60mm of th e arable soil on the pipeline trench top
and 500mm on e ither side shall be excavated and stored separately to be replaced in
original position after backfilling and compacting rest of the trench.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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(ONSHORE)
EDITION : 1

Suitable crossing shall b e p rovided and maint ained o ver t he o pen ROW where
necessary, to pemit ge neral public , prope rty owne rs or his te nants to c ross or move
stock or equipment from one side of the trench to the other.

Care shall b e ex ercised t o see t hat fresh so il reco vered from trenching operation,
intended to be used for backfilling over the laid pipe in the trench, is not mix ed with
loose debris or foreign material. The excavated material shall never be deposited over
or against the strung pipe.

6.2.2 In steep slope area or on the hillside, before commencing the works, proper barriers or
other protection shall be provided to prevent removed materials from rolling downhill.

6.2.3 On slopes where t here is d anger of landslide, the pipeline trench shall be maintained
open only for the time stric tly ne cessary. Forever, the COMPANY may require
excavation of trench by hand, local route detours and limiting the period of e xecution
of the works.

6.2.4 In c ertain slope se ctions be fore th e tre nch c uts th rough the water table, proper
drainage shall be e nsured both ne ar the ditch and the Right- of-Way in orde r to
guarantee soil stability.

6.2.5 All sewers, drains ditches and other natural waterways involved in the ex ecution of the
works shall be maintained open and funct ional. The same applies to canals, irrigation
canals, pipelines and buried facilities crossed by the ditch for which temporary pipeline
shall be laid, if required, and proper temporary installations provided.

6.3 Blasting

Blasting for trenching and the related removal of sc attered rock and de bris caused by
the bla sting f rom th e Right-of-Way and/or adjacent prope rty, shall be pe rformed by
CONTRACTOR as part of his work.

Every possible pre caution shall be take n to prevent injuries and damage s to pe rsons
and properties during blasting operations, which shall be performed in accordance with
Standard Rules for Blasting.

CONTRACTOR shall obtain ne cessary p ermits fo r st orage and use o f ex plosives and
comply with the laws, rules and regulations of the respective Governmental agencies
having jurisdiction thereof. No blasting will be allowed without prior and due notice
given by CONT RACTOR t o COMP ANY, Government authorities, land -owners, property
occupants, adjacent work crew, and other concerned parties.

CONTRACTOR shall emp loy o nly such wo rkmen who are ex perienced in t he t ype o f
work to be performed, to supervise, handle and use explosives.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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(ONSHORE)
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6.3.1 Areas to be blasted are to be categorised as follows:

a) Where blasting is t o be carried out beyond 50 met ers away from any existing
pipeline o r st ructures (eit her ab ove or below ground) the CONTRACTOR shall
submit his propose d blasting proc edure and pe rform a trial blast for
COMPANY's approval.

b) Where blasting is to be c arried out be tween 50 and 15 meters from any

existing pipeline or structure (either above or below ground) the CONTRACTOR
shall submit a procedure for controlled blasting e.g. break-holes, slit trench etc.
which will also detail out safety precautions to safeguard the existing pipelines.
This procedure will be approved by COMPANY prior to commencement and
performing of trial blasting.

c) No blasting is allowed within 15 metres o f any ex isting p ipeline o r st ructure

(either above or below around).

6.3.2 All necessary precaution s shall be taken to prevent st ones from falling outside the
Right-of-way and in cult ivated areas and t o avoid any damage to the installation and
properties existing nearby.

6.3.3 Blasting and removal of debris shall be carried out prior to stringing the pipes.

6.3.4 Ground vibration due to blasting n ear th e e xisting stru ctures shall be cont inuously
monitored using certified in struments to be provided by CON TRACTOR and approve d
by COMPANY and the peak particle velocities shall not exceed 50 mm/ sec.

COMPANY reserves the right to refuse b lasting where p ossible d anger ex ists t o
property, ex isting utilities or other structures. In such locations other methods of
extracting roc k shall be propose d by CON TRACTOR and shall be approved by
COMPANY.

6.4 Normal Cover and Trench Dimensions

The trench sh all be e xcavated to a m inimum so a s to provide , on both side s of th e

installed pipeline, a clearanc e as indicated in the job st andard/ drawings and to a
depth sufficient to provide the minimum c over as indic ated below. The dimensions in
the table below shall govern except as noted herein or as shown on the job standards
or de tailed c onstruction drawings or as re quired by authorities having jurisdict ion,
whichever is greatest. Minimum depth of cover shall be measured from the top of pipe
corrosion/ concrete weight coating (as applicable) to the to p of undisturbed surface of
the soil or top of grade d working strip or top of road or top of ra il whichever is lower.
Fill material in working strip shall not be considered to add to the depth of cover.
However, surface of fill materi al placed to fill hollows ma y be used to determine the
depth of cover subject to prior approval by COMPANY.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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(ONSHORE)
EDITION : 1

Sl. Location Minimum Cover in meters

No.

a) Industrial, Commercial & 1.0

Residential Areas

b) Rocky Terrain 1.0

c) Minor water crossings/ canals / drain / 1.5

nala / stream

d) River crossings for which scour depth is 1.5

de fined (below scour)

e) River crossings (Bank width < 50 m) 1.5

below lowest bed level)

f) Other crossings (Bank width > 50 m) 2.5 (for normal soil)

( below lowest bed level) 1.5 (for rocky strata)

g) Water crossing by HDD 2.5

(below least bed level)

h) Uncased/ Cased Road Crossings/ 1.2

Station approach

i) Railroad Crossings 1.7

j) Drainage, ditches at roads / railway crossings 1.0

k) Marshy land and creek area 1.5

Notes :

In case pipeline is located within 1.5 m from any dwelling unit, the cover shall be
increased by 300 mm over and above that specified.

6.5 Cutting and Removal of Paving

Whenev er it is permitted by Authorities and / or COMPAN Y to ope n cut a pave d road

crossing, o r where t he line is ro uted wit hin t he ro ad pavement, CONTRACTOR shall
remove th e pa ving in a ccordance w ith the rest rictions and req uirements o f t he
authorities hav ing j urisdiction t hereof o r as d irected b y COM PANY. The open cut for
the road crossing shall be carried out only when the section of pipeline to be laid is
complete. After laying the pi peline, backfilling sh all be immediately performed and all
the area connected with the works shall be temporarily restored.
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Throughout t he period of execution of such works, CONTRA CTOR shall provide and
use warning signs, t raffic lights or lanterns, barricades, fencing, wat chman, et c. as
required by the local authorities having jurisdiction and/ or COMPANY.

For all roads, pat hs, walkway et c. wh ich are o pen-cut, CONT RACTOR shall p rovide
temporary diversions properly constructed to allow the passage of normal t raffic with
the minimum of inconvenience and interruptions.

The paving shall be restored to its original condition after the pipeline is installed.

6.6 Extra Depth and Clearance

At points where t he contour of the earth way require extra depth to fit the minimum
radius of t he bend as specified or t o eliminate unnecessary bending of t he pipe
according to c ustomary good pipe line practice, or where a deep trench is req uired at
the approaches to crossings of roadways, ra ilroads, rivers, streams, drainage ditches,
and the like, CONTRACTOR shall ex cavate such additional depth as may be necessary
at no extra cost to the COMPANY.

CONTRACTOR sh all e xcavate to a dditional depth whe re the pipe line approac hes and
crosses othe r pipe lines, se wers, drain pipe s, water mains, te lephone, c onduits, a nd
other underground st ructures, so t hat t he pipeline may be laid with at least 50
centimeters free clearance from the obstacle or as sp ecified in t he drawings, or such
greater minimum distances as may be required by authorities having jurisdiction.

Where t he p ipeline cro sses areas, who se easement s sp ecifically req uire greater than
normal depths of cover, the trench shall be e xcavated to e xtra de pth in accordance
with the Right-of-way Agreements or as required.

CONTRACTOR shall ex cavate all such additi onal de pths as may be ne cessary at no
extra cost to the COMPANY.

6.7 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. COMPANY reserves the right to se t the grade of the trench and locate the
bends if so de sired, in whic h case CONT RACTOR shall ex cavate, at no extra cost, the
trench and bend the pipe to such a grade. COMPANY desires to reduce to a minimum
the re quired numbe r of c old fie ld be nds to la y th e pipe to c onform to th e ge neral
contour of t he ground and maint ain a normal co ver. T his can b e acco mplished b y
cutting the trench slightly deeper at the crest of ridges and by gradually deepening the
trench in aproaches to crossings. Such tr enching work shall be done by CONTRACTOR
at no extra cost to the COMPANY.

COMPANY intends that there will be a minm um of hand grading of the trench bottom.
However, to achieve this, CONTRACTOR will have to dig as square a bottom of the
trench as p ossible with his eq uipment. This in part c an be obtained by adjusting and
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adopting the crumbling shoe and digging t eeth of the trenching machines and by use
of a drag be hind the tre nching mac hines o r manually d ressing-up t he same.
CONTRACTOR shall d o such hand wo rk in t he 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.

6.8 Padding

In all cases where ro ck o r g ravel o r hard so il is enco untered in t he b ottom of the

trench, COMPANY will decide the exact extent of trench pa dding, that will be required.
The thickness of the compacted padding shall not be less than 150mm. In those areas
that are to be padde d, the tre nch shall be at least 150mm d eeper t han o therwise
required, and evenly and suffic iently padded to keep the pipe, when in p lace, at least
150mm above bottom of excavated trench.

Acceptable padding shall be plac ed unde r the pipe line be fore its installation, and
around after installation to establish at bo th sides and on top of the pipe a permanent
layer of padding. The thickness of compacted padding on top of pipe corrosion coating
shall be at least 150mm. P adding materials that are approved by COMPAN Y shall be
graded soil/ sand and/ or other materials containing no grav el, rock, or lumps of hard
soil. Sand used for padding shall pass through sieve size ASTM-10 or ISO-2.00.

When specified in the CONTRACT, rock shield may be used in place of or in addition to
sand padding as indic ated above . Suc h roc k shield shall be in accordance with the
specification issued for the purpose and shall be subject to COMPANY approval.

6.9 Protection of Trench

CONTRACTOR shall keep t he t rench in g ood condition until the pipe is laid, and no
claim is to be made to the COMPANY by reason of its caving either before or after pipe
is laid.

All lumber, sheet-piling jacks or other mate rials, that may be necessary to shore the
trench, in order to prevent caving are to be furnished and removed by CONTRACTOR.

CONTRACTOR shall dewater if necessary, using well point system or other suitable
systems, shore, or do what else mig ht be required to excavate the trench, install the
pipe in it and backfill the trench in accordance with these specifications at no extra cost
to COMPANY.

6.10 Protection of Underground Utilities and Special Methods

Details of some underground utilities, as far as acquired by COMPANY, shall be

indicated in the Drawings. However, CONTRACTOR shall obtain plans and full details of
all existing and planned underground services from the relevant Local Authorities and
shall follow t hese p lans clo sely at all t imes d uring t he p erformance o f wo rk.
CONTRACTOR shall be responsible for location and prote ction of all unde rground lines
and structures. In sp ecial locations the use o f trenching machine, backhoe may result
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in d amage t o p roperty and sub surface st ructures lik ely to be encountered during
excavation. At such p laces, CONTRACTOR shall ex cavate the trench manually to same
specification at no extra cost.

Where the pipeline crosses other undergr ound utilities/ struct ures, the CONTRACTOR
shall first manually ex cavate to a depth and in such a manner that the utilities/
structures are located.

Temporary under pinning or any othe r type of supports and othe r protective devices
necessary to keep the interfering structure int act shall b e p rovided b y t he
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 struct ure/ utility etc., occur, the
Owner/ Authority concerned shall be contacted by the CONTRACTOR and re pair shall
forthwith be carried out by the CONTRACTOR at his ex pense under the direction and
to the satisfaction of COMPANY and the concerned Owner/ Authority. If CONTRACTOR
fails to re pair in re asonable tim e, C OMPANY re serves th e righ t to h ave the repair
executed at the cost of the CONTRACTOR.

6.11 Encroachments and Working near other utilities

In locations, where pipeline has to be laid in the body of a road, c anal, dyke or othe r
locations unde r jurisdic tion of Gove rnment/ Public Bodies, the CONTRACTOR shall
perform su ch w ork w ithout e xtra c ompensation, a ccording to the requirement of
concerned Authorities. When it becomes necessary that CO NTRACTOR has to resort to
hand digging, well point, erec tion of sheet piling or any other special construction
methods in t hese areas, no ex tra co mpensation shall be paid. CONTRACTOR shall
contact the Authorities concerned in order to become familiar with their requirements.

In lo cations, where t he p ipeline has t o b e laid more or less parallel to an existing

pipeline, cable and/ or other utilities in the Right-of-way, CONT RACTOR shall perform
the w ork to th e sa tisfaction of th e Ow ner/ Authority of the existing pipeline/ cable/
utility. In such locations CONTRACTOR shall perform work in such a way that even
under the worst weather and flooding conditio ns, the ex isting pipeline/ utilities remain
stable and shall neither beco me undermined nor hav e t he tendency to slide tow ards
the trench.

CONTRACTOR shall be liable for any damage occuring to, or resulting from damage to
other pipelines, underground stru cture/ utilities, as laid do wn in clause 6.10 of this
specification.

6.12 Provisions for negative buoyancy to the pipe

CONTRACTOR shall check if up-floating danger is present in open trench and then shall
take ap propriate measures t o p revent up-floating suc h as applying soil dams and
dewatering of trench or temporary filling of water into the line (in exceptional cases).
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REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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In the case of water on the ditch bottom when the pipeline is being laid, the ditch shall
be drained to the extent and for the time required to m ake a visual inspection of the
ditch bottom. After this inspec tion, the presence of water will be allowed provided its
level does not cause sliding of the ditch side s and pipe floating be fore backfilling when
no concrete weighting is provided.

The water pumped out of the ditch shall be discharged into a natural water course.

Wherever up-floating of the pipeline after backfilling is to be reckoned with, anti-

buoyancy measures shall be provide d by CONTRACTOR for areas indicated in the
drawings or as may be encountered during construction, using one or a combination of
the following methods :

„ weighting by applying a continuous concrete coating around the pipe;

„ weighting by installing saddle weights;
„ installing metal anchors screwed into the suboil in pairs;
„ deeper burial of pipeline;
„ provision of select backfill material.

The above provisions shall be in accordance with the relevant specifications and/ or job
standards/ drawings.

7.0 BENDING

CONTRACTOR shall preferably provide for changes of v ertical and horizontal alignment
by making elastic bends. CONTRACTOR may provide cold field bends, at its option for
change of dire ction and c hange of slope. COMPANY at its option, may authorise
fabricated bends for inst allation at points where in COM PANY's judgement the use o f
such bends is unavoidable.
Overbends shall be made in such a manner that the center of the bend clears the high
points of the trench bottom. Sag be nds sh all f it th e bottom of th e tre nch a nd side
bends shall conform and leave specified clearance to the outside wall of the trench.

7.1 Elastic Bends

The minimum allowable radius for elastic bends in the buried pipeline including that for
continuous concret e weight coated pipe shall be in ac cordance with relevant job
standards. The elastic bend shall be cont inuously supported over its full length. A
radius smaller than permitted in elastic bending shall require a cold bend.

7.2 Cold Field Bends

7.2.1 The radius of cold field bends sha ll not be less than 40 tim es th e pipe n ominal
diameter for pipe diameter 18 inch and above and shall not be less than 30 times the
pipe nominal diameter for pipe diameter less than 18 inch.
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7.2.2 CONTRACTOR shall use a bending machin e and mandre l and e mploy recognized and
accepted me thods of be nding of c oated pipe in ac cordance with good pipeline
construction prac tice. Howe ver, be nding ma chines shall be c apable of making be nds
without wrinkles, buckles, stretching and with minimum damage to the coating.

7.2.3 CONTRACTOR shall, before the start of the work, submit and de monstrate to
COMPANY a bending procedure which shall co nform with the recommendations of t he
manufacturer o f t he b ending machine. T he p rocedure shall includ e amo ngst o ther
steps - lengths, maximum de gree per pull an d method and accuracy of measurement
during pulling of the be nd. This procedure and the equipm ent used shall be subject to
COMPANY's approval.

7.2.4 Pipes with longitudinal welds shall be bent in such a way that the weld lies in the plane
passing t hrough t he neut ral ax is of t he bend which shall be installed positioning the
longitudinal weld in the upper quadrants. If horizontal deviations are to be achieved by
joining more adjac ent be nds, the be nding of the pipe le ngths shall be made by
positioning the longitudinal welds alte rnatively 70mm abov e and below the plane
passing t hrough t he neut ral ax is in such a w ay th at th e be nds a re w elded w ith th e
longitudinal welds displaced by about 150mm and sit uated in the upper quadrants. I n
case of v ertical bends formed from a numbe r of pipe lengths, the longitudinal welds
shall be positioned on the plane passing through the neutral a xis of the bend to the
right and left alternatively.

7.2.5 The pads, dies and rolls of the bending equipment shall have relatively soft surfaces to
avoid damage to the pipe coating. Where applicable, fully retaining bending shoes shall
be used. Roller type bending machines are preferred.

7.2.6 The ends of each bent length shall be straight and not involved anyway in the bending.
The length of the straight section shall permit easy joining. In no event shall the end of
the b end b e clo ser t han 1. 5m fro m t he end of a pipe or within one meter of a girth
weld.

7.2.7 The ovalisation caused on each pipe by bending shall be less than 2.5% of the nominal
diameter at any point. Ovalisation is defined as the reduction or increase in the internal
diameter o f t he p ipe co mpared wit h t he no minal int ernal d iameter. A check shall b e
performed on all bends in the presence of COMPANY by passing a gauge consisting of
two discs with a d iameter equal to 95% of the nominal internal diameter of the pipe
connected rigidly together at a distance equal to 300mm.

7.2.8 The wall thickness of fini shed bends, taking into acco unt wall t hinning at t he out er
radius, should not be less than the design thickness. An indication of wall thinning as a
percentage is given by the following empirical formula :

50
Wall Thinning = ---------------
n+1
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834002 OIL & GAS SBU, DELHI

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Where ‘n’ is the inner bend radius divided by pipe diameter. Pipes with measured wall
thickness greater than the n ominal w all th ickness (i.e . w ith +ve tole rance) sh all
normally be used for making cold field bends.

7.2.9 Cold bent pipes on site shall have the corrosion coatin g carefully checked with the aid
of a holiday detector for crack s in t he coat ing down to the pipe wall. I t must also be
checked whe ther the c oating has disbonde d from the pipe wall during be nding by
beating with a wooden mallet along the outer radius. Any defects or disbonding of the
coating caused during be nding (also forc ed ridges in the coating) shall be repaired at
the CONTRACTOR's expense in accordance with COMPANY approved procedures.

7.2.10 When pipelines are laid in parallel, the horizontal bends shall be concentric.

7.3 Miter and Unsatisfactory Bends

All bends showing buckling, wrinkles, cracks or other visible defects or which are in any
way in disagreement, in whole or in part, with this specification shall be rejected.

No miter bends shall be permitted in the construction of the pipe line. CONTRACTOR
shall cut out and re move any bend or bends which do not meet the specifications and
shall replace the same with satisfactory bends at no additional cost to th e COMPANY.
In t he ev ent t he CONT RACT p rovides fo r supply of line pipe by COMPAN Y, the pipes
required for replacement will be furnished by COMPANY, but the cost of replacement of
such pipes shall be borne by CONTRACTOR.
Cutting of factory made bends and cold field bends for any purpose are not permitted.

8.0 LINING UP AND WELDING

Each length of pipe shall be thoroughly ex amined intern ally and ex ternally to make
sure t hat it is free from v isual defect s, damage, severe corrosion (sea water pitting),
dirt, animals or any other foreign object s. Each length of the pipe shall be adequately
swabbed, e ither by use of c anvas be lt disc of proper diame ter or by othe r me thods
approved by the COMPAN Y. D amaged/corroded pipe s shall be ke pt separate. Each
length of pipe shall be pulled through just before being welded.

All rust and foreign matters shall be re moved from the be veled e nds by power
operated brush. This shall be affect ed inside & out side and for a minimum dist ance of
25 mm from e dge of be vel. The be vel shall be thoroughly inspe cted at this stage.
Should laminations, spilt ends or manufac turing defects in the pipe obse rved, the
length of the pipe cont aining such de fects shall be remove d from the line in
accordance with relevant specification.

Contractor sh all a lign a nd w eld toge ther th e J oints of pipe so a s to c onstruct a

continuous pipeline. All welds in the pipeline made by Contrac tor shall be of stre ngth
equal to that of pipe . All welding shall conform to Comp any’s welding specifications
enclosed with the Contract.
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REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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8.1 Pipe Defects and Repairs

It is CONTRACTOR's responsibility to repair all internal and/or external defects.

8.1.1 Acceptability of defects in the pipe detected duri ng inspection at the work site shall be
determined in acco rdance with latest edition of COMPANY' s own material specification
or CODE ANSI B31.8/B 31.4 whichever is more stringent.

8.1.2 The maximum permissible depth of dents in pipes upto and including 123/4" OD is 5mm
and for pipes over 12 3/4" OD is 2% of the nominal pipe diameter.

8.1.3 Dents which contain a stress concentrator such as scratch, gauge, arc burn or groove,
and dents located at the longitudinal, spiral or circumfere ntial weld sha ll be removed
by cutting out the damaged portion of pipe as a cylinder.

8.1.4 Repair on line pipe shall be executed as specified in COMPANY's material specification
or Code ANSI B 31.8/B 31.4, whichever is more stringent. A record of all repairs is to
be maintained by CONTRACTOR. This recor d, provide d with the pipe ide ntification
number is to be submitted to the COMPANY.

8.1.5 If due to c utting or re pairs, the pipe ide ntification n umber is removed, it shall be
reprinted immed iately b y CONT RACTOR in t he p resence o f COM PANY. In the event,
the CONTRACT provides for supply of line pipe by COMPANY, CONTRACTOR shall be
charged for any pipe le ngth due to loss of ide ntification n umber. N o pipe without
identification number shall be transported and/or welded into the pipeline.

8.1.6 Repair of damage d pipe e nds by hamme ring and/or heating is not allowed. If the
dented area is minor and at least 200mm away from the pipe end, and the steel is not
stretched, se vered, or split in the COMPAN Y's opinion, the pipe may be straightened
with a proper jack.

8.2 Pipe Handling And Skid Spacing

8.2.1 When lifting pipe , care must be taken not to kink or ove rstress it. Proper pipe slings
approved by COMPAN Y shall be use d. CONTRACTOR shall submit his method of
skidding and skid spac ing for COMPAN Y's appr oval. A st rip of soft material shall be
placed in be tween skid and pipe to protect t he ex ternal co ating o f t he p ipe. T he
material shall be approved by the COMPANY.

8.2.2 The max imum skid spacing is not allowe d before the stringer be ad and the top and
bottom re inforcements a re c ompleted, provide d th at th e distance between the
incomplete weld and the skid shall not exceed 9 (nine) percent of the skid spacing.

8.2.3 Skids shall be atleast 1. 20 meter long. For pipe with an O.D. of 12-3/4 inch and larger
the skids in contact with the pipe shall have a width of at least 200mm. For pipe with
an O.D. of less than 12 inch the skids in co ntact with the pipe shall have a width of
atleast 150mm. Pipe supports sh all be stable, so that pi pe movement will not cause
the supports to move. Skids shall not be re moved under a st ring before lowering in.
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The welded pipe shall be maintained on skids at t he minimum dist ance of 500mm
above ground. Crotches shall be installed at freq uent int ervals (at least ev ery 10t h
support) with a greater number required at bends and undulation grounds.

8.3 Night Caps

At the end of each d ay's work or every time when j oining and welding operations are
interrupted, the o pen end s o n t he weld ed strings of pipe s shall be c apped with a
securely closed metal cap or plug as approved by COMPANY so as to prevent the entry
of dirt, w ater, or a ny f oreign m atter in to th e pipe line. Th ese c overs sh all not be
removed until the work is to be re sumed. The c aps/plugs use d shall be me chanical
type and shall not be attached to pipe by welding or by any other means which may
dent, scratch or scar the pipe.

8.4 Temporary Caps

Whenever the welded strings of pipes are left open at intervals to be tied in later after
an appre ciable time lag, unde r roads, ra ilroads, rive rs, marshy c rossings, e ts.,
temporary caps approved by COMPANY shall be welded to the ends of the pipe.

9.0 LAYING OF PIPE

9.1 Lowering In Trench

9.1.1 Lowering can st art aft er remov al from ditch bottom of all off c uts, pipe supports,
stones, roots, de bris, stakes, rock projections below underside of pipe and any othe r
rigid materials which could lead to perforation or tearing of the coating. Sand padding
and / or rock shield shall be provided as required in accordance with clause 6.8 of this
specification.

9.1.2 Lowering shall follow as soon as possible, after the completion of the joint coating of
the pipeline. In t he case o f parallel pipelines, layi ng shall be carried out by means of
successive operations, if possible without interruption.

9.1.3 Before lowering in, a co mplete check by a full circle holiday detector for pipe coating
and for field joint coat ing shall be carried out and all damage s re paired at
CONTRACTOR's cost. All p oints on the pipeline where t he coating has b een in contact
with e ither th e skids or w ith th e lif ting e quipment during laying, shall be carefully
repaired. If, after c hecking, it be comes ne cessary to plac e the pipe line again on
supports a t th e bottom of th e tre nch, th ese must be padde d in suc h a way as to
prevent damage to the c oating, thus avoidi ng necessity for further repairs when the
pipe is finally raised and lai d. Before the last operation, a check must be made of the
coating at points of contact with the supports.

9.1.4 Before lowering in, sh ort c ompleted se ctions of th e pipeline shall be c leaned with
compressed air in order to remove all dirt, etc. from the inside of pipe sections.
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834002 OIL & GAS SBU, DELHI

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9.1.5 The pipeline shall be lifted and laid using, for all movement s nece ssary, suitable
equipment of non-abrasive material having adequate width for the fragility of the
coating. Care shall be exercised while removing the slings from around the coated pipe
after it has b een lowered into the trench. Any damage caused to the coating shall be
promptly repaired. Lowering in utilizing standard pipe cradles shall be permitted if
CONTRACTOR demonstrates that pipe c oating is not damage d. N o sling shall be put
around field joint coating.

9.1.6 Wherever t he p ipeline is laid und er t ension, as a result of an assembly error (for
example, incorrect positioning of bends, either horizontal or vertical), the trench shall
be rectified or in ex ceptional cases a ne w assembly shall be carried ou t, to be
approved by COMPANY, so that it fits the excavation and the laying bed.

9.1.7 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 co ating. In lo calised p oints where t he right-of-way is restricted to the minimum
necessary for the transit of mechanical equipment, the laying shall be carried out using
other suitable means. The pipe shall be placed on the floor or th e excavation, without
jerking, falling, impact or other similar stresses. In partic ular, care must be taken that
the deformat ion caused during t he raising of the pipe work from the supports, doe s
not exceed the values for the minimum allo wable radius of elastic curvature, so as t o
keep the stresses on the steel and on the coating within safe limits. The portion of the
pipeline be tween tre nch and bank shall be supported by as many side -booms as
required and approved by COMPANY for holding the line in gentle S-curve maintaining
minimum elastic bend radius as specified in job standard. Lowering in and back-filling
shall preferably be carried out at the highest ambient temperature.

9.1.8 The pipeline must be laid w ithout in terruption f or th e w hole or th e le ngth 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 be d on whic h the pipe is to be laid. Following such insp ections, t he p resence o f
water will be permi tted, provided that it is not so high as to cause cave-in of the walls
of the trench or floating of the pipeline before backfilling, wh en weighting is not
provided for the pipe.

9.1.9 CONTRACTOR shall t ake p recautions immed iately aft er lo wering in t o prevent the
movement of the pipe in trench.

9.1.10 In lay ing p arallel p ipelines in t he same t rench, the minimum distances between the
pipeline indicated in the approved drawings shall be observed. Once the first pipe line
has be en positione d, it shall in no way be disturbe d by laying of the subse quent
pipeline.

At every seven meters along the trench sa nd/earth filled bags shall be placed between
the parallel pipelines so as to ensure maint enance of t he minimum st ipulated distance
between the parallel lines.
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9.2 Overhead Sections and Sections in Tunnel

9.2.1 The following works sh all be c ompleted be fore proc eeding with the assembly and
laying of overhead pipelines :

- Construction of the pipe support structures or of mounts on supports.

- Paints and/or coating of the pipe work, as indi cated in t he eng ineering
specification.

9.2.2 The erect ion o f t he sup ports shall b e carried o ut t aking care that the elevation and
alignment is in accordance with the drawings.

In the case of metal work supports, pre fabrication and/or assembly shall t ake int o
account the maximum allowed free span and the supports shall no t interfere with the
pipeline welds.

9.2.3 In case roller supports are used, the roller shall be lubricated, then checked for smooth
rotation and, in case of seizure, the defect shall be repaired or ro ller shall be replaced.
In the case of overhead section where the pipeline is slanting, the alignment of the end
supports shall be made after placing the pipeline in position. Be fore installation of the
pipe section, all the rollers shall be perfectly centered acting on the seat of the support
plates.

The above alignment operations shall be carried o ut b efore co nnecting t he o verhead

section with the ends of the buried section.

9.2.4 Lifting, moving and laying of the pipeline shall b e carried o ut in acco rdance wit h t he
provisions of clause 9.1.5.

An insulation sheet shall be installed to isolate the pipe from the support or support
from the earth.

The sheet shall be hard polyethylene at least 5mm thick.

It shall extend at least to 1cm outside the saddles or clamps.

9.2.5 Moving supports, if any, shall be cent ered on their support and allow for a mov ement
of at least 300mm in both directions.

9.2.6 A comprehensive report/method statement on the laying operation to be used shall be

submitted to th e C OMPANY w ell in a dvance for approv al. T he report as a minimum
shall include, but not limited to the following:

(a) Method of installation by lifting (as a preferred method).

(b) Pulling method and re lated calculations, whenever lifting method cannot be
used.
(c) Pulling device and its characteristics
(d) Method of anchoring the pulling device
(e) Characteristics of the pulling rope
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(f) Braking device, if any

(g) Pipeline assembly systems.

10.0 BACK-FILLING

10.1 Backfilling shall not be done until the pipe and appurtenan ces have the proper fit 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 re st smoothly and e venly. Be fore any such work is done, it shall be the
CONTRACTOR's responsibility to first secu re the approval of COMPANY. If any
backfilling is done without COMPANY's approval, COMPAN Y will have the right to
require removal of the backfill for ex amination, and the cost of such uncovering and
refilling shall be borne by CONTRACTOR. Backf illing of trench in water courses shall be
carried out as per the relevant specifications issued for the purpose.

10.2 Backfilling shall be carried out immediatel y after the pipeline has been laid in the
trench, inspected and approve d by the COMPANY, so as to provide a natural
anchorage for t he pipeline, thus avoiding long e xposure of c oating to high
temperature, damaging act ions of adverse weather conditions, sliding down of
trench sides and pipe movement in the trench. If immediate back filling is not
possible, a cov ering of at least 200mm of eart h, free of rock and hard lumps shall be
placed over and around the pipe and coating.

On n o a ccount th e top soil f rom th e ROW be u sed for this purpose. In general, the
trench shall be dry during ba ckfilling. Deviations there of mu st have prior approval of
the COMPANY. The backfill material shall cont ain no extraneous material and/or hard
lumps of soil which could dama ge the pipe / coating or leave voids in the backfilled
trench. After the initial backfill has been placed into the trench to a level slightly above
the surrounding ground, CONTRACTOR shall compact the backfill material. The
surplus material shall be neatly cro wned d irectly o ver t he t rench and t he ad jacent
excavated areas on both sides of the trench as per clause 6.2.1, to such a height which
will, in COMPANY's opinion, provide adequately for future settlement of the trench
backfill during the maintenance period and thereafter. The crown shall be high enough
to prevent the formation of a depression in the soil when backfill has settled into its
permanent position. Should depression occur after back fill, CONTRACTOR shall be
responsible for remedial work at no extra cost to COMPANY. Surplus material, including
rock, left from this operation shall be disposed of to the satisfaction of land owne r or
authority having jurisdiction at no extra cost to the COMPANY.

For further requirements reference is made to Se ction of 14.0 "Cle an-up and
Restoration of Right-of-Way" of this specification.

10.3 Rock, gravel, lumps of hard soil or like materials shall not be backfilled directly onto the
pipe unle ss ' padding' and/or roc k she ll has be en provide d as pe r Section 6.0 of this
specification. When "Padding" as de scribed in Section 6.0 of this sp ecification is to be
used, the following shall be applicable.
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Where rock, gravel, lumps of hard soil or like materials are encountered at the time of
trench ex cavation, sufficient earth, sand or select backfill materi als shall be placed
around and over the pipe to form a protective cushion extending at least to a height of
150mm above the top of the pipe. Select backfill materials for padding that are
acceptable to COMPANY shall be soil, sand, clay or other material containing no gravel,
rock or lumps or hard soil. Whether such padding material would be take n from the
adjacent spoil bank or impo rted fro m elsewhere shall b e d irected b y COMPANY. All
these works shall be carried out by CONTRACTOR at no extra cost to COMPANY. Loose
rock may be returned to the trench after the required selected backfill material has
been placed, provided the rock placed in th e ditch will not interfere with the use of the
land by landowner, or tenant.

10.4 When the trench has been dug through dr ive ways or roads, all backfills shall be
executed wit h sand o r a suit able mat erial as approve d by COMPAN Y and shall be
thoroughly co mpacted. In certain cases, special compaction methods, such as
moistening or ramming of the backfill in layers may be requ ired by COMPANY.
COMPANY and any public or priv ate 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 t he road shall be re paved. In such instances,
CONTRACTOR shall comply with said requirements at no extra cost to COMPANY.

10.5 Trenches excavated in dykes which are the property of railways or which are p art of
main roads shall be graded an d backfilled in their original profile and condition. If
necessary, new and/or specia l backfill materials shall be supplied and worked-up. The
materials required may include gravel, sp ecial stabilization mate rials or stabilized
mixtures. Howe ver, spe cial proc essing and/ or c ompacting m ethods sh all re quire th e
approval of COMPANY and/or competent authorities.

10.6 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 co mpletely back filled. Surplus
material remaining after the operation shall be sp read o ver t he ROW as sp ecified in
Section 14.0 "Clean-up and Restoration of Right-of-Way", of this specification.

10.7 At the end of each day's work, backfilling shall not be more th an 500 meters behind
the head end of lowered-in pipe, which has been padded and approved for backfill.
The backfill shall be maintained by CO NTRACTOR against washouts etc., until the
completion and final acceptance of the work by COMPANY.

10.8 CONTRACTOR shall furnish mat erials and inst all breakers in t he trench in steep areas
(slope generally 10% and more ) for the purpose of preventi ng erosion of the backfill.
The type of breakers installed shall be as per the approved drawings. Breakers shall be
constructed of grout bags filled with a mix ture of 4: 1 Sand: Portland cement at
COMPANY's direction. CONTRACTOR may prop ose other methods such as foam dams
etc. which shall be subject to approval by COMPANY. Such works shall be at no extra
cost to COMPANY. CONTRACTOR shall pay atte ntion to the direction of backfilling in
such steep areas.
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834002 OIL & GAS SBU, DELHI

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10.9 When backfilling the trenches in sloping terrains or steep areas, where in the opinion
of the COMPANY, the backfill may be washed out of the trench, sheet piling or other
effective water breakers across the trench shall b e provided by CONTRACTOR. This is
to divert the flow of water away from the trench into normal drainage followed before
laying th e 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.

10.10 CONTRACTOR shall leave the pipe uncovered at certain locations to allow COMPANY to
survey the center line of the pipe and the level of the pipeline in the backfilled trench.
Within 48 hours after backfilling, COMPANY sh all have carried out such survey and
informed CONTRACTOR of any realigning, if req uired. T hereafter CONTRACTOR shall
compact the backfill.

The maximum allowable deviat ion from t he centerline for land sect ions as st aked out
by COMPANY and as referenced by CONTRACTOR after backfilling is limited to:

Pipeline dia upto and including 24" : 200mm

P ipeline greater than 24" : 300mm

10.11 Before backfilling of the trench, CONTRA CTOR shall comply with the requirements of
Clause 6.12 of this specification.

10.12 Stabilization of backfill shall be carried out by the CONTRACTOR in sandy areas and
other such places t o o btain co nsolidated co ver as d irected b y t he COM PANY.
CONTRACTOR shall carry out th e stabilization over the pipe line at no ex tra cost to
COMPANY.

The backfill shall be stabilized preferab ly with 150mm layer of marl, mattresses of
gatch othe r than straw or othe r stable mate rials. The width of stablisation shall be
atleast 5.0 meters on either side of the pipeline, plus one meter for every 10 met ers
height of dune (where the line passes through the dune areas).

10.13 Temporary workers shall be installed during backfilling an d the survey as per clauses
10.10 to locate the pipeline axis. These markers shall then be replaced with permanent
pipeline markers.

10.14 Backfilling shall be preferably carried out at the highest ambient temperature.

11.0 TIEING-IN

11.1 The unconnected sections of the pipe line at various locations have to be tied in aft er
the sections are coated, lowered and backf illed. The sections to be connected shall
have at the e nds, se ctions of ove r lappin g, unc overed pipe of suffic ient le ngth to
absorb, without inducing excessive stresses in the steel, small displacements necessary
for perfect alignment and connection of the ends.
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11.2 Tie-in shall p referably b e carried o ut at ambient temperatures corresponding to the

average o perating t emperature in t he case o f a p ipeline co nveying fluid s at no rmal
temperatures and at the maximum ambient temperature in the case where the pipeline
is carrying fluids at high temperature.

11.3 CONTRACTOR shall carry out tie-in-weld ing (including necessa ry cutting, bevelling,
grinding of pipe weld seam s and line-up etc.) cleaning, priming, coating and backfilling
for the tie-in portion as per relevant specifications. CONT RACTOR shall also ex cavate
the required bell-holes for the connection. Bell-holes made to facilitate welding shall
provide adequate clearance to enable the welders to ex ercise normal welding ability
and skill. All tie-in welds shall be radiographically examined.

11.4 The tie-in should be done in such a way as to leave a minimum of st rain in the pipe. If
necessary, with respect to the trench, realigning of the pipe shall be done to eliminate
force or strain in the pipe by the CONTRACTOR at no extra cost to COMPANY.

11.5 If a pup e nd cannot be avoided for tie -in, the minimum le ngth that shall be added is
1.0 meters and two or more such pups shall not be welded together. All cut-off lengths
greater than 1.0 m eters shall be moved ahead in order to be welded into the pipeline
at a suit able locat ion. T ie-in wit h t wo or mo re pups may be used provided that they
each have minimum length of 1.0 meter and are separated by an entire length of pipe.
In no c ase m ore th an th ree (3) w elds sh all be pe rmitted on a 10 m eter le ngth of
pipeline.

11.6 In co nnecting p ipes, sp ecial it ems, fit tings and eq uipment where different wall
thickness are to be we lded, CONTRACTOR shall follow the procedures indicated in
ANSI B31.8/ANSI B31.4, as applicable. T he required tapering shall be done by
CONTRACTOR at no extra cost to COMPANY.

11.7 For tie-in of adacent sections of pipeline already pressure tested, the pup used for tie-
in shall be of single length or off-cuts of pipe which hav e already been hy drostatically
tested. C ONTRACTOR sh all ta ke c are th at sufficient number of pre tested pipe s with
different wall thicknesses are readily available.

12.0 SPECIAL INSTALLATIONS ON THE PIPELINE.

12.1 General

12.1.1 In a ddition to c onstructing th e pipe line, 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 operation.

Without limiting the generality thereof, 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, pipework, pipe supports,
pressure gauges, mechanical facilities, civil work, painting, in stallation of all electrical
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
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834002 OIL & GAS SBU, DELHI

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equipments, motors, c ables, c onduIt, wiring and fixtures and hook ing up of same;
installation of all instrument s, piping, valve s and fitting s; mount all instruments and
make all piping and electronic connections, etc.

On completion, all elements of each installation shall be checked our and tested for full
and correct operation in the presence of and to the satisfaction of COMPANY. All work
shall be carried our strictly in acco rdance wit h t he ap propriate co des, t he ap proved
drawings, and this and other related specifications.

CONTRACTOR shall fabricate all piping and install valves and fittings as required by the
detailed engineering drawings prepared by him and approved by COMPANY.

Stainless steel lines will be "swaged" usin g permanent fittings installed with a hydraulic
device.

Cold bending for t he fit ting of 1/2" and 1/4" pipe s is allowe d when special bending
tools are used with guides to prevent flattening. The minimum radius allowed shall not
be less than R = 10 D where D is the outside diameter of pipe.

The bending tool shall be subject to COMPANY's approval.

CONTRACTOR shall ensure that the piping assemblies are not in a strain prior to the
final bolting or welding. CONTRACTOR shall al so ensure that all e quipment and piping
are thoroughly swabbe d c lean of all dust, re fuse, welding-spat ter, scale, or any
potentially detachable matter prior to the tie-in or final bolting.

12.1.2 Dimensional tolerances.

These tolerances apply to in line items and corrections for other lines. These tolerances
can b e ex ecuted o n it ems such as v ents, drains, dummy supports, fie ld supports,
temperature and pressure connections, wh ere the deviation will not affect another
spool.

a) General dimension such as face t o face, face o r end t o end , face o r end to
center, and center to center : ± 3 mm.
b) Inclination of flange face from true in any direction: 4 mm per meter.
c) Displacement of branch connection from ind icated lo cation: ± 1. 6mm. W hen
multiple branches are involved, the di splacement of the branches shall not
exceed 3mm from a common point.
d) Rotation of flange bolt holes shall not exceed 1.6 mm.

12.1.3 Flanged connections.

CONTRACTOR shall ensure t hat 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 gaske t of prope r size and quality shall be installed
between the flanges at each joint.
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REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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Bolts shall be tighte ned in diagonal sequence and shall b e cent ered wit h eq ual
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 remover and discarded. It
is mandatory that a torque wrench is used for bolt tightening.

12.1.4 Threaded connections.

Damaged threads shall be cut from the end of a run and the pipe shall be rethreaded.

CONTRACTOR shall properly align all threaded joints. Pipe entering unions shall be true
to centreline so the union will not be forced during tightening. The threaded pipe shall
not project through fittings to c ause in terference w ith va lves or oth er ope rating
mechanisms.

Except for the threaded connections of in struments, which will re quire periodic testing
and maintenance, all t hreaded connections shall be seal welded. Th e latter joints shall
be made up without pipe joint compound and with a minimum of oil from the threaded
cutter. Seal welds should taper into the pipe with as little discontinuity as possible and
should cover all threads.

12.1.5 Welded connections

Where t he E nds o f t he p iping co mponents b eing welded have an internal surface

misalignment exceeding 1. 6mm, t he wall o f the co mponent ex tending internally shall
be trimmed by machining so th at the adjoining internal surfaces will be approximately
flush. All welding shall be performed in accordance with the specification " Specification
for welding of pipelines and related facilities".
Tie - ins between fixed points shall be made at maximum ambient temperature.
.
12.1.6 Civil Work

Civil work shall be provided in accordance with Specifications issued for the purpose.

12.1.7 Painting

All e xposed surfac es like piping, valve s, structures, and misc ellaneous appurtenances
shall be painted in accordance with the specifications issued fo r t his p urpose. T he
corrosion coating on pipe surface will end approximately 0.3 meter above the finish
grade and it will be necessary for CONTRACTOR to provide a clea n interface at the
junction of the protective coating and the paint.

12.1.8 Coating of buried-Installations, etc.

All buried valves, insulating joints, flowtees, b ends, o ther in-line fit tings and
appurtenances shall be coat ed with minimum three coats of approve d quality of c oal-
tar epoxy or any other equivalent suitable COMPANY approved coating at no extra cost
to the COMPANY. For bu ried pipes either heat shrink tapes conforming to COMPANY's
specification or coal tar epox y shall be used. CONTRACTOR shall submit to COMPANY
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REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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a report used alongwit h all t he test certificates. Only after obtaining written approval
from the COMPANY, CONTRACTOR shall commence the work of coating.

12.1.9 Clean-up

After all required tests ha ve been concluded satisfactorily CONTRACTOR shall clean up
the site as laid down in the specifications issued for the purpose. The Site finish shall
be graded in accordance with the approved drawings.

12.2 Installation of Valves and Valve Stations

12.2.1 Block and sectionalising valve stations shall be insta lled as shown on the approve d
drawings. It is CONTRACTOR's responsibility to have the units co mpletely assembled,
tested and made fully functional including all related instruments etc.

12.2.2 The civil and structural work shall be carried our in accordance wit h t he relev ant
specifications issued for the purpose and in accordance wit h the approved drawings as
directed by COMPAN Y. This work as a minimum shall include clearing, grading,
fencing, foundations, e tc, as re quired. All above ground struc tures shall be painted as
per the specification and color code given by the COMPANY.

12.2.3 A suitable concrete found ation as directed by COMPANY shall be constructed on which
the valve shall be firmly in stalled, afte r e mbedding an insulating sheet of hard
polyethylene with a thickness of at least 5mm or equiv alent. Such insulating sheet is
also to be installed under pipe clamps, etc.

12.2.4 Valves with flow arrows shall be installe d according to the normal flow in the pipeline.
During, we lding, the valve s shall be in fully open po sition. In addition all
manufacturer's instructions shall be followed.

Care shall be taken to avoid entry of sand particles etc. to valve body, seals etc. during
transportation, storage, assembly and installation.

12.2.5 For valves and piping installe d below ground and/or above ground, the anti-corrosion
coating/painting shall be as pe r the requirements of the relevant specifications issued
for the purpose. The ant i-corrosion co ating b elow g round shall ex tend up to 300mm
above grade at the lowest point.

12.2.6 Sectionalizing valves sha ll be installed on sections of the p ipeline in t he ho rizontal

position on ly or w ith a n in clination n ot gre ater than that allowed by the valve
manufacturer. Inst allation sha ll be done in such a way that there is no strain in the
welded joint while the pipeline at upstream and downstream sides are straight.

12.2.7 All valves shall always be handled using e quipment and me thods to avoid impac t,
shaking and other stresses. In partic ular, the e quipment and tools for lifting and
handling shall nev er be done t hrough handwheel, valve stem, joints and othe r parts
which may suffer damage.
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REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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12.2.8 All sectionalizing valve and any other inline assemblies shall be pre fabricated and
tested h ydrostatically ex-situ as per applicable sp ecification. All su ch assemblies shall
be installed at the locations shown in the drawings only aft er successful completion of
the h ydrostatic te st a nd de watering. Th ereafter th e ends of the assembly shall be
closed off. CONTRACTOR sha ll carry out necessary ex cavation, cutting, bevelling and
welding o f t he t ie-ins req uired fo r t he inst allation of such assembly. The tie-in joints
shall be radiographically ex amined over 100% length an d also 100% ultrasonically
examined prior to backfilling. All works sha ll be ex ecuted in accordance with the
relevant specifications issued for the purpose.

12.3 Installation of Scraper Launchers and Receivers

12.3.1 Scraper st ations shall be fabricat ed an d installe d as pe r the approved drawings and
whenever applicable as p er the requirements of clause 12.2 of this specification. It is
CONTRACTOR's responsibility to have the units completely a ssembled, tested and
made fully functional including all instruments & related piping.

12.3.2 The civil and structural works for the scraper stations sh all be carried out as per the
relevant specifications, in accordance with the drawings and as directed by the
COMPANY. The work as a minimum shall includ e 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 pipework adjustments, necessary for this purpose. Field
cuts shall be square and accurat e and fiel d welds shall not be performed under stress
of pipe ends.

12.3.4 The painting for the scra per stations shall be carried out as per "Specificat ions for
Painting". The underground sect ions shall be coated as sp ecified for the pipeline upto
atleast 300mm above grade.

12.3.5 The h ydrostatic te sting of th e sc raper sta tions shall be ex ecuted after installation in
accordance with the relevant specification issued for the purpose.

12.4 Installation of Insulation Joints

12.4.1.1 Insulation joints shall be installed at the locations shown in the drawings.
CONTRACTOR shall obt ain approv al from t he COMPANY before installation of the
insulation joints.

12.4.2 Handing and installation of the insulating joints shall be carried out with all precautions
required to avoid damage and e xcessive stre sses and that the original pup length is
not reduced.

12.4.2 The insulating joints and th e welded joints shall be prote cted by e xternal c oating as
per relevant specifications issued for the purpose.
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REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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12.4.4 The in-line inserting sha ll be made on the burie d pipe line; care shall be taken to
operate at an ex ternal t emperature as clo se as p ossible to the pipeline operating
temperature.

The joints 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 ac hieve this, the joint shall be kept cold by means of nags cont inuously
wetted.

12.4.6 Insulating joints shall be elect rically t ested b efore welding into the pipeline. The
electrical conductance test shall b e carried o ut using a M egger. M easurement o f t he
insulation resistance across the joints shall be approx. one (1) Mega Ohm. T he tests
shall be repeat ed aft er inst allation and welding of the joint into the pipeline to ve rify
that the assembly is undamaged.

13.0 WORKING SPREAD LIMITATIONS

CONTRACTOR shall, in general, observe the following maximum distances between the
working mainline spread:

Between ROW grading, clearing and backfilling : 30 Kms

Between backfilling and final clean-up : 05 Kms

The above limitations do not apply to poin t spreads such as cont inuous rock blasting,
river crossing, etc.

Any deviations from t he abov e shall re quire prior approval of COMPAN Y. COMPAN Y
reserves the right to st op t he wo rk, in case t he ap proved sp read limit ations are
exceeded and CONTRACTOR shall not be paid any compensation for stoppage of work.

14.0 CLEAN-UP AND RESTORATION OF RIGHT OF WAY

14.1 CONTRACTOR sh all re store th e ROW a nd a ll site s u sed f or th e construction of

pipelines, wat er cro ssing and o ther st ructures in acco rdance with COMPANY's
instructions, and deliver them to the satisfaction of COMPANY.

14.2 Surplus Materials

The following stipulations shall apply in c ase CON TRACT provide s for supply of line
pipe, bare and/or corrosion coated, by COMPANY.

All surplus and defective materials supplied by COMPAN Y shall be c ollected by

CONTRACTOR and delivered to designated stockpile areas.

All Pipe-ends shorter than 1.0m shall b e returned to COMPANY being scrap, all p ipes
longer than 8.0m shall be reconditioned (b evels, c oating, provide d with pipe letter,
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number and le ngth) and be re turned to COMPANY's designated stockpile areas

together with all undamaged, unused COMPANY supplied materials. All pieces between
1.0 and 8.0m shall be charged to th e CONT RACTOR by COMP ANY. CONT RACTOR
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.

14.3.2 The ROW shall be cleared of all rubbish, broken skids, empty cans, card board, sacks,
stamps, trash, and left over construction material. All burnable ma tter shall be burned,
but only after obtaining appropriate permits for such burning. If burning is not allowed,
CONTRACTOR shall haul t he clean-up mat erial to approve d dumping are a. All sc rap
metal and unburnable mate rial shall be disp osed of, in an appropriate manner, but
never be buried in the ROW.

14.3.3 Surplus soil can only be removed from t he Owner's plot aft er aut horisation by
COMPANY.

14.3.4 All du mping f ees c onnected w ith th e disposa l of m aterials sh all be to th e account of
CONTRACTOR.

14.3.5 All loose stone s and roc k e xposed by th e construction operations and scattered over
the ROW or adjacent grounds shall be re moved by CON TRACTOR and be transported
to a location considered suitab le by th e authorities having jurisdiction, for satisfactory
disposal. For stones, gravel or othe r hard ma terial which may be buried in the trench
the provisions of the specifications shall ap ply with the understanding that the use of
the land by the land-owner and/or tenant will not be interfered with.

14.4 Temporary Structures

All auxiliary structures such as bridges, culverts, sheet piling, post s, signs, etc., which
were erected or installed by CON TRACTOR as te mporary measure, shall be removed.
However, it ma y be n ecessary to re move th e f ence of ROW du ring the maintenance
period.

14.5 Repair of Damage

Damages to roads, bridge s, private property shall be repaired by CONTRACTOR. All

fences and ot her structures which are damage d during const ruction shall be restored
to original condition.

Slopes, water course sides or banks whic h have been partially or totally demolished
during the execution of the works shall b e properly consolidated and restored without
waiting for their natural consolidation and settling.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
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All boundary st ones which hav e been mo ved or re moved during the work must be
reset in their original location to the satisfaction of the landowner concerned.

14.6 On completion of clean-up, the ROW shall be restored to such stable and usable
condition as may be reasonab ly c onsistent w ith th e c ondition of the ROW prior to
laying the pipeline. The COMPANY shall be completely in demnified and held harmless
by CONTRACTOR from any and against all claims, demands, losses, expenses etc. that
may arise in this behalf or the COMPANY ma y any way suffer or sustain, relative to,
arising out of, or in connection with same. T he COM PANY may req uire fro m t he
CONTRACTOR signed Releases from la nd owners regarding satisfactory
indemnification and restoration of their lands.

14.7 Special precautions shall be taken near slopes prone to erosions and land slides. 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 works shall be restored in their exact position.

14.9 Ditches for which no instructions for restoration hav e been i ssued, or restoration
cannot be done according to existing banks b ecause o f t he ab sence o f it , shall b e
restored as inst ructed by COMPANY. The bed of ditches crossed by the pipeline, shall
be cleaned o ver t he full wid th o r t he ROW, also outside the ROW if necessary. This
restoration might involve the supply and inst allation proper materials for backfill and
protection, sodding or other precautions to prevent erosio n or guarantee the stability.
Work has to be done after deliberation and accept ance of t he aut horities and
COMPANY. Other field drains hav e to be restored by hand and/or special equipment to
be used for that purpose as soon as possible and if necessary, also outside the ROW.

14.10 Any subsidence, cav e-ins, wash-o uts, which hav e b een caused d uring t he p ipeline
construction and maintenance, caused by w hatever reason within the edge of ditches
and open drains, shall be re paired by CON TRACTOR imme diately or at first notic e
given by COMPANY.

14.11 After the clean-up, t he ROW o f p astures has to remain fenced and to be removed
during the maintenance period. When agri cultural and ot her t raffic (request ed by
tenant) h ave to c ross th e ROW th e c ross-overs h ave to be f enced with the same
material as the ROW. If necessary, special materials have to be used to allow traffic on
the cro ss-over. Fencing o f t he rig ht-of-way as specified shall not be remov ed unt il
CONTRACTOR has obtained written permission by COMPANY. In general this has to be
done during the maintenance period.

14.12 All openings in or damage to the fence or enclosures shall be repaired by installing new
fencing of quality which sha ll be at le ast e qual to the parts damage d or re moved.
Provisional gates shall be removed and replaced with new fencing. All repairs to fences
and enclosures shall be carried ou t to th e c omplete sa tisfaction of C OMPANY, la nd
owner and/or tenant.
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14.13 If, in the opinion of COMPANY, the sod in pasture land has be en damaged by vehicles
and wheel tracks are visible, the ROW sha ll be tilled with a di sc-harrow or rotary
cultivator several times. The damaged sod shall be firmly cut up and thoroughly mixed
through the top-soil. In general the ROW h as also to be ripped. After this procedure
no closed-in layers must be found and sufficiently loose top-soil 25 to 30cm thick must
be present. The whole procedure has to be approved by COMPANY. Subsequently, the
entire ROW which is part of pasture land, shall be prepared for seeding and fertilized
according to the instructions of COMPANY.

14.14 In crop fields the tillage shall consist of passing over the land se veral times with a disc
harrow, cultivating with a spading machine, or plow, to a depth of approx. 20 c m. In
general the ROW has also to be rippe d. Afte r this c ultivation proc ess no c losed-in
layers must b e fo und in t he ROW. The equipment used and methods adopted shall
require the approval of COMPANY. Ripping, has to be done with rippers with a distance
of 50 c m be tween the ripper blades. The type to be use d shall be approve d by
COMPANY.

14.15 A sapling of any plant/tre e uprooted or cut during c onstruction shall be planted along
the route as per the direction of th e C OMPANY a nd in a ccordance w ith th e Fore st
Preservation Act, 1981. T he cost of sapling and its planta tion shall be to
CONTRACTOR's account.

14.16 The ROW and the backfilled trench in partic ular has 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 cert ain parts of the ROW are lower than the original
level, COMPANY can order CONT RACTOR to bring these parts to the original level. If
the lev el o f t he ROW fo r clean-up is o rdered by COMPAN Y, risk of above mentioned
additional restoration shall not be to CONTRACTOR's account.

In cases where heavy damage has occurred to the structure of the subsoil as a result
of special circumstances, CO MPANY reserves the right to order CONTRACTOR to carry
out special work. Said special work can include:

- spading with dragline (depth 30 - 80 cm);

- spading with dragline (depth 80 - 100 cm);
- fertilizing;
- cover with sand.

If during clean-up operat ions, soil shortages be come appare nt outside the tre nch,
CONTRACTOR shall supplement said soil shorta ge using suitable mate rials, approved
by COMPANY.

If site and/or climatic conditions should render this necessary, COMPANY shall have the
right to order C ONTRACTOR to su spend c ertain pa rts of th e WORK re lated to th e
clean-up and postpone it to a later date.
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(ONSHORE)
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14.17 Soil Surplus

If on site, as a result of the work an d after careful backfillin g and compacting, a sub-
soil surplus ex ists, 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 reject ed
soil which has to be removed. Working up surplus soil or re moval of rejected soil shall
be considered to pertain to the WORK.

To work a soil surplus into the ground CONTRACTOR shall remov e an addit ional strip
of top soil be side the trench. Next the upper layer of sub-soil sh all also be removed.
Both soil types shall be stored separately across a width de pending 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 subse quently the top laye r of sub-
soil and the top-soil shall be re placed in t he co rrect o rder, in acco rdance wit h t he
Specifications.

In case COMPANY has given prior permission for mixe d excavation of the sub-soil as
well as in cases where COM PANY d eems mix ed ex cavation permissible, the above
provision of se parate storage of the uppe r layer of sub-soil sh all not a pply to th e
working up of the soil surplus.

In cases where the soil surplus can be wo rked up in other plots where soil shortages
have arisen due to the WORK, this shall only be done after prior pe rmission by land-
owner, land-user and COMPANY.

14.18 Soil Shortages

If due to unforeseen circumstances duri ng backfilling and compacting there isn't

enough soil to fill the trench properly, or to install the crown he ight as stipulated,
CONTRACTOR shall supply the necessary backfill material.

Soil shortages shall be supplemented and applied before the top-soil is replaced.

The soil to be supplied sha ll be worked up in those loca tions a nd in to th ose la yers
where a soil shortage has been established. The quality of the supplemented soil shall
be equal to that of the shortage.

15.0 MAINTENANCE DURING DEFECTS LIABILITY PERIOD

Defects liability Period (d efined as period of liabilit y in the CONTRACT) means the
period of 12 months calculated from the date certified in the Completion Certificate.

COMPANY reserves the right to carry out inst rumented p igging surv ey o f t he
completed pipeline.

CONTRACTOR shall be responsible for maki ng good with all possible speed at his
expense any de fect in or damage to any portion of the Work whic h may appe ar or
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occur during the Defects liability Period and which arise either:

a) from any defective material (other than supplied by COMPAN Y), workmanship
or design (other than a de sign made, furnished or specified by COMPAN Y and
for which CONTRACTOR has disclaimed responsibility in writing), or

b) from any ac t or omission of CONTRACTOR done or omitte d during the said

period.

If suc h de fect shall appe ar or damage o ccur, COM PANY sh all forthwith inform
CONTRACTOR thereof stating in writing the nature of the defect or damage.

If any such defect or damage be not re medied within a re asonable time , COMPAN Y
may proceed to execute the work at CONTRACTOR's risk and expense, provided that
he does so in a re asonable manner. Such defect or damage can be, but is not limited
to:

- Clean up of ROW, including water courses

- Sagging or sinking of site level or pipe supports
- Sliding of ditch banks
- Repair of fencing or removal of construction fencing
- Repaving of pavements, repair of pavements, repair of coating, painting
- Realigning markers, signs
- Leak/burst of pipe, leaking flanges, washouts
- Short-circuit in casings
- Construction defect s such as dent s, ovality, welding offsets/defects, et c.
detected during intelligent pigging survey.
- etc.

Company reserves the right to have the required Computerised Potential Logging Test
executed during the DE FECTS L IABILITY P ERIOD and whenev er co nditions are mo re
favorable for this job. The work shall at or as soon as practicable after the expiration of
the Defects Liability Period be delivered to COMPANY in the conditions required by the
CONTRACT, fair wear and tear ex cepted, t o t he sat isfaction of COMP ANY.
CONTRACTOR sh all f inish th e w ork, if a ny ou tstanding, a t th e da te of completion as
soon as possible after such date and shall execute all such work.
 Edition : 1

SPECIFICATION
FOR
WELDING OF ONSHORE GAS PIPELINES

SPECIFICATION NO.: MEC/S/05/21/02

(OIL & GAS SBU)

MECON LIMITED
DELHI 110 092
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
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CONTENTS

SL.NO. DESCRIPTION

01.0 SCOPE
02.0 APPLICABLE CODES, STANDARDS & SPECIFICATIONS
03.0 MATERIAL SPECIFICATIONS
04.0 WELDING CONSUMABLES
05.0 EQUIPMENT & ACCESSORIES
06.0 WELDING PROCESSES
07.0 BEVEL CLEANING AND BEVEL INSPECTION
08.0 ALIGNMENT AND SPACING
09.0 WEATHER CONDITIONS
10.0 WELDING
11.0 HEAT TREATMENT
12.0 INSPECTION AND TESTING
13.0 REPAIR OF WELDS
14.0 DESTRUCTIVE TESTING OF WELDED JOINT - BUTT WELDS
15.0 ULTRASONIC INSPECTION
16.0 AUTOMATED ULTRASONIC TESTING (AUT)
17.0 RADIOGRAPHY

ANNEXURE-I - ELECTRODE QUALIFICATION TEST RECORD

ANNEXURE-II - STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION
ANNEXURE-III - FORMAT FOR WELDING PROCEDURE SPECIFICATION (WPS)
ANNEXURE-IV - FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR)
ANNEXURE-V - FORMAT FOR MANUFACTURER'S RECORD FOR WELDER OR WELDING
OPERATOR QUALIFICATION TESTS
ANNEXURE-VI - RADIOGRAPHIC PROCEDURE QUALIFICATION RECORD FOR PIPE WELDING
ANNEXURE-VII - WELDERS IDENTIFICATION CARD
ANNEXURE-VIII - TYPE OF SOURCE AND FILMS TO BE USED FOR RADIOGRAPHY

PREPARED BY: CHECKED BY: APPROVED BY: ISSUE DATE :

(Shalini Singh) (Sunil Kumar) (A.K. Johri) Jan. 2009

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01. SCOPE

This specification stipulates requirements for fabrication of all types of welded joints of
carbon steel main pipeline systems covering the pipeline and its facilities, which will
include the following:

• All line pipe joints of the longitudinal and circumferential butt welded and socket
welded types.

• Branch connections

• Joints in welded/ fabricated piping components.

• Attachments of castings, forgings, flanges and supports to pipes.

• Attachments of smaller connections for vents/ drain pipes and tappings for
instrumentation.

• Welded manifold headers and other sub-assemblies.

Note: Any approval accorded to the Contractor shall not absolve him of his
responsibilities and guarantees.

02. APPLICABLE CODES, STANDARDS & SPECIFICATIONS

All welding works, equipment for welding, heat treatment, other auxiliary functions and
the welding personnel shall meet the requirements of the latest editions of the
following codes, standards and specifications as listed below :-

• Code for Gas Transmission and Distribution Piping System (ANSI B31.8).

• Standard for welding of Pipelines and Related Facilities (API 1104).

• Specification for welding Electrodes and Filler Materials (ASME Sec. II C).

• Non Destructive examination (ASME Sec. V).

• Welding and Brazing Qualification, ASME Sec. IX.

03. MATERIAL SPECIFICATIONS

• In general carbon steel is used in this specification. The details of material

specifications will be given in a welding Specification Chart attached alongwith
other project data sheets.

• The CONTRACTOR will keep a record of test certificates of all the materials for the
reference of the welding engineer.
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04. WELDING CONSUMABLES

The CONTRACTOR shall provide at his own expenses all the welding consumbles
necessary for the execution of the job such as electrodes, oxygen, acetylene etc. and
the same shall be approved in advance by the Purchaser/ Consultant.

The welding electrodes/ filler wires supplied by the CONTRACTOR shall conform to the
class specified in the welding specification chart. The materials shall be of the make
approved by the COMPANY.

The electrode shall be suitable for the welding process recommended and base metal
used. Physical properties of the welds produced by an electrode recommended for the
welding of a particular base metal shall not be lower than the minimum values
specified for the base metal unless otherwise specified in Welding Specification Chart
and shall correspond to the physical properties of the class of electrode adopted. The
choice of electrode shall be made after conducting the required tests on the electrodes
as per relevant standards, and shall be the sole prerogative of the COMPANY.

The CONTRACTOR shall submit batch test certificates from the electrode
manufacturers giving details of physical and chemical tests carried out by them for
each batch of electrode to be used.

Electrode Qualification test records shall be submitted as per Annexure-I with respect
to the electrodes tested by the CONTRACTOR and submitted for approval of the
COMPANY, f or each batch of electrode.

All electrodes shall be purchased in sealed containers and stored properly to prevent
deterioration. The electrodes removed from the containers (except cellulosic 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 any damage to the flux covering.

The electrodes used shall be free from rust, oil grease, earth and other foreign matter
which affect the quality of welding.

Different grades of electrodes shall be stored separately. Cellulosic electrodes used

shall however be used as per specific recommendations of manufacturer.

04.01 Shielding Gas

The composition and purity of shielding gas when required by the welding processes
other than shielded metal arc welding, when permitted by the COMPANY, shall have
prior approval of the COMPANY. Where appropriate, gases or gas mixture of the
following quality shall be used.

a) argon complying with BS 4365

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b) carbon dioxide complying with type 1 specified in BS 4105

c) gas mixture that have been proved to be satisfactory as a result of procedure
approval tests.

When a gas mixture is used which has specified additions, e.g. 2% O2, 5% CO2 the
variation of such addition shall not exceed ± 10% of that stated. Moisture content shall
correspond to a dew point of - 30°C or lower.

05. EQUIPMENT & ACCESSORIES

5.1 The CONTRACTOR shall have sufficient number of welding and cutting equipment,
auxiliaries and accessories of sufficient capacities to meet the target schedule.

5.2 All the equipment for performing the heat treatment including transformers,
thermocouples, pyro-meters, automatic temperature recorders with suitable calibration
arrangements, etc. shall be provided by the CONTRACTOR, at his own expenses and
these shall bear the approval of the COMPANY. Adequate means of measuring current
and voltage shall be available.

5.3 Redoing of any work necessitated by faulty equipment or operation used by the
CONTRACTOR, will be done at his own expense.

06. WELDING PROCESSES

6.1 Welding of various materials under this specification shall be carried out using following
process.

6.1.1 Main line (24” φ & above API 5L Gr. X-70, PSL-2)

Welding shall be carried out by automatic or semi automatic welding process.

6.1.2 Main line (24” φ & above API 5L Gr. X-80, PSL-2)

Welding shall be carried out by automatic welding process. When welding is carried out
only from outside, copper backing shall be used at the root side.

6.2 Tie-Ins and Crossings

Shielded Metal Arc Welding and Semi-automatic Flux Cored Arc Welding shall be used
for tie-ins and crossings.

6.3 Any deviation desired by the Contractor shall be obtained through the written consent
of the Company.

Following agencies for Automatic Welding Systems are acceptable:

a) CRC-Evans Automatic Welding Systems, Houston

b) Pipe Welding Technology, Italy
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c) RMS Welding Systems, Canada

d) Sermier Dasa, France

In case, the bidder proposes to employ any other agency, the proposed agency shall
meet the qualification criteria mentioned in the following paragraph and shall submit
necessary documentation meeting the criteria. The detailed system description and the
procedure shall be submitted to the COMPANY for evaluation and approval

“Automatic welding systems and agencies who have proven track record of high
productivity with satisfactory quality of weld and have done a single project of
diameter 20” or above for a minimum length of 50 km and for a cumulative length of
500 km or above on large diameter Pipe lines in the last ten years shall only be
accepted. CONTRACTOR shall engage only such automatic welding systems and
agencies for the work to be covered by main line automatic welding. The track record
shall be submitted to the COMPANY for approval prior to engagement”.

6.4 The welding specification charts specifically developed for welding of the pipeline under
this project shall be followed. The welding procedure adopted and the consumables
used shall be specifically approved.

6.5 A combination of different welding processes or a combination of electrodes of

different classes/ makes could be employed for a particular joint only after qualifying
the welding procedures to be adopted and obtaining the approval of the COMPANY.

07. BEVEL CLEANING AND BEVEL INSPECTION

Line pipe supplied by COMPANY shall have bevel ends as specified in the applicable
specification for Line Pipe attached with the Bid Package. Any modification thereto, if
required by CONTRACTOR due to his special welding technique shall be carried out by
the CONTRACTOR at his own cost.

Before welding, all rust and foreign matter shall be removed from the bevelled ends by
power operated tools. This shall be effected inside and outside and for a minimum
distance of 25mm 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 COMPANY, satisfactory weld spacing cannot be obtained and
local repair by grinding cannot be successfully done, the damged ends shall be cut and
re-bevelled to the satisfaction of the COMPANY, with an approved bevelling machine.
Manual cutting and weld repairs of bevels is not allowed. Should laminations, split ends
or inherent manufacturing defects in the pipe be discovered, the lengths of pipe
containing such defects shall be removed from the line to the satisfaction of COMPANY.
On pipes which have been cut back, a zone extending 25mm 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 subjected to 100% visual
and 100% dye penetrant/ MPI tests. A report shall be written for all testing and
records kept.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
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834002 OIL & GAS SBU, DELHI

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08. 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 joining the sections of the pipelines, 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 pad or other suitable means approved by COMPANY, at
least 500mm above the ground, unless approved by the COMPANY 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 90° of the pipeline, or
250mm whichever is the lesser. A longitudinal joint shall pass an appurtenance of a
structural element at a minimum distance of 50mm. Should a section of the line
containing uncompleted welds fall from the skids, the CONTRACTOR shall immediately
inform COMPANY.

Every effort shall be made to reduce misalignment by the use of the clamp and
rotation of the pipes to obtain the best fit. For pipe of same nominal wall thickness off-
set shall not exceed 1.6mm. The off set may be checked from outside using dial
gauges. Any branch connection, sleeve, etc. shall be atleast 150mm from any other
weld. 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
COMPANY) 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 internal line-up clamps is mandatory for pipe diameters 10" and
above. However, in some cases (tie-in welds, flanges, fittings, diameter of pipe 10"
etc.) where it is impossible to use internal clamps, an external line-up clamp may be
used.

The internal line-up clamp shall not be released before the entire root pass has been
completed.

When as external line-up clamp is used, all spaces between bars or atleast 60% of the
first pass shall be welded before the clamp is released and the pipe remaining
adequately supported on each side of the joint.

Segments thus welded shall be equally spaced around the circumference of the pipe.
Slag, etc. shall be cleaned off and the ends of the segments shall be prepared by
grinding, so as to ensure continuity of the weld bead.
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09.0 WEATHER CONDITIONS

The parts being welded and the welding personnel shall be adequately protected from
rain and strong winds. In the absence of such a protection no welding shall be carried
out. The completed welds shall be suitably protected in case of bad weather
conditions.

10.0 WELDING

10.1 Root Pass

a) Root pass shall be made with electrodes/ filler wires recommended in the
welding specification chart attached along with other project data sheets. The
size of the electrodes used shall be as per the approved welding procedure.

b) Position or roll welding (for yard double jointing) may be permitted. Separate
procedures shall be submitted and qualified for up hill, down hill, vertical down
and roll welding. The vertical up method of welding shall be used for the root
pass of the tie-ins, special crossings, fittings and special parts, filled welds,
repairs and when an external line up clamp is used. The down hill welding may
be used for root run welding of tie-ins and special crossings when (a) the edges
are machined or have equivalent preparation (b) line up clamps are used and
the fit up is geometrically and mechanically similar to one of the oridinary line
welding without misalignment or uneveness.

c) 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 1.6 mm wherever not specified by the applicable code.

d) Any deviation desired from the recommended welding technique and electrodes
indicated in the welding specification chart shall be adopted only after obtaining
express approval of the COMPANY.

e) Welding shall be continuous and uninterrupted during a pass.

f) On completion of each run, craters, welding irreigularities, slag, etc., shall be

removed by grinding and chiselling.

g) 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
occurance of weld cracks.

h) Fillet welds shall be made by shielded metal arc welding process irrespective of
the thickness and class of piping. Electrode size shall not exceed 3.25mm
diameter for socket joints. Atleast two passes shall be made on socket weld
joints
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i) Root pass of fillet weld for branch connection can also be made by GTAW
process. However other pass shall be made by SMAW process as mentioned
above (point h).

j) Peening shall not be used.

10.2 Joint Completion

The first pass shall be carried out by a minimum of two welders, working
simultaneously and so placed as to cause minimum distortion of the pipe.

The number of welders and the allowable welding sequences shall be as those laid
down in the qualified welding procedure specification. 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 (QWPS).

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 8.0 above. Before
starting the second pass, the first pass shall be cleaned and flattened with rotating
grinders.

The interruption between completion of the first pass and starting the second pass
shall be as stated in the procedure specification.

For crack prevention a top and bottom reinforcement of at least one electrode shall be
applied before lowering the pipe on the skid.

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 atleast 100°C 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.

Electrodes 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 arcs
between the electrodes, electrode holder, welding cable shall be removed by grinding
in accordance with a procedure approved by COMPANY and the repair checked by
ultrasonic, radiographic, magnetic particle or dyepenetrant tests which the COMPANY
feels necessary. The pipe wall thickness after grinding shall not be less that the
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minimum thickness limit permitted for the pipe. Repair of arc-strikes by welding is
prohibited.

The completed weld shall be carefully brushed and cleaned and shall appear free from
spatters, scales, etc.

These requirements apply not only to completed welds but also to the bare strip at
least so wide so as to allow full skid examination at both ends of the pipe to allow a
good ultrasonic inspection when it is required.

11.0 HEAT TREATMENT

11.1 Preheating

Preheating, if required, shall be carried out as per the following :

a) Preheating requirements for the various materials shall be as per the welding
specification chart.
b) Preheating shall be performed using resistance or induction/ heating methods.
Preheating by LPG flame with ring burner may be used with the permission of
the COMPANY under careful supervision.
c) Preheating shall extend uniformly to atleast three times the thickness of the
joint, but not less than 50mm, on both sides of the weld.
d) Preheating temperature shall be maintained over the whole length of the joint
during welding. Temperature indicating crayons or other temperature indicating
devices shall be provided by the CONTRACTOR to check the temperature.

11.2 Postweld Heat Treatment

a) Post weld heat treatment, wherever required for joints between pipes and
fittings, pipe body and supports shall be carried out by the CONTRACTOR at his
expense as per the relevant specifications, applicable standards and the
instructions of the COMPANY.

b) The heat treatment of welded joints shall be carried out as per the
requirements laid down in ANSI B31.8 and other special requirements
mentioned in welding specification chart.

c) The CONTRACTOR shall submit for the approval of the COMPANY, well before
carrying out actual heat treatments the details of the post weld heat treatment
procedure, as per Annexure-II attached, that he proposes to adopt for each
of the materials/ assembly/ part involved.
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d) Post weld heat treatment shall be done in a furnace or by using an electric

resistance or induction heating equipment, as decided by the COMPANY.

e) While carrying out local post weld heat treatment, technique of application of
heat must ensure uniform temperature attainment at all points of the portion
being heat treated. Care shall be taken to ensure that width of heated band
over which specified post weld heat treatment temperature is attained is atleat
as that specified in the relevant applicable standards/ codes.

The width of the heated band centered on the weld shall at least be equal to
the width of weld plus 2" (50mm). The temperature gradient shall be such that
the length of the material on each side of the weld, at a temperature exceeding
half the heat treatment temperature, is atleast 2.5 rt where is the bore radius
and t is the pipe thickness at the weld.

f) Throughout the cycle of heat treatment, the portion outside the heat band shall
be suitably wrapped with insulation so as to avoid any harmful temperature
gradient on the exposed surface of pipe. For this purpose temperature at the
exposed surface of the pipe shall not be allowed to exceed 400°C.

g) The temperature attained by the portion under heat treatment shall be

recorded by means of thermocouple pyrometers. Adequate number of
thermocouples shall be attached to the pipe directly at equally spaced locations
along the periphery of the pipe joint. The minimum number of thermocouples
attached per joint shall be 2 upto 10" dia and 3 for 12" dia and above.
However, the COMPANY can increase the required minimum number of
thermocouples to be attached, if found necessary.

h) Automatic temperature recorders which have been suitably calibrated shall be

employed. The calibration chart of each recorder shall be submitted to the
COMPANY prior to starting the heat treatment operation and its approval shall
be obtained.

i) Immediately on completion of the heat treatment, the post weld heat

treatment charts/ records alongwith the hardness test results on the weld joints
(whenever required as per the welding specification chart) shall be submitted
to COMPANY for its approval.

j) Each joint shall bear an identification number which shall be maintained in the
piping sketch to be prepared by the CONTRACTOR. The joint identification
number shall appear on the corresponding post weld heat treatment treatment
charts. The same identification numbers shall also be followed for identification
on corresponding radiographic films. The chart containing the identification
number and piping sketch shall be submitted to the COMPANY in suitable
folders.
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k) Vickers hardness/ Brinnel hardness of the heat affected zone as well as of the
weld metal, after heat treatment shall be measured using a suitable hardness
tester and shall not exceed the maximum hardness specified in the welding
specification chart. The weld joint shall be subjected to reheat treatment, when
hardness measured exceeds the specified limit, at the CONTRACTOR's own
expense.

l) The CONTRACTOR shall arrange for the hardness testing and shall maintain the
records of all the joints tested. These records shall be checked by the
COMPANY.

12.0 INSPECTION AND TESTING

12.1 General

a) The COMPANY's Inspector shall have free access to all concerned areas, where
the actual work is being performed. The CONTRACTOR shall be also provide
the COMPANY's inspector all means and facilities necessary to carry out
inspection.

b) The COMPANY is entitled to depute its own inspector to the shop or field where
pre-fabrication and erection of pipelines are being done, with (but not limited
to) the following objectives :-

i. To check the conformance to relevant standards/ specifications and

suitability of various welding equipment and the welding performance.
ii. To supervise the welding procedures qualification.
iii. To supervise the welder's performance qualification.
iv. To carry out visual/NDT examination of the weldings.
v. To check whether shop/ field welding is being executed is in
conformity with the relevant specification and codes of practice
followed in pipe construction.

c) CONTRACTOR shall intimate sufficiently in advance the commencement of

qualification tests, welding works and acceptance tests, to enable the
Company’s inspector to be present to supervise the same.

12.2 Welding Procedure Qualification

a) Welding procedure qualification shall be carried out in accordance with the

relevant requirements of API 1104 latest edition or other applicable codes and
other special requirements of the specification / job requirements by the
CONTRACTOR at his expense. The CONTRACTOR shall submit the welding
procedure specification chart format as per Annexure-III (attached)
immediately after the receipt of the order.
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b) COMPANY's inspector will review, check and approve the welding procedure
submitted and shall release the procedure for procedure qualification tests. The
procedure qualification test shall be carried out by the CONTRACTOR under
field conditions at his own expense. A complete set of test results in format as
per Annexure-III & Annexure-IV (attached) shall be submitted to the
COMPANY's Inspector for approval immediately after completing the procedure
qualification test and atleast 2 weeks before the commencement of actual
work. 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 penetrant examination, charphy V-notch etc. shall be
carried out on specimens. It shall be the responsibility of the CONTRACTOR to
carry out all the tests required to the satisfaction of the COMPANY's Inspector.
The destructive testing of welded joints shall be as per Clause 14.0.

12.3 Welder's Qualification

a) Welders shall be qualifed 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 12.5 and 16.0 of this specification. The COMPANY's Inspector shall
witness the test and certify the qualification of each welder separately. Only
those welders who have been approved by the COMPANY's Inspector shall be
employed for welding. CONTRACTOR shall submit the welder qualification test
reports in the standard format as shown in Annexure-V and obtain express
approval, before commencement of the work. It shall be the responsibility of
CONTRACTOR to carry out qualification tests of welders and obtain written
approval, before commencement of works.
b) The welders shall always have in their possession the identification card as
shown in Annexure-VII and shall produce it on demand by the COMPANY's
Inspector. It shall be the responsibility of the CONTRACTOR to issue the
identity cards after it has been duly certified by the COMPANY.
c) No welder shall be permitted to work without the possession of identity cards.
d) 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 unqualfiied welder shall be cut and redone by a qualified
welder at the expense of the CONTRACTOR.

12.4 Visual Inspection

Inspection of all welds shall be carried out by COMPANY as per the latest editions of
the applicable codes and specifications. All finished welds shall be visually inspected for
parallel and axial alignment of the work, excessive reinforcement, concavity of welds,
shrinkage, cracks, under-cuts, dimensions of the weld, surface porosity and other
surface defects. Undercutting adjacent to the completed weld shall not exceed the
limits specified in the applicable standard/ code.
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12.5 Non Destructive Examination

12.5.1 The non destructive examination of one hundred percent (100%) girth welds will be
required by the COMPANY.

The non-destructive examination shall mainly consist of examination using Automated

Ultrasonic Testing (AUT) as detailed in clause no. 16.0. This shall be applicable for all
welds made by automatic GMAW process with narrow gap edge preparation and welds
made by semi-automatic FCAW process.

The CONTRACTOR shall make all the arrangements for the AUT of work covered by
the specification at his expense. The CONTRACTOR shall furnish all the reports to the
COMPANY, immediately after examination together with the corresponding
interpretation reports on the approved format. The details of the AUT reports along
with the joint identification number shall be duly entered in a register and signed by
the CONTRACTOR and submitted to the COMPANY for approval. The COMPANY will
review all the AUT records of welds and inform the CONTRACTOR to those welds,
which are unacceptable. The decision of the COMPANY shall be final and binding in this
regard.

For 150# Rating Pipeline, welds shall meet the standards of acceptability as set forth in
API 1104. However for higher class rating pipeline welds shall meet the standards of
acceptability as set forth in API 1104 and as well as the requirements laid in
subsequent paragraphs.

The CONTRACTOR shall make all the arrangements for the NDT work covered by the
specification at his expense.

All requirements mentioned in the specification shall be arranged and executed by the
CONTRACTOR through his own resources. In addition, Radiography examination shall
be required in the following cases as per clause no. 17.0 of this specification :

a) On the first 100 welded joints corresponding to each automatic GMAW welding
procedure used.
b) When welds are repaired.
c) When in the opinion of COMPANY, radiography inspection is required to confirm
or clarify defects indicated by Ultrasonic examination.
d) Welding of Transition piece of pipe.

In addition, Radiography inspection may be required for certain critical welds of the
pipeline, i.e. tie-ins, welding of valves, flanges, randomly selected at COMPANY
discretion. All fillet and groove welds, other than those AUT examined, shall be
subjected to Dye-Penetrant /MP testing followed by manual Ultrasonic testing.

The non-destructive testing system used for inspecting welds must be approved by the
COMPANY.
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All other welds and Tie-in joints having API bevel shall be examined by Radiography.
When Radiography is used, the provisions stated in this para shall be applicable.

- For all production welds, X-ray Radiography by internal crawlers be used.

Welds shall meet the standards of acceptability as set forth in API 1104 and as well as
the requirements laid in subsequent paragraphs.

The CONTRACTOR shall make all the arrangements for the Radiography examination
of work covered by the specification at his expense.

The COMPANY will review all the radiographs of welds and inform the CONTRACTOR
regarding unacceptable welds. The decision of the COMPANY shall be final and binding
in this regard.

All the 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 clause no. 15.0 of this specification:

a) On the first 10 welded joints corresponding to each automatic GMAW welding

procedures used.
b) When welds are repaired.
c) When in the opinion of COMPANY, Ultrasonic inspection is required to confirm
or clarify defects indicated by Radiography.

In addition, Ultrasonic inspection may be required for certain critical welds of the
pipeline, i.e. tie-ins, welding of valves, flanges, randomly selected at COMPANY
discretion. All fillet and groove welds, other than those are subjected to Radiography,
shall be subjected to Dye-Penetrant/MP inspection. The non-destructive testing system
used for inspecting welds must by approved by the COMPANY.

Acceptance Criteria

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 COMPANY exhibits imperfections greater than the limits stated in API-1104
latest edition or as superseded in this specification shall be considered defective and
shall so be marked with an identification point marker.

In addition to the API-1104 requirements, the welds containing cracks including crater
cracks regardless of size of location are unacceptable.

1. Any length of inadequate penetration of the root bead as defined by API-

1104 is not acceptable except that root concavity is allowed as per API 1104.
2. Any amount of incomplete fusion at the root of the joint as detailed in API
1104 is considered unacceptable.
3. Unrepaired burn through areas are unacceptable.
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Suitable records shall be maintained by the CONTRACTOR as desired by the COMPANY

on the day to day work done on welding, radiography, ultrasonic testing. The
CONTRACTOR shall present the records to the COMPANY on day to day basis and
whenever demanded, for approval.

12.6 Destructive Testing

The COMPANY has the authority to order the cutting of upto 0.1% of the total number
of welds completed for destructive testing at no extra cost of COMPANY. The
destructive testing of weld joints shall be made as per Clause 14.0.

In addition, welds already cut out for defects for any reason may also be subjected to
destructive testing. The sampling and the re-execution of welds shall be carried out by
the CONTRACTOR at his own expense. 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 COMPANY's opinion the procedure shall be re-qualified.
The weld joint represented by unsatisfactory welds shall stand rejected unless
investigation prove otherwise.

13.0 REPAIR OF WELDS

13.1 With the prior permission of COMPANY, 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) thorough thickness repair (b)
external repair and (c) internal repair. Welders shall be qualified in advance for repairs.
The root pass, for repairs opening the root, shall be done by the vertical uphill
technique. The procedure shall be proven by satisfactory procedure tests to API 1104
including the special requirement of the specification, and shall also be subject to
metalographic examination, hardness surveys and Charpy tests to determine the
effects of repair welding on the associated structure.

Root sealing or single pass repair deposit shall not be allowed. Internal root defects
shall be ground thoroughly and welded with a minimum of two passes. However, while
grinding for repairs, care shall be taken to ensure that no grinding marks are made on
the pipe surface anywhere.

The repair shall be subjected, as a minimum requirement to the same testing and
inspection requirements as the original weld. The re-radiography of repaired weld shall
be limited to 6” weld length on either edge of the repaired area. 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. Single pass repairs
shall be subjected to 100%, Dye-Penetrant / MP testing.
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Repairs are limited to a maximum of 30% of the weld length. Not more than two
repairs are permitted on the same location. All repairs shall be carried out the day after
initial Radiography or earlier. A report of all repairs shall be maintained by
CONTRACTOR and submitted every day to the Company / Consultant.

13.2 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.

14. DESTRUCTIVE TESTING OF WELDED JOINT - BUTT WELDS

14.1 Preparation

Having passed the visual and the non-destructive-inspection the test weld shall be
subject to mechanical test.

After satisfactory completion of all visual and non-destructive testing the test weld shall
be set aside for a period not less than 24hours. 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. Having passed the visual and the nondestructive inspection, the
test weld shall be subjected to mechanical test.

Weld specimens shall be taken from the positions indicated in Fig. 1 of this
specification from areas as free from defects as possible; for this reason it is necessary
to take the previous non-destructive tests into account. The minimum number of tests
to be carried out is given in Table-1 of this specification.

The tests shall be carried out in laboratories approved by the COMPANY. The
specimens shall be prepared in accordance with the figures given in the paragraphs
which refer to the individual tests.

14.2 Tensile Strength

Specimens shall be taken from the position indicated in Fig. 1 & 1A of this
specification. Two ISO type specimens and two API - type specimens shall be taken.

The ISO test specimen are shown in Fig. 2 of this specification.

14.2.1 Method

The test shall be carried out in accordance with ISO:375.

Table-1
Type and Number of Test Specimens for
Procedure Qualification Test & Production Welds

Pipe Size, Number of Specimens

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Out Side
Tensile Tensile Nick Root Face Side Macro Hard- Impact Total
Diamter-
API ISO Break Bend Bend Bend Bend ness
Inches
Wall Thickness - ½ inch (12.7mm) and Under

Under 2-3/8 0 0 2 2 0 0 0 0 0 4

2-3/8 to 4- 0 0 2 2 0 0 0 0 0 4
½ incl.

Over 4-½ 2 0 2 2 2 0 2 2 12 24
less than
12.75

12- 3/4 and 2 2 4 4 4 0 2 2 24 44

over

Wall Thickness - Over ½ inch (12.7mm)

4-½ and 0 2 0 0 0 2 0 0 0 4
smaller

Over 4-½ 2 0 2 2 2 0 2 2 12 24
less than
12-3/4

12-3/4 and 2 2 4 0 0 8 2 2 24 44
over

14.3 Nick-Break Test

14.3.1 Preparation

Specimens for Nick-break test with notches thus worked can break in the base metal,
instead of in the fusion zone; therefore an alternative test piece may be used after
authorisation by the COMPANY with a notch cut in the reinforcement of outside weld
bead to a maximum depth of 1.5mm measured from the surface of the weld bead.

14.4 Macroscopic Inspection

14.4.1 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 macrosection 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.

14.4.2 Method

Specimens shall be carefully examined under the microscope, with a magnification of

atleast 25 times (25:1). The COMPANY may ask for a macrograph with 5 times (5:1)
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magnification for DOCUMENTATION purposes.

14.4.3 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.

14.5 Hardness Test

14.5.1 Preparation

The prepared macrosection is to be used for hardness testing using the Vickers
method with 10 kg load Indentations are to be made along traverses each
approximately 1mm below the surface on both sides 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 0.5mm each into unaffected materials, and starting as close to the
fusion line as possible.

One indentation on each side of the weld along each traverse is to be made on parent
metal. Refer Fig.3. The indentations are to be made in the adjacent regions as well on
the opposite sides of the macrosection along the specified traverses.

14.5.2 Method

The test shall be carried out in accordance with Recommendation ISO R81, Vickers
hardness, using a laboratory type machine controlled as pre-recommendation ISO R146
and using a diamond pyramid penetrator set at 2.37 rad (136°) with a load of 10 kg.

14.5.3 Requirements

Hardness value shall not exceed the limit specified in welding Specification chart. In
case of a single reading having a slightly (+10 HV) higher value 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 affected zone shall not exceed 100 HV
with respect to the average hardness of the values obtained for the base metal. If
these additional tests give a hardness within the specification limit the slightly higher
value may be accepted.

14.6 Charpy - V - Notch Impact Test

14.6.1 Specimens shall be taken from the position indicated in Fig. 1 of this specification. The
test specimens will be prepared in accordance with ISO R148. Charpy V-notch
specimens shall have dimensions as given in Fig. 3 of this specification.
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Three test specimens shall be taken from each sample and they shall be cut and
worked so that their length is transverse 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 :
Sl. Nominal Wall Thickness in mm Test Specimen width mm
No.
1. Over 12 10
2. Over 9.5 and upto 12 7.5
3. From 7 upto 9.5 5
4. Less than 7 2.5

14.6.2 Test Method

The test shall be carried out as indicated in ISO R148 "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 bath. The test temperature
shall be as mentioned in Special conditions of the Contract.

14.6.3 Requirements (Note-1)

The impact energy shall be as follows :

Sl. Test Specimen in "Average of three Minimum Single

No. mm Specimens (Note-2) Value (Note-1)
Joules (Min.) Joules

1. 10.0 27.0 22.0

2. 7.5 21.5 17.0
3. 5.0 18.5 15.0
4. 2.5 10.0 8.0
Note :

1) Only one value is permitted to be lower than average value upto the value
specified.
2) These values are specified for resistance to brittle fracture only, where
additional requirements are specified in project data sheet. (Ex. pipeline
materials with arrest properties i.e. a higher upper shelf charpy V-energy for
resistance against propagating ductile fractures) the same shall be followed.

14.7 Bend Test Requirements

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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' : 3 t + 1.6mm
Width of the die `C' : 50.8mm

The acceptance criterion on shall however be as per para 2.643 and 2.653 of API 1104
nineteenth edition Sept. 1999.

Note : t = thickness of specimen

15. ULTRASONIC INSPECTION

In addition to the radiographic inspection, ultrasonic inspection is required as per

conditions listed in paragraph 12.5 of this specification. This section concerns manual
ultrasonic inspection. However ultrasonic by automatic equipment may be used if
approved by the COMPANY.

15.1 Equipment and Operators

The CONTRACTOR who carries out the ultrasonic inspection 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 recognised standard (ASME Sec. V or
equivalent) and they shall have as minimum level II as described in para 11.4.3, API
1104; nineteenth edition. 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

The COMPANY 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 inspection shall supply all the
instruments necessary for their execution on site.

15.2 Specification for Ultrasonic Inspection Procedure Qualification

Before work begins, the CONTRACTOR shall present a specification describing the
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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.

15.3 Qualification of Ultrasonic Inspection Procedure

The ultrasonic inspection procedure shall be approved by the COMPANY. Before

inspection begins, the COMPANY may require the qualification test of the ultrasonic
inspection procedure. This specification test consists in testing (under normal operating
conditions) some CONTRACTOR welds made according to the same production
procedure, where there are typical defects the test intends to detect.

This test shall be conducted in the presence of the COMPANY. The Ultrasonic
inspection procedure shall be approved by the Company.

15.4 Test Procedure

Circumferential welds shall be inspected from both sides using angled probes.

The surface with which the probes 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 50mmwide on both sides of the weld with steel wire brushes and anyhow the
cleaned strip must be atleast wide enough to allow full skip examination.

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.
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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 the COMPANY, are satisfied.

b) continuous operation

All the instruments and equipment shall be approved by the COMPANY before
being used. The COMPANY has the authority to reject any item which is
considered unsuitable. The decision of the COMPANY is final. The
CONTRACTOR appointed to carry out ultrasonic inspections shall also ensure
the operational efficiency and maintenance of the instruments and equipment,
and shall immediately substitute any item rejected by the COMPANY.

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'.

15.5 Ultrasonic Instruments

The Ultrasonic Instruments shall satisfy the following:

 be pulse-echo type, able to generate, receive and display, on the screen a

cathode ray tube (CRT) pulse at frequencies between 1 and 6 MHz. The useful
part of the CRT screen shall be at least 70mm wide and at least 50mm 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 this accuracy shall
be certified by the instrument manufacturer.

 may be powered by a battery or an electric generator. In the first case, the

autonomy of operation (endurance) of the instrument shall be sufficient to
carry on working without frequent interruptions, and the instruments 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 stabilising device with a
tolerance of ±2 Volts.

15.6 Probes

The probes used shall have dimensions, frequencies, and a refraction angle suited to
the type of steel, the diameter, the thickness of the pipe and to the joint design.

15.7 Reference Sample Pieces

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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
calibration block ASTM E-428.

For manual Ultrasonic testing and automated Ultrasonic testing, the reference sample
pieces shall be as described in API 1104, Nineteenth Edition, para 11.4.5.

15.8 Calibration

The calibration, qualification of the testing procedure shall be done as provided in API
1104.

15.9 Regulation of Amplification During Production Testing

Scanning sensitivity shall be as provided in API 1104 para 11.4.7.2 &11.4.7.3.

15.10 Qualification of Ultrasonic Testing Operators

Before the inspection begins or during the same inspection, the COMPANY may require
a qualification test for the ultrasonic equipment operators.

15.11 Evaluation of Indications Given by Ultrasonic Tests

Each time that echoes from the weld bead appear during production testing, the
instrument amplification shall be altered to coincide with the reference amplification
and the probe shall be oved until maximum response is obtained, paying attention all
the time of the probe-tube coupling.

If, under these conditions, the heights of the defect echo is equal to or greater than
that of the reference echo, the defect shall be evaluated according to other clauses 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 that 50% of the
reference echo, will not be considered. If returns are above 50% but lower than 100%
of the reference echo, and if the operator has good reasons to suspect that the returns
are caused by unfavourably oriented cracks, the same shall be informed to the
COMPANY. 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.

15.12 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
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paste appropriate for the temperature of the section to be examined.

16.0 AUTOMATED ULTRASONIC TESTING (AUT)

 INTRODUCTION

The specification shall be applicable for Automated Ultrasonic Testing (AUT) system
suitable for pipeline girth welds. The system shall be based on focused pulse-echo,
tandem or through transmission methods enhanced with mapping image and
augmented by Time Of Flight Diffraction (TOFD) technique.

 REFERENCE DOCUMENTS

ASTM E 1961-98 “Standard Practice for Mechanized Ultrasonic examination of Girth

Welds using Zonal Discrimination with Focused Search Units”. The inspection system
shall meet and exceed the requirements of ASTM E 1961-98.

Appendix-E, “Automated Ultrasonic Girth Weld Testing”, OS-F101, Submarine Pipeline

Systems, January 2000.

API Std. 1104 – “Welding of Pipeline and Related Facilities”.

 APPROVED AGENCIES

Following agencies for Automatic Ultrasonic Testing (AUT) are acceptable:

a) RTD Quality Services, Rotterdam, Netherlands

b) SHAW Pipeline Services, Canada
c) WELDSONIX, USA
d) UT Quality, Canada
e) SCI, Spain
f) SIEVERT India Private Ltd., India

In case bidder proposes to employ any other agency, the proposed agency shall meet
the qualification criteria listed below and shall submit necessary documentation. The
detailed system description and procedure shall be submitted for COMPANY evaluation/
approval.

Automatic Ultrasonic Testing (AUT) systems and agencies who have proven track
record and have done a single project of diameter 20” or above and minimum length
of 50 km and also have inspected a cumulative length of 500 km or above on large
diameter Pipe lines in the last ten years shall only be accepted. The agency should
have been approved by the reputed inspection agencies. The track record shall be
submitted to the COMPANY for approval prior to engagement.
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 AUT SYSTEM

The system shall meet and exceed the requirements of ASTM E1961-98.

The system shall provide an adequate number of examination channels to ensure the
complete volumetric examination of the weld through the thickness in one
circumferential scan. The evaluation zones should be of maximum 2.0mm height. The
instrument linearity should be such that the accuracy is within 5%.

Each examination channel should be selective for pulse-echo or through transmission

mode gate position and length for a minimum of two gates and gain.

TOFD techniques & B-scan mapping should be available to improve characterization.

Recording thresholds should be selectable to display signals between 0 and 100% of
full screen height for simple amplitude and transit time recording and it should be from
0 to 100% for B-scan or mapping type recording of data. Two recordable signals
output per gate should be available being either analog or digital and representative
of signal height and time of flight. Measuring distance accuracy of circumferential weld
shall be within 1.0 cm from zero (0) position.

Electronic noise shall be lower than acoustical noise in all channels for the probes and
sensitivities to be used during inspection. The signal to noise ratio for each channel
during examination shall be at least ≥ 20 dB for shear waved probes.

 COUPLING

The coupling shall be obtained by using a medium suitable for the purpose. It shall be
suitable for the temperature used. No residue shall remain on the pipe surface. A
method should be employed to determine that constant coupling is achieved during
examination. An examination of the test piece with its surface wiped dry should
produce a record showing an absence of the couplant recording signal.

 SEARCH UNITS

The search unit shall meet all the requirements specified in Para 6.4 of ASTM E1961¬-
98.

 CALIBRATIONS

Reference standards shall be manufactured from a section of unflawed project specific

line pipe supplied by pipeline CONTRACTOR. The agency shall then submit the
reference standard design to the COMPANY before manufacturing. No design changes
in the reference standard shall be made without the prior approval. Annexure A3 of the
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standard ASTM E1961-98 provides an example for minimum requirements for

reference standards.

The system shall be optimized and calibrated as stated in Para 7.0 and 8.0 of ASTM E
1961-98. Static and Dynamic calibration shall be done and the approved procedure
shall clearly state the gain setting fixed for each channel.

The reference standard should be used to verify the scanning sensitivity at the start of
each shift and thereafter at intervals not exceeding two (2) hours or ten (10) welds.

A re-calibration shall be carried out if :

a) The calibration of an inspection function differs more than +/- 3dB from the
previous calibration
b) The gate settings need to be adjusted with more than +/- 1.5 mm with the
previous calibration
c) After a weld repair
d) After equipment breakdown.

In case the calibration differs from the initial setting, outside the given tolerances, the
applicable probe(s) and coupling shall be checked. If the calibration has to be changed,
the welds before this calibration upto the previous calibration will be re-examined.

The reference standard design for calibration shall be approved separately. The
procedure for calibration and verification shall be same as given above.

 PROCEDURE

A detailed AUT procedure shall be prepared and qualified for each wall thickness and
joint geometry to be examined prior to the start of any NDT work. Repair procedure
shall be separately qualified for each joint geometry. All the requirements of ASTM
E1961-98 should be met. The procedure as a minimum shall include the following:

- Functional description of equipment

- Reference standards and guidelines controlling equipment maintenance
- Instructions for scanning device, Ultrasonic instrument, Ultrasonic electronics,
Hard & Software for recording processing, Display presentation and storage of
inspection data
- Transducer configuration(s), characteristics types coverage.
- Number of examination zones for each wall thickness to be examined.
- Gate settings
- Equipment settings -Description of calibration blocks including type, size and
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location of calibration reflectors, a) calibration intervals, b) calibration records -

Static and dynamic calibration procedure
- Identification of inspection starting point scanning direction and indication of
length inspected
- Method for scanner alignment and maintenance of alignment
- Allowed temperature range
- Couplant coupling and coupling control and channels provided to indicate lack
of coupling and method to ensure constant coupling
- Transducer and over all functional checks
- Height and length sizing methodology
- Surface condition and preparation
- Description of inspection work
- Acceptance criteria and instructions for reporting including example of recorder
chart and form to be used.
- A table indicating corresponding channel no., probe, type, location of reflector,
probe coupling etc.

 Setting of Inspection Gates

Pulse-echo and Tandem Channels

With each transducer positioned for the peak signal response from the calibration
reflector the detection gates are to be set. The gate shall start 2-6mm (allowance for
width of heat affected zone) before the theoretical weld bevel preparation. The gate
ends shall be after the theoretical weld centerline. All gates will be programmed to
record amplitude and/or transit distance information. The length of the transit distance
in the root channel will be extended to enable root penetration registration.

Mapping Channels

The mapping gates in the body of the weld shall start 2-6mm (allowance for width of
heat affected zone) before the theoretical weld bevel preparation. The gate length will
be extended to enable cap reinforcement registration. The mapping gates in the root
will be set identical to the pulse-echo transit distance channels to enable the
registration of the root penetration.

TOFD Channel

The TOFD gate start will be set 1 µSec before the arrival of the lateral wave and
should extend up to the first back wall echo to achieve full cover of wall thickness.

Note: The gate settings may be altered if geometry indications dictate.

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Sensitivity Settings

With each transducer positioned for the peak signal response from the calibration
reflector (flat bottom holes), the detection gates are to be set. In this position, the
probe holder is fixed to the probe frame. The equipment sensitivity (echo amplitude)
for all inspection channels shall be set at 80% Full Screen Height (FSH).

Mapping channels in the body of the weld will be used to detect the presence of
porosity and in addition to identify the position of the weld cap reinforcement for
pattern recognition purpose. The sensitivity as a minimum is equal to the related
pulse- echo channels, increased with additional gain to ensure proper detection.

Mapping channels in the root will be used to identify the position of the root
penetration for pattern recognition purpose. The sensitivity as a minimum shall be
equal to the related pulse-echo channels, increased with additional gain to ensure
proper detection.

The lateral wave of the TOFD channel sensitivity is set at 80% FSH.

 TRAINING AND QUALIFICATION

1. All Inspectors’ of the COMPANY (Owner) shall be imparted training at the

CONTRACTOR’s cost. The inspector shall be provided complete awareness and
knowledge regarding the equipment, limitations, capabilities complete range,
method of operation, calibration, scanning, including development of suitable
procedure, training on variables effecting the system performance and
interpretation of results.

2. The Ultrasonic lead operator performing the examination shall be qualified in

accordance with the COMPANY’s written practice and in accordance with ASNT
Practice SNT-TC-1A and EN 473 Level II. He should have experience in
multichannel UT equipment and be trained in using mechanized UT
manipulators.

 FIELD EXAMINATIONS AND REPORTING

All the requirements stated in Para 9 and 10 of ASTM E1961-98 shall be followed a
minimum.

 INTERPRETATION OF RESULTS

General
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With the transit distance measurements and with the information from the mapping
and TOFD channels visible on the result presentation, indications shall be judged
whether they are from the weld geometry or from the defects. The coupling channels
will check for coupling loss; in case of coupling loss, a re-scan shall be carried out.

Inspection Result

The inspection result should be evaluated and/or reported as follows:

Welds shall be evaluated using both the pulse-echo and TOFD criteria shown below.

This shall be performed in parallel and rejection against either of these criteria shall be
cause for rejection of the weld. The exceptions to this are described in the following
notes:

1. All indications in the pulse echo channels should be evaluated which exceed the
threshold level of 20% FSH.
2. Defect length shall be measured for the pulse-echo channels from the point
where the signal exceeds 20% FSH to the point the signal falls below. The
largest height assessed with TOFD or the greatest measured amplitude with
pulse-echo shall be assumed to apply over the whole defect length.
3. If the indication cannot be resolved by TOFD i.e. the upper and lower flaw
diffraction tips cannot be separately distinguished, no measurement can be
made to determine the defect height. In this case, the signal from the pulse-
echo channels will be solely used to determine that particular area of the scan.
4. Defects shall be assessed for interaction as follows:

a) Horizontal interaction
If the distance between two adjacent defects is less than the length of
the smaller of the two defects, then the defect shall be treated as a
single defect.

b) Vertical interaction
Vertical interaction of defects shall be assessed using TOFD. If the
distance between the two adjacent defects is less then the height of the
shorter of the two defects, than the defect shall be treated as a single
defect. Where the individual defects cannot be resolved by TOFD for
the vertical interaction, then the defects are assumed to interact and
shall be treated as a single defect.

5. The maximum allowable accumulated defect length shall be as per the criteria
given in welding specification.
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 ACCEPTANCE CRITERIA

Weld quality shall be judged on the basis of the acceptability criteria mentioned in
welding specification.

17.0 RADIOGRAPHY

17.1 Scope

This covers the radiographic inspection of all types of welded joints of the main
pipeline.

The welded joints shall include the following :-

i. Full girth welds on the mainline construction including double jointing of pipe, if
adopted.

ii. Welds for installation of block valves, insulating joints and other appurtenances
and tie-ins.

iii. Welds at scraper launching and receiving barrels.

iv. Terminal Piping

17.2 Applicable Standards

This specification shall apply in conjunction with the following (all latest edition):

i. API 1104, Standard for welding Piplines and Related Facilities.

ii. ANSI B31.8, Code for Gas Transmission and Distribution Piping Systems.

iii. ANSI B31.4, Code for Liquid Petroleum Transportation Piping Systems.

iv. ASTM E94, Recommended practice for Radiographic Testing.

v. ASTM E142, Standard Method for Controlling Quality of Radiographic Testing.

vi. The American Society for Non-destructive Testing. Recommended Practice No.
SNT - TC-1A Supplement A.

17.3 Procedure

17.3.1 The radiographic examination procedure to be adopted shall be submitted by the

CONTRACTOR as per Annexure VI.
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17.3.2 The procedure of radiographic examination shall be qualified to the entire satisfaction
of COMPANY prior to use. It shall include but not be limited to the following
requirements :

i. Lead foil intensifying screens, at the rear of the film shall be used for all
exposures.

ii. Type 2 and 3 films as per ASTM E-94 shall be used.

iii. A densitometer shall be used to determine film density. The transmitted film
density shall be 2.0 and 3.5 throughout the weld. The unexposed base density
of the film shall not exceed 0.30.

iv. Radiographic identification system and documentation for radiographic

interpretation reports and their recording system.

17.3.3 The CONTRACTOR shall qualify each procedure in the presence of the COMPANY prior
to use.

17.3.4 The procedure of radiographic examination shall produce radiographs of sufficient

density, clarity and contrast so that defects in the weld or in the pile adjacent to the
weld, and the outline and holes of the penetrameter are clearly discernible.

17.3.5 All the girth welds of mainline shall be subjected to 100% radiographic examination.
The CONTRACTOR shall furnish all the radiographs to the COMPANY, immediately after
processing them, together with the corresponding interpretation reports on approved
format. The details of the radiographs all alongwith the joint identification number shall
be duly entered in a register and signed by the CONTRACTOR and submitted to the
COMPANY for approval.

17.3.6 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 Table-4 of API 1104. The minimum film
overlap, in such cases, shall be 40mm. 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.

17.3.7 Three copies of each acceptable radiographic procedure (as per Annexure-VI) and
three copies of radiographic qualification records, shall be supplied to COMPANY. One
set of the qualifying radiographs on the job shall be kept by the CONTRACTOR's
authorised representative to be used as a standard for the quality of production
radiographs during the job. The other two sets shall be retained by COMPANY for its
permanent record.

17.3.8 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 COMPANY by the
CONTRACTOR.
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17.3.9 The CONTRACTOR shall, on a daily basis, record for each radiograph (1) radiograph's
number, (2) welder's number (3) approximate chainage of weld location, (4) whether
or not the welds meet the specified acceptance standards and (5) 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.

17.3.10 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 COMPANY daily
when possible, but in no event later than noon of the following day.

17.3.11 The CONTRACTOR shall provide all the necessary facilities at site, such as a dark room
with controlled temperature, film viewer etc. to enable the COMPANY to examine the
radiographs.

17.3.12 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 COMPANY.

17.3.13 COMPANY shall have free access to all the CONTRACTOR's work facilities in the field.

17.3.14 Any approval granted by the COMPANY shall not relieve the CONTRACTOR of his
responsibilities and guarantees.

17.4 Radiation Source

17.4.1 Radiographic examination shall be carried out using x-radiations, Radiographic

examination by Gamma rays may be allowed, at the discretion of the COMPANY, in
case of inaccessible joints. Radiography by Gamma-Ray for tie-in-joints shall be
acceptable provided D4 AGFA film or equivalent is used and the required sensitivity
obtained.

17.4.2 Whenever possible, pipeline welds will be inspected by placing the radiation source
inside the pipe, on the pipeline axis, with a radiation of 6.28 rad. (360°C).

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 40mm 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.

17.5 Level of Quality

The quality level of Radiographic sensitivity required for radiographic inspection shall
be at least equivalent to the values in Fig. 6
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17.6 Penetrameters

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 DIN54109 or ISO1027. For radiographs made with the
source on the outside, a penetrameter shall be placed on each side of the film with the
smaller wiere 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 penetrameter approximately equally spaced around the circumference shall be
used. During the procedure qualification, IQI shall be placed both on the source side
and on the film side. The sensitivity obtained with IQI on the source side shall not be
less than the values shown in Fig. 6 of this 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.

The COMPANY may authorise use of types of IQI other than those planned, provided
that they conform with recognised standards and only if the CONTRACTOR is able to
demostrate that the minimum sensitivity level required is obtained. For this
demostration, 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, which must be visible in the test radiograph.

17.7 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 interpretation.
These markers positions shall also be marked on the part to be radiographed and shall
be maintained during radiography.

17.8 Protection and care of film

17.8.1 All unexposed films shall be protected and stored properly as per the requirements of
API 1104 standard and ASTM E.94.

17.8.2 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.

17.9 Re-radiography

17.9.1 The weld joints shall be re-radiographed in case of unsatisfactory quality of the
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radiographs, at the expense of the CONTRACTOR.

17.9.2 All the repaired weld joints shall be re-radiographed at no extra cost to the COMPANY
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.

17.9.3 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.

17.9.4 The COMPANY 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 the COMPANY.

17.10 Qualification of Radiographers

17.10.1 Pipeline radiographers shall be qualified in accordance with the requirement of API
1104 and to the full satisfaction of COMPANY.

17.10.2 Certification of all the radiographers, qualified as per 16.10.1 above, shall be furnished
by the CONTRACTOR to the COMPANY before a radiographer will be permitted to
perform production radiography. The certificate record shall include :

i. Background and Experience Record

ii. Training Course Record
iii. Technical Examination Record
iv. Doctor's report on radiographer's Oaecuer 0-1 acquity eye test.
v. Date of qualification

17.10.3 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.

17.11 Preservation of Radiographs

17.11.1 The radiographs shall be processed to allow storage of films without any discoloration
for at least three years. All the radiographs shall be presented in suitable folders for
preservation alongwith necessary documentation.

17.11.2 All radiographs shall become property of the COMPANY.

17.12 Equipment and Accessories

17.12.1 CONTRACTOR shall make necessary arrangement at his own expense, for providing
the radiographic equipment, radiographic film and all the accessories for carrying out
the radiographic examination for satisfactory and timely completion of the job.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 34 of 54

TITLE WELDING OF ONSHORE GAS MEC/S/05/21/02 REVISION : 1

PIPELINES
EDITION : 1

17.12.2 For carrying out the mainline radiographic examination the 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 upto 4.0 without damaging the film.

17.13 Radiation Protection

17.13.1 CONTRACTOR shall be responsible for the protection and personnel monitoring of
personnel with or near radiation sources.

17.13.2 The protection and monitoring shall comply with local regulations.

17.13.3 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 agency of India in
this regard and COMPANY 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 the COMPANY for all necessary personnel shall
be made available for use and maintained for immediate and proper use by the
CONTRACTOR.

17.14 Display of Safety Instructions

17.14.1 The safety provisions shall be brought to the notice of all concerned by display on a
notice board at a prominent place at the work spot. The person responsible for the
"safety" shall be named by the CONTRACTOR.

17.15 Enforcement of Safety Regulations

17.15.1 To ensure effective enforcement of the rules and regulations relating to safety
precautions, the arrangement made by CONTRACTOR shall be open to inspection by
COMPANY or its representatives.

17.16 First Aid and Industrial Injuries

17.16.1 CONTRACTOR shall maintain first aid facilities for its employees and sub-contractors.

17.16.2 CONTRACTOR shall make outside arrangements for ambulance service and for
treatment of industrial injuries. Names of those providing these services shall be
furnished to COMPANY prior to start of work and their telephone no. shall be posted
prominently in CONTRACTOR's field office.

17.16.3 All critical industrial injuries shall be reported promptly to the COMPANY and a copy of
CONTRACTOR's report covering each personal injury requiring the attention of
physician shall be furnished to the COMPANY.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 35 of 54

TITLE WELDING OF ONSHORE GAS MEC/S/05/21/02 REVISION : 1

PIPELINES
EDITION : 1

17.17 No Exemption

17.17.1 Notwithstanding the above there is nothing in these to exempt the CONTRACTOR from
the operation of any other act or rules in force.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 36 of 54

TITLE WELDING OF ONSHORE GAS MEC/S/05/21/02 REVISION : 1

PIPELINES
EDITION : 1

ANNEXURE-I
Sheet 1 of 3
ELECTRODE QUALIFICATION TEST RECORD

A. Tested at (Site name) Date :

Manufacturer's Name :

Brand Name :

Batch Number & Size Tested :

Classification & Code :

Intended for Welding in Position :

In combination with (if any) :

Code of Reference :
(used for testing)

Special requirements (if any) :

B. All Weld Tensile Test

Base Material used :

Pre-heat temp. :

Postweld Heat Treatment Details :

Visual Examination :

Radiographic Examination Results :

Tensile Test Results :

Sl.No. Identification No. U.T.S. Yield Point Elongation

1.
2.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 37 of 54

TITLE WELDING OF ONSHORE GAS MEC/S/05/21/02 REVISION : 1

PIPELINES
EDITION : 1

ANNEXURE-I
Sheet 2 of 3
C. Impact Test Results

Test Temperature : Notch in :

Type of Specimens : Size of Specimens :

(Charpy)

Sl.No. Specimen No. Impact Valve Average

1.
2.
3.
4.
d 5.
6.

D. Chemical Analysis Result

Electrode Size used :

Batch No. :

%C %S %P %SI %Mn %Cr %Ni %Mo Other

E. Fillet Weld Test Results

Welding Positions :

Base Materials :

Size of Electrode used :

Visual Inspection Results : 1)

2)
3)

Macro Test results :

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 38 of 54

TITLE WELDING OF ONSHORE GAS MEC/S/05/21/02 REVISION : 1

PIPELINES
EDITION : 1

ANNEXURE-I
Sheet 3 of 3
Fracture Test Results :

Remarks :

F. Other Test Results

1. Transverse Tensile Test :

In combination with :

Base Material used :

Position of Welding :

Preheat Temperature :

Post Weld Heat Treatment :

Radiography :

Identification No. U.T.S. Fracture in Remarks

2. Guided Bend Test

Position ID No. Root, Face or Side Bend Remarks

1.
2.
3.
4.
5.

Any other Tests :

Conclusion :
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 39 of 54

TITLE WELDING OF ONSHORE GAS MEC/S/05/21/02 REVISION : 1

PIPELINES
EDITION : 1

ANNEXURE-II
Sheet 1 of 2

STRESS RELIEF HEAT TREATMENT PROCEDURE SPECIFICATION

Name of the Heat-Treater :

Name of the Project : Specification Reference No.:

1. General Details

Name of the Equipment :

Name of the Assembly/ Part :

Assembly/ Part Drawing No. :

Material :

2. Furnace Details

Type of Heating : Gas/ Oil/ Elec. Res./ Induction Type of Heating

(Tick mark)

Capacity (Size) :

Maximum Temp.(°C) :

Method of Temp. :
Measurement

Atmosphere Control :

3. Heat Treatment Cycle Details

Changing Temp. °C :

Rate of Heating, °C/ Hr. :

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 40 of 54

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PIPELINES
EDITION : 1

ANNEXURE-II
Sheet 2 of 2

Soaking Temp. °C :

Soaking Time, Hrs. :

Rate of Cooling, °C/ Hr. :

Mode of Cooling :

4. Other Details, if any.

Notes :
The following documents shall be furnished alongwith the specifications :
i. Material Test Certificates
ii. Assembly/ Part Drawing.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 41 of 54

TITLE WELDING OF ONSHORE GAS MEC/S/05/21/02 REVISION : 1

PIPELINES
EDITION : 1

ANNEXURE-III
Sheet 1 of 3
FORMAT FOR WELDING PROCEDURE SPECIFICATION (WPS)
________________________________________________________________________________
Company Name ________________________ By __________________________________
Welding Procedure Specification No. _____________ Date __________ Supporting PQR No. (S)
_________ Revision No. ________________ Date ________________
Welding Process (es) _________________________ Type (s) _____________________________
(Automatic, Manual, Machines or Semi Auto)
________________________________________________________________________________
JOINTS

Joint Design ____________________________________________________________

Backing (Yes) _________________________________________(No) ___________________
Backing Material (Type) _________________________________________
Sketches Production Drawings. Weld Symbols Written
Description should show the general arrangement of the parts to be welded. Where applicable, the
root specing and the details of weld groove may be specified.

(At the option of the Manufacturer sketches may be attached to illustrate joint design weld layers
and bead sequence e.g. for notch toughness procedures, for multiple process procedures, etc.)
________________________________________________________________________________

BASE METALS

P.No. ____________ Group No. ____________ to P. No. ____________ Group No. ___________
OR
Specification type and grade _______________________________________________________
to Specification type and grade ________________________________________________
OR
Chern. Analysis and Mech. Prop. ____________________________________________________
to Chern. Analysis and Mech. Prop. ___________________________________________
Thickness Range :
Base Metal: Groove ____________________________________ Fillet ________________
Deposited Weld Metal: Groove ___________________________ Fillet ________________
Pipe Dia Range : Groove : _____________________________________ Fillet ________________
Other ______________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 42 of 54

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PIPELINES
EDITION : 1

ANNEXURE-III
Sheet 2 of 3
FILLER METALS

F.No. ___________________________________________ Other _____________________________

A.No. ___________________________________________ Other _____________________________
Spec. No. (SFA) _____________________________________________________________________
A WS No. (Class) ____________________________________________________________________
Size of filler metals __________________________________________________________________
____________________________________________________________________
(Electrodes, Cold Wire, Hot Wire etc.)
Electrode-Flux (Class) ________________________________________________________________
Flux Trade Name ________________________________________________________________
Consumable Inset ________________________________________________________________
Each base metal/filler metal combination should be recorded individually.

WPS NO. _____________________ Rev. _______________

POSITIONS : POSTWELD ED HEAT TREATMENT

Position (s) of Groove ______________________ Temperature Range ___________________

Welding Progression: UP _____ Down ____ Time Range _________________________

Position (s) of Fillet _______________________

PREHEAT GAS
Shielding Gas (es) ___________________
Preheat Temp. Min. ___________________ Percent Composition (mixtures) _________
___________________________________
Interpass Temp. Max. ___________________ Flow Rate __________________________
Gas Backing ________________________
Preheat Maintenance ___________________
Trailing Shielding Gas Composition _______

ELECTRICAL CHARACTERISTICS

Current AC or DC__________________________ Polarity _______________________

Amps (Range) ____________________________ Volts (Range) _______________________
(Amps and volts range should be recorded for each electrode size, position, and thickness, etc. This
information may be listed in a tabular form similar to that shown below).
Tungsten Electrode Size and Type ______________________________________________
(Pure Tungsten, 2% Ceriated, etc)

Mode of Metal Transfer for GMAW ______________________________________________

(Spray arc, short circuiting arc, etc.)
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 43 of 54

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EDITION : 1

ANNEXURE-III
Sheet 3 of 3

Electrode Wire feed speed range _________________________________________________________

_______________________________________________________________________________________

TECHNIQUE

String or Weave Bead ___________________________________________________________

Orifice or Gas Cup Size___________________________________________________________
Initial and Interpass Cleaning (Brushing, Grinding, etc.) _________________________________
________________________________________________________________________________

Method of Back Gouging ___________________________________________________________

Oscillation _______________________________________________________________________

Contact Tube to Work Distance ___________________________________________________________

Multiple or Single Pass (per side) ___________________________________________________________
Multiple or Single Electrodes ___________________________________________________________
Travel Speed (Range) ___________________________________________________________

Peening _____________________________________________________________________________
Other _______________________________________________________________________________
_____________________________________________________________________________________

Weld Process Filler Metal Current Volt Travel Others

Layer(s) Class Dia Type Amp. Range Speed
Polarity Range Range
e.g.
Remarks,
comments,
Hot wire
Addition,
Technique
Torch Angle,
etc.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 44 of 54

TITLE WELDING OF ONSHORE GAS MEC/S/05/21/02 REVISION : 1

PIPELINES
EDITION : 1

ANNEXURE-IV
Sheet 1 of 3
FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR)
RECORD ACTUAL CONDITIONS USED TO WELD TEST COUPON

________________________________________________________________________________________
Company Name __________________________________________________________________________
Procedure Qualification Record No. _____________________________________ Date _________________
WPS No. _____________________________

Welding Process (es) _____________________________________________________________________

Types (Manual, Automatic, Semi-Auto) _______________________________________________________

JOINTS

Groove Design of Test Coupon

(For combination qualification the deposited weld metal thickness shall be recorded for each Filler metal or process weld)
________________________________________________________________________________________
BASE METALS POSTWELD HEAT TREATMENT
Material Sepc. ____________________________ Temperature _____________________________
Type of Grade ____________________________ Time ___________________________________
P.No. __________ to P.No. _____________________ Other ___________________________________
Thickness of Test Coupon _____________________ ________________________________________
Diameter of Test Coupon _____________________ ________________________________________
Other __________ ___________________________ ________________________________________

FILLER METALS GAS

Weld Metal Analysis A No. _____________________ Type of Gas on Gases _____________________
Size of Filler Metal ___________________________ Composition of Gas Mixture _________________
Filler Metal E.No. ___________________________ Other ___________________________________
SF A Specification ___________________________ ________________________________________
A WS Classification ___________________________ ________________________________________
Other __________ ___________________________ ________________________________________

POSITION ELECTRICAL CHARACTERISTICS

Position of Groove ___________________________ Current _________________________________
Weld Progression (Uphill, Downhill) ______________ Polarity _________________________________
Other __________ ___________________________ Amps. _________________________________
Tungsten Electrode Size ___________________
Other __________________________________

ANNEXURE-IV
Sheet 2 of 3

PREHEAT TECHNIQUE
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 45 of 54

TITLE WELDING OF ONSHORE GAS MEC/S/05/21/02 REVISION : 1

PIPELINES
EDITION : 1

Phreheat Temp. ___________________________ Travel Speed ___________________________

Interpass Temp. ___________________________ String or Weave Bead ______________________
Oscillation _______________________________
Multipass or Single Pass (per side) ___________
Single or Multiple Electrodes ________________
Other __________________________________

GUIDED BEND TESTS

Type of Figure No. Result

TOUGHNESS TESTS

Specimen Notch Notch Test Impact Lateral Exp. Drop Weight

No. Location Type Temp. Value % Shear Mils Break No Break

FILLET WELD TEST

Result - Satisfactory: Yes _______ No _______ Penetration into Parent Metal: Yes ______ No. ______
Marco – Results _______________________________________________________________________

OTHER TESTS
Type of Test _______________________________________________________________________________
Deposit Analysis ____________________________________________________________________________
Other _____________________________________________________________________________________
__________________________________________________________________________________________

Welder's Name ___________________ Clock No. __________________ Stamp No. _____________________

ANNEXURE-IV
Sheet 3 of 3

Test Conducted by _______________________ Laboratory Test No. _______________________

We certified that the statements in this record are correct and test welds were prepared, welded and tested in
accordance with the requirements of Section IX of the ASME Code.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 46 of 54

TITLE WELDING OF ONSHORE GAS MEC/S/05/21/02 REVISION : 1

PIPELINES
EDITION : 1

Date : ___________ Manufacturer : ____________________

By : _____________________________

(Detail of record of tests are illustrative only and may be moulded to conform to the type and number of tests
required by codes and specifications).
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 47 of 54

TITLE WELDING OF ONSHORE GAS MEC/S/05/21/02 REVISION : 1

PIPELINES
EDITION : 1

ANNEXURE-V
Sheet 1 of 2
FORMAT FOR MANUFACTURER'S RECORD FOR WELDER OR WELDING OPERATOR
QUALIFICATION TESTS

Welder Name ________________ Check No. __________________ Stamp. No. __________________

_____________________________________________________________________________________

Using WPS No. ________________ Rev. ________________

The above welder is qualified for the following ranges

Variable Record Actual Values Qualification Range

Used in Qualification

Process __________________ __________________

Process Type __________________ __________________

Backing (metal,
Weld metal, flux, etc) __________________ __________________

Material Spec. _________ to _________ _________ to _________

Thickness
Groove __________________ __________________
Filler __________________ __________________

Diameter
Groove __________________ __________________
Filler __________________ __________________

Filler Metal
Spec. No. __________________ __________________
Class __________________ __________________
F. No. __________________ __________________

Position __________________ __________________

Weld Progression __________________ __________________

Gas Type __________________ __________________

Electrical Characteristics
Current ________________ __________________
Polarity __________________ __________________
ANNEXURE-V
Sheet 2 of 2

Guided Bend Test Results

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 48 of 54

TITLE WELDING OF ONSHORE GAS MEC/S/05/21/02 REVISION : 1

PIPELINES
EDITION : 1

Type and Fig. No. Result

Radiographic Test Results

For alternative qualification of groove welds by radiography

Radiographic Results _______________________________________________________________

Fillet Weld Test Results

Fracture Test (Describe the location, nature and size of any crack of tearing of the specimen _____
Length and Per Cent of Defects _________________________ inches _____________%
Macro Test – Fusion _______________________________________________________________
Appearance - Fillet Size (ing) ______________x___________ Convexity or Concavity ___________

Test Conducted by _____________________________ Laboratory - Test No. _________________

We certify that the statements in this record are correct and that the test welds were prepared.
Welded and tested in accordance with the requirements of Section IX of the ASME Code.

Date ___________________ Organization __________________

By ___________________________

(Details of record tests are illustrative only and may be modified to conformation to the type &
number of tests required by the Code).

Note: Any essential variables in addition to those above shall be recorded.

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 49 of 54

TITLE WELDING OF ONSHORE GAS MEC/S/05/21/02 REVISION : 1

PIPELINES
EDITION : 1

ANNEXURE-VI
Sheet 1 of 1
RADIOGRAPHIC PROCEDURE QUALIFICATION RECORD
FOR PIPE WELDING
1. Location
2. Date of Testing
3. Name of the Contractor / Agency
4. Material : Carbon steel / Alloy Steel / Stainless Steel
4.A Technique: DWSI / SWSI / DWDI
5. Diameter & Thickness:
6. Type of Weld Joint:
7. Radiation Source:
8. Intensifying Screens/Lead Screens:
9. Geometric Relationship:

10. Limit of Film Coverage:

11. Film Type and Make:

12. Exposure Time:

13. Processing:

14. Density:

15. Sensitivity:

16.* Type of penetrameter:

(Source side)

17.* Type of penetrameter:

(Film side)

Signature of Contractor / Agency with Seal

Approval of MECON’s Inspector

* Ref. Para regarding recommended practice on placement of penetrameters Article 22, SE 142, ASME
Sec. V.
* For "Random Radiography" lines placement of penetrameters as per Article 2, ASME, Sec. V is
permitted.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 50 of 54

TITLE WELDING OF ONSHORE GAS MEC/S/05/21/02 REVISION : 1

PIPELINES
EDITION : 1

ANNEXURE-VII
Sheet 1 of 1

WELDERS IDENTIFICATION CARD

Name :
Photograph
Identification :

Date of Testing :

Process :

Diameter and Thickness :

Thickness Range Qualified :

Diameter Range Qualified :

WPS No. :

Welding Position & Progression :

Type of welding consumables used :

Valid Till :

Approved by : Employer's Signature with seal

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 51 of 54

TITLE WELDING OF ONSHORE GAS MEC/S/05/21/02 REVISION : 1

PIPELINES
EDITION : 1

ANNEXURE-VIII
Sheet 1 of 1

Type of Source and Films to be used for RADIOGRAPHY

NOMINAL WALL SHOP WELDED JOINTS IN-SITU WELDS

THICKNESS (T) IN mm SOURCE FILM : CEN Class SOURCE FILM : CEN Class
T> 19 All Materials Gamma Ray C5 Gamma Ray C5
8T< 19 Carbon Steel Gamma Ray C4 Gamma Ray C4
All other Gamma Ray C3 Gamma Ray C3
materials
<8 Carbon Steel Gamma Ray C3 Gamma Ray C3/C1
Other than
Inspection
Class IV *
All other X-Ray C4 X-ray with C4 or Equivalent to be
materials and used. Gamma Ray (Se 75 Source
Carbon Steel only) with C3/C2 Equivalent may
of Inspection be allowed only if in the
Class IV * assessment of the owner's
inspector, Joints are inaccessible
for X-ray equipment and
radiographic sensitivity is achieved.

Note: Integral to above table

1) Films slower than the above may have to be used, if required radiographic sensitivity is not achieved
consistently.

* Piping classes where 100% RT is specified. Refer Std. Spec. No. ____________.

COMPARISON OF FILMS FROM DIFFERENT MANUFACTURERS

CEN Classification KODAK AGFA FUJI

--- CX D8 ---
C5 AA400 D7 IX 100
C4 T200 D5 IX80
C3 MX125 D4 IX50
C2 M100 D3 ---
CI DR50 D2 IX25
--- SR** --- ---

* * Special films, extremely fine grain & very high resolution

 WELDING SPECIFICATION CHARTS TO SPECIFICATION FOR WELDING OF
ONSHORE GAS PIPELINES NO. : MEC/S/05/21/02
10” Dia THK. RANGE: 7.8 mm
PIPES API 5L Gr X-42 PSL 2 LINE PIPE
MATERIAL FITTINGS -
SPECIFICATIONS FLANGES -
OTHERS -

BASE METAL ‘P’ NO 1

GROOVE JOINTS
BUTT OTHER THAN BUTT
WELDING PROCESS FILLER PASS :
ROOT PASS : SMAW ROOT PASS : N.A. FILLER PASS : N.A.
SMAW
FILLET JOINTS / SOCKET JOINTS : N.A.

GROOVE JOINTS
BUTT OTHER THAN BUTT
HOT, FILLER & CAP
ROOT PASS : E6010 ROOT PASS : N.A.
WELDING MATERIAL PASS FILLER PASS : N.A.
E8010-P1
FILLET JOINTS / SOCKET JOINTS : N.A.
BACKING RING : N.A. CONSUMABLE INSERT : N.A.

JOINT PREPARATION API 1104 / ASME SEC. –IX

GASES PURGING : SHIELDING :

GAS COMPOSITION PURGING : SHIELDING :
PREHEATING PREHEAT TEMP: As Applicable POST HEATING :
CONTINUITY OF WELDING AND PREHEAT : REFER TO SPECIFICATION
HOLDING TEMP : HOLDING TIME :
POST WELD HEAT
RATE OF HEATING: MIN. HOLDING TIME :
TREATMENT
METHOD OF COOLING : RATE OF COOLING :

MECHANICAL CHARPY ‘V’ NOTCH VALUE : MIN: 27 J at 0° C AVERAGE :

PROPERTY AT TEMPERATURE : 22 J at - 29° C
REQUIREMENTS HARDNESS : or 0°C Design temperature whichever is less

CODE OF FABRICATION : API 1104 / ASME SEC. –IX

Technical Notes :
1. The Non-Destructive Testing (NDT) shall be examined with radiography by X-ray .

WELDING SPECIFICATION CHART Specification No. : Rev.

REALIGNMENT OF NATURAL GAS MEC.WSC _ML 01 0
PIPELINE OF DFPCL
MECON Limited
PIPING CLASS : B1A
PIPES ASTM A106 GR.B, API 5L GR. B PSL2 ASSORTED PIPES
MATERIAL FITTINGS ASTM A105, ASTM A234 GR.WPB
SPECIFICATIONS FLANGES ASTM A105
OTHERS -

BASE METAL ‘P’ NO 1

GROOVE JOINTS SINGLE SIDE BEVEL
BUTT OTHER THAN BUTT
WELDING PROCESS
ROOT PASS : SMAW FILLER PASS : SMAW ROOT PASS : SMAW FILLER PASS : SMAW
FILLET JOINTS / SOCKET JOINTS : SMAW

GROOVE JOINTS
BUTT OTHER THAN BUTT
FILLER & CAP PASS
WELDING MATERIAL ROOT PASS : E6010 ROOT PASS : E6010 FILLER PASS : E7018-1
E7018-1
FILLET JOINTS / SOCKET JOINTS : E7018-1
BACKING RING : N.A. CONSUMABLE INSERT : N.A.

JOINT PREPARATION API 1104 / ASME SEC. –IX

GASES PURGING : SHIELDING : NA

GAS COMPOSITION PURGING : SHIELDING : NA
PREHEATING PREHEAT TEMP: 10- 100 Deg. POST HEATING :
INTERPASS: Max 200 Deg.
CONTINUITY OF WELDING AND PREHEAT : REFER TO SPECIFICATION
HOLDING TEMP : N.A. HOLDING TIME :
POST WELD HEAT
RATE OF HEATING: N.A. MIN. HOLDING TIME :
TREATMENT
METHOD OF COOLING : N.A. RATE OF COOLING :

MECHANICAL CHARPY ‘V’ NOTCH VALUE : MIN: 27 J at 0°C AVERAGE :

PROPERTY AT TEMPERATURE : 22 J at -29°C
REQUIREMENTS HARDNESS : 0°C or Design Temperature whichever is less

CODE OF FABRICATION : API 1104 / ASME SEC. –IX

TECHNICAL NOTES :

WELDING SPECIFICATION CHART Specification No. : Rev.

REALIGNMENT OF NATURAL GAS MEC.WSC_AG 01 0
PIPELINE OF DFPCL
MECON Limited
 Rev. : 0
Edition : 1

SPECIFICATION
FOR
HYDROSTATIC TESTING OF ONSHORE
PIPELINE

SPECIFICATION NO.: MEC/S/05/21/03

(OIL & GAS SBU)

MECON LIMITED
DELHI 110 092
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 1

TITLE HYDROSTATIC TESTING OF MEC/S/05/21/03 REVISION : 0

ONSHORE PIPELINE
EDITION : 1

CONTENTS
SL.NO. DESCRIPTION

1.0 SCOPE

2.0 REFERENCE CODES, STANDARDS AND SPECIFICATIONS

3.0 GENERAL

4.0 HYDROSTATIC TEST PROCEDURE MANUAL

5.0 TEST PRESSURE

6.0 EQUIPMENT AND INSTRUMENTATION

7.0 PROCEDURES

8.0 ACCEPTANCE

9.0 TERMINATION

10.0 TEST REPORT

11.0 MEASUREMENTS

12.0 CALCULATION

13.0 PRECAUTIONS DURING THE TEST

14.0 PRESERVATION OF PIPELINE

TABLES
TABLE A DIFFERENCE BETWEEN WATER THERMAL EXPANSION FACTOR AND STEEL THERMAL
EXPANSION FACTOR.

FIGURES
FIG.1 WATER COMPRESSIBILITY FACTOR VS PRESSURE AND TEMPERATURE.

PREPARED BY: CHECKED BY: APPROVED BY: ISSUE DATE :

(Shalini Singh) (Sunil Kumar) (A.K. Johri) Nov. 2008

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 17

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ONSHORE PIPELINE
EDITION : 1

1.0 SCOPE

1.1 This specification covers the minimum requirements of supply, works and operations to be
performed by CONTRACTOR for hydrostatic testing of cross-country steel pipelines
transporting hydrocarbons in liquid or gaseous phase under high pressure. This specification
does not cover the requirements of drying/precommissioning of the tested pipelines. This
specification shall be read in conjunction with the conditions of all specifications and
documents included in the CONTRACT between COMPANY and CONTRACTOR.

2.0 REFERENCE CODES, STANDARDS AND SPECIFICATIONS

2.1 Reference has been made in this specification to the latest edition/ revision of the following
codes, standards and specifications.

a) ANSI B 31.8 Gas Transmission and Distribution Piping Systems.

b) ANSI B 31.4 Liquid Petroleum Transportation Piping Systems.
c) API RP 1110 Pressure Testing of Liquid Petroleum Pipelines.
d) ASME Sec. VIII Div-1 Boiler & Pressure Vessel Code.
e) OISD 226 Natural Gas Transmission Pipelines and City Gas Distribution
Networks

2.2 In case of conflict between the requirements of this specification and that of the above
referred coded, standards, and specifications, the requirements of this specifications 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.

3.0 GENERAL

3.1 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 50 kms.

3.2 For pipeline sections which in COMPANY's opinion, once installed would require an inordinate
amount of effort for repair in case of a leak, a provisional pre-test shall be conducted.
However, after installation, such pretested sections shall be tested again alongwith the entire
pipeline.

3.3 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 backfilled according to the
specifications. Hydrostatic test shall include those sections which have been previously tested,
viz. Rail/ road crossing, 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 COMPANY.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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3.4 The pipeline shall be tested in accordance with the requirements of the latest edition of ANSI
B 31.8 or ANSI B 31.4, OISD 226 as applicable, and requirements laid down in this
specification.

4.0 HYDROSTATIC TEST PROCEDURE MANUAL

CONTRACTOR shall prepare for COMPANY's approval a hydrostatic test procedure manual. The
procedure shall strictly comply with the requirements of this specification and shall be
submitted to COMPANY for approval well in advance. The procedure manual shall include all
temporary materials & equipment, but not be limited to the following items:

a) 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.

b) Estimated amount of test water, water sources, including required concentration of

corrosion inhibitors and additives, procedure for inhibitor injection and control of
concentration.

c) Filling and flushing procedures, including a complete description of all proposed

equipment and instruments (including spares), their location and set-up.

d) The type and sequence of pigs and the pig tracking systems for cleaning and removal
of air pockets. Pig inspection procedures, including procedure to be followed in case
the calliper pig indicates damage.

e) Procedures for levelling and stabilization after filling and for pressurization and to allow
for temperature stabilization.

f) 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.

g) Procedure for detection and location of leaks.

h) Procedure for dewatering 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.

i) Forms for recording the test data.

5.0 TEST DURATION AND PRESSURE

5.1 The duration of hydrostatic test shall be a minimum of 24 hours after stabilization and the test
pressure shall be as indicated in the approved hydrostatic test diagram.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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ONSHORE PIPELINE
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5.2 Unless specified otherwise in the CONTRACT, the hydrostatic test pressure shall be as follows :

For pipeline handling hydrocarbon in gaseous phase :

a) 1.25 times the design pressure for pipeline located in Class-1 and Class-2 locations as
per ASME B 31.8.

b) 1.4 times the design pressure for pipeline located in Class-3 and Class-4 locations as
per ASME B 31.8.

6.0 EQUIPMENT AND INSTRUMENTATION

The CONTRACTOR shall furnish all necessary equipment for performing the work as stated
in cleaning, flushing, filling, levelling, stabilizing, testing and dewatering procedures. This
shall include the following :

a) Pigs for filling , cleaning and gauging including

- Cleaning pigs with spring loaded steel wire brushes except for internal coated pipes. In
this case pigs to be provided with nylon / polyurethane brushes.

- Four cup batching pigs

- Calliper pigs with gauge plate diameter equal to 95% of the heavy wall pipe in the pipe
sections. Gauging pig fitted with gauge plate.

The CONTRACTOR shall provide sufficient number of pigs including spares.

b) Fill pumps : The CONTRACTOR shall determine the type and number of fill pumps
in order to guarantee the following :

Differential head 20% greater than the maximum required.

Flow rate : 400m3 / hr. min. ; 1000m3 / hr. max.
If a single pump is used, a standby unit must be available.

c) Variable speed positive displacement pumps equipped with a stroke counter to

pressurise the line with a known stroke and capable of exceeding the maximum test
pressure by at least 20 bar.

d) Two positive displacement meters to measure the volume of water used for filling
the line. These meters shall be provided with a callibration certificate not older than
one month.

e) Portable tanks of sufficient size to provide a continuous supply of water to the pump
during pressurizing.

f) Bourdon pressure gauges of suitable pressure range and accuracy.

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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g) Dead weight testers with an accuracy of 0.01 bar measuring in increments of 0.05 bar
provided with a calibration certificate not older than one month.

h) Two 48 hours recording pressure gauges tested with charts and ink gauges tested with
dead weight tester prior to use. These shall be installed atp the test heads.

i) Pressure recording charts.

j) Two temperature recorders for fill water.

k) Thermocouples for measuring the pipe wall temperature.

l) Two laboratory thermometers 0°C to 60°C range, accuracy ± 0.1 degree to be used in
thermowells.

m) Means to measure the volume of water necessary to drop the line pressure by 0.5 bar
(container on scales or graduated cylinder).

n) Injection facilities to inject additives into the test medium in the required proportions.

o) Communication equipment suitable for a continuous connection 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.

p) The temporary scraper traps shall be installed according to the testing sections fixed in
the test procedure manual. Proper piping and valuing 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.

q) Thermocouples for assuring the temperature of the pipe wall shall be installed on the
pipeline to be tested:

- 1 thermocouple at about 500m distance from the pumping head.

- 1 thermocouple every 2500m of the pipe the spacing may be increased to maximum
5000m depending on the terrain and nature of sub-soil along the alignment of section.
- 1 thermocouple at about 500m distance from the terminal head.

The spacing may be increased to maximum 5000 metre depending on the terrain and nature
of sub soil along the alignment of test section.

Thermocouples shall be attached on the external surface of the pipe after removal of external
coating and shall be adequately protected and COMPANY's coating instructions shall be
followed.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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ONSHORE PIPELINE
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7.0 PROCEDURES

7.1 Equipment and/or parts which need not or must not be subjected to the test pressures, must
be disconnected or separated from the pipeline to be tested.

7.2 If the difference of minimum and maximum atmosphere 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 shall be tested separately.

7.3 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. The possible use
of sea water shall be subject to its degree of cleanliness, the possibility of obtaining a pre
determined salinity neutralization and the use of corrosion inhibitors, this at the sole discretion
of COMPANY. CONTRACTOR shall provide COMPANY approved corrosion inhibitors, 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/ tankage.

7.4 Before filling operation the CONTRACTOR shall clean the pipeline by air driven pigs provided
with spring loaded bushes and chisels to remove all mill scale rust/ sand from the inside of
pipe section. For this purpose temporary headers for air cleaning shall be attached to the
pipeline. The number of pig runs is depending upon the cleaning results and shall be
determined by the COMPANY at site.

7.5 “After cleaning the pipeline by using air and acceptance by Company, gauging shall be carried
out by using gauging pig. The gauge plate diameter shall be equal to 95% of inside diameter
of the heaviest wall pipe in the test section. While computing the ID of heaviest wall pipe,
pipe manufacturing tolerance shall not be considered. A 10mm thick aluminium plate shall be
used for making gauge plate.

After receipt of gauging pig at the other end, the gauge plate shall be inspected in the
presence of Company representative. A deformed, bent or severally nicked plate or damaged
pig shall be evidence of gauging pig run failure and the same is not acceptable to company.
In such cases the Contractor shall repair and rectify the line and repeat the gauging pig run to
the satisfaction and approval of the Company Representative. Any obstruction and/ or faults
such as dents, buckles, flat spots, etc. analysed and noted during gauging pig run shall be
located and any necessary repair work shall be performed to rectify the same to the
satisfaction of the Company. A written approval shall be obtained from Company regarding
successful completion of gauging pig run.

After acceptance of gauging operation, air header shall be cut and removed. Pre-tested test
headers loaded with three numbers of four cup batching pig shall be welded to test Section.
Un-inhibited water equal to 10% of the volume of test section shall be introduced in front of
the first pig. The first pig shall be launched by introducing about 1.5 km un-inhibited water.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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Then the second pig shall be launched by pumping the inhibited water till the second pig is
received at the other end. The thermal stablisation and pressurisation can now the started”.

7.6 Thermal Stabilization

After a check has been made to confirm if the pressure has attained at least 1 bar (g) on the
highest section, thermal stabilization can be started.

Thermal equilibrium between the pipeline and environment shall be checked through the
thermocouples installed on the pipeline.

Temperature readings shall be made at 2 hours-intervals. Thermal stabilization shall be

considered to have been achieved when a difference not higher than 1°C is attained between
the average values of the last two readings. Thermal stabilization completion shall be
approved by COMPANY.

7.7 Pressurisation

Pressurisation shall be performed in the presence of COMPANY at moderate and constant rate
not exceeding 2 bars/min. One pressure recording gauge shall be installed in parallel with the
dead weight tester. Volume required to reach the test pressure shall be recorded periodically
throughout the pressurization as follows:

- each 5 bar increments up to 80% of test pressure as recorded by the dead weight
tester;
- each 2 bar increment between 80% to 90% of test pressure as recorded by the dead
weight tester;
- each 0.5 bar increment between 90% of test pressure to full test pressure as recorded
by the dead weight tester.

The pressurizing shall be cycled according to the following sequence:

a) Pressurize to 50% of test pressure, hold pressure for 1 hour.

b) Drop pressure to static head of test section at test head.
c) Pressurize to 75% of test pressure, hold pressure for 1 hour.
d) Drop pressure to static head of test section at the test head.
e) Pressurize to test pressure.

During the pressurization to each test pressure, two tests shall be carried out for the
calculation of air volume in the pipeline under test.

In case, during the hold pressure periods indicated above, a decrease in pressure is observed,
the operations shall not be repeated more than twice, after which the line shall not be
considered capable of test, until the CONTRACTOR has isolated and eliminated the cause for
the lack of water tightness.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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7.8 Air Volume Calculation

In order to check the presence of air in the pipeline, two separate consecutive pressure
lowering of 0.5 bar shall be carried out.

For calculation of air in the pipeline the second pressure lowering shall be used, and the
relevant drained water shall be accurately measured (V1). This amount measured shall be
compared to the theoretical amount (Vp) corresponding to the pressure lowering that has been
carried out, by using the procedure outlined in clause 12.1 of this specification.

If no air is present in the length under test:

V1
--- = 1
Vp

In order that the above ratio is acceptable, it shall not differ from 1 by more than 6% (i.e.
1.06).

If the air found in the pipeline is within the above established tolerance, then the pressurizing
can continue. If the ratio V1 / Vp exceeds 1.06, the hydrostatic testing cannot go on and
additional pig passages shall be performed to remove the air pockets.

The test shall be repeated as per the above procedure until above estimated tolerances are
satisfied. The pressurizing can then continue, to reach the value of test pressure.

7.9 Testing

After the section has been pressurized and the air volume test has given acceptable results the
test pressure shall be held for a minimum of 24 hours after stabilization. After temperature
and pressure has stabilized, the injection pump shall be disconnected and all connections at
the test heads shall be checked for leakage. The pressure recorders shall then be started with
the charts in a real time orientation for continuous recording throughout the test.

During the testing period the following measurements shall be recorded :

- every one hour pressure measurements form dead weight testers.

- every two hours the ambient temperature and the pipe temperature at the
thermocouples.

All data shall be recorded on appropriate forms attached to the hydrostatic test procedure
manual. Care shall be taken that the maximum test pressures are not exceeded.

Bleed-off water shall be accurately measured and recorded.

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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8.0 ACCEPTANCE

8.1 The hydrostatic test shall be considered as passed if pressure has kept a constant value
throughout the test duration, except for change due to temperature effects. Such change 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.

8.2 If test section fails to maintain the specified test pressure after isolation, CONTRACTOR shall
determine by search 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 circumferential welds the method of repair shall be determined by the
COMPANY. CONTRACTOR shall comply with instructions of the COMPANY whether to replace
a section of the line pipe that includes the line leak or whether to repair the circumferential
weld. This repair should however meet the requirements of 'Specification for Welding Pipelines
and Related Facilities'. Where failure 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.

8.3 The cost of repairs or replacements, followed by refilling and repressurizing the line, due to
poor workmanship, shall be borne by the CONTRACTOR. In the event of leaks or failures
resulting form faulty COMPANY furnished materials, CONTRACTOR shall be reimbursed for
furnishing all labour, equipment, materials, except those materials furnished by the COMPANY,
and transportation necessary to repair and repressurize 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 pipe failures shall be done in accordance with the relevant specification included in the
CONTRACT.

8.4 CONTRACTOR shall haul and stockpile all damaged and defective pipes to storage locations
designated by the COMPANY. All cracks and splice 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.

9.0 TERMINATION

After the positive results of testing and collection of all data the test shall be terminated upon
written approval given by the COMPANY.

9.1 CONTRACTOR shall dewater the tested line as per the following requirement after test
acceptance.

The dewatering shall be carried out by using four cup pigs and foam pigs driven by
compressed air. The detailed dewatering procedure shall be developed by the CONTRACTOR
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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in such a way as to provide adequate control of pigs during dewatering. Pigs and equipment
required for dewatering the line shall be furnished by CONTRACTOR and shall be approved in
advance by the COMPANY. 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 dewatering.
CONTRACTOR shall use a number of foam pigs, each in different colors/ numbered for this
purpose. The line shall be considered dewatered when a negligible amount of water is flushed
out by the last foam pig and approval is given by the COMPANY.

9.2 During dewatering, care shall be taken to properly dispose the discharging water in order to
avoid pollution, damages to fields under cultivation and/or existing structures and interference
with the traffic. Before start of dewatering and disposal of hydrotest water, a procedure for
treatment of inhibited water to prevent pollution shall be submitted by contractor to owner/
consultant for review and approval.

9.3 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.

10.0 TEST REPORT

A complete report signed by CONTRACTOR and the COMPANY shall be submitted upon
completion of the hydrostatic test for each test section.
This report shall contain as a minimum:

- the cleaning, flushing, filling and testing procedures used;

- schematic layout of cleaning, filling and testing facilities;

- instruments calibration certificates;

- a profile of the pipeline that shows the test sites, all instrument and injection
connections;

- pipe filling logs and records;

- additive specification, required concentration and additive injection records;

- pig specifications;

- pig inspection records including photographs of the damages;

- records of gauging pig survey and photographs;

- pressurization and stabilization records;

- pressure and temperature recording charts with appropriate information inscribed

thereon;
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 10 of 17

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- temperature data along the pipeline;

- dead weight tester logs and recording;

- air volume calculations;

- pressure change due to temperature change calculations;

- environmental data;

- depressurization logs and records;

- dewatering procedure and schematic layout of relevant facilities;

- dewatering logs and records;

- records and photograph of all leaks.

11.0 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). In the calculation,
as per clause 12.1 of this specification, use shall be made of the geometrical volume of the
section in question.

11.2 Pressure Measurement

Pressure shall be measured with a dead weight tester with an accuracy of 0.01 bar that shall
permit readings of at least 0.05 bar.

During the test the pressure shall be recorded by means of a pressure recorder featuring the
following specifications:

Accuracy : ± 0.1% of the full-scale value

Recording : continuous on tape or disk, graph width 100mm

Feed : 20mm/h for tape diagrams, 7.5°/h for disk diagrams

Recording : to be such as to record pressure between 50% and 90% of the diagram
width.

The pressure recorder shall be checked by means of dead weight tester at the beginning,
during and at the end of the hydrostatic test.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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A pressure gauge tested with dead weight tester shall be connected in parallel to the dead
weight tester at the test head.

11.3 Temperature Measurements

Water temperature shall be taken at every 2 hours through the thermocouple that have been
installed on the pipe wall 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 thermocouple’s sensitivity shall enable temperature readings with an accuracy of ±0.2°C.

b) Water temperature shall also be measured on the pump delivery by means of a

recording thermometer (temperature recorder) throughout the filling stage.

The recording thermometer shall have the following features :

Accuracy ± 1% of the scale range

Scale - 10° to + 40° C

Recording: Continuous on tape or disk, diagram within 100mm

Feed : 20mm/h for tape diagrams, 7.5°/h for disk diagrams.

c) Ground temperature shall be taken by measuring pipe temperature at the

thermocouple prior to starting the filling operation.

d) Environmental temperature shall be recorded from the beginning of pressurization to

the end of the test by means of a recording thermometer featuring the following
characteristics:

Accuracy ± 1% of the scale range

Scale - 0° to + 60° C

Recording: Continuous on tape or disk, diagram width 100mm

Feed : 20mm/h for tape diagrams, 7.5°/h for disk diagrams.

12.0 CALCULATIONS

12.1 The theoritical 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.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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The theoretical water amount that is necessary for pressurizing the section shall be calculated
by means of the following formula:

Vp = (0.884 r i/t +A) x 10-6 x Vt x ∆ P x K

Where:

Vp = computed water amount required to raise by P the 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)

t = 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). For

temperature above 30°C the values may be extrapolated.

K = a dimensionless 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 by the following
formula:

B
∆P = -------------------------- ∆T
0.884 r i/ t +A

Where,

∆P = pressure change resulting from a temperature change (bar)

∆T algaebrical difference between water temperature at the beginning of the test and
water temperature as measured at the end of the test (°C).

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 (°C-1) x 106

(Refer table – A)

A= Isothermal compressibility value of water as estimated at the pressure and

temperature values obtained at the end of test (bar-1) x 106 (Refer Figure 1)
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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ri= nominal inner radius of the pipe (mm).

t = nominal thickness of pipe (mm).

13.0 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 thermocouple installed in the pipeline
shall be removed and damaged corrosion coating shall be repaired using COMPANY approved
materials and procedure.

14.0 PRESERVATION OF PIPELINE

When so stated in the CONTRACT, to preserve/conserve the pipeline for a specified duration,
CONTRACTOR shall completely fill the pipeline with water, with sufficient quantity of corrosion
inhibitors depending upon quality of water and the period of conservation, at a pressure to be
agreed upon with the COMPANY at a later stage. CONTRACTOR shall obtain necessary
approval from the COMPANY of the procedure and the type and quantity of the inhibitors
used before commencement of the works.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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TABLE - A
0
C 1 2 3 4 5 6 7 8
Bar
0.981 -98.62 -79.89 -61.81 -44.34 -27.47 -11.14 +4.66 +19.98
10 -95.55 -76.94 -58.99 -41.65 -24.89 -8.67 +7.02 +22.23
20 -92.15 -73.68 -55.86 -38.64 -22.01 -5.92 +9.65 +24.74
30 -88.74 -70.40 -52.72 -35.63 -19.14 -3.16 +12.29 +27.26
40 -85.32 -67.12 -49.58 -32.62 -16.24 -0.41 +14.93 +29.78
50 -81.90 -63.84 -46.43 -29.60 -13.36 +2.36 +17.57 +32.31
60 -78.47 -60.55 42.27 -26.58 -10.46 +5.15 +22.89 +34.85
70 -75.03 -57.25 -40.10 -23.54 -7.56 +7.92 +22.89 +37.39
80 -71.60 -53.96 -36.94 -20.51 -4.65 +10.70 +25.55 +39.94
90 -68.16 -50.66 -33.77 -17.47 -1.73 +13.50 +28.23 +42.50
100 -64.72 -47.35 -30.60 -14.43 +1.18 +16.29 +30.90 +45.05
110 -61.28 -44.05 -27.43 -11.38 +4.10 +19.08 +33.58 +47.61
120 -57.84 -40.74 -24.26 -8.34 +7.02 +21.88 +36.26 +50.18
130 -54.40 -37.44 -21.08 -5.29 +9.95 +24.68 +38.94 +52.75
140 -50.96 -34.13 -17.90 -2.25 +12.87 +27.49 +41.63 +55.32
150 -47.53 -30.83 -14.73 +0.80 +15.79 +30.29 +44.31 +57.89
160 -44.10 -27.53 -11.56 +3.85 +18.72 +33.10 +47.00 +60.46
170 -40.67 -24.23 -8.40 +6.89 +21.64 +35.90 +49.69 +63.04
180 -37.24 -20.94 -5.23 +9.94 +24.56 +38.70 +52.37 +65.62
190 -33.83 -17.65 -2.06 +12.98 +27.48 +41.51 +55.06 +68.19
200 -30.42 -14.37 +1.09 +16.01 +30.40 +44.30 +57.75 +70.77
210 -27.02 -11.09 +4.25 +19.04 +33.31 +47.10 +60.43 +73.34
220 -23.63 -7.82 +7.40 +22.06 +36.22 +49.90 +63.12 +75.90
230 -20.24 -4.56 +10.54 +25.08 +39.13 +52.69 +65.80 +78.48
240 -16.87 -1.30 +13.67 +28.10 +42.03 +55.48 +68.48 +81.05
250 -13.50 +1.94 +16.79 +31.11 +44.92 +58.26 +71.15 +83.61
260 -10.14 +5.17 +19.90 +34.12 +47.81 +61.04 +73.81 +86.81
270 -6.80 +8.39 +23.00 +37.11 +50.69 +63.80 +76.48 +88.73
280 -3.48 +11.60 +26.11 +40.09 +53.56 +66.57 +79.14 +91.29
290 -0.17 +14.80 +29.19 +43.07 +56.43 +69.33 +81.78 +93.83
300 +3.13 +17.98 +32.27 +46.03 +59.29 +72.06 +84.83 +96.38

DIFFERENCE BETWEEN THE WATER THERMAL EXPANSION FACTOR AND THE STEEL THERMAL
EXPANSION FACTOR ( 0 C -1 ) (10 -6)
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 15 of 17

TITLE HYDROSTATIC TESTING OF MEC/S/05/21/03 REVISION : 0

ONSHORE PIPELINE
EDITION : 1

TABLE - A
0
C 9 10 11 12 13 14 15
Bar
0.981 +34.82 +4922 +63.20 +76.78 +89.99 +102.83 +115.34
10 +36.97 +51.26 +65.15 +78.64 +91.75 +104.51 +116.93
20 +39.36 +53.55 +67.33 +80.71 +93.72 +106.39 +118.71
30 +41.76 +55.84 +69.51 +82.79 +95.70 +108.26 +120.49
40 +44.18 +58.14 +71.70 +84.87 +97.68 +110.14 +122.28
50 +46.60 +60.45 +73.90 +86.96 +99.68 +112.04 +124.07
60 +49.02 +62.76 +76.10 +89.07 +102.67 +113.93 +125.88
70 +51.44 +65.08 +78.32 +91.17 +103.68 +115.84 +127.69
80 +53.88 +67.40 +80.53 +93.29 +105.69 +117.76 +129.50
90 +56.32 +69.73 +82.75 +95.41 +107.70 +119.67 +131.32
100 +58.77 +72.07 +84.98 +97.53 +109.73 +121.59 +133.15
110 +61.21 +74.41 +87.22 +99.66 +111.75 +123.52 +134.98
120 +63.67 +76.74 +89.45 +101.79 +113.79 +125.46 +136.82
130 +66.12 +79.09 +91.69 +103.93 +115.83 +127.39 +138.67
140 +68.58 +81.45 +93.93 +106.07 +117.67 +129.34 +140.51
150 +71.05 +83.80 +96.18 +108.21 +119.90 +131.20 +142.37
160 +73.51 +86.15 +18.43 +110.36 +121.96 +133.74 +144.22
170 +75.97 +88.51 +100.68 +112.51 +124.01 +135.19 +146.08
180 +78.44 +90.87 +102.94 +114.66 +126.06 +137.15 +147.94
190 +80.91 +93.23 +105.19 +116.82 +128.12 +139.11 +149.81
200 +83.37 +95.59 +107.45 +118.97 +130.17 +141.07 +151.68
210 +85.84 +97.95 +109.71 +121.13 +132.24 +143.03 +153.55
220 +88.30 +100.31 +111.97 +123.29 +134.29 +144.99 +155.42
230 +90.67 +102.67 +114.23 +125.45 +136.36 +146.96 +157.30
240 +93.22 +105.03 +116.48 +127.60 +138.42 +148.93 +159.18
250 +95.69 +107.39 +118.74 +129.76 +140.48 +150.90 161.05
260 +98.14 +109.74 +121.00 +131.92 +142.54 +152.87 +162.93
270 +100.60 +112.10 +123.25 +134.08 +144.61 +154.84 +164.81
280 +103.05 +114.44 +125.50 +136.24 +146.67 +156.84 +166.69
290 +105.50 +116.79 +127.75 +138.39 +148.73 +158.78 +168.57
300 +107.94 +119.13 +130.00 +140.54 +150.79 +160.75 +170.45

DIFFERENCE BETWEEN THE THERMAL EXPANSION FACTOR THE STEEL THERMAL EXPANSION
FACTOR ( 0 C -1 ) (10 -6)
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 16 of 17

TITLE HYDROSTATIC TESTING OF MEC/S/05/21/03 REVISION : 0

ONSHORE PIPELINE
EDITION : 1

TABLE - A

0
C 16 17 18 19 20 21 22 23
Bar
0.981 +127.52 +139.41 +151.00 +162.31 +173.37 +184.18 +194.75 +205.08
10 +129.02 +140.83 +152.36 +163.58 +174.56 +185.30 +195.79 +206.07
20 +130.71 +142.42 +153.85 +165.00 +175.90 +186.55 +196.96 +207.16
30 +132.40 +144.02 +155.35 +166.42 +177.23 +187.80 +198.14 +208.26
40 +134.10 +145.62 +156.87 +167.85 +178.58 +189.07 +199.33 +209.37
50 +135.80 +147.24 +158.39 +169.85 +179.93 +190.34 +200.52 +210.49
60 +137.51 +148.86 +159.92 +170.73 +181.29 +191.62 +201.72 +211.61
70 +139.22 +150.49 +161.46 +172.18 +182.66 +192.91 +202.93 +212.74
80 +140.95 +152.11 +163.00 +173.64 +184.03 +194.20 +204.14 +213.88
90 +142.67 +153.75 +164.56 +175.10 +185.41 +195.50 +205.36 +215.03
100 +144.42 +155.40 +166.11 +176.58 +186.80 +196.80 +206.59 +216.17
110 146.15 +157.04 +167.66 +178.05 +188.20 +198.12 +207.82 +217.33
120 +147.90 +158.70 +169.24 +179.54 +189.59 +199.44 +209.06 +218.49
130 +149.65 +160.36 +170.81 +181.02 +191.00 +200.75 +210.31 +219.66
140 +151.40 +162.03 +172.39 +182.51 +192.41 +202.09 +211.56 +220.84
150 +153.16 +163.70 +173.98 +184.00 +193.82 +203.42 +212.81 +222.02
160 +154.93 +165.37 +175.56 +185.51 +195.24 +204.76 +214.08 +223.20
170 +156.69 +167.05 +177.15 +187.02 +196.66 +206.10 +215.34 +224.39
180 +158.47 +168.73 +178.75 +188.53 +198.09 +207.45 +216.61 +225.55
190 +160.24 +170.42 +180.35 +190.05 +199.52 +208.80 +217.89 +226.79
200 +162.01 +172.10 +181.95 +191.57 +200.97 +210.16 +219.17 +227.99
210 +163.80 +173.80 +183.55 +193.09 +202.40 +211.53 +220.46 +229.20
220 +165.58 +175.43 +185.16 +194.62 +203.85 +212.89 +221.74 +230.41
230 +167.36 +177.19 +186.78 +196.14 +205.30 +214.26 +223.04 +231.63
240 +169.16 +178.89 +188.39 +197.68 +206.75 +215.63 +224.33 +232.85
250 +170.94 +180.59 +190.01 +199.21 +208.20 +217.00 +225.63 +234.08
260 +172.73 +182.30 +191.63 +200.75 +209.66 +218.40 +226.93 +235.31
270 +174.53 +184.00 +193.25 +202.29 +211.12 +219.77 +228.24 +236.54
280 +176.32 +185.70 +194.88 +203.83 +212.59 +221.16 +229.55 +237.77
290 +178.11 +187.42 +196.50 +205.37 +214.05 +222.54 +230.86 +239.01
300 +179.90 +189.13 +198.13 +206.92 +215.51 +223.93 +232.18 +240.26

DIFFERENCE BETWEEN THE WATER THERMAL EXPANSION FACTOR AND THE STEEL THERMAL
EXPANSION FACTOR ( 0 C -1 ) (10 -6)
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 17 of 17

TITLE HYDROSTATIC TESTING OF MEC/S/05/21/03 REVISION : 0

ONSHORE PIPELINE
EDITION : 1

TABLE -A
0
C 24 25 26 27 28 29 30
Bar
0.981 +215.22 +215.14 +234.88 +244.41 +253.79 +263.00 +272.03
10 +216.13 +225.99 +235.66 +245.13 +254.44 +264.59 +272.57
20 +217.15 +226.94 +236.53 +245.94 +255.18 +264.27 +273.18
30 +218.18 +227.88 +237.41 +246.75 +255.93 +264.95 +273.80
40 +219.21 +228.85 +238.30 +247.58 +256.69 +265.64 +274.42
50 +220.25 +229.82 +239.20 +248.40 +257.45 +266.33 +275.07
60 +221.30 +230.79 +240.11 +249.24 +258.22 +267.04 +275.70
70 +222.35 +231.78 +241.02 +250.08 +258.99 +267.75 +276.35
80 +223.42 +232.77 +241.94 +250.93 +259.78 +248.47 +277.01
90 +224.48 +233.76 +242.87 +251.79 +260.57 +269.19 +277.66
100 +225.56 +234.76 +243.79 +252.66 +261.36 +269.92 +278.33
110 +226.64 +235.78 +244.73 +253.53 +262.17 +270.77 +279.01
120 +227.73 +236.79 +245.68 +254.40 +262.98 +271.41 +279.69
130 +228.82 +237.81 +246.63 +255.28 +263.69 +272.16 +280.38
140 +229.92 +238.84 +247.59 +25618 +264.62 +272.92 +281.08
150 +231.03 +239.87 +248.55 +257.07 +265.44 +273.69 +281.78
160 +232.14 +240.91 +249.52 +257.97 +266.28 +274.46 +282.49
170 +233.26 +241.96 +250.49 +258.88 +267.12 +275.23 +283.20
180 +234.38 +243.01 +251.47 +259.79 +267.97 +276.01 +283.92
190 +235.51 +244.06 +252.46 +260.71 +268.82 +276.80 +284.64
200 +236.64 +245.12 +253.45 +261.63 +269.67 +277.59 +285.37
210 +237.77 +246.18 +254.45 +262.50 +270.54 +278.39 +286.11
220 +238.91 +247.26 +255.45 +263.49 +271.40 +279.19 +286.85
230 +240.06 +248.33 +256.46 +264.43 +272.28 +280.00 +287.59
240 +241.21 +249.41 +257.46 +265.37 +273.16 +280.82 +288.35
250 +242.36 +250.49 +258.48 +266.31 +274.04 +281.63 +289.11
260 +243.52 +251.58 +259.49 +267.27 +274.92 +282.46 +289.86
270 +244.68 +252.66 +260.52 +268.23 +275.82 +283.29 +290.64
280 +245.84 +253.76 +261.54 +269.18 +276.71 +284.12 +291.40
290 +247.01 +254.86 +262.57 +270.15 +277.61 +284.95 +292.18
300 +248.18 +255.96 +263.60 +271.11 +278.51 +285.79 +292.95

DIFFERENCE BETWEEN THE WATER THERMAL EXPANSION FACTOR AND THE STEEL THERMAL
EXPANSION FACTOR ( 0 C -1 ) (10 -6)
 Rev. : 0
Edition : 1

SPECIFICATION
FOR
MAJOR WATER CROSSINGS
(CONVENTIONAL)

SPECIFICATION NO.: MEC/S/05/21/04

(OIL & GAS SBU)

MECON LIMITED
DELHI 110 092
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 1

TITLE MAJOR WATER CROSSINGS MEC/S/05/21/04 REVISION : 0

(CONVENTIONAL)
EDITION : 1

CONTENTS
SL.NO. DESCRIPTION

0.0 DEFINITION

1.0 SCOPE

2.0 GENERAL

3.0 TRENCHING

4.0 CONTINUOUS CONCRETE COATING

5.0 HYDROSTATIC PRE-TESTING

6.0 INSTALLATION

7.0 BACKFILLING AND BANK PROTECTION

8.0 FINAL HYDROSTATIC TEST

9.0 POST-CONSTRUCTION SURVEY

10.0 FINAL CLEAN-UP

11.0 DOCUMENTATION

PREPARED BY: CHECKED BY: APPROVED BY: ISSUE DATE :

(Shalini Singh) (Sunil Kumar) (A.K. Johri) Nov. 2008

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 11

TITLE MAJOR WATER CROSSINGS MEC/S/05/21/04 REVISION : 0

(CONVENTIONAL)
EDITION : 1

00 DEFINITION

A major water crossing shall be reckoned the one wh ich will necessitate passing
the gas pipe line across a wate r body suc h as perennial river, major irrigation canal,
pond, lake , lagoon, c reek e tc. using spe cial attention and mean s. The parameters
required t o classify a part icular wat er body as a major water crossing shall
comprise of size , hydrologic al data, authority/ownership, importanc e and othe r
ecological/ env ironmental fact ors asso ciated wit h it , and t he aut hority to classify it
such, shall rest with the COMPANY.

1.0 SCOPE

1.1 This sp ecification co vers t he minimum req uirements fo r t he v arious act ivities t o be
performed by CONTRACTOR for the construction of pipeline major water crossings by
conventional trenching method. Provisions of this specification are applicable only for
"major water crossings" specifically named as such in the CONTRACT.

1.2 This specification shall be read in conjunction with the conditions of all specifications
and documents included in the CONTRACT between COMPANY CONTRACTOR.

1.3 CONTRACTOR shall, with due care and diligence, ex ecute the work in compliance
with all laws, by- laws, ordinanc es, re gulations etc. and provide all services and
labour, inclusive of supervision thereof, all materials excluding the materials indicated
as "Company supplie d Materials" in the CONTRACT, equipment, appliances or othe r
things of whatsoever nature required in or about the execution of the work, whether
of a temporary or permanent nature.

1.4 CONTRACTOR shall take full responsib ility for the stability and safety of all
operations and methods involved in the work.

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

1.6 CONTRACTOR shall be deemed to have obtained all necessary information as to

risks, contingencies and all other circumstances, which may influence the work w.r.t.
the above.

1.7 CONTRACTOR shall, in co nnection wit h t he work , prov ide and maint ain at his own
costs all lights, guards, fencing, watching et c., when and where necessary o r
required by C OMPANY or by a ny duly constituted authority for the protection of the
work and properties or for the safety and the convenience of public and/ or others.

1.8 For the purpose of this specification, the following definitions shall hold :

• the words `Shall' and `Must' are mandatory

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 2 of 11

TITLE MAJOR WATER CROSSINGS MEC/S/05/21/04 REVISION : 0

(CONVENTIONAL)
EDITION : 1

• the words `Should', `May' and `W ill' are non-mandatory, advisory, or

recommended.

2.0 GENERAL

2.1 All works of the pipeline major water cro ssing shall be performed in accordance with
the approved construction drawings, procedures, other applicable documents as pe r
the CONTRACT, good pipeline practice and as directed by COMPANY.

2.2 Before start of the field construction, CONTRACTOR shall submit to COMPANY, for
approval for each major water crossing a complete report cont aining at t he
minimum:

i) installation method

ii) proposed time schedule indicating start and finish dates and de tailed break-
up of time period for all critical activities associated with the work.

iii) required work area along with layout and location

iv) equipment to be used (including number and capacity of equipment).

v) manpower deployment during construction

vi) proposed sub-contractors and/ or vendors along with their scope of work.

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

a) Study of water currents in relation t o t he met hod of launching (on bot tom
and on surface).

b) Calculation for stability of pipeline during launching and final test.

c) Buoyancy studies

d) Preparation of fabrication yard and launching areas.

e) Pipeline construction de tails (h andling, stringing, we lding, c oncrete c oating

etc.)

f) Pre-test procedure including trial mix, design & tests for concrete coating.

g) Procedure for corrosion coating of field joint

h) Dredging, anc horing program, sp oil-deposit and tre nch surve y me thod
including facilities for COMPANY.

i) Pulling or other installation method and related calculations.

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 3 of 11

TITLE MAJOR WATER CROSSINGS MEC/S/05/21/04 REVISION : 0

(CONVENTIONAL)
EDITION : 1

j) Pulling arrangement including launchway and anchoring and breaking device.

k) Trench correction before launching.

l) Method of positioning and sinking of pipeline.

m) Method of rectification of damages to the pipeline, during launching.

n) Method of backfilling, bank protection and survey.

o) Final test procedure after backfilling.

p) Safety systems during launching, rope tests.

q) Communication.

r) Abandonment and recovery procedures concurred.

s) Necessary permission from concerned authorities for crossing.

COMPANY shall inform CONTRACTOR within 21 day s if any object ion against the
document and procedure described requires resubmission by CONTRACTOR.

Approval by COMPANY of the methods used by CONTRACTOR shall in no way relieve

CONTRACTOR from the sole resp onsibility for safe and satisfactory installation of the
crossing.

2.3 CONTRACTOR shall comply with all the co nditions and requirements issued by
authorities hav ing j urisdiction in t he area where t he work is to be performed.
CONTRACTOR shall, at his ow n responsibility, obtain ne cessary permits from the
authorities having jurisdiction, for performing his work.
If no public roads ex ist, CONTRACTOR shall arrange on his own for access to his
work area at no extra cost to COMPANY.

2.4 Pre-construction Surveys

Prior to start of any work, CONTRACTOR sh all carry out a survey of the major water
crossings and acquaint himself with site co nditions and to collect any data re garding
the water velocity and the tidal va riations in th e f low pa ttern a nd sh all ve rify th e
suitability of his equipment and the methods of construction.

3.0 TRENCHING

3.1 Dredging/ Excavating

3.1.1 CONTRACTOR sh all dre dge or e xcavate th e tre nch f or the water crossing in
conformity with the approved drawings. Dredging of the trench shall be executed as
accurately as possible.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 4 of 11

TITLE MAJOR WATER CROSSINGS MEC/S/05/21/04 REVISION : 0

(CONVENTIONAL)
EDITION : 1

3.1.2 The trench shall be ex cavated to such depth as required to provide the minimum
cover and the pipeline configuration as spec ified. The pipeline profile of the crossings
shall be followed as accurately as possible. Before laying, the trench shall be cleaned
and le velled. The tre nch shall be subject to in spection by C OMPANY prior to
installation of the pipe.

3.1.3 Navigational traffic shall not be ob structed, unless permi ssion has been given
thereto. CONTRACTOR shall issue all necessary publications according to the local
regulations. Instructions give n by auth orities shall be follo wed ac curately and
immediately, so t hat t here in no hindrance to traffic . For stoppage of navigational
traffic public notification, PA system, signal/ sign etc. shall be provided.

CONTRACTOR cannot req uest a co mpensation if his wo rk is hamp ered o r d elayed

due to weather conditions, any obstacles/ or by any traffic on t he spot, where work
is executed.

3.1.4 CONTRACTOR is fully resp onsible fo r t he ex ecution o f t he b lasting (whenev er

permitted) the dre dging and e xcavation wo rk, h opping of th e soil, tra nsportation,
dumping on land or in water, all t o b e ex ecuted in ag reement with authorities, land
owners and COMPANY.

3.1.5 CONTRACTOR may be obliged to dredge or excavate a trench deeper or wider than
indicated in the drawings in order to properly la y the pipe line in unstable
(underwater) areas, or near and adjacent to the banks of water courses. It shall be
understood that CONTRACTOR is aware of such problems at the time of this bid and
that, when such additional excavation is required, it shall be done by CON TRACTOR
as part of the work and that he will insta ll the necessary provision and/ or temporary
works such as sheet-piling, special filling ma terials, etc. at no ex tra cost to
COMPANY.

3.1.6 During, the e xecution of dredging work of CON TRACTOR, be arings, me asurements
and levels shall be take n by or on be half of COMP ANY. CONT RACTOR shall render
assistance for t his purpose and mak e av ailable for COMPANY appropriate survey
boats, fully manne d and e quipped before the start of excavation work of the water
crossing trench. CONTRACTOR, if so desire d by COMPAN Y, shall make cross profiles
at in tervals of n ot m ore th an 10.0m of th e bottom of th e w ater-course a long the
surveyed center line o f the water crossing. In such a case ho rizontal measurements
shall be t aken by t riangulation or t aping be tween known points and shall be made
with su ch a ccuracy th at th e loc ation of e ach ve rtical m easurement is kn own within
1.0m. Vert ical measurement s shall be t aken wit h a so nic reco rding device, or with
line and rod, as dire cted by COMPAN Y and sh all b e t aken wit h such accuracy t hat
each de pth is known within 0.2m. Ve rtical m easurements sh all be ta ken a t points
averaging not more t han 5.0m apart and no two measurements shall be more than
7.0m apart. The cross profiles shall extend at least 10m on both sides of the top of
the trench.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 5 of 11

TITLE MAJOR WATER CROSSINGS MEC/S/05/21/04 REVISION : 0

(CONVENTIONAL)
EDITION : 1

All measurements shall be witnessed by COMPAN Y. The re sulting profile , c orrected

to the elevation of the undisturbed water-course, shall then be the reference profile.
Said profile shall be plotted on a 1:200 vertical and horizontal scale.

3.1.7 CONTRACTOR shall k eep t he t rench in good condition until the pipe is laid, and no
claim is to be made to the COMPANY by re ason of its c aving either before or a fter
the pipe is laid. CONTRACTOR shall d o whatever is req uired to excavate the trench,
install the pipe in it and backfill the trench in accordance with these specifications at
no extra cost to COMPANY.

3.1.8 Immediately before installation of th e w ater c rossing in th e e xcavated tre nch,

CONTRACTOR shall prepare a profile of the trench bottom along the surveyed center
line of th e w ater c rossing f or c omparison w ith th e re ference prof ile. C ONTRACTOR
shall also make cross sections of the tren ch at intervals of not more than 100m. All
profile and cross section measurements shall be taken as spec ified and shall be
witnessed by COMPANY. These data shall be submitted to COMPANY for approval and
COMPANY will approve or reject the trench excavation as completed within 24 hours
after receipt of the profile and cross sections.

3.1.9 CONTRACTOR shall grade the trench in such a m anner a s to give th e m aximum
amount of uniform support to the pipeline when it is lowered or pu lled into place. The
maximum unsupported span shall not exceed 10.0m.

3.1.10 In sub merged sect ions, where ro ck o r g ravel is enco untered in t he b ottom o f the
trench, padding is re quired. The thic kness of t he p adding und er t he co ncrete co ated
pipe shall at least be 50 cm and after installation at least 50 cm around the pipe.

Blasting, if any, and padding shall be included in the work.

3.2 Pumping Line

In case CONTRACTOR uses pumping lines to discharge the spoil, he shall take care of
the necessary permits.

Pumping lines, disc harges and siphon s shall be installe d by CON TRACTOR and
removed before the completion of the w ork. At c rossings w ith e xisting roa ds, th e
pumping lines shall be led through a c asing pipe bored/ jacked under the road or le d
through a porch over the road. A stress calculation must t hen be handed ov er t o
COMPANY. The necessary provisions to embank the dumping are a and also the spoil
basins shall be made by CONTRACTOR. CONTRACTOR is responsible for transportation
of the soil and dumping on land and is liable for damage to works of third partie s
caused by le akage of pumping line s, e tc. CONTRACTOR shall at all time prevent
overflow of pumping water, spoil or sand over embankments, parcels or roads. Further
more, CONTRACTOR shall safeguard COMP ANY from claims of c ompensation by third
parties due to encountered damage.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 6 of 11

TITLE MAJOR WATER CROSSINGS MEC/S/05/21/04 REVISION : 0

(CONVENTIONAL)
EDITION : 1

3.3 Spoil

Spoil which is not dumped on and includ ing sp oil acq uired aft er cleaning t he wat er
crossing tre nch, shall be transported and dumped in plac es, de signated the reto by
agreement b etween CONT RACTOR and aut horities and approve d of by COMPANY.
Spoil shall be transported in (split) barges; only those barg es shall be used t hat avoid
spilling during transportation du e to incorrect closing of the flaps, etc. Spoil which is
dumped outside t he d esignated p laces sh all be re moved by CON TRACTOR at first
notice by COMPANY.

3.4 Dykes, Dams and Weirs

CONTRACTOR shall install temporary provisio ns in t he ex isting d ykes, dams, etc. to

prevent flooding of low areas.

Therefore in g eneral, in existing dykes, dams, etc a double substituting we ir must be

installed before start of ex cavation in th e e xisting dyke or dam. Such a double
substituting weir can be a closed wall of sh eet piling, supported by soil. The provisions
shall be such that the underwater profile of the dredged trench, the water movement
caused by ships, etc. cause no slides/ cave-ins of the dyke or dam.

4.0 CONTINUOUS CONCRETE COATING

CONTRACTOR shall provide co ncrete coating over the pipeline including the bends in
accordance wit h t he sp ecification issued fo r t he p urpose (refer sp ecification no .
MEC/S/05/11/03 and approved procedure. CONT RACTOR shall coat the weld joints in
order t o arriv e at a continuously concrete c oated pipe line. Ho wever this concrete
coating shall be applied after the hydrostatic pretest.

5.0 HYDROSTATIC PRE-TESTING

CONTRACTOR sh all h ydrostatically pre -test th e pipe strin g of e ach w ater c rossing
before installation as per approved procedure.

Joint coating of the welds shall be done after this pre-test.

The section of t he p ipeline co rresponding to th e m ajor w ater c rossing sh all, be fore

installation, be subjected to h ydrostatic pre-testing to a combined equivalent stress
of 90% of the SMYS of the pipe material.

After the temperature has been stabilised, the pressure shall be maintained in the
pipeline for at least twenty four (24) hours and recorded by manothermograph. During
the test CONTRACTOR shall check all welds for leakage. Failure, if any, during the test
shall be rectified by the CONT RACTOR. If the same is due to failure on account of any
cause ot her t han defect in mat erial supplie d by COMPANY, the repairs shall be done
free of cost, to the satisfaction of COMPANY.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 7 of 11

TITLE MAJOR WATER CROSSINGS MEC/S/05/21/04 REVISION : 0

(CONVENTIONAL)
EDITION : 1

6.0 INSTALLATION

6.1 CONTRACTOR shall submit a detailed scheme for the method he proposes to adopt for
installing the pipeline to COMPANY for a pproval. CONTRACTOR shall calculate all
stresses in the pipeline while la ying a nd c heck wh ether the stresses remain within
permissible limits. A set of all calculations shall be su bmitted to th e C OMPANY f or
approval.

6.2 CONTRACTOR shall perform all work required to install the water crossings, including
the possible appurte nances indic ated in th e drawings. The wate r c rossings shall be
installed in such a manner as to comply with the requirements and conditions stated
by the Authorities issuing the permits. CONTRACTOR sha ll pay special attention to
minimize any damage to embankments and dykes in the vicinity of water crossings.

6.3 The equipment for launching shall be arrang ed in such a way that the pipeline is laid
without impact or jerking and is not subjected to stresses of any type other than those
which are allowable. Minimum allowed ra dius of c urvature shall be followe d,
particularly at the end of the launching way towards the water in the freely suspended
section.

6.4 After the water-crossing section has been installed in pl ace, CONTRACTOR shall fill this
section including the pertaining land sections with water for the final testing.

6.5 CONTRACTOR shall check if the position and de pth of the wate r c rossing are in
accordance with the approved drawings, by me ans of a prof ile of the pipeline, before
and after the water-crossing section is filled with water. CONTRACTOR shall lower each
pipeline section which is not sufficiently de ep by dre dging or je tting the unde rlying
ground.

6.6 The max imum allowed horizont al deviat ion from the required cent er line shall b e
limited to the following :-
For pipeline dia. upto and including 24" - 300 mm
For pipeline dia greater than 24" - 500 mm

6.7 Prior to backfill the pipeline shall, when laid in the trench, conform to the bottom
contour of the trench grade, so that it will be firmly , uniformly and continuously
supported. COMPANY may employ a diver or use other suitable methods to inspect the
bottom of the trench and/ or after the pipe is installed prior to backfilling of the trench.
CONTRACTOR shall facilitate the work of the diver and shall furnish the necessary
equipment and help ers (o ther t han act ual d iving equipment) necessary for the diver/
inspector to perform his work.

6.8 If the pipe does not properly fit the trench or does not rest at sufficient depth to satisfy
the minimum requirement s of cover as specified in approve d drawings, the
CONTRACTOR shall mak e necessary corrections to either trench or the pipe alignment
or to both so th at the pipe, when finally in position in the trench, shall fully meet the
specifications, failing which CONTRACTOR may be asked to remove the pipeline. This
shall be done at no extra to the COMPANY.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 8 of 11

TITLE MAJOR WATER CROSSINGS MEC/S/05/21/04 REVISION : 0

(CONVENTIONAL)
EDITION : 1

6.9 Installation of Parallel Pipelines

When parallel pipelines are required to be installe d for a major wate r crossing.
CONTRACTOR shall further comply with the following requirements.

6.9.1 Depending on the diameters of the parallel pipelines, the characteristics of the crossing
and the limitations of CONTRACTOR's equipment, CONT RACTOR may propose
installation of the parallel pipelines eit her t ogether in a co mbined o peration or
separately in a common trench.

6.9.2 If the pipelines are installed together, the minimum clear distance between the parallel
pipelines (measured from the outside diameters of the concrete coated pipes) shall be
300mm. CONTRACTOR shall provid e spacers at sufficient intervals along t he length of
the pipe se ction(s), se curely fixe d to th e pipe s, or shall propose other suitable
alternative m ethods, so a s to e nsure th at t he st ipulated minimum clear distance is
maintained. The spacers may be removed before the trench is backfilled.

CONTRACTOR shall furnish detailed drawin gs for the pipe asse mbly showing the
details o f sp acers/ o ther arrang ements for COMP ANY's approv al before st art of
construction.

6.9.3 If the parallel pipelines are installed separately in a common trench, the minimum clear
distance between the paralle l pipelines in the trench shall be 5000mm. CONTRACTOR
shall ensure that this mini mum spacing be maintained till the time the trench is
backfilled.

7.0 BACKFILLING AND BANK PROTECTION

7.1 Backfilling of the water-crossing sectio n shall be performed as described in the

following clauses.

7.1.1 The bottom of the waterway shall be reinstated to its original level by backfilling the
trench in a manner and wit h suitable material and as pre scribed and approve d by the
authorities and COMP ANY. In case mat erial other th an th e origin al spoil is required,
this shall be supplied and applied by CONTRACTOR.

Wherever boulders, rock, gravel and other hard object are encountered, they shall not
be placed directly on the pi pe. Sufficient earth, and or se lected and approved backfill
material shall be backfilled in itially around and over the pipe to provide a protective
padding or cushion ex tending t o a minimu m t hickness o f 50 cent imeters around the
pipe before backfilling remainder of the trench with excavated or other material.

Wherever required by COMPANY, CONT RACTOR shall cover the (nearly) backfilled
trench with a layer of rock boulders to be approved by COMPANY over a width equal to
the width of the excavated trench with an extra of 5 m o n either side at no extra cost
to COMPANY.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 9 of 11

TITLE MAJOR WATER CROSSINGS MEC/S/05/21/04 REVISION : 0

(CONVENTIONAL)
EDITION : 1

7.1.2 Backfilling progress of th e trench shall be checked cont inuously, and a daily progress
report shall be made and handed over to COMPANY.

7.1.3 All e mbankments and/ or dyke s, be d and banks shall be reinstated to th eir origin al
state and lev els, unless o therwise p rescribed in t he d rawings or by the Competent
authorities or COMPANY.

7.1.4 All remaining spoil-de posits sh all be c leaned by C ONTRACTOR to th e sa tisfaction of

COMPANY.

7.2 Bank Protection

7.2.1 Trenches in banks of major water crossi ngs shall be backfilled with soil approved by
COMPANY. The fill at the banks shall be ta mped firmly and reinforced with sacked
earth, rip-rap, or by other me ans as dire cted by COMPAN Y to the satisfac tion of
authorities having jurisdiction thereof. In areas where the backfilled soil is ex pected to
be of loose type which is pr one to flow, the trench shall be backfilled with boulder/
crushed rock of minimum 75mm thickness. The boulder/ crushed rock shall be derived
from solid, stable, non-soluble and approved quality store approved by COMPANY and
pipe shall be provide d with ade quate pa dding of soil of a quality approve d by
COMPANY. Wherever necessary the boulder/ crushed rock shall be held to the bed by
use of 6.1 wire net s of minimum dia. of 3.2mm, made from st eel hav ing t ensile
strength of 400 N/mm 2 and wit h a minimum elongat ion at failure of 12%. T he
minimum zinc coating of 275 gm -2 shall be applied on single/ double twisted wire. After
the trench has been backfilled and during th e clean up works, the water crossing shall
be cleaned acro ss t he who le wid th o f ROW. The e xisting be d profile shall be
maintained after restorations.

7.2.2 Unless stipulated otherwise by the authorities or by COMP ANY, CONT RACTOR shall
protect the banks of the major water crossings by using gravel and boulders filled
embankment mattresses of galvan ized iron wire (of specification as in 7.2.1 above) to
be laid over the backfilled, co mpacted and graded banks. In case slope of the banks is
1:1 or more, bank protection shall be carried out using gabions. Bank prote ction works
shall be carried out by CONTRACTOR in accord ance with the drawings included in the
CONTRACT. All materials required for such works shall be supplied by CON TRACTOR
and all works carried out in accordance with spe cifications, approve d drawings,
instructions of C OMPANY a nd to th e c omplete sa tisfaction of a uthorities h aving
jurisdiction at no extra cost to COMPANY.

The length of the above protection shall b e equal to the actual bank excavation edge
including damage and furthe r e xtending 10 m o n eit her sid es, T he wid th o f t he
restoration on the slope shall be determined by the levels :

• 2m above Highest Water Level, (recordable) or upto the top of bank, whichever
is higher.

• 5m below Low Water Level (recordable) or upto pipe trench level in the bed.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
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834002 OIL & GAS SBU, DELHI

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TITLE MAJOR WATER CROSSINGS MEC/S/05/21/04 REVISION : 0

(CONVENTIONAL)
EDITION : 1

7.2.3 Before f inal h ydrostatic te sting, C ONTRACTOR sh all `prove ' th e dia meter of th e
pipeline by passing a gauging (c aliper) pig through the pipeline. The gauging pig
shall have a diameter equal to 95% of the internal diameter of the pipe.

CONTRACTOR shall supply and install all temporary scraper, launchers. Receiv ers
and other equipment, piping and materials and consumables for the purpose.

8.0 FINAL HYDROSTATIC TEST

The complete water crossing must be tested immediately after the approved backfilling
of the trench. The test procedure shall result in a hoop stress in pipe corresponding to
90% SMYS of the pipe mate rial. After temperature stab ilisation pressure shall be
retained in the p ipeline fo r a minimum o f t wenty fo ur (24) ho urs and reco rded b y
manothermograph. Th e h ydrostatic te sting sh all be carried out in accordance with
approved procedures.

9.0 POST-CONSTRUCTION SURVEY

After laying of the pipeline, CONTRACTOR shall carry out a post -construction survey
jointly with COMPANY. Any defects brou ght to th e n otice of C ONTRACTOR sh all be
promptly corrected by C ONTRACTOR at his own expense to the complete satisfaction
of COMPANY.

10.0 FINAL CLEAN-UP

After c ompletion of c onstruction, C ONTRACTOR sh all c lear th e site of all balance

material and de bris. All balanc e pipe lengths, in case supplied by COMPANY, shall be
returned to COMPANY's designated stock yard(s). Site shall be cleared to the complete
satisfaction of COMP ANY and aut horities hav ing jurisdiction. All such works shall be
done at no extra cost to COMPANY.

11.0 DOCUMENTATION

11.1 In addition to the doc uments spe cified elsewhere in t his sp ecification. CONTRACTOR
shall submit to the COMPANY six copies of each of the following documents / records.

• Complete record of pipes `taken-over' from COMPANY, number of pipe lengths

used, and record of return of balanc e pipe le ngths to COMPANY's designated
stock-yard(s).
• Copies o f t he p ermits o btained fro m authorities having jurisdiction for the
various works.
• Records of Non-destructive testing of welds.

• Clearance cert ificates fro m t he land owners and authorities having jurisdiction
regarding satisfactory clean-up and restoration of pipeline ROU and work areas.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 11 of 11

TITLE MAJOR WATER CROSSINGS MEC/S/05/21/04 REVISION : 0

(CONVENTIONAL)
EDITION : 1

11.2 After c ompletion of c onstruction C ONTRACTOR sh all pre pare & f urnish six se ts of
copies and two sets of reproducible of As-built drawing for the crossings.

As-built drawings shall be as a minimum, include the following information.

• True profile of the bed and banks of the water crossing along the pipeline after
backfilling.

• True profile of the pipeline as installed and the top of cover to top of pipe at
regular intervals.

• Location and angle of sag and over bends.

• Extent of backfill.

• Extent of bank protection.

11.3 All documents shall be in English Language

 Rev. : 0
Edition : 1

SPECIFICATION
FOR
PIPELINES CROSSING ROADS, RAILROADS,
MINOR WATER AND OTHER CROSSINGS

SPECIFICATION NO.: MEC/S/05/21/05

(OIL & GAS SBU)

MECON LIMITED
DELHI 110 092
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 1

TITLE PIPELINES CROSSING ROADS, MEC/S/05/21/05 REVISION : 0

RAILROADS, MINOR WATER
AND OTHER CROSSINGS EDITION : 1

CONTENTS
SL.NO. DESCRIPTION

1.0 SCOPE

2.0 REFERENCE CODES, STANDARDS AND SPECIFICATIONS

3.0 GENERAL

4.0 ROAD AND RAIL-ROAD CROSSINGS

5.0 CROSSINGS OF BURIED SERVICES

6.0 MINOR WATER COURSE CROSSINGS

PREPARED BY: CHECKED BY: APPROVED BY: ISSUE DATE :

(Shalini Singh) (Sunil Kumar) (A.K. Johri) Nov. 2008

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 8

TITLE PIPELINES CROSSING ROADS, MEC/S/05/21/05 REVISION : 0

RAILROADS, MINOR WATER
AND OTHER CROSSINGS EDITION : 1

1.0 SCOPE

1.1 This specification co vers t he minimum req uirement fo r t he v arious act ivities t o b e
carried out by the CONTRACTOR for or about the installation of pipelines crossing
roads, railroads, minor water courses and other services.

The provisions of this specification are not applic able for pipe lines crossing water
courses, which are specifically designated as "Major Water Courses" in the CONTRACT.

1.2 This specification shall be road in conjunction with the conditions of all specifications
and documents included in the CONTRACT between COMPANY and CONTRACTOR.

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

• the words "Shall" and "Must" are mandatory

• the words "Should, "May" and "W ill" are non-mandatory, advisory
recommended.

2.0 REFERENCE CODES, STANDARDS AND SPECIFICATIONS

2.1 Reference has b een made in this specification to the late st edition (edition enforce at
the time of floating the enquiry) of the following codes, standards and specifications.

a) ASME B 31.4 - Pipeline Transportation Systems for Liquid

Hydrocarbons and Other Liquids.

b) ASME B 31.8 - Gas Transmission and Distribution Piping

Pipelines Crossing Railroads and Highways.

c) API RP 102 - Recommended practice for Liquid P etroleum

Pipelines Crossings Railroads and Highways.

d) OISD 226 - Natural Gas Transmission Pipelines and City Gas

Distribution Networks

e) Part 192, Title 49 - Transportation of Natural and Other Gases by

Pipeline.

f) Part 195 - Transportation of liquids by Pipeline.

2.2 In case o f co nflict b etween t he req uirements o f ab ove ment ioned co des, standards,
specifications and practices, the most stringent requirement shall govern.

3.0 GENERAL

3.1 Crossing of roads, railroads, buried se rvices, canals and minor water courses with
equipment and/ or pe rsonnel is allowed only aft er acquiring approv al from t he
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
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834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 2 of 8

TITLE PIPELINES CROSSING ROADS, MEC/S/05/21/05 REVISION : 0

RAILROADS, MINOR WATER
AND OTHER CROSSINGS EDITION : 1

authorities hav ing jurisdict ion and after making arrangement s for safeguarding t he
roads, etc. and the buried services with appropriate provisions.

Highways, main-roads and railroads and their verges and banks of wate r crossings are
not allowe d to be use d for loading, unloading or st acking of mat erials and/ or
equipment. For secondary roads, such loading/ unloading is permitted only afte r prior
approval from the concerned authorities CONTRACTOR is not allowed to close or divert
roads or water courses without prior approval from the COMPANY and the concerned
authorities. CONTRACTOR sha ll never unnecesarilly hamper the users of the roads,
railroads, buried services and/ or water courses. The water flow shall not be obstructed
in any way.

3.2 COMPANY reserves the right to dema nd for indiv idual crossings from t he
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.
• Approval letter from Competent Authority.

Such works shall be without any extra cost to COMPANY.

3.3 Pipeline c rossings for road, railroad, c anals and rive rs e tc., shall be hydrostatically
pretested ex-situ, prior to joint coating, whenever,

• Crossing is executed by boring ;

• Crossing is installed in casing pipe;

• River crossing pipes whic h are to be continuously concret e weight coated (to
be tested prior to concrete coating);

• Whenever, in COM PANY's opinion, the repair of pipeline at crossing, in case of

a leak during final hydrostatic testing, would require inordinate amount of effort
and/ or time;

• Whenever p retesting is insist ed up on b y t he Aut horities having jurisdication

over the utility crossed.

The section of the pipeline for the crossings shall be tested as a single string. Unless
specified otherwise in the CONTRACT, the test pressure sha ll be the one resulting in a
hoop stre ss c orresponding to 90% of SMYS of pipe mate rial. Te st pre ssure shall be
retained in the pipeline for minimum period of 4 hours. Test section shall be visually
examined for leaks/ defects, etc.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 3 of 8

TITLE PIPELINES CROSSING ROADS, MEC/S/05/21/05 REVISION : 0

RAILROADS, MINOR WATER
AND OTHER CROSSINGS EDITION : 1

4.0 ROAD AND RAILROAD CROSSINGS

4.1 The work under crossings shall includ e necessary cleari ng, grading and tre nching to
required depths and widths, welding of c asing (whe n re quired) and c arrier pipe s,
coating, lowering-in, backfilling, clean-up, re storation to the orig inal condition and
further strengthening and pr otective w orks, te sting, in stallation of assemblies,
insulators and seals, and temporary works such as sheet pilling, bridges, etc.

The work shall be carried out in accordance with the approve d drawings and job
standards, as dire cted by COMPAN Y and to the satisfaction of C OMPANY a nd th e
authorities having jurisdication over th fac ility crossed. The work carried out for road
and railroad crossings shall meet the mini mum requirements of AP I RP 1102, latest
edition.

Before the installation work of crossi ngs is started, the CONTRACTOR shall provide
suitable barricades, temporary bridge/ bypass work (especially where ro ads are o pen-
cut) with railing, if required by COMPANY for safety of tr affic. Adequate traffic warning
signals and/ or t raffic light s and suitable diversions shall be prov ided as direct ed by
COMPANY/ Authority having ju risdication o ver t hese areas. Such diversions shall not
cross t he p ipeline where it has alread y b een inst alled, unless p roper safeguarding in
COMPANY's opinion is ensured.

Prior approval from the statutory authorities shall be obtained to lay the pipeline across
highways/ roads e ither by boring or by ope n-cut method. Installation of the crossing
shall be by the me thod (i.e ., boring/ open-cut) ap proved b y Aut horities hav ing
jurisdiction. Railroad crossings shall always be bored/ jacked.

4.2 Boring/ jacking of carrier pipes for crossi ngs is allowed only if the pipes for boring/
jacking are provided with a suitable corrosion coating and CONTRACTOR remains liable
for the suitablity of the pipe and we ld-coating of c arrier pipe s to be bore d and for
which coating and method of application are any how t o be aut horised by COMP ANY
without prejudice to CONTRACT OR's liability. In all other ca ses the carrier pipes shall
be cased.

Before start of th e borin g/ ja cking C ONTRACTOR shall ex ecute a soil investigation

and determine the ground water table. Based on these investigations CONTRACTOR
shall prepare a const ruction drawing and su bmit to COMPANY for approval inc luding
time schedule and soil in vestigation report. The CO NTRACTOR shall submit for
approval of COMPANY the me thod of bo ring / tre nchless to be c arried ou t,
depending on the nature of soil conditions, nature of crossing, local requirements
etc.

During the execution of boring the ground water table over the length of the boring
shall be lowered up to atle ast 0.50 M be low bottom of the pipeline. This water table
is to be re gularly inspe cted and main tained by CON TRACTOR and reported to
COMPANY. To safeguard the stability of the borepit, CONTRACTOR shall, if necessary
in COMPANY's opinion, use a closed sheetpiling which sha ll extend atleast over 50%
of the length in undisturbed soil. The length of the boring shall be in accordance with
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 4 of 8

TITLE PIPELINES CROSSING ROADS, MEC/S/05/21/05 REVISION : 0

RAILROADS, MINOR WATER
AND OTHER CROSSINGS EDITION : 1

the le ngth of th e ROW of th e c rossing (roa d, ra ilroad, e tc.) w ith minimum 0.6 m
extra on either side.

If the soil conditions and groundwater for a part icular boring giv e reasons for t his,
CONTRACTOR is e ntitled to su ggest to C OMPANY f or a re laxation of on e or more of
the following requirements as defined hereforth :

• Soil investigation
• Lowering of groundwater table
• Sheetpiling
• Length of boring etc.

In approaches t o t he crossing, CONT RACTOR shall eliminat e unnecessary bending of

pipe by c onforming to the contour of the ground by gradually de epening the ditch at
such approaches as directed by the COMPANY.

4.3 The bottom of th e tre nch a nd/ or th e pit f or a t le ast tw elve (12) m etres a t th e
approach to each end of a casing shall be graded and if necessary backfilled with clean
sand and compacted upto atle ast 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 backfilling.

4.4 The d iameter o f t he ho le fo r a b ored sect ion shall hav e a hole diamet er as close as
practicable t o t he o utside d iameter o f t he carrier o r casing pipe. If excessive void or
too large hole results, or if it is necessary, in the opinion of COMPANY, to abandon the
bored hole, prompt remedial me asures such as filling the ho le with suitable material
shall be ta ken to th e e ntire sa tisfaction of th e COMPANY and Authorities having
jurisdication thereof at no ex tra cost to COMPANY. Equipment used for installation of
casing pipe shall be of the type approved by COMPANY.

An installation consisting of hydraulic jacks shall be pr ovided with easily readable

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

At the front of the pipe there may be a cutting ring which may be 12mm larger than
the o utside d iameter fo r t he p ipe o r casin g. A lubricating pipe c an also be use d in
jacking, the nipples of which shall not protrude from the c utting e dge. Said
lubricating pipe shall not be fixed to the pipe casing. When jacking, only biologically
degradable lubricants shall be used (e.g. WRC Medlube or an emulsion of bentonite).

Removal of soil from the pipeline during ja cking shall be done mechanically by means
of a standard, locked auger, which has to be safeguarded against jacking ahead of the
pipe.

During ja cking th e progre ss of th e pipe to be ja cked a nd th e c utting capacity of the

auger shall be mutually adjust ed, by regulating the speed of the auger, to prevent the
road from bulging (rpm too low) or cave-ins (rpm too high). In any case no more soil
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 5 of 8

TITLE PIPELINES CROSSING ROADS, MEC/S/05/21/05 REVISION : 0

RAILROADS, MINOR WATER
AND OTHER CROSSINGS EDITION : 1

shall be removed than the volume of the pipe. The auger drive shall be provided with a
clutch.

The p rogress in t he work, the readings of the gauge pipe s, the jacking pressures
observed, e tc., shall be re corded in a log book, to be shown to COMPANY upon
request. All information shall be supplied to COMPANY on completion of the work.

If the jacking fails, the casing shall not be withdrawn. It shall be filled with sand and
plugged at either end. T he diameter of the casing pipe shall conform to AP I RP 1102
recommendations or as directed by the Engineer – in - charge.

COMPANY reserves the right to inspect certain lengths of pipes t o assess damages, if
any, to the corrosion coating of the carrier pipe used for boring. CON TRACTOR shall
weld additional le ngths of pipe and pull the req uired ex tra leng ths o f COM PANY's
inspection. If during inspection any defects are noticed, CONTRACTOR, in consultation
with COMPANY, shall carry out the remedial measures required.

4.5 While welding of the casing and ve nt/ drain pipes, internal high or low is not allowed.
Welding of c asing and ve nt/ drain pipe s n eed not be radiographe d, howe ver, 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 notic ed, the se must be c ompletely re moved be fore joining the pipe s. If
these defects cannot be repaired, the defective section shall be cut out.

4.6 In the case o f cro ssing where ex cavation has b een aut horised, t he weld ing fo r t he
casing pipe and for a c ontinuous sectio of the pipeline corresponding to the expected
length shall be carried out in the proximity of the cro ssing. Casing must be laid
immediately afte r the tre nching. Casing pipe must be laid with a single gradient in
order to allow for an easy insertion and, if necessary at a future date, to allow for t he
removal or replacement of the pipeline, leaving the casing undisturbed.

4.7 The assembly of v ent pipe unit s as a pproved by COMPAN Y shall be c arried out by
direct insertion and welding to the ends of the c asing pipe be fore introduc ing the
carrier pipe. The operation of assembling and extending the vent pipe shall be carried
out in such a way that there is n o contact with the carrier pipe. The painting/ coating
of the vent pipes shall be applied before backfilling as per relevant specifications.

4.8 The c asing pipe shall be c onsidered re ady for installation of the c arrier pipe , afte r
careful inspection and internal cleaning with the removal of soil, mud, stones and other
foreign materials.

4.9 Insulators, as approve d by COMPAN Y, sha ll be securely fastened to the pipe with all
bolts and fixtures firmly tighte ned. The number of insulators and spacing shall be as
shown in the drawings or at 2.5m intervals (whichever is more stringent). At the end of
both sides of the casing, a double set of insulators shall be installed.

4.10 Care must be taken in push ing or pulling carrier pipe into th e casing so that the pipe is
aligned correctly in the casing and that the pushing or pulling force is evenly and
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 6 of 8

TITLE PIPELINES CROSSING ROADS, MEC/S/05/21/05 REVISION : 0

RAILROADS, MINOR WATER
AND OTHER CROSSINGS EDITION : 1

constantly applied to avoid damage s 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 ca sing and to keep it dry and
clean.

4.11 After in stallation of th e c arrier pipe se ction, th e casing and the appurtenances, but
prior to making tie-in welds and backfilling, an electrical test shall be conducted by the
CONTRACTOR in t he presence of the COMPANY, to determine the resistance between
the casing and the carrier pipe or the carrier p ipe and the soil. These tests shall sho w
at least a resistance of 100 kohm/m 2. After backfilling and compaction, additional tests
shall be conducted to de termine if the casing is e lectrically shorted to th e pipe. If the
installation is found to be shorted, CONTRACTOR shall make the necessary corrections
and repairs at his cost, until a test to the satisfaction of the COMPANY is obtained.

5.0 CROSSINGS OF BURIED SERVICES

5.1 The pipeline under construction may pass abov e or below the ex isting buried facilities
such as pipelines, cables, etc. Type of crossing shall be such that a minimum depth of
cover as re quired in the drawings and specifications are guarant eed. T he minimum
clearance required between pipeline and the existing facility shall be 500mm.

5.2 Whenever buried services in the ROW are t o b e cro ssed b y CONT RACTOR, he shall
safeguard the buried facilities and the required precautions shall be taken as approved
by Owner of the buried services and by COMPANY.

5.3 For buried services to be crossed by boring/ jacking, the relevant provisions of Section
3.0 shall apply.

6.0 MINOR WATER COURSE CROSSINGS

6.1 Minor water crossings are crossings of ditches, canals, wat er courses, rivers, streams
etc, whet her t he b ed(s) contain(s) water or not, and not be ing spe cified as `Major
Water Crossings' in the CONTRACT.

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

6.3 Whenever mino r wat er cro ssings in t he ROW are t o b e cro ssed, CONTRACTOR shall
install/ temporary bridges to facilitate movement.

6.4 In c rossings of w ater c ourses w ith e ither m oderate f low ra te or of torrential nature
with mark ed and unpredict able flooding, an adequate surv ey shall b e carried o ut
before starting the work with the object of determining what precautions are necessary
and the most favourable period for executing the work.

6.5 In case of crossings of water courses for which no special methods of laying are
required, a pipe section of a size as per the the approved drawings shall be assembled
and subsequently laid. Bends shall be of cold field type.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 7 of 8

TITLE PIPELINES CROSSING ROADS, MEC/S/05/21/05 REVISION : 0

RAILROADS, MINOR WATER
AND OTHER CROSSINGS EDITION : 1

Whenever req uired b y COM PANY, CONT RACTOR shall, b efore st art o f construction,
execute a soil investigation. Based on this soil invest igation he shall prepare
construction drawings, work me thod and time schedule for approval of COMPAN Y as
well as concerned local agencies.

The de pth of th e e xisting bottom of a minor water course crossing shall be

determined in relation to th e adjacent stable ground level by taking the average of
four measurements. Measurement shall b e taken with a gauge and wit h dimensions
60 x 60mm and having a flat bottom. The minimum force to be ex erted shall be 360
N (36 kgf).

CONTRACTOR shall take special care to check wit h t he resp onsible aut horities fo r
special conditions applying to working on, over, under or t hrough minor wat er
crossings and CONTRACTOR shall comply with any such condit ions. Writ ten
arrangements with authorities shall be drawn up in cooperation with COMPANY.

6.7 For crossings beneath the bed of water courses, the pipe section shal be made in such
a w ay th at it c onforms to th e e xisting or f uture be d a s in dicated in the approved
drawings. I n c rossings for which an individual drawing has not be en pre pared, the
minimum cover of t he pipeline shall not be less th an th at in dicated in th e sta ndard
drawings for a similar type of crossing.

6.8 Whenever t he cro ssing req uries a st raight sect ion o f pipe between the lower bends
coinciding with the river bed, this section shall be laid at a single horizontal level.

6.9 For crossings of ditches, canals, banked channels, etc. by boring, the pipe section shall
be prepared, laid and tested in accordance with the applicable clauses of Section 3.0 of
this specification.

6.10 The CONT RACTOR shall arrange temporary installation of dive rsions as may be
necessary, to ensure the effective functioning of these water courses crossed, to th e
entire satisfaction of the concerned Local Authorities as well as the COMPANY.

6.11 Banks and trenches of minor water crossings shall be backfilled with soil which is to be
approved by COMPAN Y and shall be thoroughly c ompacted to pre vent soil and bank
erosion as pe r the drawings and standards to th e sa tisfaction of a uthorities h aving
jurisdication t hereof and t he COM PANY. Whenev er boulders, rock, gravel and other
hard objects are enco untered, they shall no t be placed directly on the pipe. Sufficient
earth, sand or selected and approved backfill material shall be backfilled initially around
and over the pipe to provide a protective padding or cushion extending to a minimum
thickness of 30 centimeters around the pipe before backfilling rema inder of the trench
with excavated or other material as per approved drawings and standards.

After the trench has been backfilled and during the clean up works, the minor water
crossing shall be cleaned at least across the whole of the ROW.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 8 of 8

TITLE PIPELINES CROSSING ROADS, MEC/S/05/21/05 REVISION : 0

RAILROADS, MINOR WATER
AND OTHER CROSSINGS EDITION : 1

When directed by the COMPANY, CONTRACTOR shall st abilise and restore the bank
of the water crossings with materials to be supplied by him as follows.

The ex cavation shall be trimmed in steps-and-berms backfille d with well compacted

solid soil, followed by a minimum 0.25m thick layer of prope rly shaped boulders (75-
150mm) encased in a net of galvanised iron wire of dia 3mm spaced at a maximum
distance of 50mm to be laid over the backfilled, compacted and graded banks.

The GI wire shall be made from steel having tensile strength of 400 N/mm2 and with a
minimum elongation at failure of 10%. The minimum zinc coating of 200 gm -2 shall be
applied on single/ double twisted wire.

The length of the above protection shall b e equal to the actual bank excavation edge
including damage and e xtending 2m o n eit her sid es. T he wi dth of this prote ction on
the slope shall be determined by the following :

• 2m plu s th e h ighest w ater le vel (re coverable) or upto the top of bank
whichever is higher.

• Upto the bottom of th e c rossing or 20m be low th e h ighest w ater le vel

whichever is smaller.

Bank stabilisation for certain minor water crossings shall be determined by COMPANY
based on nature of c rossing e .g. type of river, c anal, major nallah, flood c ontrol
banks and othe r water bodies; type of soil, regulations of local authorities; and any
other socio-economic consideration evaluated by the COMPANY.

6.12 The crossing o f any emb ankments shall b e carried o ut st rictly in acco rdance wit h
approved drawings.

No drilling work on embankments shall be permitted without pr ior written approval

from the competent authorities.
 Rev. : 0
Edition : 1

SPECIFICATION
FOR
REPAIR OF PIPELINE CORROSION COATING

SPECIFICATION NO.: MEC/S/05/21/08

(OIL & GAS SBU)

MECON LIMITED
DELHI 110 092
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 1

TITLE REPAIR OF PIPELINE MEC/S/05/21/08 REVISION : 0

CORROSION COATING
EDITION : 1

CONTENTS

SL.NO. DESCRIPTION

1. SCOPE

2. MATERIAL AND EQUIPMENT

3. APPLICATION PROCEDURE

4. INSPECTION/ TEST

5. HOLIDAY INSPECTION

6. DOCUMENTATION

PREPARED BY: CHECKED BY: APPROVED BY: ISSUE DATE :

(Shalini Singh) (Sunil Kumar) (A.K. Johri) Nov. 2008

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 3

TITLE REPAIR OF PIPELINE MEC/S/05/21/08 REVISION : 0

CORROSION COATING
EDITION : 1

1.0 SCOPE :

This specification covers t he minimum req uirement o f mat erial and eq uipment,
installation procedure and insp ection of re pair of damage d polyethylene coatings on
steel pipes.

1.1 The repair shall be carried out using repair patch made of radiation c rosslinked
Polyolefin backing, coated on the inside with semi-crystalline thermoplastic Adhesive
and filler mastic

1.2 The repair patch shall have thermal indicators to e nsure correct heat is be ing applied
during application.

2.0 MATERIAL AND EQUIPMENT

2.1 CONTRACTOR shall supply a ll ,equipment and manpower required for a skillful and
adequate application in the field in accordance with the specification.

2.2 The repair material shall be :

• Repair patch shall be cro ss linked polyolefin with se mi-crystalline thermoplastic

adhesive (PERP 80 patch make of Covalence Raychem or equivalent).

• Filler mastic : PERPFILLER of make Covalence Raychem or equivalent.

• PERP melt stick of make Covalence Raychem or equivalent.

• Certified by DIN to meet the requirement of EN12068 stress class CHT 80.

2.3 The material shall not be older than their period of validity at the time of Application by
CONTRACTOR. Deteriorated/decomposed materials shall not be used.

2.4 Material shall be stored in sheltered storages in the manufacturer's original packing and
away from direct sunlight and in accordance with manufacturer's recommendations.

3.0 APPLICATION PROCEDURE

The application procedure to be followed for Holiday type of damage shall be in

accordance with manufacturer’s instructions and minimum requirement s specified
below whichever is more stringent.

Preparation : Remove coating from damaged area with knife, scraper or power brush.
Scrap off t he damaged area and adjacent coating to remove oil, grease, ruse dirt and
moisture.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 2 of 3

TITLE REPAIR OF PIPELINE MEC/S/05/21/08 REVISION : 0

CORROSION COATING
EDITION : 1

Preheating : Preheat the exposed bare metal surface t o about 80°C and adjacent pipe
coating to about 60°C with a torch moved back and forth over the surface.

Application of the Filler : Plastic filler shall be applied to all exposed metal surface. The
mastic is heated and smoothe d down with a paint scraper to cover all bare metal in a
manner such that all entrapped air is removed.

Application of repair tape : Cut a patch from the tape in a manner such that it extends
50 mm be yond the damaged area, position it over the damaged area, heat until the
temperature sensit ive p aint o n t he o utside o f the patc h c hanges c olour. I t shall be
smoothed down to c onfirm w ith th e c ontour of lap, and shall be freed of any air
bubbles or wrinkles.

For cosmetic type of defects such as minor gauging t earing, scrat ches which do not
indicate holiday during holiday inspection, following procedure shall be adopted :

The defect area shall be roughened to re move loose polyethylene coating, oil gre ase,
dirt etc.

This shall be followed by application of repair patch as described above.

4.0 INSPECTION, TEST

A visual inspection shall be carried out for the following :

- Mastic extrusion on ends of the patch shall be examined.

- There shall b e no sign of punctures or pin holes or bend failure. T he external
appearance of the patch shall be smooth, free from dimples, air ent rapment or
void formation.
- The entire repair patch shall have changed colour uniformly.

5.0 HOLIDAY INSPECTION

- The holiday detector used shall be checked and c alibrated e asily with an
accurate D.C. Voltmeter. The detector electrode shall be in direct contact with
the surface of coating to be inspected.

- The entire surface of the repaired section shall be inspected by means of a full
circle holiday detector approved by company set to a DC Volt age of at least 25
KV. I nspection of re paired patc h shall be conduct ed only aft er it has cooled
below 50°C.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 3 of 3

TITLE REPAIR OF PIPELINE MEC/S/05/21/08 REVISION : 0

CORROSION COATING
EDITION : 1

- No re paired point shall be c overed or lowered in the trench until it has been
approved by the COMPANY.

- Procedure qualification shall be carried ou t for repair patch. The value for peel
strength to pipe surfac e and to factory coating carried out as per E N 12068
shall be 0.5 N/mm minimum at 60°C.

6.0 DOCUMENTATION

6.1 Prior to procurement of coating repair materials, Contractor shall furnish four copies of,
but not limited to, the following for qualification of the Manufacturer and material :

i) Complete de scriptive te chnical c atalogs de scribing the materials offered

alongwith samples of repair coat ing mat erials, it s pr operties and installation
instruction as applicable specifically to the project.

ii) Test certificate and result s of pre viously c onducted te sts from independent
inspection agency.

iii) Reference list of previous su pplies of the similar material indicating the project
details suc h as diame ter, quantity, service c onditions, ye ar of supply, proje ct
name, contact person and feed back on performance.

Once the Company’s approval has been given, any change in mat erial or Manufacturer
shall be not ified t o Company , whose appr oval in writing of all changes shall be
obtained before the materials are manufactured.

6.2 Prior to shipment of materials from the Manufacturer’s works. Cont ractor shall furnish
six copies of the following :

i) Test Certificates for each batch of materials.

ii) Specific installation instruction with pictorial illustrations.
iii) Specific storage and handling instructions.

6.3 All documents shall be in English Language only.

 Rev. : 0
Edition : 1

SPECIFICATION
FOR
PIPELINE MARKERS

SPECIFICATION NO.: MEC/S/05/21/10

(OIL & GAS SBU)

MECON LIMITED
DELHI 110 092
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 1

TITLE PIPELINE MARKERS MEC/S/05/21/10 REVISION : 0

EDITION : 1

CONTENTS
SL.NO. DESCRIPTION

1.0 SCOPE

2.0 REFERENCE CODES AND DRAWINGS

3.0 GENERAL

4.0 AERIAL MARKERS

5.0 KILOMETRE MARKERS

6.0 PIPELINE WARNING SIGN

7.0 ROW BOUNDARY MARKERS

8.0 DIRECTION MARKERS

9.0 NAVIGABLE WATERWAY PIPELINE CROSSING WARNING SIGN

REFERENCE DRAWINGS

MECON STANDARD DRAWINGS

MEC/TYP/05/21/10/001 : TYPICAL ROW BOUNDARY

MARKER
MEC/TYP/05/21/10/002 : K.M. POST
MEC/TYP/05/21/10/003 : PIPELINE WARNING SIGN
MEC/TYP/05/21/10/004 : NAVIGABLE WATERWAY PIPELINE
CROSSING WARNING SIGN
MEC/TYP/05/21/10/005 : AERIAL MARKER
MEC/TYP/05/21/10/006 : DIRECTION MARKER

PREPARED BY: CHECKED BY: APPROVED BY: ISSUE DATE :

(Shalini Singh) (Sunil Kumar) (A.K. Johri) Jan. 2009

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 3

TITLE PIPELINE MARKERS MEC/S/05/21/10 REVISION : 0

EDITION : 1

1.0 SCOPE

1.1 This specification covers the minimu m requirement s for supply , fabricat ion and
erection of pipeline markers to be installed by CONTRACTOR at various loc ations along
the route of a cross-country pipeline.

1.2 This specification shall be read in conjunction with the conditions of all specifications
and documents included in the CONTRACT between COMPANY and CONTRACTOR.

2.0 REFERENCE CODES

Reference has b een mad e in this specification to the late st revision of the following
code :

AP I RP 1109 : Recommended practice for marking liquid petroleum pipeline

facilities.

3.0 GENERAL

3.1 CONTRACTOR shall supply, fabricate and install the pipeline markers along the pipeline
route. The locations of markers as indicated in the approved drawings shall be treated
for guidance purposes only and the exact location of the markers shall be based on AS
BUILT drainage and as directed by COMPANY.

3.2 The pipeline markers shall be fabricated, painted (Painting shall be in acco rdance with
the ME CON St andard Specific ation for Shop & Field P ainting) and installed in
accordance wit h t he ME CON st andard draw ings included herein . Before st art of
fabrication of the markers, CONTRACTOR shall prepare and submit for COMP ANY's
approval the detailed scheme for the marker plates as applicable for the project.

3.3 The p ipeline mark ers shall b e inst alled, as far as possible, at locat ions such that to
cause no hindrance to the regular use of the land or to the traffic.

4.0 AERIAL MARKERS

Aerial markers shall in general be installe d along the pipe line at e very five (5)
kilometres intervals and at places spec ified by COMPAN Y. Re fer MECON Standard
Drawing No. MEC/TYP/05/21/10/005 for details.

5.0 KILOMETRE MARKERS

Kilometre markers shall in general be installed along the pipe line be tween the ae rial
markers at every one (1) kilometre interval. Markers shall indicate cumulative distance
in kilometres from the reference station, as directed by COMPANY. A kilometre marker
is not required if the relati ve length between its location and any pipeline warning sign
is less than 200 metres. Refer ME CON Standard Drawing No. ME C/TYP/05/21/10/002
for details.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 2 of 3

TITLE PIPELINE MARKERS MEC/S/05/21/10 REVISION : 0

EDITION : 1

6.0 PIPELINE WARNING SIGN

Pipeline Warning Sign shall in general be installed at

• National and State Highway Crossings (2 Nos.)

• Other Road Crossings (1 No.)
• Railway Crossings (2 Nos.)
• Minor Water Crossings (less than 15m width) (1 No.)
• Minor Water Crossings (above 15m width) (2 Nos.)
• Major Water Crossings (2 Nos.)
• Valve Station (1 No.)
• And at any other location as shown in the approved drawings and as dire cted
by the COMPANY.

Pipeline Warning Sign shall identify the ex istence of the pipeline and display the name
of the COMPANY, with an emergency telephone number, as shown in MECON Standard
Drawing No. MEC/TYP/05/21/10/003 for details.

7.0 ROW BOUNDARY MARKERS

Right-of-Way boundary markers shall be fabricated and installed as per the drawings at
every 250 metres interval along the entire pi peline route. T hese shall be installed on
either side of the pipeline alig nment t o d efine t he ROW b oundary limit s. T hese shall
also be installed at pipeline turning points to maintain the continuity of the ROW limits.
Refer MECON Standard Drawing No. MEC/TYP/05/21/10/001 for details.

8.0 DIRECTION MARKERS

Direction markers as shown in ME CON Standard Drawing No. ME C/TYP/05/21/10/006

shall be installed to id entify the significant turning points of the pipeline during aerial
traverse. One direction marker shall be insta lled at each turning point, in addition, two
more direction markers shall be inst alled alo ng t he p ipeline alig nment, o ne o n either
side of the turning point at 200m from the turning point.

9.0 SPECIAL MARKERS

As d irected b y Co mpany, Sp ecial M arker shall be installed at Location w here th e

following changes takes place :

- Change in pipeline diameter and wall thickness.

- Change in type of pipe.
- Change in class locations for pipeline conveying gas.

The above data may be provide d on othe r types of marker (ex cept RoU boundary
marker), if the relative distance between the two does not exceed 100 m.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 3 of 3

TITLE PIPELINE MARKERS MEC/S/05/21/10 REVISION : 0

EDITION : 1

10.0 NAVIGABLE WATERWAY PIPELINE CROSSING WARNING SIGN

The N avigable Wate rway Pipe line Crossing Warning Sign shall be fabric ated in
accordance with MECON Standard Drawing No. MEC/TYP/05/21/10/004. Such Warning
Sign shall be installed one on e ach bank of navigable water courses at the pipeline
crossing location, in lieu of the Pipeline Warn ing Sign de scribed in c lause 6.0 of this
specification.
 SPECIFICATION
FOR
CASING INSULATORS
AND END SEALS

SPECIFICATION NO. MEC/S/05/62/12

(PROCESS & PIPING DESIGN SECTION)

MECON LIMITED
DELHI - 110 092

C:\Documents and Settings\hcl\Desktop\Specs\WORKS\12 casing insulator & end seals\12_CASING INSULATORS AND END SEALS.doc
 MECON LIMITED PROCESS & PIPING STANDARD SPECIFICATION
REGD. OFF: RANCHI (BIHAR) DESIGN SECTION
NEW DELHI

TITLE CASING INSULATORS AND END SPECIFICATION NO. PAGE 1 OF 6

SEALS MEC/S/05/62/12 REVISION 0

CONTENTS

PART-A CASING INSULATIONS

1.0 SCOPE

2.0 FUNCTION

3.0 DESIGN

4.0 MATERIAL

5.0 INSPECTION AND TESTING

PART-B CASING END-SEALS

1.0 SCOPE

2.0 FUNCTION

3.0 DESIGN

4.0 MATERIAL

5.0 INSPECTION AND TESTING

PART-C SUPPLEMTARY REQUIREMENTS

PREPARED BY CHECKED BY APPROVED BY

C:\Documents and Settings\hcl\Desktop\Specs\WORKS\12 casing insulator & end seals\12_CASING INSULATORS AND END SEALS.doc
 MECON LIMITED PROCESS & PIPING STANDARD SPECIFICATION
REGD. OFF : RANCHI (BIHAR) DESIGN SECTION
NEW DELHI

TITLE CASING INSULATORS AND END SPECIFICATION NO. PAGE 2 OF 6

SEALS MEC/S/05/62/12 REVISION 0

PART-A CASING INSULATORS

1.0 SCOPE

This specification covers the minimum requirements of design, material,

manufacture and supply of casing insulators intended to be used for cased
pipeline crossings.

2.0 FUNCTION

Pipeline insulators shall be used to support the carrier pipe inside the casing
pipe and electrically isolate the carrier pipe from the casing pipe at the cased
crossings.

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 maintain electrical isolation between carrier and
casing pipes

- Have high compressive strength in order to assure a permanent support

to the carrier pipe.

3.0 DESIGN

The arrangement of insulator shall be generally in accordance with Fig. 3.0. It

shall be made in segments duly held together with cadmium plated bolts and
nuts, to be supplied with casing insulators.

The number of segments shall be two for pipe diameters upto 12” (generally).
For larger diameters, the number of segments may be more than two, but their
number shall be kept minimum.
The skid height shall be such that it is slightly less than the value obtained by
following formula.

C:\Documents and Settings\hcl\Desktop\Specs\WORKS\12 casing insulator & end seals\12_CASING INSULATORS AND END SEALS.doc
 MECON LIMITED PROCESS & PIPING STANDARD SPECIFICATION
REGD. OFF : RANCHI (BIHAR) DESIGN SECTION
NEW DELHI

TITLE CASING INSULATORS AND END SPECIFICATION NO. PAGE 3 OF 6

SEALS MEC/S/05/62/12 REVISION 0

Casing internal dia-carrier outer dia

2

Manufacturer shall obtain prior approval from COMPANY on casing insulators

drawings/designs.

4.0 MATERIAL

Casing insulators shall be made of injection moulded high density polyethylene

or other material equivalent or superior as approved by COMPANY and shall
meet the following specifications:

Property Value ASTM Test Method

Dielectric strength 450-500 Volts/Mil D-149

Compresssive strength 3200 psi D-695i

Tensile strength 3100-5000 D-638, D-651

Impact strength 4.Oft. 1b./inch of notch D-256

Water Absorption 0.01% D-570

5.0 INSPECTION AND TESTING

Manufacturer shall furnish material test certificates of the components used in

the assembly of casing insulations as per the requirements of clause 4.0 of this
specification.

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 MECON LIMITED PROCESS & PIPING STANDARD SPECIFICATION
REGD. OFF : RANCHI (BIHAR) DESIGN SECTION
NEW DELHI

TITLE CASING INSULATORS AND END SPECIFICATION NO. PAGE 4 OF 6

SEALS MEC/S/05/62/12 REVISION 0

PART-B CASING END-SEALS

1.0 SCOPE

This specification covers the minimum requirements of design, material,

fabrication and supply of casing end-seals intended to be used for pipeline
cased crossings.

2.0 FUNCTION

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.

3.0 DESIGN

The scale 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-scale shall permit easy installation of the seal to
the cased pipeline crossing.

It shall provide moisture-proof seals when installed for the entire anticipated life
of the buried pipeline.

Manufacturer shall obtain prior approval from COMPANY on casing end seals
design/drawings.

4.0 MATERIAL

The casing end-scale shall be made of head shrink high density radiation
crosslinked 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.
Manufacturer shall confirm compatibility of end seals with carrier pipe coating.

C:\Documents and Settings\hcl\Desktop\Specs\WORKS\12 casing insulator & end seals\12_CASING INSULATORS AND END SEALS.doc
 MECON LIMITED PROCESS & PIPING STANDARD SPECIFICATION
REGD. OFF : RANCHI (BIHAR) DESIGN SECTION
NEW DELHI

TITLE CASING INSULATORS AND END SPECIFICATION NO. PAGE 5 OF 6

SEALS MEC/S/05/62/12 REVISION 0

Casing end seals shall meet following minimum property requirements:

Property Minimum Value Test Method

a) Backing (Sleeve and closure patch)

Tensile strength 2200 psi ASTM D-638

Ultimate Elongation 400% ASTM D-638

Heat Shock No visual cracks, ASTM D-2671

flow or drips
(at 225°C, 4 hours)

b) Adhesive

Ring and Ball softening 90°C ASTM E-28

point

Lap Shear 60°C - 25 psi ASTM D-1002

23°C - 250 psi
(2 inch/min)

c) System (as applied)

Peel strength 5 pli ASTM

(To casing and carrier (10 inch/min.) D-1000
pipe and closure patch)

5.0 INSPECTION AND TESTING

Manufacturer shall furnish material test certificates of the components used in

the assembly of casing end-seals as per the requirements of this specification.

C:\Documents and Settings\hcl\Desktop\Specs\WORKS\12 casing insulator & end seals\12_CASING INSULATORS AND END SEALS.doc
 MECON LIMITED PROCESS & PIPING STANDARD SPECIFICATION
REGD. OFF : RANCHI (BIHAR) DESIGN SECTION
NEW DELHI

TITLE CASING INSULATORS AND END SPECIFICATION NO. PAGE 6 OF 6

SEALS MEC/S/05/62/12 REVISION 0

PART-C SUPPLEMENTARY REQUIREMENTS

1.0 The Manufacturer shall replaces, at no extra cost, any material not conforming
to the material and performance requirements of this specification.

2.0 Manufacturer shall submit detailed specification of the materials used in the
assemblies, along with instructions for handling, use and installation of the
material for COMPANY approval prior to procurement.

3.0 Manufacturer shall submit all the documents, test reports, records and other
information in six copies to the COMPANY for record after approval as per
clause 2.0 above.

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 Rev. : 0
Edition : 1

SPECIFICATION
FOR
FIELD JOINT COATING
(ONSHORE PIPELINES)

SPECIFICATION NO.: MEC/S/05/21/13

(OIL & GAS SBU)

MECON LIMITED
DELHI 110 092
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 1

TITLE FIELD JOINT COATING MEC/S/05/21/13 REVISION : 0

(ONSHORE PIPELINES)
EDITION : 1

CONTENTS

SL. NO. DESCRIPTION

1.0 SCOPE

2.0 REFERENCE DOCUMENTS

3.0 MATERIAL AND EQUIPMENT

4.0 APPLICATION PROCEDURE

5.0 INSPECTION

6.0 TESTING

7.0 REPAIRS

8.0 DOCUMENTATION

PREPARED BY: CHECKED BY: APPROVED BY: ISSUE DATE :

(Shalini Singh) (Sunil Kumar) (A.K. Johri) May 2009

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 13

TITLE FIELD JOINT COATING MEC/S/05/21/13 REVISION : 0

(ONSHORE PIPELINES)
EDITION : 1

1.0 SCOPE

This specification covers the minimum requirements of materials, equipment and

installation of field joint anti-corrosion coating of underground onshore factory coated
pipelines with either three layer polyethylene or fusion bonded epoxy (FBE) coating by
heat shrink wraparound sleeves conforming to DIN EN 12068 – “Cathodic Protection –
External Organic Coatings for the Corrosion Protection of Buried or Immersed Steel
Pipelines used in Conjunction with Cathodic Protection – Tapes and Shrinkable
Materials” and the requirements of this specification. Unless modified / replaced by
this specification, all requirements of DIN EN 12068 shall remain fully applicable and
complied with.

This specification shall be read in conjunction with the conditions of all specifications
and documents included in the Contract between Company and Contractor. Unless
specified otherwise, all sections of this specification shall apply to all specifications
referred in this specification.

2.0 REFERENCE DOCUMENTS

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

a) ASTM D-149 : Standard Test Methods of Dielectric Breakdown voltage

and Dielectric Strength of solid electrical insulating
materials at commercial frequencies.

b) ASTM D-257 : Standard Test Methods for D-C Resistance or

conductance of insulating materials.

c) ASTM D-570 : Standard Method of Test for Water Absorption of

Plastics.

d) ISO 8502-3 : Preparation of Steel Stubstrates before Application of

Paints and Related Products – Part-3 – Assessment of
Dust on Steel Surfaces Prepared for Painting (Pressure
Sensitive Tape Method).

e) ISO:8503-1 : Part-1 : Specification and definitions for ISO surface

profile comparator for the assessment of abrasive blast
cleaned surfaces.

f) ISO:8503-4 : Part-4 : Methods for calibration of ISO surface profile

comparator and for the determination of surface profile –
Stylus instrument procedure.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 2 of 13

TITLE FIELD JOINT COATING MEC/S/05/21/13 REVISION : 0

(ONSHORE PIPELINES)
EDITION : 1

g) SIS-055900 : Pictorial surface Preparation Standard for Painting Steel

Surfaces.

h) SSPC-SP 1 : Steel Structure Painting Council.

In case of conflict between the requirements of this specification and that of above
referred documents, the requirements of this specification shall govern.

The Contractor shall be familiar with the requirements of these documents and shall
make them readily available at the site to all personnel concerned with carrying out the
works specified in this specification.

3.0 MATERIALS AND EQUIPMENT

3.1 Contractor shall supply joint coating materials, all equipment and manpower required
for a skillful and adequate application of coating in the field in accordance with the
specifications.

Contractor shall submit and demonstrate to Company proposed materials and works
procedures for applying field coating and repair procedures for same. These
proposed procedures and all materials, equipment and tools used in the work shall
be subject to Company’s approval.

3.2 Field Joint Corrosion Coating Material

Field joint anti-corrosion coating material shall be either heat shtrinktable wraparound
sleeve or cold applied tape suitable for a maximum operating temperature of (+) 65°C
(Tmax) and shall conform to designation EN 12068 – C HT 60 UV. In addition the field
joint anti-corrosion coating shall comply the requirements specified in para 3.3 of this
specification.

3.2.1 Heat Shrinkable Wraparound Sleeve

Heat shrinkable wrap around sleeve shall consist of radiation cross-linked thermally
stabilised, ultraviolet resistant semi-rigid polyolefin backing with a uniform thickness of
high shear strength thermoplastic/copolymer hot melt adhesive. The joint coating
system may consist of a solvent free epoxy primer applied to the pipe surface prior to
sleeve application. The backing shall be coated with thermochrome paint which will
change colour when the desired heat during shrinking is attained. The wraparound
sleeve shall be supplied in pre-cut sizes to suit the diameter and the requirements of
overlap.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 3 of 13

TITLE FIELD JOINT COATING MEC/S/05/21/13 REVISION : 0

(ONSHORE PIPELINES)
EDITION : 1

The total thickness of heat shrinkable wraparound sleeve in the as applied condition
shall be as follows :

Pipe Size Thickness (mm)

(Specified Outside Diameter) On Pipe Body On Weld Bead
(Min.) (Min.)
4” (114.3 mm) to 10” (273.0 mm) 2.0 mm 1.6 mm
12” (323.9 mm) to 18” (457.2 mm) 2.2 mm 1.8 mm
20” (508.0 mm) to 30” (762.0 mm) 2.5 mm 2.0 mm
≥ 32” (812.8 mm) 3.0 mm 2.5 mm

The heat shrink wraparound sleeve shall have the required adhesive properties when
applied on various commercial pipe-coating materials. The pre-heat and application
temperatures required for the application of the shrink sleeve shall not cause loss of
functional properties of the pipe coating.

Heat shrinkable wraparound field joint coating system manufactured by M/s Covalence
and M/s Canusa are acceptable for the supply of field joint coating materials. The
Contractor shall propose the specific grade of field joint coating system meeting the
requirements of this specification from these manufacturers. In case the Contractor
proposes to supply heat shrinkable wraparound sleeve from any other manufacturer,
then the Contractor shall propose only those coating systems that have been
previously used for pipelines of size same or higher than the size indicated in tender,
for a length of 50 km and above in a single project for similar operating conditions.

3.2.2 Cold Applied Tapes

Cold applied tape system shall comprise of primer, an inner wrap and an outer wrap.
The inner and outer wraps shall be asymmetric 3-ply tape with co-extruded
polyethylene carrier film and butyl rubber adhesive layers on both sides. The inner
layer of butyl rubber adhesive of inner wrap shall have a thickness of min. 1.0 mm. The
inner and outer wraps are to be spirally wrapped with 55% overlap, equivalent to two
layers each providing a total minimum thickness of 3.0 mm on the pipe body and 2.5
mm on the weld.

The Contractor shall propose only those cold applied tape coating systems that have
been previously used in pipelines of size 16" and above and a length of 50 km and
above in a single project for similar operating conditions.

3.3 Functional Requirements of Field Joint Coating

3.3.1 Properties of the PE backing and the as applied joint corrosion coating shall be as
follows :
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 4 of 13

TITLE FIELD JOINT COATING MEC/S/05/21/13 REVISION : 0

(ONSHORE PIPELINES)
EDITION : 1

Sl. Property Unit Requirement Test

No. Method
i) Tensile Strength @+25°C N/mm2 ≥12 DIN EN
12068
ii) Ultimate Elongation % @+ % ≥250 DIN EN
25°C 12068
iii) Dielectric withstand KV with kv ≥30 ASTM D
1000 Volts/sec 149
iv) Water absorption % ≤0.05 ASTM D
@+ 25°C for 24 hours 570
v) Volume Resistivity @+25°C Ohm-cm ≥1015 ASTM D
257
vi) Resistance to thermal aging % Change in DIN 30672
at 100°C elongation ≤ 250

3.3.2 Functional Properties of Joint Coating System (As applied)

As applied field joint coating system shall comply the requirements of DIN EN 12068.
Table 1 and 2 corresponding to designation DIN EN 12068 – C HT 60 UV, except as
modified below :

a) Cathodic Disbondment Resistance at Tmax i.e. 60°Cshall be 20mm when

tested as per Annexure K of DIN EN 12068. Test shall be carried out at (+)
60°C.

b) Peel Strength shall be as follows :

Peel Strength Unit Requirement for Test

Mech Resistance Method as
Class C per DIN EN
(Minimum) 12068
Inner to Inner + @23°C N/mm 1.5
Outer to Inner @Tmax N/mm 0.3
Annexure-B
Outer to Outer @23°C N/mm 1.5
@Tmax N/mm 0.3
To Pipe Surface @23°C N/mm 3.5
@Tmax N/mm 0.3
Annexure-C
To Factory @23°C N/mm 3.5
Coating @Tmax N/mm 0.3

Notes
(Tmax shall be (+) 60°C)
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 5 of 13

TITLE FIELD JOINT COATING MEC/S/05/21/13 REVISION : 0

(ONSHORE PIPELINES)
EDITION : 1

Contractor shall obtain prior approval from Company regarding the manufacturer of the
joint coating material. Complete technical details alongwith test certificates complying
with the requirements of clause 3.2.1 and 3.2.2 shall be submitted to Company for this
purpose. The Contractor shall furnish test certificates from an independent DIN
recognized / approved laboratory for all the properties required for the specified EN
designation of field joint coating and the requirements of this specification.

3.3 The materials shall not be older than their period of validity at the time of application by
CONTRACTOR. Deteriorated/ decomposed material shall be disposed of and replaced
by CONTRACTOR at his own expense.

CONTRACTOR shall ensure that the coating materials supplied by him are properly
packed and clearly marked with the following :

- Manufacturer’s name
- Material qualification
- Batch number
- Date of manufacturing and date of expiry.

3.4 CONTRACTOR shall ensure that the manufacturer has carried out all quality control
tests on each batch and manufacturer shall provide test certificates to certify that the
supplied materials meet the manufacturer’s specifications as indicated in the purchase
order and as approved by COMPANY. Certificates and data sheets certifying the
qualities of the coating materials shall be submitted by CONTRACTOR to COMPANY
prior to application. COMPANY reserves the right to have the materials tested by an
independent laboratory.

3.5 Materials shall be stored in sheltered storage in the manufacturer’s original packing
and away from direct sunlight and in accordance with manufacturer’s instructions.

3.6 CONTRACTOR shall provide and maintain mobile facilities which contains all
necessary equipment and its spares for cleaning, coating repairs, inspection and tests.

3.7 CONTRACTOR shall furnish sufficient number of the following equipment and the
required spares as a minimum for inspection and test purpose for each crew.

a) Fully automatic full circle adjustable holiday detector with a visible and audible
signal system for inspection of coatings.
b) Thickness gauge for measuring thickness.
c) Contact type temperature recording thermometer (Digital Pyrometer with flat
probe type contact).
d) Roughness profile measuring (Stylus) instrument
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 6 of 13

TITLE FIELD JOINT COATING MEC/S/05/21/13 REVISION : 0

(ONSHORE PIPELINES)
EDITION : 1

4.0 APPLICATION PROCEDURE

4.1 General

4.1.1 The application procedure shall be in accordance with manufacturer’s instruction and
the minimum requirements specified below whichever are the most stringent and
shall be demonstrated to and approved by the Company. Manufacturer’s expert
shall supervise the application and shall be available at site upon request during
qualification of application procedure and during construction at Contractor’s cost.

4.1.2 Operators for coating application shall be given necessary instructions and training
before start of work, by the Contractor. To verify and qualify the application
procedures, all coating applied during the qualification test, shall be removed for
destructive testing until the requirements stated in sections “Inspection” and
“Testing” of this specification are met.

4.1.3 Oil, grease and salt shall be removed from steel surface by wiping with rags soaked
with suitable solvents such as naphtha or benzene. Kerosene shall not be used for
this purpose. Solvent cleaning procedure according to SSPC-SP1 shall be followed.

4.1.4 Each field joint shall be blast cleaned using a closed cycle blasting unit or an open
expendable blasting equipment. With the first equipment type, steel or chilled shot
and iron grit shall be used and Garnet material with the second one (in case the
authority having jurisdiction have no objection, the contractor may adopt sand
blasting instead of garnet material). During blast cleaning the pipe surface
temperature shall be simultaneously more than 5° and more than 3°C above ambient
Dew Point, while the ambient Relative Humidity shall not be greater than 85%. Prior
to surface cleaning the surface shall be completely dry. The surface shall be
cleaned to a grade Sa 2½ in accordance with Swedish Standard SIS-055900 with a
roughness profile of 50-70 microns. Surface roughness profile shall be measured
using an approved profile comparator in accordance with ISO 8503-1 and shall be
calibrated prior to the start of the work in accordance with ISO:8503-3 or ISO:8503-
4. The blast cleanliness shall be checked on every joint and the roughness profile
shall be checked 1 every 10 joints.

Dust grit or foreign matter shall be removed from the cleaned surface by an industrial
vacuum cleaner. The dust contamination allowed shall be of a rating max 2 as per
ISO:8502-3. The frequency of checking for dust contamination shall be 1 every 10
joints.

Blast cleaned field joint shall be coated within 2-4 hours according to the conditions
below :
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 7 of 13

TITLE FIELD JOINT COATING MEC/S/05/21/13 REVISION : 0

(ONSHORE PIPELINES)
EDITION : 1

- Relative Humidity (RH) > 80% - 2 Hours

- Relative Humidity (RH) 70-80% - 3 Hours
- Relative Humidity (RH) < 70% - 4 Hours

Pipes delayed beyond this point or pipes showing any visible rust stain shall be blast
cleaned again.

4.1.5 The field joint surface shall be inspected immediately after blast cleaning and any
feature of the steel surface such as weld spatter, scabs, laminations or other
imperfections considered injurious to the coating integrity made visible during blast
cleaning shall be reported to the Company Representative and on permission from
Company Representative, such defects shall be removed by filing or grinding. Pipes
affected in this manner shall be then re-blast cleaned if the defective area is larger
than 50 mm in diameter.

4.1.6 The ends of existing pipe protective coating shall be inspected and chamfered.
Unbounded portions of the coating shall be removed and then suitably trimmed.
Portions where parent coating is removed shall be thoroughly cleaned as specified.
The adjacent chamfered areas of the line pipe coating shall be cleaned and abraded,
to expose a clean uniform fresh surface of uncontaminated factory applied coating.

4.1.7 All steel joint surfaces shall be thoroughly examined before the application of the
coating in order to ensure the surface are free of soil, grease, rust, mud, earth or any
other foreign matter. All these substances shall be removed before coating, to the
procedures herein described.

4.1.8 Protection coating shall be applied on the joints immediately after the completion of
cleaning operation.

4.2 Application of Heat Shrink Wraparound Sleeves

In addition to the general requirements stated above, following shall be taken into
account :

4.2.1 The wrap around sleeves shall be of a size such that a minimum overlap of 50mm is
ensured (after shrinking) on both sides of yard applied corrosion coating of the pipes.

In cases 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 200mm. 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.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 8 of 13

TITLE FIELD JOINT COATING MEC/S/05/21/13 REVISION : 0

(ONSHORE PIPELINES)
EDITION : 1

4.2.2 Before centering the wraparound sleeve, the bare steel surface shall be preheated
with torch moved back and forth over the surface or by induction heating. The
minimum preheat temperature shall be as recommended by manufacturer and shall
be checked by means of contact type temperature recording thermometer (Digital
Pyrometer with flat probe type contract) to check this, approved temperature
indicates shall be used. Temperature indicating crayons shall not be used. Pre-heat
temperature shall be checked on every joint. Care shall be taken to ensure that the
entire circumference of the pipe is heated evenly. Temperature measuring
instruments shall be calibrated immediately before the start of the works and
thereafter at intervals recommended by the manufacturer of the instrument.

4.2.3 Upon pre-heating the pipe surface shall be applied with two pack epoxy primer of wet
film thickness 150 microns or as per manufacturer’s recommendation whichever is
higher, to cover the exposed bare metal of the welded field joint and 10mm min. onto
the adjacent pipe coating if recommended by the manufacturer. The wet film
thickness of the primer shall be checked or every joint with a wet film thickness
gauge prior to installation of sleeve. Thickness gauge shall be calibrated once per
shift.

4.2.4 Immediately after application of epoxy primer, the wraparound sleeve shall be
entirely wrapped around the pipe within the stipulated time recommended by the
manufacturer. Sleeve shall be positioned such that the closure patch is located to
one side of the pipe in 10 or 2 O’clock position, with the edge of the undergoing layer
facing upward and an overlap of min. 50mm. Gently heat by appropriate torch the
backing and the adhesive of the closure and press it firmly into place.

4.2.5 A heat shrinking procedure shall be applied to shrink the sleeve in such a manner to
start shrinkage of the sleeve beginning from the center of the sleeve and heat
circumferentially around the pipe. Continue heating from the center towards one end
of the sleeve until recovery is completed. In a similar manner, heat and shrink the
remaining side. Shrinking has been completed when the adhesive begins to ooze at
the sleeve edges all around the circumference.

The complete shrinking of the entire sleeve shall be obtained without undue heating
of existing pipe coating and providing due bonding between pipe, sleeve and pipe
coating. The installed sleeve shall not be disturbed until the adhesive has solidified.

The coatings mentioned are for undergrounds installations.

For HDD Joint Coating fiber glass reinforced heat shrinkable sleeve certified to
Stress class C60 type CANUSA-TBK or COVALENCE / DlRAX shall be used.
Directional drilling kit, multilayer sleeve system or equivalent to be approved by
Owner / Engineer.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 9 of 13

TITLE FIELD JOINT COATING MEC/S/05/21/13 REVISION : 0

(ONSHORE PIPELINES)
EDITION : 1

Only coating material C-60 Class as per EN 12068 and DVGW certified (wrapping
tape and heat shrinkable material) will be accepted for all material to be coated.

For the buried valve station (moulded piece, valves, elbows etc) Thermoset plastic
coatings may be used. They will be of type S50 certified as per DIN 30671 & DIN
30677.

Underground bare valves if any will be coated with above material.

At the point of transition from the aboveground pipe to underground pipe special
coating material FIBAROLL or equivalent to be used over the coated part of U.G.
pipe and painted part of A.G. Pipe end over lapping shall be at least 500 mm inside
the ground and 500 mm on painted AG line. Minimum thickness shall be 1.5 mm.
The application of the material will be as per supplier's specification.

Wherever Thrust Boring (Jacking) method is carried out, for mechanical protection of
coating of carrier pipe extra layer of hard cold applied tapes C-70 class as per DIN
30675-1 or solvent free PUR (1000 microns) as per DIN 3067712 Ep-50 types shall
be applied. Surface preparation (sand blasting) of PE layer shall be appropriate as
per applicator's recommendations. The type & thickness of coating must got
approved by Owner / Engineer prior to coating.

4.3 Application of Cold Applied Tapes

In addition to general requirements stated above following shall be taken care of:-

4.3.1 Cold applied joint protection tapes shall be of the type which can be applied by spirally
wrapping on the pipe.

4.3.2 Immediately after the completion of surface preparation the approved primer of wet
film thickness 150 microns or as per manufacturer’s recommendation whichever is
higher to cover the exposed bare metal of the welded field joint and 10mm min. onto
the adjacent pipe coating if recommended by the manufacturer. Any dirt on the
primed surface shall be removed. If the primer is damaged, the damaged area shall
be cleaned and re-primed.

4.3.3 Approximately 100mm of tape interleaving paper shall be peeled back and tape shall
be applied with the adhesive 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 conformity, avoiding air
pockets and also continuously smooth out as the wrapping proceeds. The wrapping
shall start and finish to give a minimum of 50mm overlap on to the adjoining yard
applied coating. Outer wrap shall also be applied in similar method.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 10 of 13

TITLE FIELD JOINT COATING MEC/S/05/21/13 REVISION : 0

(ONSHORE PIPELINES)
EDITION : 1

In the cases 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 200mm. 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.

4.4 Pre-Qualification of Field Joint Coating System

The field joint coating system materials and the procedures proposed by the Contractor
shall be pre-qualified during the sleeve installation start-up phase. Five joints (5) shall
be coated with the requirements of this specification and then inspected and tested in
accordance with the requirements of this specification with respect to the following :

i) Surface preparation cleanliness, roughness profile and dust contamination

ii) Pre-heat temperature (as applicable)
iii) Primer thickness
iv) As applied coating thickness
v) Holiday detection
vi) Peel test at (+) 23°C & (+) 60°C on pipe surface & factory applied coating and
at over laps (as applicable). If required to achieve the temperature of (+) 60°C,
suitable thermal blanket may be used.
vii) Visual appearance and void after installation on the body, area adjoining the
weld and area adjoining the factory applied coating. (To establish voids
adjoining the weld and factory coating a strip of 50 mm wide and 200 mm long
shall be stripped and examined).

Company Representative shall witness the tests and inspection. Regular application of
field joint coating shall commence only upon successful completion of the pre-
qualification testing.

After successful completion of the pre-qualification testing as above, the entire field
joint coating shall be removed, the pipe surface re-blasted and field joint coating re-
applied as per the requirements of this specification.

5.0 INSPECTION

5.1 A visual inspection shall be carried out for the following :

- Mastic extrusion on either ends of the sleeve shall be examined. (applicable
for heat shrink wraparounds).
- There shall be no sign of punctures or pinholes or bend failure. The external
appearance of the sleeve shall be smooth, free of dimples, air entrapment or
void formation.
- Weld bead profile shall be visible through the sleeve.
- The entire closure patch shall have changed colour uniformly (applicable for
heat shrink wraparounds).
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 11 of 13

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(ONSHORE PIPELINES)
EDITION : 1

5.2 Holiday Inspection

The holiday detector used shall be checked and calibrated daily with an accurate DC
voltmeter. The detector electrode shall be in direct contact with the surface of coating
to be inspected.

The entire surface of the joint section shall be inspected by means of a full circle
holiday detector approved by Company set to a DC voltage of at least 25 kV.
Inspection of the sleeves shall be conducted only after the joint has cooled below 50°C.
(applicable for heat shrink wraparounds).

5.3 No field joint shall be covered or lowered in the trench until it has been approved by the
Company.

5.4 As-applied Coating Thickness

Coating thickness shall be checked by non-destructed methods for each field joint.
Average thickness of the as-applied coating on pipe body shall be established based
on measurement at min. eight locations i.e. four measurement on either sides of the
girth weld at 3, 6, 9, & 12 O’clock positions. To establish the minimum thickness on
the girth weld, four measurement shall be taken on apex on the weld at 3, 6, 9 & 12
O’clock positions. All such measurements shall be recorded. Company
Representative reserves the right to ask for additional measurement at any location
on the field joint coating, whenever doubt arises.

6.0 TESTING

6.1 Company reserves the right to remove and test one out of every 50 joint coatings or
one joint coating out of every day’s production whichever is stringent. Contractor shall
provide all assistance in removing and testing of field joint coatings.

6.2 From each test sleeve, one or more strips of size 25mm x 200 shall be cut
perpendicular to the pipe axis and slowly peeled off.

The required peel strength shall meet the requirements of clause 3.2.4.2 (ii) as
applicable for 23°C or 60°C whichever is feasible. This test shall be conducted
between wrapping & metal and mill coating & between layers at overlap with joint
coating (wherever applicable). After removal of strip the bulk of adhesive shall remain
adhered to the pipe showing on bare metal, otherwise, test shall be considered failed.
The adhesive layer that remains on the pipe surface shall generally be free of voids
resulting from air or gas inclusion. In case the peel strength test at a different
temperature than that specified in warranted due to the ambient site conditions, then
the peel strength shall comply the recommendation of the manufacturer. Manufacturer
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 12 of 13

TITLE FIELD JOINT COATING MEC/S/05/21/13 REVISION : 0

(ONSHORE PIPELINES)
EDITION : 1

shall be asked to furnish peel strength values corresponding to various expected

temperatures, prior to start of the works.

6.3 If the sleeve taken away for test does not meet the requirements of clause 6.2 the
adjacent two sleeves shall also be removed and inspected.

If the adjacent two sleeves are acceptable the test rate shall be increased to one
sleeve in every twenty five until Company's Representative is satisfied. The test rate
can then be reduced as per clause 6.1.

If either or both of the adjacent two sleeves do not meet the requirements of clause
6.2, the field coating shall be stopped. (Refer clause 7.0).

6.4 Company Representative reserve the right of 100% removal of sleeves if he is not
convinced that the requirements of clause 6.2 are achieved.

6.5 Coating thickness shall be checked by non-destructive methods for each fields joints.

7.0 REPAIRS

7.1 If a field joint is detected to be unacceptable after testing as per section 6.0 of this
specification the Contractor shall, at his own cost :
- determine the cause of the faulty results of the field coating.
- mobilise the expert of manufacturer, if required.
- test to the complete satisfaction of the Company, already completed field
coatings.
- stop field coating until remedial measures are taken against the causes of
such faults, to the entire satisfaction of the Company.

7.2 Contractor shall replace all joint coating found or expected to be unacceptable a per
section 6.0 of this specification.

7.3 Contractor shall, at his own cost repair all areas where the coating has been removed
for testing by the Company.

7.4 After the coating work on welded joints, fittings and repairs to the coating have been
completed the coating as a whole shall be tested with a spark-tester before lowering or
jacking the pipeline.

7.5 Company shall be entitled to check the coating on buried pipelines or parts of pipelines
with equipment such as the "Pearson Meter" and the resistance meter. If Coating
defects are establish, the Contractor shall be responsible for excavations at such
points, repairing the coating, spark testing and backfilling the excavation without extra
charge.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 13 of 13

TITLE FIELD JOINT COATING MEC/S/05/21/13 REVISION : 0

(ONSHORE PIPELINES)
EDITION : 1

8.0 DOCUMENTATION

8.1 Prior to procurement of coating materials, Contractor shall furnish the following
information for qualification of the Manufacturer and material :

i. Complete descriptive technical catalogs describing the materials offered

along with samples of corrosion coating materials, its properties and
application instruction as applicable specifically to the project.

ii. Test certificates and results of previously conducted tests, for all properties
listed in clause 3.2.4 of this specification.

iii. Reference list of previous supplies, in last 5 years, of the similar material
indicating the project details such as diameter, quantity, operating
temperature, years of supply, project name, contact person and feed back on
performance.

Once the Company’s approval has been given, any change in material or
Manufacturer shall be notified to Company, whose approval in writing of all changes
shall be obtained before the materials are manufactured.

8.2 Prior to shipment of materials from the Manufacturer’s Works Contractor shall furnish
the following documents :

i. Test certificates/ results as per Manufacturer’s Quality Control Procedure for

each batch of materials.
ii. Specific application instructions with pictorial illustrations.
iii. Specific storage and handling instructions.

8.3 All documents shall be in English Language only.

 Rev. : 0
Edition : 1

SPECIFICATION
FOR
VENTS, DRAINS AND WELLS

SPECIFICATION NO.: MEC/S/05/21/15

(OIL & GAS SBU)

MECON LIMITED
DELHI 110 092
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 1

TITLE VENTS, DRAINS AND WELLS MEC/S/05/21/15 REVISION : 0

EDITION : 1

CONTENTS

SL. NO. DESCRIPTION OF DRAWING DRAWING NO.

1. Vent & Drain for Line 2” & above MEC/SD/05/21/15/01

2. Wells Installation 1½ Dia Taps MEC/SD/05/21/15/02 (Sheet 1 of 2)

3. Wells Installation 1½ Dia Taps MEC/SD/05/21/15/02 (Sheet 2 of 2)

4. Vent & Drain for lines 1½” & below MEC/SD/05/21/15/03

5. Pressure Tapping MEC/SD/05/21/15/05

PREPARED BY: CHECKED BY: APPROVED BY: ISSUE DATE :

(Binita Brahma) (Sunil Kumar) (A.K. Johri) Feb. 2009

 Rev. : 0
Edition : 1

STANDARD SPECIFICATION
FOR
BLASTING

SPECIFICATION NO.: MEC/S/05/21/18

(OIL & GAS SBU)

MECON LIMITED
DELHI 110 092
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 1

TITLE BLASTING MEC/S/05/21/18 REVISION : 0

EDITION : 1

CONTENTS

Sl.No. Description

1.0 SCOPE

2.0 REFERENCE DOCUMENTS

3.0 GENERAL

4.0 MATERIALS

5.0 PERSONNEL

6.0 STORAGE OF EXPLOSIVES

7.0 PREPARATION OF EXPLOSIVES

8.0 PREPARATION OF PRIMERS

9.0 CHARGING OF HOLES

10.0 ELECTRICAL FIRING

11.0 VIBRATION RECORDING

12.0 MISFIRES

13.0 DISPOSAL OF DETERIORATED EXPLOSIVES

PREPARED BY: CHECKED BY: APPROVED BY: ISSUE DATE :

(Shalini Singh) (Sunil Kumar) (A.K. Johri) Jan. 2009

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 9

TITLE BLASTING MEC/S/05/21/18 REVISION : 0

EDITION : 1

1.0 SCOPE

¾ This specification covers the minimum requirements for materials, personnel, transportation,
storage and use of explosives for grading of Right of Use (RoU) and excavation of trenches
for onshore pipeline installation in rocky terrain.

¾ This specification does not cover the construction or operation of permanent magazines.

2.0 REFERENCE DOCUMENTS

Reference has also been made to the latest edition of the following standards, codes and
specifications. The edition enforce at the time of floating the enquiry shall be termed as
latest edition.

a) BS-5607 : Safe use of Explosives in the Construction Industry

b) IS4081 : Safety Code for Blasting and Related Drilling Operations

c) NFPA-495 : Manufacture, Transportation, Storage & Usage of Explosive

Materials.

d) Safety Rules of Chief Controller of Explosives, Nagpur

3.0 GENERAL

¾ The Contractor shall acquaint himself and comply with all the applicable local laws and
regulations concerning storing, handling and the use of explosives. All such laws,
regulations and rules etc., as enforced from time to time shall be binding upon the
Contractor. National / Local Laws and Regulations shall take precedence over this
specification in the event of conflict. All conflicts shall be brought to the notice of the
Company.

¾ The requirements stated herein however in no way relieve the Contractor of his
responsibility of carrying out safe blasting operations. The Contractor shall be solely
responsible for damages and claims thereof.

¾ The use of explosives requires an approval from the Chief Controller of Explosives and/or
his authorized Inspector. It shall be the responsibility of the Contractor to obtain all such
permits and. approvals and comply all requirements regarding the safe storage, handling
and use of explosives. All expenses incurred in this regard shall be to Contractor's account.

¾ Contractor shall inform the Company in writing at least four (4) weeks prior to planned use
of explosives.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 2 of 9

TITLE BLASTING MEC/S/05/21/18 REVISION : 0

EDITION : 1

¾ Contractor shall notify the Company prior to any blasting in the proximity of overhead power
lines, roads, communication lines, pipelines, utility services or other services and structures
above and below ground. Before, starting blasting operations, local authorities and owners
of utilities shall be consulted to check on the presence of services, which could be damaged
and their approval obtained to undertake blasting operations. The distances to nearest
structures (houses, offices, factories) or service shall also be taken into consideration when,
planning blasts so that ground vibration and air-over pressure is kept within acceptable
levels as given in section 11.0 of this specification

¾ Contractor shall prepare an Explosives Handling and Usage Procedure for the information of
the Company, which shall include the following:

- Detailed procedure and calculations.

- Nature of blasting operations, including hole diameter, depth and presence of
cavities
- Rock characteristics
- Type of explosives
- Temperature likely to be encountered in use

¾ Unless specified otherwise, blasting shall not be allowed within 20 m of any above ground or
underground structure, pipelines or other facilities. However, in case it is necessary to carry
out blasting operation within 20 m from any under ground or above ground structures,
pipelines or other facilities, the blasting may be allowed, at discretion of Company, subjected
to the following :

a) Minimum clear distance from the facility is 5 m.

b) Contractor demonstrates the blasting technique proposed by him doesn't result in

any damage to the existing facility. (Contractor shall carry out mock demonstration
as per the direction of Company Representative for this purpose).

c) Contractor fulfills the conditions laid out by the Owner of the existing facilities.

d) Contractor fulfills the requirements laid-out by National / Local Laws and Regulations
and other statutory/regulatory Authorities.

In case of presence of overhead power lines/cables, specific approvals shall be obtained by

Contractor from the concerned Authorities having jurisdiction over it.

4.0 MATERIALS

¾ All materials such as explosives, detonators; fuses, tamping materials etc. that are proposed
to be used by the Contractor in blasting operations, shall be as approved for use in the
Country.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 3 of 9

TITLE BLASTING MEC/S/05/21/18 REVISION : 0

EDITION : 1

¾ All electric detonators used in the blast shall be of the same electrical sensitivity and be
produced / procured from the same manufacturer.

¾ The detonators used shall be capable of giving effective blasting of the explosives.
Damaged explosive materials shall be destroyed by a responsible person as per
manufacturer's instructions or returned to the manufacturer.

¾ No explosive material shall be abandoned.

¾ All blasting materials and testing equipment shall be regularly tested for correct
performance. The intervals between test shall be decided after consideration of the local
factors, but tests shall always be carried out if the blasting materials and / or test equipment
have been subjected to abnormal conditions, or following any misfires. Guidelines /
recommendations of the manufacturer shall be adhered to.

¾ All packaging and other waste materials gathered together during blasting operation shall be
burnt after the blast has been fired. The burning site shall be chosen at a safe distance with
due respect to prevailing wind strength and direction, at least 100 meters from explosives
stores and other premises. A minimum of two fire extinguishers shall be on hand during
burning activities.

5.0 PERSONNEL

¾ Excavation by blasting will be permitted only under personal supervision of competent and
licensed persons and by trained workmen.

¾ The storage of explosives shall be in the charge of a person approved by the Company.
Company may, if necessary, ask police inquiries being made as to his reliability,
antecedents etc.

6.0 STORAGE OF EXPLOSIVES

¾ The Contractor shall build a magazine for storing the explosives. The site of the magazine,
its capacity and design shall be subject to approval by the Company and the Inspector of
Explosives before the fabrication is taken up. As a rule the explosives should be stored in a
clean, dry, well ventilated, bullet proof and fire proof building, at an isolated site. Adequate
security shall be provided to ensure no unauthorized entry into the magazine. A notice shall
be hung next to magazine entrance prohibiting entry of unauthorized persons.

¾ Contractor shall comply with National / Local Regulations and specifications for truck
mounted mobile explosives store. Mobile stores shall only carry ONE DAY's Explosives
requirements and shall be parked overnight inside the compound at the authorized
magazine.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 4 of 9

TITLE BLASTING MEC/S/05/21/18 REVISION : 0

EDITION : 1

¾ All safety precautions and necessary equipment for maintenance, operation of mobile
stores, as required by local authorities or regulatory bodies shall also be installed / provided
on the Mobile Store.

¾ A careful and day-to-day account of all explosives shall be kept by the Contractor in a
register and in an approved manner. The register shall be produced by the Contractor, for
the inspection of the Company / Inspector of Explosives when so required by the later.

Any loss, damage or theft shall be reported immediately to the necessary local authorities
and to the Company.

¾ The magazine shall on no account be opened during or on the approach of a thunderstorm

and no person shall remain in the vicinity of the magazine during such period.

¾ Magazine-shoes without nails shall, at all times, be kept in the magazine, and a wood-tub or
cement trough, filled with water shall be fixed near the door of the magazine.

¾ Persons entering the magazine must put on the magazine-shoes and shall comply to
following:

I) not to put their feet on the clean floor unless they have magazine-shoes on.

II) not to allow the magazine-shoes to touch the ground outside the clean floor.

III) not to allow any dirt or grit to fall on the clean floor.

¾ No matches or inflammable material shall be allowed in the magazine. Light shall be

obtained from an electric storage battery lamp.

¾ No person having articles of steel or iron on him shall be allowed to enter the magazine. No
tools or implements other than those of copper, brass, gun metal or wood shall be allowed
inside the magazine.

Oily cotton. rags, waste and articles liable to spontaneous ignition, shall not be allowed
inside the magazine.

¾ Boxes of explosives shall not be thrown down or dragged along the floor and shall be
stacked on wooden trestles. Open boxes of explosives shall never be exposed to the direct
rays of the sun. Empty boxes or loose packing materials shall not be kept inside the
magazine.

¾ The magazine shall have a lightning conductor, which shall be got tested periodically, by an
officer authorized by the Company, the testing fee shall be to the Contractor's account.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 5 of 9

TITLE BLASTING MEC/S/05/21/18 REVISION : 0

EDITION : 1

¾ The magazine shall be inspected periodically by an officer representing the Company, who
will see that all the rules are strictly complied with. He will notify all omissions etc. to the
Contractor, who shall rectify the defects within a period of 3 days from the date of receipt of
the notice, failing which the Company may take whatever actions it considers suitable.

7.0 PREPARATION OF EXPLOSIVES

¾ Contractor shall submit the following procedures for INFORMATION of the Company as a
minimum.

- Loading of explosives
- Drilling of new holes and extending existing holes
- Handling of explosives at site
- Tamping explosives into holes,
- Machines, tools and cables required
- Initiation of blasting
- Safety of personnel
- Vibration control
- Blast pattern and shot size establishment
- Misfires
- Emergency procedures

¾ Trial blasts in conjunction with vibration recording shall be carried out for each rock and
trench type, in order to assess rock breakability and vibration levels. These trial blasts shall
be carried out prior to actual trench blasting of the pipeline route. Contractor shall conduct
trial digs as directed by Company in order to check suitability of the blasting pattern and to
measure vibration levels to ensure vibration levels are below the allowable maximum.

¾ "Weight per Distance Tables" shall be drawn up from these trials.

¾ The detonators shall never be forced into the primer cartridge. It shall be inserted in a hole
made by a wooden, copper, brass or aluminum pricker. The detonator shall be firmly
embedded in the primer so that it is not pulled out of place during loading.

¾ Detonators shall be activated electrically. In proximity of electric over-head power lines,

Contractor may use non-electric system with the approval of Company. Fly rock shall be
minimized by the use of approved blast mats and by careful selection of shot size and drill
hole configuration.

¾ Use of explosives is prohibited in areas exposed to flammable gasses or dust.

¾ Explosive and detonators shall be carried in separate boxes, tightly closed, and transported
separately. For the conveyance of primers special containers shall be used.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 6 of 9

TITLE BLASTING MEC/S/05/21/18 REVISION : 0

EDITION : 1

¾ Explosives shall be stored and used chronologically to ensure that the ones received earlier
are being used first.

¾ A make-up house shall be provided at each working place in which cartridges shall be made
up by experienced men as required. The make-up house shall be separated from other
buildings. Only electric storage battery lamps shall be used in this house.

¾ No smoking shall be allowed in the make-up house.

8.0 PREPARATION OF PRIMERS

The primers shall not be prepared near open flames or fires. The work of preparation of
primers shall always be entrusted to the qualified and approved personnel. Primers shall be
used as soon as possible after they are ready.

9.0 CHARGING OF HOLES

¾ The work of charging shall not commence before all the drilling work at the site is completed
and the Company has satisfied itself to that effect by actual inspection.

¾ The lead wires shall be kept away from conductors or sources of stray current. While
charging, open lamps/flames shall be kept away.

¾ Only wooden tamping rods without any kind of metal on them shall be used.

¾ Only one cartridge shall be inserted at a time and gently inserted to the required depth with
the tamping rod. The sand, clay or other tamping material used for filling the hole completely
shall not be tamped too hard.

¾ Blasting shall not take place after sunset or before sunrise unless specific approval is first
obtained by Contractor from local authorities and the Company.

¾ The site of blasting operations shall be prominently demarcated by red danger flags. The
order of fire shall be given only by the Supervisor-In-Charge of the work and this order shall
be given only after giving the warning signal three times, so as to enable all the labor,
watchmen etc. to reach safe shelter and after having ascertained that nobody is within the
danger zone.

¾ A buegle with a distinctive note shall be used to give the warning signals. The buegle shall
not be used for any other purpose. All the labor shall be made acquainted with the sound of
the buegle and shall be strictly warned to leave their work immediately at the first warning
signal and to take safe shelters, and not to leave the shelters until the all clear signals have
been given.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 7 of 9

TITLE BLASTING MEC/S/05/21/18 REVISION : 0

EDITION : 1

¾ All the roads and footpaths leading to the blasting area shall be watched. All the escape
routes shall have been clearly marked.

10.0 ELECTRICAL FIRING

¾ Only the Supervisor-In-Charge shall keep the key of the firing apparatus and shall keep it
always with himself.

¾ Special apparatus shall be used as source of current for the firing operations. Power lines
shall not be tapped for the purpose.

¾ The firing cable shall have a proper insulating cover so as to avoid short circuiting due to
contact with water, metallic parts or rock.

¾ The use of earth as a return line shall not be permitted.

¾ The firing cable shall be connected to the source of current only after ascertaining that
nobody is in the area of blasting.

¾ Before firing, the circuit shall be checked by a suitable apparatus.

¾ After firing, whether with or without an actual blast, the contact between the firing cable and
the source of current shall be cut off before any person is allowed to leave the shelter.

¾ During storms, charging with electrical detonators shall be suspended. The charges already
placed into the holes shall be blasted as quickly as possible after taking all the safety
precautions and giving necessary warning signals. If this is not possible, the site shall be
abandoned till the storm has passed.

11.0 VIBRATION RECORDING

¾ Contractor shall use Company approved vibration recording system capable of

measurement in three axes (tri-axial). The device shall have an accuracy of 0.0025 mm and
a resonance of2 Hz.

- The device shall measure both frequency and amplitude of vibration.

¾ All the measurement devices shall be calibrated by an APPROVED certification body.

¾ Particle velocity shall not exceed the following:

• Areas beyond 500 m of proposed pipeline centreline

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 8 of 9

TITLE BLASTING MEC/S/05/21/18 REVISION : 0

EDITION : 1

- 50 mm/sec at a surface distance of 15 m from trench centerline.

• Areas with existing buried or above ground facilities within 500 m of proposed
pipeline centreline.

- 20 mm/sec at a surface distance from the trench centre line towards the
nearest existing facilities.

¾ The particle velocity levels are provided for the guidance only, Contractor shall be
responsible and liable for any injury to life or damage to property/facilities.

¾ Air-over pressure/sound levels shall be limited to 100 db in inhabited areas.

12.0 MISFIRES

¾ If it is suspected that part of the blast has failed to fire, or is delayed, sufficient time shall be
allowed to lapse before entering the danger zone. When fuse and blasting caps are used, a
safe time should be allowed and then the Supervisor alone shall leave the shelter to see the
misfire.

¾ Drilling near the hole that has misfired shall not be permitted until one of the two following
operations have been carried out by the Supervisor:

I) The Supervisor should very carefully (when the tamping is of damp clay) extract the
tamping with a wooden scraper of jet of water or compressed air (using a pipe of soft
material) and withdraw the fuse with the primer and detonator attached. A fresh
primer and detonator with fuse shall then be placed in this hole and fired.

II) The Supervisor shall get one foot of the tamping cleaned off and indicate the
direction by placing a stick in the hole. Another hole may then be drilled at least 9"
away and parallel to it, this hole should then be charged and fired. The balance of
the cartridges and detonators found in the muck shall be removed.

¾ The Supervisor shall at once report to the office all cases of misfire, the cause of the misfire
and the steps taken in connection therewith.

¾ If a misfire has been found to be due to defective detonator, or explosive, the whole quantity
from the box from which the defective articles were taken must be returned to the
manufacturer for inspection to ascertain whether the whole box contains defective materials.

¾ Re-drilling the holes that have misfired either wholly or partly shall not be permitted.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 9 of 9

TITLE BLASTING MEC/S/05/21/18 REVISION : 0

EDITION : 1

13.0 DISPOSAL OF DETERIORATED EXPLOSIVES

All deteriorated explosives shall be disposed off in an approved manner. The Contractor
shall prepare said disposal plan, which shall be approved by Company / Local Authorities /
Controller of explosives. The quantity of the deteriorated explosives to be disposed off shall
be intimated to Company prior to its disposal. All the records of such disposal shall be
maintained by Contractor.
 Rev. : 0
Edition : 1

SPECIFICATION
FOR
GASKETS, BOLTS & NUTS

SPECIFICATION NO.: MEC/S/05/21/19

(OIL & GAS SBU)

MECON LIMITED
DELHI 110 092
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 1

TITLE GASKETS, BOLTS & NUTS MEC/S/05/21/19 REVISION : 0

EDITION : 1

CONTENTS
SL.NO. DESCRIPTION

1.0 GASKETS

2.0 NUTS AND BOLTS

PREPARED BY: CHECKED BY: APPROVED BY: ISSUE DATE :

(Shalini Singh) (Sunil Kumar) (A.K. Johri) Jan. 2009

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 4

TITLE GASKETS, BOLTS & NUTS MEC/S/05/21/19 REVISION : 0

EDITION : 1

TECHNICAL NOTES FOR GASKETS

1.0 All gaskets shall conform to the codes/standards and specifications given in the requisition.
Vendor shall strictly comply with MR / PR stipulations and no deviations shall be permitted.

2.0 Process of manufac ture, dime nsions and t olerances not specifie d in requisition shall be in
accordance with the requirements of the manufacturer's standards.

3.0 Test reports shall be supplied for all mandatory tests for gaskets as per the standards specified
in the requisition.

4.0 Chemical composition and hardness of RTJ gaskets shall also be fu rnished in the form of test
reports on samples.

5.0 For Spiral wound material following shall be furnished:

a. Manufacturer's test certificate for filler material and sp iral material as per the relevant
material specifications.

b. Manufacturer's test certificate for raw materials and tests for compressibility / seal-
ability & recovery as per the relevant material specifications.

6.0 Full face gaskets shall have bolt holes punched out.

7.0 Filler material for spiral wound gaskets shall not have any colour or dye.

8.0 All spiral wound gaskets shall be supplied with Outer ring. Material of the outer ring shall be
CS unless other wise specified in the MR.

9.0 For spiral wound gaskets, materi al of Inner Compression ring sh all be same as Spiral Strip
material. In addition to th e requirements as per code and as spe cified in the MR, inne r rings
shall be provided for the following:

a. Sizes 26" and above.

b. Class 900 and above.

10.0 Hardness of metallic RTJ gaskets shall not exceed the values specified below unless otherwise
specified in MR :

Ring Gasket Material Maximum Hardness (BHN)

Soft Iron 90
Carbon steel 120
5 Cr. ½ Mo 130
Type 304, 316, 321, 347 140
T ype 304L, 316L 120
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 2 of 4

TITLE GASKETS, BOLTS & NUTS MEC/S/05/21/19 REVISION : 0

EDITION : 1

11.0 Face finish of metallic RTJ gaskets shall be 32 to 63 AARH.

12.0 Gaskets of different types and si zes shall be placed in se parate shipping c ontainers and e ach
container clearly marked with the size, rating, material specification and item code.

13.0 All items shall be inspected and approved by MECON Inspector or any other agency authorized
by MECON.

14.0 Any additional requirements specified in the requisition, shall be fully complied with.

15.0 Non-metallic ring gaskets as per ASME B16.21 shall match flanges to ASME B16.5 upto 24"
(except 22" size) and to ASME B16.47B above 24" unless specified otherwise. For 22" size, the
matching flange standard shall be MSS-SP44 unless specified otherwise.

16.0 Spiral wound gasket as per ASME B16.20 shall match flanges to ASME B16.5 upto 24" (except
22" size) and to ASME B16.47B above 24" unless specifically mentione d otherwise. For 22"
size, the matching flange standard shall be MSS-SP44 unless specified otherwise.

17.0 The fo llowing ab breviations hav e b een used in the Material Requisition for Spiral Wound
Gaskets :

(I) : Inner Ring

(O) : Outer Ring
CAF : Compressed Asbestos Fibre
GRAFIL : Grafoil Filler
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 3 of 4

TITLE GASKETS, BOLTS & NUTS MEC/S/05/21/19 REVISION : 0

EDITION : 1

TECHNICAL NOTES FOR BOLTS & NUTS

1.0 The process o f manufact ure, heat t reatment, chemical & mechanical req uirements and
marking for all stud bolts, m/c bolts, jack screws & nuts shall be in accordance with the codes
/ standards and specification give n in the requisition. The applic able identification symbol in
accordance with the material specification shall be stamped on each bolt and nut. Vendor shall
strictly comply with MR / PR stipulations and no deviations shall be permitted.

2.0 Test reports shall be supplie d for all mandat ory t ests as per t he relev ant material
specifications.

3.0 Material t est cert ificate shall also be fu rnished. (He at Analysis, Produc t Analysis and
Mechanical Requirement)

4.0 Stress Rupture Test as detailed in AST M A453 sh all be carried out for all AST M A453 bolting
material irrespective of the temperature.

5.0 All bolting shall be as per ANSI B 18.2.1 for st uds. M/c bolts and jacksc rews and ANSI BI8.2.2
for nuts.

6.0 Threads shall be unified (UNC for 1" dia and BUN for> 1" dia) as per ANSI B.1.1 with class 2A
fit for studs, M/c bolts and jackscrews and class 2B fit for nuts.

7.0 Stud bolts shall be threaded fu ll length with two heavy hexagonal nuts. Length tolerance shall
be in accordance with the requirement as per ANSI B 16.5.

8.0 The nuts shall be double chamfered, semi-finished, heavy hexagonal type and shall be made
by the hot forged process and stamped as per respective material specification.

9.0 Heads of jackscrews and m/c bo lts shall be heavy hex agonal type. Jac kscrew e nd shall be
rounded.

10.0 Each size of studs & m/c bolts with nuts and jac kscrews shall be supplie d in se parate
containers marked with size and material specifications. 'CRYO' shall be marked additionally in
case 'CRYO' is specified in the requisition.

11.0 All items shall be inspected and approve d (stage wise) by MECON inspe ctor or any other
agency authorized by MECON.

12.0 The heat treatment for stud bolts & nuts shall be as per code unless mentioned otherwise.

13.0 All austenitic stainless steel bolt s, nuts, screws shall be supplied in solution annealed condition
unless specified otherwise in the material specification.

14.0 Any additional requirements specified in the requisition shall be fully complied with.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 4 of 4

TITLE GASKETS, BOLTS & NUTS MEC/S/05/21/19 REVISION : 0

EDITION : 1

15.0 Stud bolts, nuts & jackscrews shall b e imp act t ested wherev er sp ecified in t he mat erial
specification and also where t he mat erial sp ecification is indicated as "CRYO". For" S.S. nuts
and bolts minimum impact energy absorption shall be 27 Joules and test temperature shall be
-196°C unless mentioned otherwise. For other materials impact energy and test shall be as per
respective code.

16.0 Bolts / nuts of material of construction B7M / 2HM shall be 100% Hardness tested as per
supplementary requirement S3 of ASTM A 193.

17.0 When specified as galvanized, the studs, m/c bolts and nuts shall be 'hot dip zinc coated' in
accordance with requirements of 'class C' of 'ASTM A 153'. As an alternative, electro-
galvanizing as per IS 1573, 'Service Grade Number 2' is also acceptable.

18.0 All Stud Bolts of Bolt diameter size 1" and above shall be provided with three nuts irrespective
of whatever has been specified elsewhere in the MR.
 REALIGNMENT OF 10”NB
NATURAL GAS PIPELINE OF DFPCL
NEAR PANVEL RAILWAY YARD

DFPCL PIPING MATERIAL SPECIFICATION MECON LIMITED

Doc. No. MEC/23NN/05/28/M/000/1092, R0

PIPING MATERIAL SPECIFICATION

REALIGNMENT OF 10”NB
NATURAL GAS PIPELINE OF DFPCL
NEAR PANVEL RAILWAY YARD

DOC. NO. MEC/23NN/05/28/M/000/1092, R0

(PROCESS & PIPELINE DESIGN SECTION)

MECON LIMITED
DELHI - 110 092

Page 1 of 8
 REALIGNMENT OF 10”NB
NATURAL GAS PIPELINE OF DFPCL
NEAR PANVEL RAILWAY YARD

DFPCL PIPING MATERIAL SPECIFICATION MECON LIMITED

Doc. No. MEC/23NN/05/28/M/000/1092, R0

TABLE OF CONTENTS

1.0 SCOPE
2.0 CODES AND STANDARDS
3.0 MATERIAL SPECIFICATION
4.0 CLASS DESIGNATION CODE
5.0 PIPELINE
6.0 PIPING
7.0 FITTINGS
8.0 BENDS
9.0 FLANGES
10.0 GASKETS
11.0 BOLTING
12.0 THREAD SEALANT
13.0 VALVES
14.0 HYDROTESTING VENTS AND DRAINS
15.0 PIPELINE SPECIALITY ITEMS

TABLE-1 PIPE WALL THICKNESS DETAILS FOR MAINLINE

TABLE-2 INDEX OF PIPING MATERIAL SPECIFICATIONS
APPENDIX-I PIPING MATERIAL SPECIFICATIONS AS PER TABLE - 2

PREPARED BY: CHECKED BY: APPROVED BY: DATE ISSUED:

(Shalini Singh) (Sunil Kumar) (V. K. AGRAWAL) June, 2013

DE Sr. Manager DGM

Page 2 of 8
 REALIGNMENT OF 10”NB
NATURAL GAS PIPELINE OF DFPCL
NEAR PANVEL RAILWAY YARD

DFPCL PIPING MATERIAL SPECIFICATION MECON LIMITED

Doc. No. MEC/23NN/05/28/M/000/1092, R0

1.0 SCOPE

This specification covers the requirements of various piping materials

used in piping/ pipeline system handling Natural Gas / Regasified Liquid
Natural Gas (RLNG) and associated utilities in the pipeline.

2.0 CODES AND STANDARDS

2.1 Pipeline and terminal facilities envisaged as a part of this project shall be
designed and Engineered primarily in accordance with the provision of
ASME B 31.8 – Gas Transmission & Distribution Piping System - Latest
edition and OISD Standard 226-Natural Gas Transmission Pipeline and
City Gas Distribution Networks.

2.2 All codes standards and specifications referred herein shall be the latest
edition of such documents.

2.3 For sake of brevity, the initials of the society to which the codes are
referred are omitted in the specification, for example, B16.5 is a code
referring to ANSI/ ASME, A 105 is a code referring to ASTM.

2.4 In addition, MECON specifications for various piping and pipeline

materials shall also be applicable.

3.0 MATERIAL SPECIFICATION

Piping material specifications are classified for the general purpose of

selection of material for the class of services. The maximum design
pressure and design temperature together with the fluid in line governs the
selection of material specifications. Deviation of materials from class
specifications may occur due to specific design condition. These
deviations are permissible if they are equal or better than the individual
class requirements.

4.0 CLASS DESIGNATION CODE

The piping class designation consist of three digits numbering system

made up of letter, number and letter e. g. A1A, B1A, D1A, etc as follows:

First letter indicates ANSI class rating e. g.

A-Class 150
B-Class 300
D-Class 600

Page 3 of 8
 REALIGNMENT OF 10”NB
NATURAL GAS PIPELINE OF DFPCL
NEAR PANVEL RAILWAY YARD

DFPCL PIPING MATERIAL SPECIFICATION MECON LIMITED

Doc. No. MEC/23NN/05/28/M/000/1092, R0

The middle number indicates differences in the specification within the

same rating and material.

The last letter indicates type of material e. g.

A-Carbon Steel

5.0 PIPELINE

The material for line pipe shall be as per the requirements of specification
as indicated in Table-1.

6.0 PIPING

6.1 Carbon steel pipe shall be made by open hearth, electric furnace or basic
oxygen process only. The steel used shall be fully killed and made with
fine grain structure. The grade and wall thickness of various sizes of pipes
shall be as per piping material specification for the applicable class.

6.2 Pipe dimension shall be in accordance with ANSI B 36.10 for carbon steel
pipes and ANSI B 36.19 for stainless steel pipes.

6.3 All pipe threads shall conform to American Standard taper as per ANSI B
1.20.1 NPT, unless otherwise specified.

6.4 For butt weld end, bevel shall be in accordance to ANSI B 16.25/ API 5L
as applicable.

7.0 FITTINGS

7.1 Fully killed carbon steel shall be used in the manufacture of fittings.

7.2 Threaded joints, if used shall conform to American Standard taper as per
ANSI 1.20.1 NPT.

7.3 Dimension of socket weld/ screwed fittings shall conform to ASME B 16.11

7.4 Bore of socket welded fittings shall suit O. D. of pipe and its thickness.

7.5 Dimensions of butt welded carbon steel fittings shall be as per ASME B
16.9 / MSS-SP-75, as applicable.

Page 4 of 8
 REALIGNMENT OF 10”NB
NATURAL GAS PIPELINE OF DFPCL
NEAR PANVEL RAILWAY YARD

DFPCL PIPING MATERIAL SPECIFICATION MECON LIMITED

Doc. No. MEC/23NN/05/28/M/000/1092, R0

7.6 Butt welding ends shall conform to ANSI B 16.25/ API 5L. In case of
difference in thickness of matching ends, requirements of ASME B 31.8
shall apply.

7.7 Integrally reinforced forged branch fittings such as sockolet, threadolet,

weldolet, nippolet etc. shall be as per MSS-SP-97. Fittings not covered in
ASME B 16.9 and MSS-SP-97 shall conform to manufacturer’s standard.

7.8 Fittings thickness tolerances shall match pipe thickness tolerance.

8.0 BENDS

8.1 Unless otherwise specified for terminal piping, the elbow of radius R = 1.5
D shall only be used.

8.2 The radius of cold field bends shall not be less than 30 times the nominal
diameter for pipes upto nominal diameter of 16” and shall not be less than
40 times the nominal diameter for pipes of nominal diameter of 18” and
above. Limited use of long radius bends (R = 6D) may be permitted for
reason of space constraints.

9.0 FLANGES

9.1 Flange rating shall be same as ANSI B 16.5/MSS-SP-44/ B 16.47 Series

A as specified.

9.2 Dimensions of flanges shall be in accordance with ANSI B 16.5/ B 16.47

Series A, as applicable.

9.3 Neck of Weld Neck (WN) flanges to suit pipe bore and thickness.

9.4 Bore of Socket Welded (SW) flanges shall suit pipe O.D. and its thickness.

9.5 Threads for screwed flanges if used shall conform to American Standard
taper as per ANSI B 1.20.1 NPT.

9.6 Sizes for blind flanges shall be indicated by nominal pipe sizes.

9.7 Carbon steel flanges faces shall have smooth finish as indicated in the
material specification. Flanges faces shall have smooth finish to 125-250
micro inches AARH as per MSS-SP-6.

9.8 Butt welding ends of WN flanges shall conform to ANSI B 16.25.

Page 5 of 8
 REALIGNMENT OF 10”NB
NATURAL GAS PIPELINE OF DFPCL
NEAR PANVEL RAILWAY YARD

DFPCL PIPING MATERIAL SPECIFICATION MECON LIMITED

Doc. No. MEC/23NN/05/28/M/000/1092, R0

9.9 Spectacle blind/ spacer & blinds shall be in accordance with ASME B
16.48 / Manufacturer’s Standard. Spectacle blind shall be used for sizes
up to 8” NB and spacer & blind for 10” & above shall be used.

9.10 Two jack screws 180° apart shall be provided for all spectacle blind
assemblies. The jack screws shall be as per MECON’s standard.

10.0 GASKETS

10.1 Spiral wound metallic gaskets shall conform to B 16.20 and API 601 shall
be provided with graphite filler. All spiral wound gaskets shall be provided
with stainless steel centering ring.

11.0 BOLTING

11.1 Nuts for stud bolts shall be American Standard Hexagonal Heavy series
and double chamfered.

11.2 Dimension and tolerances for stud bolts and nuts shall be as per ANSI B
18.2.1 and 18.2.2 with full threading to ANSI B 1.1 Class 2A thread for
bolts and Class 2B for nuts. Diameter and length of stud bolts shall be as
per ANSI B 16.5/ ASME B 16.47 with full threading.

11.3 Threads for nuts shall be as per ANSI B 1.1, as follows:

Nuts for stud dia ¼” to 1” : UNC-2B

Nuts for stud bolts dia 11/8” to 3 ¼” : 8UN-2B

11.4 Threads for stud bolts shall be as per ANSI B 1.1, as follows.

Studs bolts dia ¼” to 1” : UNC-2A

Stud bolts dia 11/8” to 3 ¼” : 8UN-2A

11.5 Heads of jack screws shall be heavy hexagonal type. Jack screw end shall
be rounded. Stud bolts shall be fully threaded with two hexagonal nuts.

12.0 THREAD SEALANT

12.1 Threaded joints shall be made with 1” wide PTFE Jointing tape.

13.0 VALVES

Page 6 of 8
 REALIGNMENT OF 10”NB
NATURAL GAS PIPELINE OF DFPCL
NEAR PANVEL RAILWAY YARD

DFPCL PIPING MATERIAL SPECIFICATION MECON LIMITED

Doc. No. MEC/23NN/05/28/M/000/1092, R0

13.1 Valve ends shall be as per piping material specifications (Appendices).

13.2 Flange dimensions and face finish of flanged end valves shall confirm to
clause 9.0 of this specification.

13.3 Butt welding ends of Butt Welded valves shall conform to ANSI B 16.25.

13.4 Face to face and end to end dimensions shall conform to applicable
standards.

13.5 Buried valves on mainline shall be provided with stem extension, sealant,
vent/drain & shall have butt welded ends.

13.6 Sectionalizing Valves (Block valves) installed on the main pipeline shall be
Ball valves with butt welded ends and shall be full bore to allow smooth
passage of cleaning pigs as well as intelligent pigs.

13.7 Unless specified otherwise. Valves shall confirm to the following

standards:

Screwed / Socket welded / Flanged end valves (1 ½” and below)

Ball Valves - BS 5351(latest)

Plug Valves - BS 5353(latest)
Globe Valves - BS 5352(latest)
Gate Valves - API 602(latest)

Flanged / Butt weld end Valves (2” and above)

Ball Valves - API 6D

Plug Valves - API 6D
Check Valves - API 6D
Globe Valves - BS 1873
Gate Valves - API 6D

13.8 Manual Valve operators shall be as indicated below, unless specified

otherwise in the P&ID.

a) Gate and Globe Valves

i) For ANSI class 150 & 300 - Hand Wheel operated for size <12”NB.
Gear operated for size >14” NB.

Page 7 of 8
 REALIGNMENT OF 10”NB
NATURAL GAS PIPELINE OF DFPCL
NEAR PANVEL RAILWAY YARD

DFPCL PIPING MATERIAL SPECIFICATION MECON LIMITED

Doc. No. MEC/23NN/05/28/M/000/1092, R0

ii) For ANSI class 600 - Hand Wheel operated for size <10”NB.
Gear operated for size >12” NB.

b) Ball and Plug Valves

i) For ANSI class 150, 300, 600 – Wrench operated for size <4”NB.
Gear operated for size >6”NB.

c) Actuated Valves- Actuated valves shall be as per P & ID.

14.0 HYDRO TESTING VENTS AND DRAINS

High point vents and low point drains required for the purpose of hydro
testing shall be of size 1” and consist of sockolet, Plug & Ball valve for
vent, Globe & Ball Valve for drain, flange & blind flange.

15.0 PIPELINE SPECIALITY ITEMS

Pipeline Specialty items viz., LR bends, shall be as per respective data

sheets, specifications and Project Specific drawing showing Mainline &
Terminal materials.
TABLE-1
PIPE WALL THICKNESS DETAIL FOR MAIN LINE

Sl. Pipe Material Description Size Thickness Length

No. (NB) (mm)
1. API 5L GR X-42, PSL-2 10” 7.8 As per SOR Quantity

TABLE-2
INDEX OF PIPING MATERIAL SPECIFICATIONS

Class Service C.A. Basic Material Design Code Enclosed as

(mm)
B1A Natural Gas 1.5 ASTM A 106 Gr. B ANSI B31.8 Appendix-I
/API 5L Gr. B

Page 8 of 8
 TECHNICAL SPECIFICATION
FOR
PRE-COMMISSIONING AND COMMISSIONING
OF
REALIGNMENT OF 10”NB
NATURAL GAS PIPELINE OF DFPCL
NEAR PANVEL RAILWAY YARD

TS NO.: MEC/S/05/62/61, R-1

(OIL & GAS SBU)

MECON LIMITED
DELHI 110 092
MECON LIMITED PROCESS & PIPING STANDARD SPECIFICATION
REGD. OFF : RANCHI (BIHAR) DESIGN SECTION
NEW DELHI

TITLE PIPELINE PRE-COMMISSIONING SPECIFICATION NO. PAGE 1 OF 8

AND COMMISSIONING OF
PIPELINE PROJECT MEC/S/05/62/61 REVISION 1

CONTENTS

Sl.No. Description Page No.

1.0 INTRODUCTION 2

2.0 GENERAL 2

3.0 THE WORK 3

4.0 PRE-COMMISSIONING CHECKS 3–7

5.0 DOCUMENTATION 7–8

PREPARED BY CHECKED BY APPROVED BY

MECON LIMITED PROCESS & PIPING STANDARD SPECIFICATION
REGD. OFF : RANCHI (BIHAR) DESIGN SECTION
NEW DELHI

TITLE PIPELINE PRE-COMMISSIONING SPECIFICATION NO. PAGE 2 OF 8

AND COMMISSIONING OF
PIPELINE PROJECT MEC/S/05/62/61 REVISION - 1

1.0 INTRODUCTION

This specification covers the minimum technical requirements for pre-

commissioning and commissioning of gas pipeline, including pre-
commissioning activities such as pre-commissioning checks, flushing of
terminal piping, dewatering, swabbing and nitrogen purging.

2.0 GENERAL

The scope of work for testing and commissioning including pre-commissioning

activities shall include, but not limited to the manpower, machinery &
equipment, detailed procedures, materials and consumables, communications
etc. to perform the work satisfactorily.

Contractor shall prepare detailed procedures for flushing of terminal piping,

dewatering, swabbing, inertisation and commissioning of the pipeline, covering
all aspects of work for company’s approval. This shall include, but not limited
to, the sequence and description of all operations, data on materials,
equipment, instruments, consumables, communications systems, necessary
calculations, detailed time schedule and organisation chart.

The Contractor shall be responsible for demonstrating the successful

completion of all the activities i.e. flushing of terminal piping, dewatering,
swabbing, inertisation and commissioning of the pipeline. All necessary work
to perform the job successfully including necessary modifications required shall
be the responsibility of the Contractor.

Contractor shall design and supply all temporary line connections, valves,
instruments, etc. as required during the various operations.

In the event of any detail which is not fully addressed, it is warranted by

Contractor that work shall be performed in accordance with company’s
specification and the best recognised practices in the on-shore pipeline
industry.
MECON LIMITED PROCESS & PIPING STANDARD SPECIFICATION
REGD. OFF : RANCHI (BIHAR) DESIGN SECTION
NEW DELHI

TITLE PIPELINE PRE-COMMISSIONING SPECIFICATION NO. PAGE 3 OF 8

AND COMMISSIONING OF
PIPELINE PROJECT MEC/S/05/62/61 REVISION – 1

3.0 THE WORK

The work to be performed by the Contractor shall consist of the following

activities :

Pre-commissioning : Entire pipeline project shall be checked with respect

to latest P&ID’s and other design specification.

Dewatering : Removal of hydrotest water from the entire pipeline

network system.

Swabbing : Reducing the amount of remaining water in the

main pipeline system which is left behind after
completion of the dewatering operations to make
the pipeline free of water.

Inertisation : Inertising the entire pipeline with nitrogen.

Commissioning : Charging the entire pipeline network with the

product and achieving normal operating conditions
of the pipeline.

4.0 PRE-COMMISSIONING CHECKS

4.1 The pre-commissioning checks shall be carried out for the pipeline to ascertain
that the pipeline system has been mechanically completed in all respects.
These checks shall cover the main pipeline including distribution network
system and sectionalising valve stations. The pre-commissioning checks shall
include the following:

i) System Checks

The entire facilities shall be checked against the latest P&ID’s and other
design specification codes.
MECON LIMITED PROCESS & PIPING STANDARD SPECIFICATION
REGD. OFF : RANCHI (BIHAR) DESIGN SECTION
NEW DELHI

TITLE PIPELINE PRE-COMMISSIONING SPECIFICATION NO. PAGE 4 OF 8

AND COMMISSIONING OF
PIPELINE PROJECT MEC/S/05/62/61 REVISION - 1

ii) Checking of Field Instruments

All the field instruments like control valves, sectionalising valves,

transmitters, solenoid valves, shut down switches, alarms etc. shall be
checked physically and also for their intended application by simulating
the operating conditions. It will also include checking of different
meters, gauges action of shutdown valves etc. as applicable.

iii) Survey of the Pipelines

This shall be performed to confirm that proper fittings/ supports, route

markets, fencing around SV Stations etc. have been intalled along the
pipeline.

iv) Checking of Communications System

This is to check that there is proper communications with adequate

back-up power to ensure uninterrupted communication.

v) Checking of Electrical Distribution System

This is to ensure safety and also to ensure an uninterrupted power

supply during startup and normal pipeline operation.

vi) Checking of Instruments, Controls & Interlocks

This is to check that instrument controls and interlocks are functional as

per the normal operating conditions.

vii) Checking of Utilities

This is to check that utilities like power, nitrogen, UPS system

instrument air, etc. are available prior to startup.

viii) Any other checks as may be considered necessary.

MECON LIMITED PROCESS & PIPING STANDARD SPECIFICATION
REGD. OFF : RANCHI (BIHAR) DESIGN SECTION
NEW DELHI

TITLE PIPELINE PRE-COMMISSIONING SPECIFICATION NO. PAGE 5 OF 8

AND COMMISSIONING OF
PIPELINE PROJECT MEC/S/05/62/61 REVISION - 1

4.2 DEWATERING

4.2.1 General

During the dewatering operation the major quantity of hydrotest water shall be
removed from the main pipeline and distribution network. It is the responsibility
of the Contractor to develop suitable dewatering procedure and submit for
Company’s approval.

The disposal of the water shall be performed such that no harm is done to the
environment.

4.2.2 Operational Requirements

The dewatering operation shall consist of number of dewatering pig runs when
air is used as propellant for pig trains.

Bi-directional cup pigs shall be used and will be suitable for traversing the
entire length of the pipeline/ pipe segment being dewatered. Contractor shall
ensure that all the pigs are designed to prevent damage to the pipeline internal
coating, if any.

The Contractor shall propose the minimum speed and the back pressure of the
pigs in order that continuous operation will be performed without the pig getting
stuck. Contractor shall submit all the calculations regarding this procedure and
a contingency plan for implementation in case the pigs get stuck.

Contractor shall provide a suitable compressor for oil-free air with sufficient
capacity and pressure.

Upon arrival of the pigs at the receiving end the Contractor in the presence of
Company’s representative shall remove the pigs without delay.
MECON LIMITED PROCESS & PIPING STANDARD SPECIFICATION
REGD. OFF : RANCHI (BIHAR) DESIGN SECTION
NEW DELHI

TITLE PIPELINE PRE-COMMISSIONING SPECIFICATION NO. PAGE 6 OF 8

AND COMMISSIONING OF
PIPELINE PROJECT MEC/S/05/62/61 REVISION – 1

4.2.3 Acceptance Criteria

Before proceeding to the next stage of the inertisation operation Contractor

shall ensure that bulk of the water has been removed from the pipeline.
Contractor shall specify when the dewatering phase if finished and shall obtain
approval of the company before proceeding to the next inertisation phase.

4.3 Swabbing

4.3.1 General

The swabbing operation is meant to reduce the remaining water in the pipeline
to bring the pipeline into touch dry condition.

Swabbing operation shall be carried out to ensure that there is no free water
left inside the pipeline. This is done by driving number of swabbing pigs so that
the weight increase in pig before and after the swabbing operation is not more
then 25%. The Contractor shall submit the detailed procedure along with the
duration of the swabbing operation and obtain approval of the company before
starting the operation.

4.3.2 Acceptance Criteria

The Contractor shall ensure that the swabbing operation is considered to be

completed when it is established that there is no free water left in the pipeline
and the pipeline has achieved a touch dry condition. This shall be subject to
company’s approval.

4.4 Inertisation

During the inertisation operation, the air left in the pipeline shall be replaced by
nitrogen before admitting the product natural gas that the pipeline will
ultimately carry.
MECON LIMITED PROCESS & PIPING STANDARD SPECIFICATION
REGD. OFF : RANCHI (BIHAR) DESIGN SECTION
NEW DELHI

TITLE PIPELINE PRE-COMMISSIONING SPECIFICATION NO. PAGE 7 OF 8

AND COMMISSIONING OF
PIPELINE PROJECT MEC/S/05/62/61 REVISION - 1

The inertisation operation shall start as soon as possible after the swabbing
operation has been completed and approved by the company. Contractor
shall submit the detailed purging procedure for approval for the company prior
to its implementation.

Nitrogen needed for inertisation of the pipeline, shall be provided by the

Contractor. The maximum allowable oxygen content inside the pipeline shall
be less than 1% by volume.

Multiple separation pigs with nitrogen slugs in between shall be used for
pipeline commissioning. At least three batches of nitrogen separated by four
separation pigs shall be used for inertisation of the pipeline during charging of
gas in it. The combined nitrogen column length to be used for inertisation
should be at least 5% of the total pipeline length.

4.4.1 Safety Review before start of commissioning

A pre-startup safety review shall be carried out of the pipeline system before
permitting entry of natural gas into the new facility. Owner/ Owner’s
representative shall also participate in the pre-startup safety review.

4.5 COMMISSIONING

4.5.1 General

Commissioning of pipeline shall be considered completed when the line is

charged with product natural gas at operating pressure and the total system
operated at normal operating parameters for a minimum period of 72 hours
with all the instruments, controls and interlocks working satisfactorily at normal
operating conditions. Contractor shall submit a detailed commissioning
procedure for company’s approval.

5.0 DOCUMENTATION

Contractor shall submit for approval of the company the complete description,
detailed procedure and time schedule of all the dewatering, swabbing, purging
and commissioning operations, as applicable.
MECON LIMITED PROCESS & PIPING STANDARD SPECIFICATION
REGD. OFF : RANCHI (BIHAR) DESIGN SECTION
NEW DELHI

TITLE PIPELINE PRE-COMMISSIONING SPECIFICATION NO. PAGE 8 OF 8

AND COMMISSIONING OF
PIPELINE PROJECT MEC/S/05/62/61 REVISION - 1

Documents shall also contain all procedures and safety plans to be followed
while carrying out the activities.

Upon successful completion of the work, Contractor shall prepare a final report
of the work which shall include necessary charts, diagrams, graphs,
calculations, recordings, daily logs, measurements, details of the operation,
etc. Report shall also include all certificates of calibration of instruments
required together with records of calibration performed at site prior to the start
of any operation.

5.1 Spares and Consumables

Supply of spares, tools and consumables for start-up & commissioning.

5.2 Safety

Follow the safety practice during execution of pre-commissioning/

commissioning works as detailed in the scope of work. Maintain and follow all
safety practices equivalent or better than those being practiced for the pipeline
during pre-commissioning and commissioning.
 Edition : 1

SPECIFICATION
FOR
HEALTH, SAFETY
AND
ENVIRONMENT (HSE)
MANAGEMENT

SPECIFICATION NO.: MEC/S/05/21/65

(OIL & GAS SBU)

MECON LIMITED
DELHI 110 092
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 1

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

CONTENTS

SL. NO. DESCRIPTION

1.0 SCOPE

2.0 REFERENCES

3.0 REQUIREMENT OF HEALTH, SAFETY & ENVIRONMENT (HSE) MANAGEMENT

SYSTEM TO BE COMPLETED BY BIDDERS.

4.0 DETAILS OF HSE MANAGEMENT SYSTEM BY CONTRACTOR

5.0 RECORDS

ANNEXURE-A
ANNEXURE-B
ANNEXURE-C
ANNEXURE-D
ANNEXURE-E

PREPARED BY: CHECKED BY: APPROVED BY: ISSUE DATE :

(Shalini Singh) (Sunil Kumar) (A.K. Johri) Feb. 2009

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

1.0 SCOPE

This specification establishes the Healthy, Safety and Environment (HSE)

management requirement to be compiled with by the Contractors during construction.

This specification is not intended to replace the necessary professional judgement

needed to design & implement an effective HSE system for construction activities and
the contractor is expected to exceed requirements given in this specification.

Requirement stipulated in this specification shall supplement the requirement of HSE

management given in relevant Act (S)/ legislations. General Condition of Contract
(GCC) Special Condition of Contract (SCC) and Job Specifications. Where different
documents stipulate different requirements, the most stringent shall be adopted.

2.0 REFERENCES

This document should be read in conjunction with following:

- General Conditions of Contract (GCC)

- Special Conditions of Contract (SCC)
- Building and other construction workers (regulation of employment and
condition of service) Act, 1996
- Job Specifications
- Relevant IS Codes (refer Annexure-A)
- Reporting Formats (refer Annexure-B)
- Statutory requirements

3.0 REQUIREMENT OF HEALTH, SAFETY & ENVIRONMENT (HSE) MANAGEMENT

SYSTEM TO BE COMPLETED BY BIDDERS.

3.1 Management Responsibility

3.1.1 The Contract should have a document HSE policy to cover commitment of the
organization to ensure health, safety and environment aspects in their line of
operations

3.1.2 The HSE management system of the Contractor shall cover HSE requirement
including but not limited to what specified under clause 1.0 & 2.0 mentioned above

3.1.3 Contractor shall be fully responsible for planning and implementing HSE requirement
to the satisfaction of the company. Contractor as a minimum requirement shall
designate/deploy the following to co-ordinate the above:

No. Of workers deployed

Up to 250 - Designate one safety supervisor who will guide
the workers from time to time, as well as impart
training basic guidelines at least weekly once.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

Above 250 & upto 500 - Deploy one qualified and experienced safety
Engineer/ Officer who will guide the workers
from time to time as well as impart basic
guideline & training at least weekly once. He /
She shall possess a recognized Degree in any
branch of engineering or technology or
architecture and had a post qualification
construction experience of minimum two years
or possess a recognized Diploma in any branch
of engineering or technology or Graduate in
Science stream and had a post qualification
construction experience of minimum five years.

Above 500 - One additional safety engineer/Officer

(for every 500 or less) whose function will be as mentioned
above

Contractor shall indemnify and hold harmless OWNER/ MECON & their
representative’s from any and all liabilities arising out of non fulfillment of HSE
requirements.

Above is the minimum requirement and the Contractor shall ensure physical
presence of a safety personnel at each place where Hot work permit is required. No
work shall be started at site until above safety personnel are physically present at
site. The contractor shall submit a safety organogram clearly indicating the lines of
responsibility and reporting system. He shall furnish Bio-Data/Resume/Curriculum
Vitae of the safety personnel he intends to mobilize, at least 1 month before the
intended mobilization, for MECON/Owner's approval.

3.1.4 The Contractor shall ensure that the Health, Safety and Environment (HSE)
requirements are clearly understood & faithfully implemented at all levels, at each
and every site/ work place.

3.1.5 The Contractor shall promote and develop consciousness for Health, Safety and
Environment among all personnel working for the Contractor. Regular awareness
programs and fabrication shop/work site meeting shall be arranged on HSE activities
to cover hazards involved in various operations during construction.

3.1.6 Arrange suitable first aid measures such as First Aid Box, trained personnel to give
First Aid, Stand by Ambulance or Vehicle and install fire protection measures such
as: adequate number of steel buckets with sand and water and adequate fire
extinguishers to the satisfaction of OWNER/ MECON. In case the number of workers
exceeds 500, the Contractor shall position an ambulance /vehicle on full time basis
very close to the worksite.

3.1.7 The Contractor shall evolve a comprehensive planned and documented system for
implementation and monitoring of the HSE requirements. This shall submitted to
OWNER & MECON for approval well in advance, prior to start of work. The
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

monitoring for implementation shall be done by regular inspection and compliance to

the observations thereof. The Contractor shall get similar HSE requirements
implemented at his sub-contractor (s) work site/ Office. However, compliance of HSE
requirement shall be the sole responsibility of the Contractor. Any review/ approval by
OWNER/ MECON shall not absolve the Contractor of his responsibility/ liability in
relation to all HSE requirements.

3.1.8 Non-Conformance on HSE by the Contractor (including his Sub-contractors) as

brought out during review/ audit by MECON/ OWNER representative shall be
resolved forthwith by Contractor. Compliance report shall be possibility submitted to
MECON/ OWNER at the earliest.

3.1.9 The Contractor shall ensure participation of his Resident Engineer/Site-in-Charge in

the Safety Committee/HSE Committee meetings arranged by OWNER/ MECON. The
compliance of any observation shall be arranged urgently. Contractor shall assist
OWNER/MECON to achieve the targets set by them on HSE during the project
implementation.

The contractor shall ensure that his staff members & workers (permanent as well
casual) shall not be in a state of intoxication during working hours and shall abide by
any law relating to consumption & possession of intoxicating drinks or drugs in force.
Awareness about local laws on this issue shall form part of the Induction Training.

The contractor shall ensure that all personnel working for him comply with No-
smoking requirements of the owner as notified from time to time. Cigarettes, lighters,
auto ignition tools or appliances shall not be allowed inside the plant complex.
Smoking shall be permitted only inside smoking booths expressly designated &
authorized by the Owner/MECON.

3.1.10 The Contractor shall adhere consistently to all provisions of HSE requirements. In
case of non-compliance or continuous failure in implementation of any of HSE
provisions; OWNER/ MECON may impose stoppage of work without any Cost & Time
implication to Owner and/or impose a suitable penalty for non-compliance with a
notice of suitable period, upto a cumulative limit of 1.0% (one percent) of Contract
value with a ceiling of Rs. 10 lakhs.

0.2% (Zero decimal two percent) of the contract value for LSTK, EPC, EPCC or
Package contracts with an overall ceiling of Rs. 1,00,00,000/- (Rupees one crore).

S. Violation or HSE norms Penalty Amount

No.
1. For not using personal protective Rs. 250/- per day / item /
equipment (Helmet, Shoes, Goggles, person
Gloves, Full body harness, Face shield,
Boiler suit, etc.)
2. Working without Work Permit / Rs.5,000/- per occasion
Clearance
3. Unsafe electrical practices (not installing Rs.3,000/- per item per day.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

S. Violation or HSE norms Penalty Amount

No.
ELCB, using poor joints of cables, using
naked wire without top plug into socket,
laying wire / cables
on the roads, electrical jobs by
incompetent person, etc.)
4. Working at height without full body Rs.1,000/ per case per day.
harness, using non-standard / rejected
scaffolding and not arranging fall
protection arrangement as
required like Safety Nets.
5. Unsafe handling of compressed gas Rs. 100/- per item per day
cylinders (No trolley, jubilee clips double
gauge regulator, improper storage /
handling).

6. Use of domestic LPG for cutting Rs.1,000/- per occasion

purpose.
7. No fencing / barricading of excavated Rs.1,000/- per occasion
areas.
8. Not providing shoring / strutting / proper Rs.5,000/- per occasion
slope and not keeping the excavated
earth at least 1.5 M away from
excavated area.
9. Non display of caution boards, list of Rs.500/- per occasion
hospitals, emergency services available
at work locations.
10. Traffic rules violations like over speeding Rs.1,000/- per occasion
of vehicles, rash driving, wrong parking,
not using seat belts, vehicles not fitted
with reverse warning alarms.
11. Absence of Contractor's top most Rs.1,000/- per occasion
executive at site in the safety meetings
whenever called by MECON / Owner

12. Failure to maintain safety records by Rs.1,000/- per month.

Contractor Safety personnel.
13. Failure to conduct daily safety site Rs.1,000/- per occasion
inspection, HSE meeting and HSE audit
at predefined frequencies.
14. Failure to submit the monthly HSE report Rs. 1,000/- per occasion and
by 5th of subsequent month to Engineer- Rs. 100/- per day for further
in-Charge. delay.
15. Poor House Keeping Rs.1,000/- per occasion
16. Failure to report & follow up accident Rs. 10,000/- per occasion
(including Near Miss) reporting system.
17. Degradation of environment (not Rs.1,000/- per occasion
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

S. Violation or HSE norms Penalty Amount

No.
confining toxic spills oil / lubricants onto
ground)
18. Not medically examining the workers Rs.1,000/- per occasion
before allowing them to work at height,
not providing ear muffs while allowing
them to work in noise polluted areas,
made them to work in air polluted areas
without respiratory protective devices,
etc.
19. Violation of any other safety condition as Rs.1,000/- per occasion
per job HSE plan, work permit and HSE
conditions of contract (using crowbar on
cable trenches, improper welding booth,
not keeping fire extinguisher ready at hot
work site, unsafe rigging practices, non-
availability of First-Aid box, etc.)
20. Any violation not covered above. To be decided by MECON /
Owner

This penalty shall be in addition to all other penalties specified else where in the
contract. The decision of imposing stoppage of work, its extent & monitory penalty
shall rest with MECON/OWNER & binding on the Contractor.

3.1.11 All fatal accidents and other personnel accidents shall be investigated by a team of
Contractor’s senior personnel for root cause and recommend corrective and
preventive actions. Findings shall documented and suitable actions taken to avoid
recurrences shall be communicated to OWNER / MECON. OWNER / MECON shall
have the liberty to independently investigate such occurrences and Contractor shall
extend all necessary help and co-operation in this regard. MECON / Owner shall
have to right to share the content of this report with the outside world.

3.2 House Keeping

3.2.1 Contractor shall ensure that a high degree of house keeping is maintained and shall
ensure the followings:

a. All surplus earth and debris are removed/disposed off from the working site to
identified location (s).

b. Unused/Surplus Cables Steel items and steel scrap lying scattered at different
places within the working areas are removed to identified location (s).

c. All wooden scrap, empty wooden cable drums and other combustible packing
materials shall be removed from work place to identified location(s).
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d. Roads shall be kept clear and materials like pipes, steel, sand, boulders,
concrete chips and bricks, etc. shall not be allowed in the roads to obstructs
free movement of men & machineries.

e. Fabricated steel structurals, pipes & piping materials shall be stacked properly
for erection.

f. Water logging on rods shall not be allowed.

g. No parking of trucks/ trolleys, cranes and trailors etc. shall be allowed on of

roads, which may obstruct the traffic movements.

h. Utmost care shall be taken to ensure over all cleanliness and proper up keep
of the working areas.

i. Trucks carrying sand, earth and pulverized materials etc. shall be covered
while moving within the plant areas.

j. The contractor shall ensure that the atmosphere in plant area and on roads is
free from particulate matter like dust, sand, etc. by keeping the top surface
wet for ease in breathing.

k. At least two exits for any unit area shall be assured at all times.

3.3 Healthy, Safety and Environment

a) The Contractor shall provide safe means of access to any working place
including provision of suitable and sufficient scaffolding at various stages
during all operations of the work for the safety of his workmen, and OWNER/
MECON. Contractor shall ensure deployment of appropriate equipment and
appliances for adequate safety and healthy of the workmen and protection of
surrounding areas.

Contractor shall ensure identification of all Occupational Health, Safety &

Environmental hazards in the type of work he is going to undertake and enlist
mitigation measures. Contractor shall carry out Job Safety Analysis (JSA)
specifically for high risk jobs like working at height & in confined space, deep
excavations, radiography jobs, electrical installations, blasting operations,
demolishing / dismantling activities, welding / gas cutting jobs and submit the
findings to MECON / Owner. The necessary HSE measures devised shall be
in place prior to start of an activity by the contractor.

b) The Contractor shall ensure that all their staff workers including their sub-
Contractor (s) shall wear Safety Helmet and Safety shoes. Contractor shall
also ensure use of safety belt, protective goggles, gloves etc. by the
personnel as per jobs requirements. All these gadgets shall conform to
relevant IS specification equivalent.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

The Contractor shall ensure that all their staff, workers and visitors including
their sub-contractor(s) have been issued (records to be kept) & wear
appropriate PPEs like nape strap type safety helmets preferably with head
& sweat band with ¾" cotton chin strap (made of industrial HDPE), safety
shoes with steel toe cap and antiskid sole, full body harness (C∈ marked and
conforming to EN361), protective goggles, gloves, ear muffs, respiratory
protective devices, etc. All these gadgets shall conform to applicable IS
Specifications / C∈ or other applicable international standards.

Owner may issue a comprehensive color scheme for helmets to be used by

various agencies. The Contractor shall follow the scheme issued by the
owner. All Safety / Fire personnel shall preferably wear red colour helmet so
that workmen can approach them for guidance during emergencies.

For shot blasting, the usage of protective face shield and helmets, gauntlet
and protective clothing is mandatory.

For offshore jobs/contracts, contractor shall provide PPEs (new) to MECON &
Owner's personnel, at his (contractor's) cost. All personnel shall wear life
jacket at all time.

An indicative list of HSE standards/codes is given under Appendix-A.

The contractor shall issue height permit for working at height after verifying
and certifying the checkpoints as specified in the attached permit (Format No.
HSE-6). He shall also undertake to ensure compliance to the conditions of the
permit during the currency of the permit including adherence to personal
protective equipments.

The permit shall be issued initially for one week or expected duration of an
activity and extended further for the balance duration. This permit shall be
applicable in areas where specific clearance from Owner's operation Deptt. /
Safety Deptt. is not required. MECON field Engineers / Safety Officers / Area
Coordinators may verify and counter sign this permit (as an evidence of
verification) during the execution of the job.

In case work is undertaken without taking sufficient precautions as given in

the permit, MECON Engineers may cancel the permit and stop the work till
satisfactory compliance is arranged. Contractors are expected to maintain a
register for issuance of permit and extensions thereof including preserving the
used permits for verification during audits etc.

Contractor shall arrange (at his cost) and ensure use of Fall Arrester Systems
by his workers. Fall arresters are to be used while climbing / descending tall
structures. These arresters should lock automatically against the anchorage
line, restricting free fall of the user. The device is to be provided with a double
security opening system to ensure safe attachment or release of the user at
any point of rope. In order to avoid shock, the system should be capable of
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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MANAGEMENT EDITION : 1

keeping the person in vertical position in case of a fall.

Contractor shall ensure that Full body harnesses conforming EN361 and
having authorized CC marking is used by all personnel while working at
height. The lanyards and life lines should have enough tensile strength to take
the load of the worker in case of a fall. One end of the lanyard shall be firmly
tied with the harnesses and the other end with life line. The harness should be
capable of keeping the workman vertical in case of a fall, enabling him to
rescue himself.

Contractor shall provide Roof Top Walk Ladders for carrying out activities on
sloping roofs in order to reduce the chances of slippages and falls.

c) Contractor shall ensure that a proper Safety Net System shall be used at
appropriate locations. The safety net shall be located not more than 30 feet
(9.0 metres) below the working surface at site to arrest or to reduce the
consequences of possible fall of persons working at different heights.

d) Contractor shall ensure that flash back arrestors conforming to BS:6158 or

equivalent are installed on all gas cylinders as well as at the torch end of the
gas hose, while in use. All cylinders shall be mounted on trolleys and provided
with a closing key. The burner and the hose placed downstream of pressure
reducer shall be equipped with Flash Back Arrester / Non Return Valve
device. The hoses for acetylene and oxygen cylinders must be of different
colours. Their connections to cylinders and burners shall be made with a
safety collar. At end of work, the cylinders in use shall be closed and hoses
depressurized. All welding machines shall have effective earthing. In order to
help maintain good housekeeping, and to reduce fire hazard, live electrode
bits shall be contained safely and shall not be thrown directly on the ground.

e) The Contractor shall assign to his workmen, tasks commensurate with their
qualification, experience and state of health for driving of vehicles, handling
and erections of materials and equipment’s. All lifting equipments shall be
tested certified for its capacity before use. Adequate and suitable lighting at
every work place and approach there to shall be provided by the contractor
before starting the actual work/ operation at night.

Contractor shall ensure installation of Safe Load Indicator (SLI) on all cranes
(while in use) to minimize overloading risk. SLI shall have capability to
continuously monitor and display the load on the hook, and automatically
compare it with the rated crane capacity at the operating condition of the
crane. The system shall also provide visual and audible warnings at set
capacity levels to alert the operator in case of violations.

The contractor shall be responsible for safe operations of different

equipments mobilized and used by him at the workplace like transport
vehicles, engines, cranes, mobile ladders, scaffoldings, work tools, etc.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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f) Hazardous and/or toxic material such as solvent coating or thinners shall be

stored in appropriate containers.

g) All hazardous materials shall be labeled with the name of the materials, the
hazards associated with its use and necessary precautions to be taken.

The work place shall be checked prior to start of activities to identify the
location, type and condition of any asbestos materials which could be
disturbed during the work. In case asbestos material is detected, usage of
appropriate PPEs by all personnel shall be ensured and the matter shall be
reported immediately to MECON / Owner.

h) Contractor shall ensure that during the performance of the work all hazards to
the health of personnel have been identified assessed and eliminated.

i) Chemical spills shall be contained & cleaned up immediately to prevent

further contamination.

j) All personnel exposed to physical agents such as ionizing or non-ionizing

radiation ultraviolet rays or similar other physical agents shall be provided with
adequate shielding or protection commensurate with type of exposure
involved. For ionizing radiation, requirements of Bhabha Atomic Research
Centre (BARC)/ Atomic Energy Regulatory Board (AERB) shall be followed.

k) Where contract or exposure of hazardous materials could exceed limits or

could otherwise have harmful affects, appropriate personal protective
equipment’s such as gloves, goggles, aprons, chemical resistant clothing and
respirator shall be used.

l) Contractor shall ensure the following facilities at work sites:

I) A Crèche where 10 or more female workers are having children below

the age of 6 years.

II) Reasonable Canteen facilities are made available at appropriate location depending
upon site conditions.

m) Suitable facilities for toilet, drinking water, proper lighting shall be provided at
site and labor camps, commensurate with applicable Laws/Legislation.

n) Contractor shall ensure storage and utilization methodology of material that

are not detrimental to the environment. Wherever required Contractor shall
ensure that only the environment friendly material are selected.

Emphasize on recycling of waste materials such as metals, plastics, glass,

paper, oil & solvents. The waste that can not be minimized, reused or
recovered shall be stored and disposed of safely. In no way, toxic spills shall
be allowed to percolate into the ground. The contractor shall not use the
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REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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empty areas for dumping the wastes.

o) All person deployed at site shall be knowledgeable of and comply with the
environmental laws, rules & regulation relating to the hazardous materials
substance and wastes. Contractor shall not dump, release or otherwise
discharge or dispose off any such materials without the authorization of
OWNER/ MECON.

Suitable scaffoldings shall be provided to workmen for all works that cannot
be safely done from the ground or from solid construction except such short
period work that can be safely done using ladders. When a ladder is used, an
extra workman shall be engaged for holding the ladder.

The contractor shall ensure that the scaffolds used during construction
activities shall be strong enough to take the designed load. Owner / MECON
reserves the right to ask the contractor to submit certification and or design
calculations from his Engineering regarding load carrying capacity of the
scaffoldings.

All scaffolds shall be inspected by a Scaffolding Inspector of the contractor.

He shall paste a GREEN tag on each scaffold found safe and a RED tag on
each scaffold found unsafe. Scaffolds with GREEN tag only shall be permitted
to be used and RED ones shall immediately be removed from the site.

All electrical installations / connections shall be carried out as per the

provisions of latest revision of following codes/standards, in addition to the
requirements of Statutory Authorities and IE / applicable international rules &
regulations:

- OISO SID 173 : Fire prevention & protection system for

electrical installations
- SP 30 (BIS) : National Electric Code

All electrical installations shall be approved by the concerned statutory

authorities.

• The contractor shall meet the following requirements:

i) Ensure that electrical systems and equipment including tools & tackles
used during construction phase are properly selected, installed, used
and maintained as per provisions of the latest revision of the Indian
Electrical / applicable international regulations.

ii) Shall deploy qualified & licensed electricians for proper & safe
installation and for regular inspection of construction power distribution
system / points including their earthing. A copy of the license shall be
submitted to MECON / Owner for records. Availability of at least one
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competent licensed electrician shall be ensured at site round the clock

to attend to the normal / emergency jobs.

iii) All switchboards / welding machines shall be kept in well-ventilated &

covered shed. The shed shall be elevated to avoid water logging. No
flammable materials shall be used for constructing the shed. Also
flammable materials shall not be stored in and around electrical
equipment / switchboard. Adequate clearances and operational space
shall be provided around the equipment.

iv) Fire extinguishers and insulating mats shall be provided in all power
distribution centers.

v) Temporary electrical equipment shall not be employed in hazardous

area without obtaining safety permit.

vi) Proper house keeping shall be done around the electrical installations.

vii) All temporary installations shall be tested before energising, to ensure

proper earthing, bonding, suitability of protection system,
adequacy of feeders/cables etc.

viii) All welders shall use hand gloves irrespective of holder voltage.

ix) Multilingual (Hindi, English and local language) caution boards, shock
treatment charts and instruction plate containing location of isolation
point for incoming supply, name & telephone No. of contact person in
emergency shall be provided in substations and near all distribution
boards / local panels.

x) Operation of earth leakage device shall be checked regularly by

temporarily connecting series test lamp (2 bulbs of equal rating
connected in series) between phase and earth.

xi) Regular inspection of all installations (at least once in a month)

• The following features shall also be ensured for all electrical installations
during construction phase by the contractor:

i) Each installation shall have a main switch with a protective device,

installed in an enclosure adjacent to the metering point. The operating
height of the main switch shall not exceed 1.5 M. The main switch
shall be connected to the point of supply by means of armoured cable.

ii) The outgoing feeders shall be double or triple pole switches with fuses
/ MCBs. Loads in a three phase circuit shall be balanced as far as
possible and load on neutral should not exceed 20% of load in the
phase.
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iii) The installation shall be adequately protected against overload, short

circuit and earth leakage by the use of suitable protective devices.
Fuses wherever used shall be HRC type. Use of rewirable fuses shall
be strictly prohibited. The earth leakage device shall have an
operating current not exceeding 30 mA.

iv) All connections to the hand tools / welding receptacles shall be taken
through proper switches, sockets and plugs.

v) All single phase sockets shall be minimum 3 pin type only. All unused
sockets shall be provided with socket caps.

vi) Only 3 core (P+N+E) overall sheathed flexible cables with minimum
conductor size of 1.5 mm2 copper shall be used for all single phase
hand tools.

vii) Only metallic distribution boxes with double earthing shall be used at
site. No wooden boxes shall be used.

viii) All power cables shall be terminated with compression type cable
glands. Tinned copper lugs shall be used for multistrand wires /
cables.

ix) Cables shall be free from any insulation damage.

x) Minimum depth of cable trench shall be 750 mm for MV & control

cables and 900 mm for HV cables. These cables shall be laid over a
sand layer and covered with sand, brick & soil for ensuring mechanical
protection. Cables shall not be laid in waterlogged area as far as
practicable. Cable route markers shall be provided at every 25 M of
buried trench route. When laid above ground, cables shall be properly
cleated or supported on rigid poles of atleast 2 M high. Minimum head
clearance of 6 meters shall be provided at road crossings.

xi) Under ground road crossings for cables shall be avoided to the extent
feasible. In any case no under ground power cable shall be allowed to
cross the roads without pipe sleeve.

xii) All cable joints shall be done with proper jointing kit. No taped /
temporary joints shall be used.

xiii) An independent earthing facility should preferably be established

within the temporary installation premises. All appliances and
equipment shall be adequately earthed. In case of armoured cables,
the armour shall be bonded to the earthing system.
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ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

xiv) All cables and wire rope used for earth connections shall be
terminated through tinned copper lugs.

xv) In case of local earthing, earth electrodes shall be buried near the
supply point and earth continuity wire shall be connected to local earth
plate for further distribution to various appliances. All insulated wires
for earth connection shall have insulation of green colour.

xvi) Separate core shall be provided for neutral. Earth / Structures shall not
be used as a neutral in any case.

xvii) ON/OFF position of all switches shall be clearly designated / painted

for easy isolation in emergency.

The contractor shall identify all operations that can adversely affect the health of its
workers and issue & implement mitigation measures.

For surface cleaning operations, sand blasting shall not be permitted even if not
explicitly stated elsewhere in the contract.

To eliminate radiation hazard, Tungsten electrodes used for Gas Tungsten Arc
Welding shall not contain Thorium.

Appropriate respiratory protective devices shall be used to protect workmen from

inhalation of air borne contaminants like silica, asbestos, gases, fumes, etc.

Workmen shall be made aware of correct methods for lifting, carrying, pushing &
pulling of heavy loads. Wherever possible, manual handling shall be replaced by
mechanical lifting equipments.

For jobs like drilling / demolishing / dismantling where noise pollution exceeds the
specified limit of 85 decibels, ear muffs shall be provided to the workers.

To avoid upper limb disorders and backaches, Display Screen Equipments'

workplace stations shall be carefully designed & used with proper sitting postures.
Power driven hand-held tools shall be maintained in good working condition to
minimize their vibrating effects and personnel using these tools shall be taught how
to operate them safely & how to maintain good circulation in hands.

The contractor shall arrange health check up for all the workers at the time of
induction. Health check may have to be repeated if the nature of duty assigned to him
is changed necessitating health check or doubt arises about his wellness. MECON /
Owner reserve the right to ask the contractor to submit test reports.

Weather Protection

Contractor shall take appropriate measures to protect workers from severe storms, solar
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 14 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

radiations, poisonous gases, dust, etc. by ensuring proper usage of PPEs like Sun glasses,
Sun screen lotions, respirators, dust masks, etc. and rearranging / planning the construction
activities to suit the weather conditions.

Communication

All persons deployed at the work site shall have access to effective means of communication
so that any untoward incident can be reported immediately and assistance sought by them.

All health & safety information shall be communicated in a simple & clear language easily
understood by the local workforce.

Unsuitable Land Conditions

Contractor shall take appropriate measures and necessary work permits / clearances if work
is to be done in or around marshy areas, river crossings, mountains, monuments, etc.

Under Water Inspection

Contractor shall ensure that boats and other means used for transportation, surveying &
investigation works shall be certified seaworthy by a recognized classification society. It shall
be equipped with all life saving devices like life jackets, adequate fire protection
arrangements and shall posses communication facilities like cellular phones, wireless,
walkie-talkie. All divers used for seabed surveys, underwater inspections shall have required
authorized license, suitable life saving kit. Number of hours of work by divers shall be limited
as per regulations. MECON / Owner shall have the right to inspect the boat and scrutinize
documents in this regard.

TOOL BOX MEETING (TBM)

Contractor shall conduct daily TBM with workers prior to start of work and shall maintain
proper record of the meeting. A suggested format is given below. The TBM is to be
conducted by the immediate supervisor of the workers.

TOOLBOX MEETING RECORDING SHEET

Date & Time

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 15 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

Subject
Presenter
Hazards involved
Precautions to be taken
Worker’s Name Signature Section

Remarks, if any

The topics during TBM shall include

- Hazards related to work assigned on that day and precautions to be taken.

- Any forthcoming HSE hazards / events / instruction / orders, etc.

The above record can be kept in local language, which workers can read. These records
shall be made available to MECON / Owner whenever demanded.

TRAINING

Contractor shall ensure that all his personnel possess appropriate training to carry out the
assigned job safely. The training should be imparted in a language understood by them and
should specifically be trained about

- Potential hazards to which they may be exposed at their workplace

- Measures available for prevention and elimination of these hazards

The topics during training shall cover, at the minimum;

- Education about hazards and precautions required

- Emergency and evacuation plan
- HSE requirements
- Fire fighting and First-Aid
- Use of PPEs
- Local laws on intoxicating drinks, drugs, smoking in force

Records of the training shall be kept and submitted to MECON / Owner whenever
demanded.

For offshore and jetty jobs, contractor shall ensure that all personnel deployed have
undergone a structured sea survival training including use of lifeboats, basket landing, use of
radio communication etc. from an agency acceptable to Owner / MECON.

INSPECTION

The contractor shall carryout daily HSE inspection and record observations at a central
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 16 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

location. These inspection records shall be freely accessible to Owner / MECON

representatives. The contractor shall also assist Owner / MECON representatives during the
HSE inspections conducted by them.

ADDITIONAL SAFETY REQUIREMENTS FOR WORKING INSIDE A RUNNING PLANT

As a minimum, the contractor shall ensure adherence to following safety requirements while
working in or in the close vicinity of an operating plant :

a) Contractor shall obtain permits for Hot work, Cold work, Excavation and Confined
Space from Owner in the prescribed format.

b) The contractor shall monitor, record and compile list of his workers entering the
operational plant/unit each day and ensure & record their return after completing the
job.

c) Contractor's workers and staff members shall use designated entrances and proceed
by designated routes to work areas only assigned to them. The workers shall not be
allowed to enter units' area, tanks area, pump rooms, etc. without work authorization
permit.

d) Work activities shall be planned in such a way so as to minimize the disruption of

other activities being carried out in an operational plant / unit and activities of other
contractors.

e) The contractor shall submit a list of all chemicals / toxic substances that are intended
to be used at site and shall take prior approval of the Owner.

f) Specific training on working in a hydrocarbon plant shall be imparted to the work

force and mock drills shall be carried out for Rescue operations / First-Aid measures.

g) Proper barricading / cordoning of the operational units / plants shall be done before
starting the construction activities. No unauthorized person shall be allowed to
trespass. The height and overall design of the barricading structure shall be finalized
in consultation with the Owner and shall be got approved from the Owner.

h) Care shall be taken to prevent hitting underground facilities such as electrical cables,
hydrocarbon piping during execution of work.

i) Barricading with water curtain shall be arranged in specific/critical areas where

hydrocarbon vapors are likely to be present such as near horton spheres or tanks.
Positioning of fire tenders (from owner) shall also be ensured during execution of
critical activities.

j) Emergency evacuation plan shall be worked out and all workmen shall be apprised
about evacuation routes. Mock drill operations may also be conducted.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 17 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

k) Flammable gas test shall be conducted prior to any hot work using appropriate
measuring instruments. Sewers, drains, vents or any other gas escaping points shall
be covered with flame retardant tarpaulin.

l) Respiratory devices shall be kept handy while working in confined zones where there
is a danger of inhalation of poisonous gases. Constant monitoring of presence of Gas
/ Hydrocarbon shall be done.

m) Clearance shall be obtained from all parties before starting hot tapping, patchwork on
live lines and work on corroded tank roof.

n) Positive isolation of line/equipment by blinding for welding/cutting/grinding shall be

done. Closing of valve will not be considered sufficient for isolation.

o) Welding spatters shall be contained properly and in no case shall be allowed to fall
on the ground containing oil. Similar care shall be taken during cutting operations.

p) The vehicles, cranes, engines, etc. shall be fitted with spark arresters on the exhaust
pipe and got it approved from Safety Department of the Owner.

q) Plant air should not be used to clean any part of the body or clothing or use to blow
off dirt on the floor.

r) Gas detectors should be installed in gas leakage prone areas as per requirement of
Owner's plant operation personnel.

s) An experienced full time safety personnel shall be exclusively deployed to monitor

safety aspects in running plants.

HSE PROMOTION

The contractor shall encourage his workforce to promote HSE efforts at workplace by way of
organizing workshops / seminars / training programmes, celebrating HSE awareness weeks
& National Safety Day, conducting quizzes & essay competitions, distributing pamphlets,
posters & material on HSE, providing incentives for maintaining good HSE practices and
granting bonus for completing the job without any lost time accident.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 18 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

4.0 DETAILS OF HSE MANAGEMENT SYSTEM BY CONTRACTOR

4.1 On Award of Contract

The Contractor shall prior to start of work submit his Health. Safety and Environment
Manual of procedure and HSE Plans for approval by OWNER/MECON. The
Contractor shall participate in the pre-start meeting with OWNER/MECON to finalize
HSE plans including the following.

- Job procedure to be followed by Contractor for activities covering Handling of

equipment’s, Scaffolding, Electric Installation, describing the risks involved,
actions to be taken and methodology for monitoring each.

- Organizations structure alongwith responsibility and authority records/ reports

etc. on HSE activities.

4.2 During job execution

4.2.1 Implement approved Health, Safety and Environment management procedure

including but not limited to as brought our under para 3.0. Contractor shall also
ensure to:

- Arrange workmen compensation insurance, registration under ESI Act, third

party liability insurance etc. as applicable.

- Arrange all HSE permits before start of activities (as applicable) like her work,
confined space, work at heights, storage of Chemicals/explosives materials
and its use and implement all precautions mentioned therein

- Submit timely the completed check list on HSE activities, Monthly HSE report,
accident report, investigation report, etc. as per OWNER/MECON
requirements. Compliance of instructions on HSE shall be done by Contractor
and informed urgently to OWNER/MECON.

- Ensure that resident Engineers/Site-In-Charge of the Contractor shall amend

all the Safety Committee/HSE meeting arranged by OWNER/ MECON only in
case of his absence from site, a seconds senior most person shall be
nominated by him in advance and communicated to OWNER/MECON.

- Display at site office and work locations caution boards, list of hospitals for
emergency services available.

- Provided posters, banners, for safe working to promote safety consciousness

- Carryout audits/inspection at sub Contractor work as per approved HSE

documents & submit the reports for OWNER/MECON review.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 19 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

- Assist in HSE audits by OWNER/ MECON and submit compliance report.

- Generate & submit HSE records/ reports as per HSE Plan.

- Appraise OWNER/MECON on HSE activities at site.

5.0 RECORDS

At the minimum, the contractor shall maintain/ submit HSE records in the following
reporting formats:

1. Monthly HSE Checklist cum compliance report HSE-1

2. Accident / Incident Report HSE-2
3. Supplementary Accident / Incident Investigation report HSE-3
4. Near Miss Incident Report HSE-4
5. Monthly HSE Report HSE-5
6. Permit for working at height HSE-6
7. Permit for working in confined space HSE-7
8. Permit for radiation work HSE-8
9. Permit for demolishing / dismantling HSE-9
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 20 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

ANNEXURE-A
A. I.S. CODES ON HSE

SP:53 Safety code for the use, Care and protection of hand operated tools.

IS: 818 Code of practice for safety and health requirements in electric and gas
welding and cutting operations

IS: 1179 Eye and Face precautions during welding, equipment etc.

IS: 1860 Safety requirements for use, care and protection of abrasive grinding wheels.

IS: 1989(Part-I & II) Leather safety boots and shoes

IS: 2925 Industrial Safety Helmets

IS: 3016 Code of practice for fire safety precautions in welding and cutting operations.

IS: 3043 Code of practice for earthing.

IS: 3764 Code of safety for excavation work

IS: 3786 Methods for computation of frequency and severity rates for industrial injuries
and classification of industrial accidents.

IS: 3996 Safety Code of scaffolds and ladders.

IS: 4082 Recommendation on stacking and storage of construction materials and

components at site.

IS: 4770 Rubber gloves for electrical purposes

IS: 5121 Safety code for piling and other deep foundations

IS: 5216 (Part-I) Recommendations on Safety procedures and practices in electrical works

IS: 5557 Industrial and Safety rubber lined boots.

IS: 5983 Eye protectors

IS:6519 Selection, care and repair of Safety footwear

IS: 6994 (Part-I) Industrial Safety Gloves (Leather & Cotton Gloves)

IS: 7293 Safety Code for working with construction Machinery

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 21 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

IS: 8519 Guide for selection of industrial safety equipment for body protection

IS: 9167 Ear protectors

IS: 11006 Flash back arrestor (Flame arrestor)

IS:11016 General and safety requirements for machine tools and their operation

IS: 11057 Specification for Industrial safety nets

IS: 11226 Leather safety footwear having direct moulded rubber sole

IS: 11972 Code of practice for safety precaution to be taken when entering a sewerage
system

IS: 13367 Code of practice-safe use of cranes

IS: 13416 Recommendations for preventive measures against hazards at working place

B. INTERNATIONAL STANDARDS ON HSE

Safety Glasses : ANSI Z 87.1, ANSI ZZ 87.1, AS 1337, BS 2092, BS 1542, BS 679,
DIN 4646 / 58211

Safety Shoes : ANSI Z 41.1, AS 2210, EN 345

Hand Gloves : BS 1651

Ear Muffs : BS 6344, ANSI S 31.9

Hard Hat : ANSI Z 89.1 / 89.2, AS 1808, BS 5240, DIN 4840

Goggles : ANSI Z 87.1

Face Shield : ANSI Z 89.1

Breathing Apparatus : BS 4667, NIOSH

Welding & Cutting : ANSI Z 49.1

Safe handling of : P-1 (Compressed Gas Association

compressed Gases 1235 Jefferson Davis Highway, Arlington VA 22202 – USA)
in cylinders
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 22 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

ANNEXURE-B
DETAILS OF FIRST AID BOX

SL.
DESCRIPTION QUANTITY
NO
1. Small size Roller Bandages, 1 inch wide (Finger Dressing small) 6 Pcs.
2. Medium size Roller Bandages, 2 inch wide (Hand and Foot Dressing) 6 Pcs.
3. Large size Roller Bandages, 4 inch wide (Body Dressing Large) 6 Pcs.
4. Large size Burn Dressing (Burn Dressing Large) 4 Pkts.
5. Cotton wool (20 gms packing) 4 Pkts.
6. Antiseptic Solution Dettol (100 ml.) or Savlon 1 Bottle
7. Mercurochrome Solution (100 ml.) 2% in water 1 Bottle
8. Ammonia Solution (20 ml.) 1 Bottle
9. A Pair of Scrissors 1 Piece
10. Adhesive Plaster (1.25 cm x 5 m) 1Spool
11. Eye pads in Separate Sealed Packet 4 Pcs.
12. Tourniqut 1 No.
13. Safety Pins 1 Dozen
14. Tinc. Iodine / Betadin (100 ml.) 1 Bottles
15. Ointment for burns (Burnol 20 gms.) 1 Bottole
16. Polythene Wash cup for washing eyes 1 No.
17. Potassium Permanganate (20 gms.) 1 Pkt.
18. Tinc. Benzoine (100 ml.) 1 Bottole
19. Triangular Bandages 2 Nos.
20. Band Aid Dressing 5 Pcs.
21. Iodex / Moov (25 gms.) 1 Bottole
22. Tongue Depressor 1 No.
23. Boric Acid Powder (20 gms.) 2 Pkt.
24. Sodium Bicarbonate (20 gms.) 1 Pkt.
25. Dressing Powder (Nebasulf) (10 gms.) 1 Bottole
26. Medicinal Glass 1 No.
27. Duster 1 No.
28. Booklet (English & Local Language) 1 No. each
29. Soap 1 No.
30. Toothache Solution 1 No.
31. Eye Ointment 1 Bottle
32. Vicks (22 gms.) 1 Bottle
33. Forceps 1 No.
34. Cotton Buds (5 nos.) 1 Pkt.
35. Note Book 1 No.
36. Splints 4 Nos.
37. Lock 1 Piece
38. Life Saving/Emergency/Over-the Counter Drugs As decided at site
Box size : 14” x 12” x 4”

Note : The medicines prescribed above are only indicative. Equivalent medicines can also be used.
A prescription, in this regard, shall be required from a qualified Physician.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 23 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

ANNEXURE – C

TYPE OF FIRES VIS-À-VIS FIRE EXTINGUISHERS

Fire Fire Extinguishers

Water Foam CO2 Dry Powder Multi Purpose
(ABC)
Originated from paper, √ √ Can control Can control √
clothes, wood minor minor
surface fires surface fires
Inflammable liquids x √ √ √ √
like alcohol, diesel,
petrol, edible oils,
bitumen

Originated from gases x x √ √ √

like LPG, CNG, H2

Electrical Fires x x √ √ √

Legend : √ Can be used

x Not to be used

Note : Fire extinguishing equipment must be checked atleast once a year and after every use by an
authorized person. The equipment must have an inspection label on which the next
inspection date is giver:. Type of extinguisher shall clearly be marked on it.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 24 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

ANNEXURE – D
Indicative List of Statutory Acts & Rules Relating to HSE

- The Indian Explosives Act and Rules

- The Motor Vehicle Act and Central Motor Vehicle Rules
- The Factories Act and concerned Factory Rules

- The Petroleum Act and Petroleum Rules

- The Workmen Compensation Act

- The Gas Cylinder Rules and the Static & Mobile Pressure Vessels Rules.

- The Indian Electricity Act and Rules

- The Indian Boiler Act and Regulations

- The Water (Prevention & Control & Pollution) Act

- The Water (Prevention & Control of Pollution) Cess Act

- The Mines & Minerals (Regulation & Development) Act

- The Air (Prevention & Control of Pollution) Act

- The Atomic Energy Act

- The Radiation Protection Rules

- The Indian Fisheries Act

- The Indian Forest Act

- The Wild Life (Protection) Act

- The Environment (Protection) Act and Rules

- The Hazardous Wastes (Management & Handling) Rules

- The Manufacturing, Storage & import of Hazardous Chemicals Rules

- The Public Liability Act

- The Building and Other Construction Workers (Regulation of Employment and Condition of
service) Act

- Other statutory acts Like EPF, ESIS, Minimum Wage Act.

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 25 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

ANNEXURE – E

CONSTRUCTION HAZARDS, THEIR EFFECTS & PREVENTIVE MEASURES

ACTIVITY TYPE OF HAZARD EFFECT OF HAZARD PREVENTIVE MEASURES

(A) EXCAVATION ¾ Falling into pit ¾ Personal injury ¾ Provide guard
rails/barricade with
Pit Excavation up warning signal.
to 3.0m ¾ Provide at least two
entries/exits.
¾ Provide escape
ladders.
¾ Earth ¾ Suffocation / ¾ Provide suitable size
Collapse Breathlessness of shoring and
¾ Buried strutting, if required.
¾ Keep soil heaps
away from the edge
equivalent to 1.5m or
depth of pit
whichever is more.
¾ Don’t allow vehicles
to operate too close
to excavated areas.
Maintain at least 2m
distance from edge
of cut.
¾ Maintain sufficient
angle of repose.
Provide slope not
less than 1:1 and
suitable bench of
0.5m width at every
1.5m depth of
excavation in all
soils except hard
rock.
¾ Battering/benching
the sides.
¾ Contact with ¾ Electrocution ¾ Obtain permission
buried electric ¾ Explosion from competent
cables authorities, prior to
¾ Gas/ Oil excavation, if
Pipelines required.
¾ Locate the position
of buried utilities by
referring to plant
drawings.
¾ Start digging
manually to locate
the exact position of
buried utilities and
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 26 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

ACTIVITY TYPE OF HAZARD EFFECT OF HAZARD PREVENTIVE MEASURES

thereafter use
mechanical means.
Pit Excavation ¾ Same as ¾ Can cause ¾ Prevent ingress of
beyond 3.0m above plus drowning situation water
¾ Flooding due ¾ Provide ring buoys
to excessive ¾ Identify and provide
rain/ suitable size
underground dewatering pump or
water well point system
¾ Digging in the ¾ Building/ ¾ Obtain prior approval
vicinity of Structure may of excavation
existing collapse method from local
Building/ ¾ Loss of health & authorities
Structure wealth ¾ Use under-pining
method
¾ Construct retaining
wall side by side
¾ Movement of ¾ May cause cave- ¾ Barricade the
vehicles / in or slides excavated area with
equipments ¾ Persons may get proper lighting
close to the buried arrangements
edge of cut. ¾ Maintain at least 2m
distance from edge
of cut and use stop
block to prevent
over-run.
¾ Strengthen shoring
and strutting

Narrow deep ¾ Same as ¾ May cause severe ¾ Battering/benching

excavations for above plus injuries or prove of sides
pipelines, etc. ¾ Frequent fatal ¾ Provide escape
cave-in or ladders
slides
¾ Flooding due ¾ May arise ¾ Same as above plus
to Hydrostatic drowning situation ¾ Bail out accumulated
testing water
¾ Maintain adequate
ventilation
Rock excavation by ¾ Improper ¾ May prove fatal ¾ Ensure proper
blasting handling of storage, handling &
explosives carrying of
explosives by trained
personnel.
¾ Comply with the
applicable explosive
acts & rules.
¾ Uncontrolled ¾ May cause severe ¾ Allow only
explosion injuries or prove authorized persons
fatal to perform blasting
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 27 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

ACTIVITY TYPE OF HAZARD EFFECT OF HAZARD PREVENTIVE MEASURES

operations.
¾ Smoking and open
flames are to be
strictly prohibited.
¾ Scattering of ¾ Can hurt people ¾ Use PPE like
stone pieces goggles, face mask,
in atmosphere helmets etc.
Rock excavating by ¾ Entrapping of ¾ May cause severe ¾ Barricade the area
blasting (Contd) persons/ injuries or prove with red flags and
animals. fatal blow siren before
blasting.

¾ Misfire ¾ May explode ¾ Do not return to site

suddenly for at least 20
minutes or unless
announced safe by
designated person.
Piling Work ¾ Failure of pile- ¾ Can hurt people ¾ Inspect Piling rigs
driving and pulley blocks
equipment before the beginning
of each shift.
¾ Noise ¾ Can cause ¾ Use personal
pollution deafness protective
¾ and psychological equipments like ear
imbalance plugs, muffs, etc.

¾ Extruding rods ¾ Can hurt people ¾ Barricade the area

/ casing an install sign boards
¾ Provide first-aid
¾ Working in the ¾ Can cause ¾ Keep sufficient
vicinity of electrocution / distance from Live-
‘Live- asphyxiation Electricity as per IS
Electricity’ code.
¾ Shut off the supply, if
possible
¾ Provide
artificial/rescue
breathing to he
injured.
(B) CONCRETING ¾ Air pollution ¾ May affect ¾ Wear respirators or
by cement Respiratory cover mouth and
System nose with wet cloth.
¾ Handling of ¾ Hand s may get ¾ Use gloves and
ingredients injured other PPE.
¾ Protruding ¾ Feet may get ¾ Use Safety shoes.
reinforcement injured ¾ Provide platform
rods. above reinforcement
for movement of
workers.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 28 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

ACTIVITY TYPE OF HAZARD EFFECT OF HAZARD PREVENTIVE MEASURES

¾ Earthing of ¾ Can cause ¾ Ensure earthing of
electrical electrocution / equipments and
mixers, asphyxiation proper functioning of
vibrators, etc. electrical circuit
not done before
commencement of
work.
¾ Falling of ¾ Persons may get ¾ Use hard hats
materials from injured ¾ Remove surplus
height material immediately
from work place
¾ Ensure lighting
arrangements during
night hours.
¾ Continuous ¾ Cause tiredness ¾ Insist on shift pattern
pouring by of workers and ¾ Provide adequate
same gang may lead to rest to workers
accident. between subsequent
pours.
¾ Revolving or ¾ Parts of body or ¾ Allow only mixers
concrete clothes may get with hopper
mixer/ entrapped. ¾ Provide safety cages
vibrators around moving
motors
¾ Ensure proper
mechanical locking
of vibrator
Super-structure ¾ Same as ¾ Shuttering / props ¾ Avoid excessive
above plus may collapse and stacking on
¾ Deflection in prove fatal shuttering material
props or ¾ Check the design
shuttering and strength of
material shuttering material
before
commencement of
work
¾ Rectify immediately
the deflection noted
during concreting
¾ Passage to ¾ Improperly tied ¾ Ensure the stability
work place and designed and strength of
props / planks passage before
may collapse commencement of
work
¾ Do not overload and
under the passage.
(C) ¾ Curtailment ¾ Persons may get ¾ Use PPE like gloves,
REINFORCEMEN and binding of injured shoes, helmets, etc.
T rods ¾ Avoid usage of shift
tools
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
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TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

ACTIVITY TYPE OF HAZARD EFFECT OF HAZARD PREVENTIVE MEASURES

¾ Carrying of ¾ Workers may ¾ Provide suitable
rods for short injure their hands pads on shoulders
distance/ at and shoulders and use safety
heights gloves.
¾ Tie up rods in easily
liftable bundles
¾ Ensure proper
staging.
¾ Checking of ¾ Rods may cut or ¾ Use measuring
clear distance/ injure the finger devices tape,
cover with measuring rods, etc.
hands
¾ Hitting ¾ Persons may get ¾ Use safety shoes
projected rods injured and fall and avoid standing
and standing down unnecessarily on
on cantilever cantilever rods
rods ¾ Avoid wearing loose
clothes
¾ Falling of ¾ May prove fatal ¾ Use helmets
material from ¾ Provide safety nets
height
¾ Transportation ¾ Protruded rods ¾ Use red flags/lights
of rods by may hit the at the ends
trucks / persons ¾ Do not protrude the
trailers rods in front of or by
the side of driver’s
cabin.
¾ Do not extend the
rods 1/3rd of deck
length or 1.5 m
which is less
(D) WELDING AND ¾ Welding ¾ Radiation can ¾ Use specified
GAS CUTTING radiates damage eyes and shielding devices
invisible skin. and other PPE of
ultraviolet and correct specifications
infrared says ¾ Avoid throated
tungsten electrodes
for GTAW.
¾ Improper ¾ Explosion may ¾ Move out any
placement of occur leaking cylinder
oxygen and ¾ Keep cylinder in
acetylene vertical position
cylinders ¾ Use trolley for
transportation of
cylinders and chain
them
¾ Use flash back
arrestors
¾ Leakage / ¾ May cause fire ¾ Purge regulators
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
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TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

ACTIVITY TYPE OF HAZARD EFFECT OF HAZARD PREVENTIVE MEASURES

cuts in hoses immediately and
then turn off
¾ Never use grease or
oil on oxygen line
connections and
copper fittings on
acetylene lines
¾ Inspect regularly gas
carrying hoses
¾ Always use red hose
for acetylene & other
fuel gases and black
for oxygen.
¾ Opening-up of ¾ Cylinder may ¾ Always stand back
cylinder burst from the regulator
while opening the
cylinder
¾ Turn valve slowly to
avoid bursting
¾ Cover the lug
terminals to prevent
short circuiting.

¾ Welding of ¾ Explosion may ¾ Empty & purge them

tanks, occur before welding
container or ¾ Never attach the
pipes storing ground cable to
flammable tanks, container or
liquids pipe storing
flammable liquids
¾ Never use LPG for
gas cutting
(E) ¾ Ionizing ¾ Radiations may ¾ Ensure safety
RADIOGRAPHY Radiation react with the skin regulations as per
and can cause BARC/AERB before
cancer, skin commencement of
irritation, job.
dermatitis, etc. ¾ Cordon off the area
and install Radiation
warning symbols
¾ Restrict the entry of
unauthorized
persons
¾ Wear appropriate
PPE and film badges
issued by
BARC/AERB
¾ Transportation ¾ Same as above ¾ Never touch or
and Storage handle radiography
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
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ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

ACTIVITY TYPE OF HAZARD EFFECT OF HAZARD PREVENTIVE MEASURES

of source with hands
Radiography ¾ Store radiography
source source inside a pit in
an exclusive isolated
storage room with
lock and key
arrangement. The pit
should be approved
by BARC/AERB
¾ Radiography source
should never be
carried either in
passenger bus or in
a passenger
compartment of
trains.
¾ BARC/AERB have to
be informed before
source movement.
¾ Permission from
Director General of
Civil Aviation is
required for booking
radio isotopes with
airlines.
¾ Loss of Radio ¾ Same as above ¾ Try to locate with the
isotope help of Survey
Meter.
¾ Inform
BARC/AERB(*)

(*) Atomic Energy

Regulatory Board
(AERB), Bhabha
Atomic Research
Centre (BARC)
Anushaktinagar,
Mumbai – 400 094
(F) ELECTRICAL ¾ Short ¾ Can cause ¾ Use rubberized hand
INSTALLATION circuiting Electrocution or gloves and other
AND USAGE Fire PPE
¾ Don’t lay wires under
carpets, mats or
door ways.
¾ Allow only licensed
electricians to
perform on electrical
facilities
¾ Use one socket for
one appliance
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
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TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

ACTIVITY TYPE OF HAZARD EFFECT OF HAZARD PREVENTIVE MEASURES

¾ Ensure usage of only
fully insulated wires
or cables
¾ Don’t place bare wire
ends in a socket
¾ Ensure earthing of
machineries and
equipments
¾ Do not use damaged
cords and avoid
temporary
connections
¾ Use spark-
proof/flame proof
type field distribution
boxes.
¾ Do not allow
open/bare
connections
¾ Provide all
connections through
ELCB
¾ Protect electrical
cables / equipment’s
from water and
naked flames
¾ Check all
connections before
energizing.
¾ Overloading ¾ Bursting of ¾ Display voltage and
of Electrical system can occur current ratings
System which leads to fire prominently with
‘Danger’ signs.
¾ Ensure approved
cable size, voltage
grade and type.
¾ Switch off the
electrical utilities
when not in use.
¾ Do not allow
unauthorized
connections.
¾ Ensure proper grid
wise distribution of
Power.
¾ Improper ¾ Can cause ¾ Do not lay
laying of electrocution and unarmored cable
overhead and prove fatal directly on ground,
underground wall, roof of trees
transmission ¾ Maintain at least 3m
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 33 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

ACTIVITY TYPE OF HAZARD EFFECT OF HAZARD PREVENTIVE MEASURES

lines / cables distance from HT
cables
¾ All temporary cables
should be laid at
least 750 mm below
ground on 100 mm
fine sand overlying
by brick soling
¾ Provide proper
sleeves at crossings/
intersections
¾ Provide cable route
markers indicating
the type and depth of
cables at intervals
not exceeding 30m
and at the diversions
/ termination.
(G) FIRE ¾ Small fires ¾ Cause burn ¾ In case a fire breaks
PREVENTION can become injuries and may out, press fire alarm
AND big ones and prove fatal. system and shout
PROTECTION may spread to “Fire, Fire”
the ¾ Keep buckets full of
surrounding sand & water/fire
areas extinguishing
equipment near
hazardous locations
¾ Confine smoking to
‘Smoking Zones’
only
¾ Train people for
using specific type of
fire equipments
under different
classes of fire
¾ Keep fire doors/
shutters, passages
and exit doors
unobstructed
¾ Maintain good house
keeping and first-aid
boxes (for detail
refer Annex-2)
¾ Don’t obstruct
assess to Fire
extinguishers
¾ Do not use elevators
for evacuation during
fire
¾ Maintain lightening
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

ACTIVITY TYPE OF HAZARD EFFECT OF HAZARD PREVENTIVE MEASURES

arrestors for
elevated structures
¾ Stop all electrical
motors with internal
combustion.
¾ Move the vehicles
from dangerous
locations.
¾ Remove the load
hanging from the
crane booms.
¾ Remain out of the
danger areas.
¾ Improper ¾ It may not ¾ Ensure usage of
selection of extinguish the fire correct fire
Fire extinguisher meant
Extinguisher for the specified fire
(for details refer
Appendix-C)
¾ Do not attempt to
extinguish Oil and
electric fires with
water. Use foam
cylinders/CO2/sand
or earth.

¾ Improper ¾ Same as above ¾ Maintain safe

storage of distance of
highly flammable
inflammable substances from
substances source of ignition
¾ Restrict the
distribution of
flammable materials
to only min.
necessary amount
¾ Construct
specifically designed
fuel storage facilities
¾ Keep chemicals in
cool and dry place
away from hat.
Ensure adequate
ventilation
¾ Before welding
operation, remove or
shield the flammable
material properly
¾ Store flammable
materials in stable
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 35 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

ACTIVITY TYPE OF HAZARD EFFECT OF HAZARD PREVENTIVE MEASURES

racks, correctly
labeled preferably
with catchments
trays.
¾ Wipe off the spills
immediately

¾ Short ¾ Same as above ¾ Don’t lay wires under

circuiting of ¾ Can cause carpets, mats or
electrical Electrocution door ways
system ¾ Use one socket for
one appliance
¾ Use only fully
insulated wires or
cables
¾ Do not allow
open/bare
connections
¾ Provide all
connections through
ELCB
¾ Ensure earthing of
machineries and
equipments

(H) VEHICULAR ¾ Crossing the ¾ Personal injury ¾ Obey speed limits

MOVEMENT Speed Limits and traffic rules
(Rash driving) strictly
¾ Always expect the
unexpected and be a
defensive drive
¾ Use sat
belts/helmets
¾ Blow horn at
intersections and
during overtaking
operations.
¾ Maintain the vehicle
in good condition
¾ Do not overtake on
curves, bridges and
slopes

¾ Adverse ¾ Same as above ¾ Read the road ahead

weather and ride to the left
condition ¾ Keep the wind
screen and lights
clean
¾ Do not turn at speed
¾ Recognize the
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
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834002 OIL & GAS SBU, DELHI

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ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

ACTIVITY TYPE OF HAZARD EFFECT OF HAZARD PREVENTIVE MEASURES

hazard, understand
the defense and act
correctly in time.

¾ Consuming ¾ Same as above ¾ Alcohol and driving

alcohol before do not mix well.
and during he Either choose
driving alcohol or driving.
operation ¾ If you have a choice
between hitting a
fixed object or an
oncoming vehicle, hit
the fixed object
¾ Quit the steering at
once and become a
passenger.
Otherwise take
sufficient rest and
then drive.
¾ Do not force the
driver to drive fast
and round the clock
¾ Do not day dram
while driving
¾ Falling objects ¾ May prove fatal ¾ Ensure effective
/ Mechanical braking system,
failure adequate visibility for
the drives, reverse
warning alarm.
¾ Proper maintenance
of the vehicle as per
manufacturer
instructions

(I) PROOF ¾ Bursting of ¾ May cause injury ¾ Prepare test

TESTING piping and prove fatal procedure & obtain
(HYDROSTATIC/ ¾ Collapse of CONSULTANT/
PNEUMATIC tanks Owner’s approval
TESTING ¾ Tanks flying ¾ Provide separate
off gauge for
pressurizing pump
and
piping/equipment
¾ Check the calibration
status of all pressure
gauges, dead weight
testers and
temperature
recorders
¾ Take dial readings at
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 37 of 59

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ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

ACTIVITY TYPE OF HAZARD EFFECT OF HAZARD PREVENTIVE MEASURES

suitable defined
intervals and ensure
most of them fall
between 40-60% of
the gauge scale
range
¾ Provide safety relief
valve (set at
pressure slightly
higher than test
pressure) while
testing with
air/nitrogen
¾ Ensure necessary
precautions,
stepwise increase in
pressure, tightening
of bolts/ nuts,
grouting, etc. before
and during testing
¾ Keep the vents open
before opening any
valve while draining
out of water used for
hydro testing of
tanks
¾ Pneumatic testing
involves the hazard
of released energy
shored in
compressed gas.
Specific care must
therefore be taken to
minimize the chance
of brittle failure
during a pneumatic
leak test. Test
temperature is
important in this
regard and must be
considered when the
designer chooses
the material of
construction
¾ A pressure relief
device shall be
provided, having a
set pressure not
higher than the test
pressure plus the
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 38 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

ACTIVITY TYPE OF HAZARD EFFECT OF HAZARD PREVENTIVE MEASURES

lesser of 345 KPa
(50 psi) or 10% of he
test pressure. The
gas used as test
fluid, if not air, shall
be nonflammable
and nontoxic.
(J) WORKING AT ¾ Person can ¾ May sustain ¾ Provide guard
HEIGHTS fall down severe injuries or rails/barricade at the
prove fatal work place
¾ Use PPE like safety
belts, full body
harness, life line,
helmets, safety
shoes, etc.
¾ Obtain a permit
before starting the
work at height above
3 meters
¾ Fall arrest systems
like safety nets, etc.
must be installed
¾ Provide adequate
working space (min.
0.6 m)
¾ Tie/weld working
platform with fixed
support
¾ Use roof top walk
ladder while working
on a slopping roofs
¾ Avoid movement on
beams
¾ May hit the scrap ¾ Keep the work place
/ material stacked neat and clean
at the ground or in ¾ Remove the scrap
between immediately

¾ Material can ¾ May hit the ¾ Same as above plus

fall down workers working ¾ Do not throw or drop
at lower levels material or
and prove fatal. equipment from
height
¾ All tools to be carried
in a toolkit bags or
on working uniform
¾ Remove scrap from
the planks
¾ Ensure wearing of
helmet by the
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 39 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

ACTIVITY TYPE OF HAZARD EFFECT OF HAZARD PREVENTIVE MEASURES

workers at low level
(K) CONFINED ¾ Suffocation / ¾ Unconsciousness, ¾ Use respiratory
SPACES drowning death devices, if required
¾ Avoid over crowding
inside a confined
space
¾ Provide Exhaust
Fans for ventilation
¾ Do not wear loose
clothes, neck ties,
etc.
¾ Fulfill conditions of
the permit.
¾ Check for presence
of hydrocarbons, O2
level
¾ Obtain work permit
before entering a
confined space
¾ Ensure that the
connected piping of
the equipment which
is to be opened is
pressure free, fluid
has been drained,
vents are open and
piping is positively
isolated by a blind
flange
¾ Presence of ¾ Inhalation can ¾ Same as above plus
foul smell and pose threat to life. ¾ Check for
toxic hydrocarbon and
substances Aromatic
compounds before
entering a confined
space
¾ Depute one person
outside the confined
space for continuous
monitoring and for
extending help in
case of an
emergency

¾ Ignition / ¾ Person may ¾ Keep fire

flame can sustain burn extinguishers at a
cause fire injuries or hand distance
explosion may ¾ Remove surplus
occur material and scrap
immediately
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 40 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

ACTIVITY TYPE OF HAZARD EFFECT OF HAZARD PREVENTIVE MEASURES

¾ Do not smoke inside
a confined space
¾ Do not allow gas
cylinders inside a
confined space
¾ Use low voltage
(24V) lamps for
lighting
¾ Use tools with air
motors or electric
tools with max.
voltage of 24V
¾ Remove all
equipments at the
end of the day
(L) HANDLING ¾ Failure of load ¾ Can cause ¾ Avoid standing under
AND LIFTING lifting and accident and the lifted load and
EQUPMENTS moving prove fatal within the operating
equipments radius of cranes
¾ Check periodically
oil, brakes, gears,
horns and tyre
pressure of all
moving machinery
¾ Check quality, size
and condition of all
chain pulley blocks,
slings, U-clamps, D-
shackles, wire ropes,
etc.
¾ Allow crane to move
only on hard, firm
and leveled ground
¾ Allow lifting slings as
short as possible
and check gunny
packings at the
friction points
¾ Do not allow crane to
tilt its boom while
moving
¾ Install Safe Load
Indicator
¾ Ensure certification
by applicable
authority.

¾ Overloading ¾ Can cause ¾ Safe lifting capacity

of lifting electrocution and of derricks and
equipments fire winches written on
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 41 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

ACTIVITY TYPE OF HAZARD EFFECT OF HAZARD PREVENTIVE MEASURES

them shall be got
verified.
¾ The max safe
working load shall be
marked on all lifting
equipments
¾ Check the weight of
columns and other
heavy items painted
on them and
accordingly decide
about the crane
capacity, boom and
angle of erection
¾ Allow only trained
operators and
riggers during crane
operation

¾ Overhead ¾ Can cause ¾ Do not allow boom

electrical electrocution and or other parts of
wires fire crane to come within
3 m reach of
overhead HT cables
¾ Hook and load being
lifted shall preferably
remain in full
visibility of crane
operator.

(M) ¾ Person can ¾ Person may ¾ Provide guard rails

SCAFFOLDING, fall down sustain severe for working at height
FORMWORK AND injuries and prove ¾ Face ladder while
LADDERS fatal climbing and use
both hands
¾ Ladders shall extend
about 1m above
landing for easy
access and tying up
purpose
¾ Do not place ladders
against movable
objects and maintain
base at ¼ unit of the
working length of the
ladder
¾ Suspended scaffolds
shall not be less
than 500 mm wide
and tied properly
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 42 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

ACTIVITY TYPE OF HAZARD EFFECT OF HAZARD PREVENTIVE MEASURES

with ropes
¾ No loose planks
shall be allowed
¾ Use PPE, like
helmets, safety
shoes, etc.

¾ Failure of ¾ Same as above ¾ Inspect visually all

scaffolding scaffolding materials
material for stability and
anchoring with
permanent
structures.
¾ Design scaffolding
for max. load
carrying capacity
¾ Scaffolding planks
shall not be less
than 50x250 mm full
thickness lumber or
equivalent. These
shall be cleared or
secured and must
extend over the end
supports by at least
150mm and not
more that 300 mm
¾ Don’t overload the
scaffolds
¾ Do not splice short
ladders to make a
longer one. Vertical
ladders shall not
exceed 6m.

¾ Material can ¾ Persons working ¾ Remove excess

fall down at lower level gets material and scrap
injured. immediately
¾ Carry the tools in a
tool-kit bag only
¾ Provide safety nets

(N) STRUCTURAL ¾ Personal ¾ Can cause injury ¾ Do not take rest

WORKS negligence or casualty inside rooms built for
and danger of welding machines or
fall electrical distribution
system
¾ Avoid walking on
beams at height
¾ Wear helmet with
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 43 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

ACTIVITY TYPE OF HAZARD EFFECT OF HAZARD PREVENTIVE MEASURES

chin strap and safety
belts when working
at height
¾ Use hand gloves and
goggles during
grinding operations
¾ Cover or mark the
sharp and projected
edges
¾ Do not stand within
the operating radius
of cranes

¾ Lifting / ¾ Same as above ¾ Do not stand under

slipping of the lifted load
material ¾ Stack properly all the
materials. Avoid
slippage during
handling
¾ Control longer
pieces lifted up by
cranes from both
ends
¾ Remove loose
materials from height
¾ Ensure tightening of
all nuts and bolts
(O) PIPELINE ¾ Erection / ¾ Can cause injury ¾ Do not stand under
WORKS lowering the lifted Load
failure ¾ Do not allow any
person to come
within the radii of the
side boom handling
pipes
¾ Check the load
carrying capacity of
the lifting tools and
tackles
¾ Use safe Load
Indicators
¾ Use appropriate
PPEs

¾ Other ¾ Same as above ¾ Wear gum boots in

marshy areas
¾ Allow only one
person to perform
signaling operations
while lowering of
pipes
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 44 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

ACTIVITY TYPE OF HAZARD EFFECT OF HAZARD PREVENTIVE MEASURES

¾ Provide night caps
on pipes
¾ Provide end covers
on pipes for
stoppage of pigs
while
testing/cleaning
operations.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 45 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

FORMAT NO. : HSE-1, REV. 0

HSE CHECKLIST CUM COMPLIANCE REPORT (1/6)

Project: _________________________ Contractor :_______________________

Date: _________________________ Owner :________________________
Inspection By:___________________ Report No. :________________________
Frequency : Fortnightly Job No :_______________________

Note: write ‘NA’ wherever the item is not applicable

SL. ITEM YES NO REMARKS ACTION

NO.
1 HOUSEKEEPING
a) Waste containers provided and used
b) Sanitary facilities adequate and clean
c) Passageways and Walkways clear
d) General neatness of working areas
e) Others
2 PERSONNEL PROTECTIVE EQUIPMENT
a) Goggles; Shields
b) Face protection
c) Hearing protection
d) Safety shoes
e) Hand protection
f) Respiratory Masks etc.
g) Safety Belts
h) Safety Helmet/Hard Hat
I) Others
3 EXCAVATIONS/OPENINGS
a) Openings properly covered or barricaded
b) Excavations shored
c) Excavations barricaded
d) Overnight lighting provided
e) Others
4 WELDING & GAS CUTTING
a) Gas cylinders chained upright
b) Cables and hoses not obstructing
c) Screens or shields used
d) Flammable materials protected
e) Fire extinguisher(s) accessible
f) Others
5 SCAFFOLDING
a) Fully decked platforms
b) Guard and intermediate rails in place
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ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

SL. ITEM YES NO REMARKS ACTION

NO.
c) Toe boards in place
d) Adequate shoring
e) Adequate access
f) Others
6 LADDERS
a) Extension side rails 1m above
b) Top of landing
c) Properly secured
d) Angle + 70 from horizontal
e) Others
7 HOISTS, CRANES AND DERRICKS
a) Condition of cables and sheaves OK
b) Condition of slings, chains, hooks and eyes OK
c) Inspection and maintenance logs maintained
d) Outriggers used
e) Signs/barricades provided
f) Signals observed and understood
g) Qualified operators
h) Others
8 MACHINERY, TOOLS AND EQUIPMENT
a) Proper instruction
b) Safety devices
c) Proper cords
d) Inspection and maintenance
e) Others
9 VEHICLE AND TRAFFIC
a) Rules and regulations observed
b) Inspection and maintenance
c) Licensed drivers
d) Others
10 TEMPORARY FACILITIES
a) Emergency instructions posted
b) Fire extinguishers provided
c) Fire-aid equipment available
d) Secured against storm damage
e) General neatness
f) In accordance with electrical requirements
g) Others
11 FIRE PREVENTION
a) Personnel instructed
b) Fire extinguishers checked
c) No smoking in Prohibited Areas
d) Hydrants Clear
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 47 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

SL. ITEM YES NO REMARKS ACTION

NO.
e) Others
12 ELECTRICAL
a) Use of 3-core armoured cables
b) Usage of 'All insulated' or 'double insulated' electrical
tools
c) All electrical connection are routed through ELCB
d) Natural Earthing at the source of power (main DB)
e) Continuity and tightness of earth conductor
f) Covering of junction boxes, panels and other
energized wiring places
g) Ground fault circuit interrupters provided
h) Prevention of tripping hazards
i) Others
13 HANDLING AND STORAGE OF MATERIALS
a) Properly stored or stacked
b) Passageways clear
c) Others
14 FLAMMABLE GASES AND LIQUIDS
a) Containers clearly identified
b) Proper storage
c) Fire extinguishers nearby
d) Others
15 WORKING AT HEIGHT
a) Erection plan and work permit obtained
b) Safety nets
c) Full body harness and lanyards; chute lines
d) Health Check record available for workers going up?
e) Others
16 CONFINED SPACE
a) Work permit obtained
b) Test for toxic gas and sufficient availability of oxygen
conducted
c) At least one person outside the confined space for
monitoring deputed
d) Availability of sufficient means of entry, exit and
ventilation
e) Fire extinguishers and first-aid facility ensured
f) Lighting provision made by using 24V lamps
g) Proper usage of PPEs ensured
17 RADIOGRAPHY
a) Proper storage and handling of source as per BARC /
AREB guidelines
b) Working permit obtained
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 48 of 59

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ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

SL. ITEM YES NO REMARKS ACTION

NO.
c) Cordoning of the area done
d) Use of appropriate PPE's ensured
e) Proper training to workers/supervisors imparted
f) Minimum occupancy of workplace ensured
18 HEALTH CHECKS
a) Workers medically examined and found to fit for
working :
i) At heights
ii) In confined space.
b) Availability of First-aid facilities
c) Proper sanitation at site, office and labour camps
d) Arrangement of medical facilities
e) Measures for dealing with illness
f) Availability of Portable drinking water for workmen &
staff
g) Provision of crèches for children
h) Stand by vehicle available for evacuation of injured.
19 ENVIRONMENT
a) Chemical and other effluents properly disposed
b) Cleaning liquid of pipes disposed off properly
c) Seawater used for hydro-testing disposed off as per
agreed procedure
d) Lubricant Waste/Engine oils properly disposed
e) Waste from Canteen, offices, sanitation etc. disposed
properly
f) Disposal of surplus earth, stripping materials, oily rags
and combustible materials done properly
g) Green belt protection

___________________ ___________________

Signature of Consultant/ Owner Signature of Resident

with Seal Engineer with Seal
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 49 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

FORMAT NO. : HSE-2, REV. 0

ACCIDENT / INCIDENT REPORT

(To be submitted by Contractor after every Accident / Incident within 24 hours)

Report No:___________________
Date: _______________________
Name of Site:-_______________________
CONTRACTOR______________________

Type of Accident / Incident : Fatal Other Lost Time Non Loss Time First-Aid case

NAME OF THE INJURED………………………………………………………………………………

AGE ……………………………………………………………………………………………………….
FATHER’S NAME………………………………………………………………………………………..
SUB-CONTRACTOR M/S………………………………………………………………………………..
DATE & TIME OF ACCIDENT………………………………………………………………………….
LOCATION ………………………………………………………………………………………………
BRIEF DESCRIPTION OF ACCIDENT

CAUSE OF ACCIDENT

NATURE OF INJURY/DAMAGE

MEDICAL AID PROVIDED/ACTIONS TAKEN

INTIMATION TO LOCAL AUTHORITIES (IF APPLICABLE)

DATE: SIGNATURE OF CONTRACTOR

WITH SEAL

To : OWNER………………………….. 1 COPY
: RCM/SITE-IN-CHARGE, MECON 3 COPIES

Divisional Head (Constn.) through RCM

Project Manager MECON, through RCM
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 50 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

FORMAT NO. : HSE-3, REV. 0

SUPPLEMENTARY ACCIDENT / INCIDENT INVESTIGATION REPORT

Supplementary to Report No: _________(Copy enclosed)

Project:_____________________ Site:________________________
Name of Work :____________________ Date:_______________________
Contractor:______________________ Work Order / LOI No. :______________

NAME OF THE INJURED …………………………………………………………………………….

AGE : …………………………………………………………………………………...
SUB-CONTRACTOR M/S……………………………………………………………………………...
DATE & TIME OF ACCIDENT / INCIDENT ……………………………………………………………
LOCATION……………………………………………………………………………………………

BRIEF DESCRIPTION & CAUSE OF A ACCIDENT/ INCIDENT

NATURAL OF INJURY/DAMAGE

COMMENTS FROM MEDICAL PRACTITIONER WHO ATTENDED THE VICTIM/INJURED

SUGGESTED IMPROVEMENT IN THE WORKING CONDITION IF ANY

LOSS OF MANHOURS AND IMPACT ON SITE WORKS

ANY OTHER COMMENT BY SAFETY OFFICER.

DATE: SIGNATURE OF CONTRACTOR

WITH SEAL

To : OWNER………………………….. 1 COPY
: RCM/SITE-IN-CHARGE, MECON 3 COPIES

Divisional Head (Constn.) through RCM

Project Manager MECON, through RCM
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 51 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

FORMAT NO. : HSE-4, REV. 0

NEAR MISS INCIDENT – SUGGESTED PROFORMA

Report No: ___________________

Name of Site :_____________________ Date :________________________
Name of Work :____________________ Contractor :_______________________

INCIDENT REPORTED BY :

DATE & TIME OF INCIDENT :

LOCATION :

BRIEF DESCRIPTION OF INCIDENT

PROBABLE CAUSE OF INCIDENT

SUGGESTED CORRECTIVE ACTION

STEPS TAKEN TO AVOID RECURRENCE YES NO

DATE: SIGNATURE OF CONTRACTOR

WITH SEAL

To : OWNER………………………….. 1 COPY
: RCM/SITE-IN-CHARGE, MECON 3 COPIES

Divisional Head (Constn.) through RCM

Project Manager MECON, through RCM
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 52 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

FORMAT NO. : HSE-5, REV. 0

MONTHLY HEALTH, SAFETY & ENVIRONMENT (HSE) REPORT
(To be submitted by each Contractor)

Actual work start Date:________________ For the Month of:__________________

Project:_____________________________ Report No:_______________________
Name of the Contractor:________________ Status as on:_____________________
Name of Work:_______________________ Name of Safety officer:______________

ITEM UPTO THIS CUMU-

PREVIOUS MONTH LATIVE
MONTH
a) Average number of Staff & Workmen (average
daily headcount, not man days)
b) Manhours Worked
c) Number of HSE meeting organized at site
d) Number of HSE awareness programmes
conducted at site
e) Number of Lost Time Accidents Fatal
(LTA) Other LTA
f) Number of Loss time Injuries Fatalities
(LTI) Other LTI
g) Number of Loss Time Accidents
h) Number of First Aid Cases
i) Number of Near Miss Incidents
j) Man-days lost due to accidents
k) LTA Free Manhours i.e. Number of LTA free
manhours from the Lst LTA
l) Compensation cases raised with Insurance
m) Compensation case resolved and paid to
workmen
n) Whether workmen compensation policy taken Y/N
o) Whether workmen compensation policy valid Y/N
p) Whether workmen registered under ESI Act Y/N
Remark

DATE: Safety Officer /Resident Engineer

(Signature and Name)

To : OWNER
: RCM/, MECON (2 COPIES)
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 53 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

FORMAT NO. : HSE-6, REV. 0

PERMIT FOR WORKING AT HEIGHT (ABOVE 2 METER)

Project Site : ……………………………………… Sr. No.: ………………………

Name of the work: ………………………………. Date: …………………………
Name of Contractor : …………………………….. Nature of Work : ……………
Total No.of Workers: …………………………….. Exact location of work : ……
Duration of work: from ..………. to …………

The following items have been checked and compliance shall be ensured during the
currency of the permit:

------------------------------------------------------------------------------------------------------------------------------
Sl. ITEM DONE NOT REQD.
------------------------------------------------------------------------------------------------------------------------------
1. Equipment/Work Area inspected

2. Considered hazard from other routine/non-routine

operations and concerned person alerted

3. ELCB provided

4. Proper lighting provided

5. Area cordoned off.

6. Precautions against public traffic taken

7. Sound Scaffolding provided

8. Adequate protected Platform provided

9. Acces and Exit to the area

(Ladder properly fixed)

10. Floor Openings covered

11. Safety Net provided

12. Heath check of personnel

-------------------------------------------------------------------------------------------------------
A. Following personal protective equipment are provided ( mark) and used as relevant
Safety helmet/Gloves/Goggles/Shoes/Face Shield/Life Line/Safety Belt/Safety Harness.

B. This permit shall be available at the work site at all times.

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 54 of 59

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ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

C. Permit shall be issued for maximum one week only (Monday to Sunday).

D. This permit shall be applicable in non-operational areas.

E. After completion of the work, used permits shall be preserved for record purposes.

F. Additional precautions, if any ………………………………………………………….

Permission is granted to work (See overleaf) = Yes/No

Name of Contractor’s Supervisor Name of Contractor’s Safety Officer

(Initiator) (Issuing Authority)

GRANT OF PERMIT AND EXTENSIONS

Issuing
Validity
Work time Initiator Authority Verification by
Sl. Period
From …..Hrs. (Supervisor of (Safety CONSULTANT
No. From ………
To ……….Hrs. Contractor) Officer) with date
To ………
of Contractor

Additional safety instructions, if any.

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 55 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

FORMAT NO. : HSE-7, REV. 0

CONFINED SPACE ENTRY PERMIT

Project Site : ……………………………………… Sr. No.: ………………………

Name of the work: ………………………………. Date: …………………………
Name of Contractor : …………………………….. Nature of Work : ……………
Exact location of work : ………………………….

Safety Requirements : POSITIVE ISOLATION OF THE VESSEL IS MANDATORY

(A) Has the equipment been ?

Y NR Y NR Y NR
isolated from power water flushed &/or radiation sources
/ steam / air steamed removed
isolated from liquid Manways open & Proper lighting
or gases ventilated provided
depressurized &/or cont. inset gas flow
drained arranged
blanked / blinded / adequately cooled
disconnected

(B) Expected Residual Hazards

Y NR Y NR Y NR
lack of O2 combustible gas / H2S / toxic gases
liquid
corrosive pyrophoric iron / electricity / static
chemicals scales
Heat / stream / high humidity ionizing radiation
frost

(C) Protective Measures

Y NR Y NR Y NR
gloves ear plug / muff goggles / face
shield
protective clothing dust / gas / air line personal gas alarm
mask
Grounded air attendant with rescue equipment /
educater / blower / SCBA / air mask team
AC
Fire fighting safety harness & communication
arrangements lifeline equipment
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 56 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

Authorization / Renewal (It is safe to enter the confirmed space)

Date No. of Name of Signature Time Signature

Persons Persons Contractor’s Contractor’s From To Workman
Allowed allowed Supervisor Safety
Officer

Permit Closure :

(A) Entry was closed stopped will continue on

(B) Site left in a safe condition

Housekeeping done

(C) Multi lock removed key transferred

Ensured all men have come out Manways barricaded

Remarks, if any :
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 57 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

FORMAT NO. : HSE-8, REV. 0

RADIATION WORK PERMIT

Project : Sr. No.:

Name of the work : Date:
Name of Contractor : Job No. :

Location of work :

Source Strength :

Cordoned distance (m) :

Name of Radiographing agency : Approved by Owner / MECON

The following items have been checked & compliance shall be ensured during currency of the
permit :

S. Item Description Done

No.
1. Safety regulations as per BARC/AERB ensured while source in use/ in transit &
during storage.
2. Area cordoned off.
3. Lighting arrangements for working during nights ensured.
4. Warning signs / flash lights installed.
5. Cold work permit taken (if applicable)
6. PPEs like film badges, dosimeters used.

Additional precautions, if any ______________________________________________________

(Radiography Agency’s BARC / AREB authorized Supervisor) (Contractor’s Safety Officer)

Permission is granted.

Permit is valid from _________ AM/PM ____________ Date to ________ AM/PM ____________
Date

(Signature of permit issuing authority)

Name : Designation : Date :

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 58 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

Permit renewal :

Permit extended upto Additional precautions Sign of issuing authority

Date Time required, if any. with date

Work completed / stopped / area cleared at ____________ Hrs. of Date _______________

(Sign of permit issuing authority)

Name :
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 59 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

FORMAT NO. : HSE-9, REV. 0

RADIATION WORK PERMIT

Project : Sr. No.:

Name of the work : Date:
Name of Contractor : Job No. :

Name of Contractor :

Line No. / Equipment No. /Structure to be dismantled :

Location details of dismantling / demolition with sketch : (Clearly indicate the area)

The following items have been checked & compliance shall be ensured during currency of the
permit :

S. Item Description Done Not

No. Applicable
1. Services like power, gas supply, water, etc. disconnected.

2. Dismantling / Demolishing method reviewed & approved.

3. Usage of appropriate PPEs ensured.

4. Precautions taken for neighboring structures

5. First-Aid arrangements made

6. Fire fighting arrangements ensured

7. Precautions taken for blasting

(Contractor’s Supervisor) (Contractor’s Safety Officer)

Permission is granted.

(Permit issuing authority)

Name :
Date :
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 60 of 59

TITLE HEALTH, SAFETY AND MEC/S/05/21/65 REVISION : 0

ENVIRONMENT (HSE)
MANAGEMENT EDITION : 1

Completion Report :

Dismantling / Demolishing is completed on __________ Date at __________ Hrs.

Materials / debris transported to identified location

Tagging completed (as applicable)

Services like power, gas supply, water, etc. restored

(Permit issuing authority)

 Rev. : 0
Edition : 2

SPECIFICATION
FOR
QUALITY ASSURANCE SYSTEMS
REQUIREMENTS

SPECIFICATION NO.: MEC/WS/05/21/66

(OIL & GAS SBU)

MECON LIMITED
DELHI 110 092
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 1

TITLE QUALITY ASSURANCE MEC/WS/05/21/66 REVISION : 0

SYSTEMS REQUIREMENTS
EDITION : 2

CONTENTS

Sl.No. Description

1.0 INTRODUCTION

2.0 DEFINITIONS

3.0 CONTRACTORS SCOPE OF WORK

4.0 QUALITY ASSURANCE REQUIREMENTS

ATTACHMENTS

TITLE NUMBER

FORMAT FOR QUALITY PLAN FORMAT 00001

FORMAT FOR OBSERVATION ON FORMAT 00002

PREPARED BY: CHECKED BY: APPROVED BY: ISSUE DATE :

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 8

TITLE QUALITY ASSURANCE MEC/WS/05/21/66 REVISION : 0

SYSTEMS REQUIREMENTS
EDITION : 2

1.0 INTRODUCTION

This specification establishes the Quality Assurance Requirements to be met

by the sub-contractors (including turnkey Contractors) and their sub-vendors.

In case of any conflict between this specification and other provisions of the
contract/ purchase order, the same shall be brought to the notice of MECON,
at the stage of bidding and shall be resolved with MECON, prior to the
placement of order.

2.0 DEFINITION

Bidder

For the purpose of this specification, the word “Bidder” means the person(s),
firm, company or organisation who is under the process of being contracted
by MECON/ Owner for delivery of some products (including service). The
word is considered synonymous to supplier, contractor or vendor.

Correction

Action taken to eliminate the detected non-conformity.

Refers to repair, rework or adjustment and relates to the disposition of an

existing non-conformity.

Corrective Action

Action taken to eliminate the causes of an existing non-conformity, defect or

other undesirable situation in order to prevent recurrence.

Preventive Action

Action taken to eliminate the causes of a potential non-conformity, defect or

other undesirable situation in order to prevent its recurrence.

Process

Set of inter-related resources and activities which transform inputs into

outputs.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 2 of 8

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SYSTEMS REQUIREMENTS
EDITION : 2

Special Process

Processes requiring pre-qualification of their process capability.

3.0 CONTRACTORS SCOPE OF WORK

3.1 Prior to award of contract

The bidder shall understand scope of work, drawings, specifications and

standards etc., attached to the tender/ enquiry document, before he makes
an offer.

The bidder shall submit milestone chart showing the time required for each
milestone activity and linkages between different milestone activities
alongwith overall time period required to complete the entire scope of work.

The bidder shall develop and submit manpower and resource deployment
chart.

The bidder shall submit, alongwith the bid, a manual or equivalent document
describing/ indicating/ addressing various control/ check points for the
purpose of quality assurance and the responsibilities of various functions
responsible for quality assurance.

3.2 After the award of contract

The bidder shall submit the schedule for submission of following documents in
the kick-off meeting or within two weeks of the placement of order,
whichever is earlier.

 Detailed Bar Chart

 Quality plan for all activities, required to be done by the bidder, to
accomplish offered scope of work.
 Inspection and test plans, covering various control aspects.
 Job procedures as required by MECON/ Owner.
 Procurement schedule for items to be supplied by contractor covering
inspection of the same.

Various documents submitted by the bidder shall be finalised in consultation

with MECON. Here it shall be presumed that ones a bidder has made an offer,
he has understood the requirements given in this specification and agrees to
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 3 of 8

TITLE QUALITY ASSURANCE MEC/WS/05/21/66 REVISION : 0

SYSTEMS REQUIREMENTS
EDITION : 2

comply with them in totality unless otherwise categorically so indicated during

pre-award stage through agreed deviation/ exception request. All Quality
Assurance Plan (QAP) documents shall be reviewed by concerned functional
groups of MECON and the bidder shall be required to incorporate all
comments within the framework of this specification at this stage of the
contract. It is also obligatory on the part of the bidder that obtains approval
on every Quality Assurance Plan (QAP) documents, before he starts using a
particular document for delivery of contracted scope of work. Participation of
MECON/ Owner in review/ approval of quality plan/ QAP documents does not
absolve the contractor of his contractual obligations towards specified and
intended use of the product (or service) provided/ to be provided by him
under the contract.

3.3 During job execution

During job execution, the bidder shall fully comply with all quality document
submitted and finalised/ agreed against the requirements of this specification.
Approval of MECON on all these documents shall be sought before start of
work.

Bidder shall produce sufficient quality records on controlled/ agreed forms

such that requirements given in this specification are objectively/
demonstrable.

Bidder shall facilitate MECON/ Owner during quality/ technical audits at his
works/ sites.

Bidder shall discharge all responsibilities towards enforcement of this

specification on all his sub-contractors for any part of the scope which is sub-
contracted.

4.0 QUALITY ASSURANCE SYSTEM REQUIREMENTS

4.1 The bidder shall nominate an overall incharge of the contract titled as “Project
Manager” for the scope of work of agreed contract. The name of this person
shall be duly intimated to MECON including all subsequent changes, if any.
MECON shall correspond only with the project manager of the bidder on all
matters of the project. The project manager of the bidder shall be
responsible for co-ordination and management of activities with bidder’s
organisation and all sub-vendors appointed by the bidder.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 4 of 8

TITLE QUALITY ASSURANCE MEC/WS/05/21/66 REVISION : 0

SYSTEMS REQUIREMENTS
EDITION : 2

After award of work, the bidder may review augmentation of manpower and
resources deployment chart (submitted earlier), detail it out, if so consented
by MECON/ Owner and resubmit the same as “issued for effective
implementation of the project”.

4.2 The bidder shall plan the contract scope of work on quality plan format such
that no major variation is expected during delivery of contract scope of work.
These quality plan shall be made on enclosed format complete in all respect.
The quality plan shall be assumed to be detailing bidder’s understanding and
planning for the contract/ offered scope of work. The bidder shall plan the
type of resources including various work methodology which he agrees to
utilize for delivery of contract scope of work.

4.3 The bidder is required to review the contract at all appropriate stages to
evaluate his capabilities with respect to timely and quality completion of all
activities pertaining to contracted scope of work and shall report for
constraints, if any to MECON/ Owner.

4.4 The design activities, if any, performed during delivery of contract scope of
work shall be so controlled that the outputs is reliable enough. It is expected
that during development of design, the bidder shall take recourse to detailed
checking, inter departmental reviews and documented verification methods.

4.5 For all documents which the bidder is likely to utilise for delivery of contract
scope of work, a system must exist which assures that latest/ required
version(s) of the document(s) is available at all location/ point of use.

4.6 In case the bidder decides to sub-contract any part/ full of the contract scope
of work (without prejudice to main Contractual condition), the bidder shall :

 Evaluate the technical and financial capabilities and past performance

of the sub-contractor(s) and their products and/ or services before
awarding them with the sub-contracted scope of work. Selection of a
sub-contractor should meet MECON approval in documented form.

 Requirement of this specification shall be enforced on sub-contracted

agency also. The bidder shall choose sub-contractor based on their
capability to meet requirements of this specification also.

Note: It may so happen that, in a given situation, a sub-contractor may not have a
system meeting the requirements of this specification. In all such
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 5 of 8

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SYSTEMS REQUIREMENTS
EDITION : 2

eventualities, bidder may lend his system to sub-contractor for the contract
such that sub-contractor effectively meets the requirements of this
specification. In all such cases MECON shall be duly informed.

4.7 Bidder shall establish adequate methodology such that the materials supplied
by the Owner/ MECON shall be adequately preserved, handled and made use
of for the purpose for which they are provided.

4.8 All output delivered against contract scope of work shall be suitably identified
in such a manner that either through identification or some other means,
sufficient traceability is maintained which permits effective resolution of any
problem reported in the outputs.

4.9 Critical activities shall be identified and the bidder is required to have
documented methodologies which he is going to utilize for carrying out such
activities under the contract scope of work. Wherever it is difficult to fully
inspect or verify the output (special process), bidder shall pre-qualify, the
performers and methodologies.

4.10 All inspections carried out by the bidder’s surveillance/ inspection staff shall
be conformity to quality plans and/ or inspection and test plans. All inspection
results shall be duly documented on controlled/ agreed forms such that
results can be co-related to specific product, that was inspected/ tested.

4.11 All inspection, measuring & test equipments (IMTEs) shall be duly calibrated
as per National/ International standards/ codes and only calibrated and
certified IMTEs shall be utilized for delivery of contract scope of work.

4.12 All outputs/ products delivered against contract scope of work shall be duly
marked such that their inspection status is clearly evident during all stages/
period of the contract.

4.13 All non-conformities (NCs) found by the contractor’s inspection/ surveillance

staff shall be duly recorded, including their disposal action. The deficiencies
observed during stage of the product, shall be recorded and resolved suitably.
Effective corrective and preventive action shall be implemented by the bidder
for all repetitive NCs, including deficiencies.

4.14 All deficiencies noticed by MECON/ Owner representative(s) shall be recorded

on a controlled form (Format No. 00002). Such deficiencies shall be analysed
by the bidder and effective and appropriate correction, corrective and
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 6 of 8

TITLE QUALITY ASSURANCE MEC/WS/05/21/66 REVISION : 0

SYSTEMS REQUIREMENTS
EDITION : 2

preventive actions shall be implemented. Bidder shall intimate MECON/

Owner of all such corrective and preventive action implemented by him.

4.15 Bidder shall establish appropriate methodologies for safe and effective
handling, storage, preservation of various materials/ inputs encountered
during delivery of contract scope of work.

4.16 Bidder shall prepare sufficient records for various processes carried out by
him for delivery of contract scope of work such that requirements of this
specification are objectively demonstrable. In case MECON/ Owner finds that
enough objective evidence/ recording is not available for any particular
process, bidder shall be obliged to make additional records so as to provide
sufficient objective evidence. The decision of MECON/ Owner shall be final
and binding on such issues.

4.17 The bidder shall arrange internal quality audits at quarterly intervals, to
independently assess the conformance by various performers to the
requirements of this specification. The findings of such assessment shall be
duly recorded and a copy shall be sent to MECON/ Owner for review.

4.18 For all special processes, bidder shall deploy only qualified performers.
Wherever MECON/ Owner observes any deficiency, the bidder shall arrange
the adequate training to the performer(s) before any further delivery of work.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 7 of 8

TITLE QUALITY ASSURANCE MEC/WS/05/21/66 REVISION : 0

SYSTEMS REQUIREMENTS
EDITION : 2

OBSERVATION OF QUALITY ASPECTS

FORMAT - 00002
Job No. and Description No. :
Issued to : M/s Date :

Location of Work :
Item of Work :

Details of Observation(Deficiency) Recommended Course of Action

Time Allowed for Correction :

Issued by : _____________________________________
Name of Signature of RCM, MECON Site

Corrective Action taken report by Contractor/ Vendor :

Date : Name and Signature

Distribution (before resolution) :

Project Manager Chief Business Executive MECON Inspection Resident Construction
Owner MECON New Delhi Manager, MECON Site

Verification of Resolution by MECON :

Date : Name of Signature

Distribution (before resolution) :

Project Manager Chief Business Executive MECON Inspection Resident Construction
Owner MECON New Delhi Manager, MECON Site
 MECON LIMITED STANDARD TECHNICAL SPECIFICATION
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834002 OIL & GAS SBU, DELHI

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TITLE QUALITY ASSURANCE MEC/WS/05/21/66 REVISION : 0

SYSTEMS REQUIREMENTS
EDITION : 2

FORMAT – 00001
Bidder’s Quality Plan Project Name : PO/ Contract Ref:
General Performing Functions Inspection Functions Audit Function
Activity Description Procedure Code of Performer Checker Reviewer/ Sampling Testing and Type of Audit Scope Owner’s/ MECON
Number Conformance Approver Plan Inspection (Approval) Review/ Audit
Code Surveillance Requirement

Note: 1) The bidder ensures that the filled up format conforms to minimum requirements on Quality Plan/ Quality Assurance, specified by MECON on drawings/ standards/ specifications/ write-up.
2) The bidder confirms that document is issued for information/ approval of Owner/ MECON for the project implementation
 Rev. : 0
Edition : 1

SPECIFICATION
FOR
DOCUMENTATION FOR PIPELINE
CONSTRUCTION

SPECIFICATION NO.: MEC/S/05/21/69

(OIL & GAS SBU)

MECON LIMITED
DELHI 110 092
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 1

TITLE DOCUMENTATION FOR MEC/S/05/21/69 REVISION : 0

PIPELINE CONSTRUCTION
EDITION : 1

CONTENTS
SL.NO. DESCRIPTION

1.0 SCOPE

2.0 RECORDS

3.0 AS-BUILT DRAWINGS AND PIPE BOOK

PREPARED BY: CHECKED BY: APPROVED BY: ISSUE DATE :

(Shalini Singh) (Sunil Kumar) (A.K. Johri) Jan. 2008

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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PIPELINE CONSTRUCTION
EDITION : 1

1.0 SCOPE

1.1 This specification covers the minimum requirements of various records, reports and
drawings for all aspects of pipeline construction to be prepared by Contractor and
submitted to the Company at intervals as described in this specification and as
directed by Company.

1.2 All document required to prepared and submitted by Contractor as per this
specification shall be in addition to the various reports, records, methodology
statement, calculation, drawings etc. to be submitted by the Contractor for
Company’s record, review or approval as per the requirements of all other
specification included in the Contract between the Company and Contractor.

1.3 This specification shall be read in conjunction with the conditions of all specifications
and document included in the Contract between Company and Contractor.

2.0 RECORDS

Contractor shall submit daily, weekly, monthly and after completion to the Company,
various records and reports for Company’s documentation purpose during and
immediately after the construction. This shall as minimum include, but not limited to
the following :

2.1 Daily

• Separate progress reports of all crews

• Daily welding results and repairs
• Actual weather conditions
• Application for deviations, if any
• Accidents
• Damages
• Activities required from Company
• Materials Receipts
• Urgently required materials

2.2 Weekly

• Up-to-date list of confirmed site instruction issued by Company

• Materials `taken over’
• Material defects and repairs
• Outstanding activities of Company
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
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834002 OIL & GAS SBU, DELHI

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PIPELINE CONSTRUCTION
EDITION : 1

• List of installed markers, chainage

• Required approval from Company
• Progress planned
• Reports of manning of all crews, equipment and plant
• Report of equipment and plant
• Report of accidents
• Report of damages
• Report of acquired release, permits
• Priced variations
• Required materials for next month

2.3 Monthly

• Progress report for payment, safety report, report of accidents, security

report, health and environment report, material balance, approved deviations.

2.4 Further, Contractor shall supply (for approval if required to the Company with
document such as but not limited :

• Organogram for construction work.

• Bio-data of key personnel (including foremen).
• (Revised) list of address of personnel in particular of medical staff, safety and
security offers.
• (Revised) list of approved coaters.
• (Revised) list of approved sub-contractors.
• Time schedule.
• Acquired permits and/ or approvals from Authorities, if any.
• Minutes of meeting with Company with comments, if any.
• Material certificates, material receipt.
• Guarantee from vendors and sub-contractor.
• Calculations, temporary works, bouyance, blasting.
• Drawings issued by Contractor.
• Vendors drawings.
• As-built of route maps, alignment sheets, details drawings and isometric
drawings.
• Procedures such as surveying, stacking, fencing.
• Welding procedure qualification records, radiographic procedure qualification,
welder qualification.
• Coating procedure.
• Installation of crossings.
• Hydrostatic testing.
• Blasting.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
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834002 OIL & GAS SBU, DELHI

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PIPELINE CONSTRUCTION
EDITION : 1

• Radiographic report alongwith original radiographs

• Pipe and welding book.
• Reports

- Material tests (coating, welding, painting)

- Computerised Potential Logging Test
- Water Samples
- Cleaning, Pigging Report before Hydrostatic Test
- Hydrostatic Test
- Calibration Test
- Blasting Trials
- Equipment certificate (dead weight tester, instruments, vessels,
equipment)
- Manuals
- Major water crossings
- Waste disposal
- Disposal of water after hydrostatic test.

2.5 Contractor shall submit to company colour photographs of various construction

activities/ operations at regular intervals. Size, number and frequency of the
photographs shall be mutually agreed upon at a later stage. Also Contractor shall
make video recordings of all operations right from the start of construction till the
completion of the work, covering to the extent as instructed by Company and submit
to Company. Upon completion of the work, Contractor and submit edited master
tape plus six copies of video recording in VHS formats or any format ordered by the
Company. The duration of video recording shall be of ½ hour and shall cover all
aspects of the job.

3.0 AS-BUILT DRAWINGS AND PIPE BOOK

3.1 General

Contractor shall prepare “as-built” drawings of all by or on behalf of Company issued

drawings and of all Contractor work drawings including vendor drawing, such as but
not limited to :

For Pipeline Section :

- Route Maps
- Alignment Sheets
- Detail Drawings (road, railway, minor water crossings, major water crossings,
valley crossings)
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
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PIPELINE CONSTRUCTION
EDITION : 1

- Isometric drawings of installations

- Special installation

Further Contractor shall prepare a pipe Weld Book.

If required by the Company, Contractor shall update the diskettes for drawings
issued for construction of the job.

3.2 “As-Built” Drawings

Contractor shall prepare a complete set of “as-built” drawings. From the start of
construction, Contractor shall on daily basis process any changes in two sets of
drawings. Deleted parts shall be indicated in red, new parts in blue, remarks in
green and unchanged parts in yellow. Said drawings shall be kept at site and be
available to Company at all times. Contractor shall prepare “as-built” drawings
based on these data. On completion of the work, one revised film transparency of all
drawing made “as-built” by Contractor containing the “as-built” information shall be
handed over to Company as well as one complete set of CD ROM/ floppy diskettes
as specified by Company.

Contractor shall prepare and submit a specimen of the layout of the drawings for
Company’s approval.

The required measurement for “as-built” drawing shall be executed by Contractor by

experienced, qualified surveyors.

The surveyors shall daily take care of all measurement required such as but not
limited to:

- Horizontal location of pipeline with regard to deviations and Permanent Grid

Pillars.
- Vertical Level with regard to Mean Sea Level of pipeline and grade.
- Location and type of bends, fittings etc. and grades, points of intersection.
- Change of wall thickness, materials.
- Location and details of valves, insulating flanges, fencing.
- Location and details of crossing pipes, vents.
- Location and type of coating.
- Location and type of weighting, anchoring.
- Location and type of markers.
- Location of further appurtenance (Pig-Signallers)
- Location of ROU and of pipeline with respect to ROU.
- Type of soil.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
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834002 OIL & GAS SBU, DELHI

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PIPELINE CONSTRUCTION
EDITION : 1

- Type of rock
- Type of blasting and ripping.
- Sand padding.
- Type of road pavement.
- Details of bank protection, number of insulators, seals.

Contractor shall also prepare isometric drawings of all installation (facilitates) etc. for
which the data as mentioned in or required for the Pipe and Welding Book can be
identified and these drawings can also be used for material accounting.

3.3 Nameplates of Equipment

All permanent equipment supplied and installed by Contractor shall be provided with
plates by Contractor. All texts shall be submitted to Company for approval before
plates may be manufactured.

3.4 Pipe Book

Every page of the pipe and Welding Book shall mention:

- Data relevant to the project and section there of.

- Sequential number.
- Length brought forward (for pipes and other materials).
- Length to bring forward (for pipes and other materials).

Alignment sheet number and atleast the location thereon of two welds on every page
of the pipe Book.

Further,

- Diameter of pipeline
- Length of each pipe
- Wall thickness
- Pipe number
- Heat number, certificate number
- Cut and re-numbered pipe ends
- Coating type
- Date of stringing
- Date of welding
- Weld number
- Welder number
- Direction of working
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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PIPELINE CONSTRUCTION
EDITION : 1

- Type of welding, electrodes, diameter of electrode etc.

- Heat treatment
- Equipment used for radiography
- Limits of water crossings
- Test pressure and date of test.

In order to achieve this, Contractor shall identify all pipe elements. Sample format of
Pipe Book shall be submitted for Company approval.

3.5 As-Built Documents

Contractor shall prepare all documents in the prescribed format as indicated below.
In addition to the hard copies, softcopies of final documents shall also be submitted
in electronic media i.e. CD / DVD format.

Software used for the preparation of these documents shall be as follows:

Type document Software

a) Reports/ Documents MS Office
b) Drawings Auto CAD

For the purpose of preparation of as-built drawings, Contractor shall update the
“Issued for construction” drawings issued by the Company. It shall be the
Contractor’s responsibility to covert the drawings furnished by the Company in hard
copy into CAD drawings including scanning, digitising and converting the drawings
into a suitable format compatible with the AutoCAD and above. As-built drawings
shall be prepared only on AutoCAD drawings.
 Rev. : 0
Edition : 1

SPECIFICATION
FOR
FIELD JOINT COATINGS OF PIPELINE
FOR HDD CROSSING

SPECIFICATION NO.: MEC/S/05/21/074

(OIL & GAS SBU)

MECON LIMITED
DELHI 110 092
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 1

TITLE FIELD JOINT COATINGS OF MEC/S/05/21/074 REVISION : 0

PIPELINE FOR HDD CROSSING
EDITION : 1

CONTENTS

1.0 SCOPE

2.0 REFERENCE DOCUMENTS

3.0 SPECIFICATION FOR FIELD JOINT COATING MATERIAL

4.0 APPLICATION PROCEDURE

5.0 INSPECTION

6.0 TESTING

7.0 REPAIR OF FIELD JOINT COATING

8.0 REPAIR OF PIPE COATING DEFECTS

9.0 DOCUMENT

PREPARED BY: CHECKED BY: APPROVED BY: ISSUE DATE :

(Binita Brahma) (Sunil Kumar) (A.K. Johri) May 2009

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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PIPELINE FOR HDD CROSSING
EDITION : 1

1.0 SCOPE

1.1 General

This specification covers the minimum requirement for application of anti-corrosion

field joints coating on welded pipe section and field tie-in joints referred to here in
after as Joint(s). The contractor shall perform all work in accordance with this
specification, latest pipeline coating practices and to the full satisfaction of the
Owner. The anti-corrosion pipe joint coating shall be compatible with yard applied,
Ultra Violet (UV) radiation protected, 3 layer side extruded polyethylene coating
conforming to DIN-30670. The sleeve width shall be suitable for cut back of 120 ±
20 mm to be left at both the ends of coated pipes. The job includes supply of all
materials equipment, consumables, labour, supervision, quality control, inspection
repairs.

1.2 Manpower, Material & Equipment

1.2.1 The Contractor shall supply wrap around heat shrinkable sleeves which is composed
of two parts such as adhesive coated wrap around and a curable modified epoxy
primer alongwith applicator pads.

1.2.2 The supply of wrap around heat shrinkable sleeve shall be under Contractor’s scope.

1.2.3 The Contractor shall provide all skilled/ unskilled personnel required for execution of
this work.

1.2.4 The joint coating operation starting from cleaning and surface preparation till
application of joint coating and wrapping of the pipe joints shall be performed under
the supervision of skilled personnel who are well versed in the work.

1.2.5 Contractor shall at his own cost provide a fully equipped laboratory and test facilities
with adequate inventory to carry out tests required for procedure qualification and
during regular production, for testing of joint coating system.

2.0 REFERENCE DOCUMENTS

2.1 Provision of the following documents/ codes shall generally be followed for standard
of specification and workmanship.

a) DIN – 30672 : Corrosion protection tapes and Heat Shrinkable Sleeves.

b) SIS – 055900 : Pictorial surface preparation standard for painting steel

surfaces.

c) SSPC – SP1 : Steel structure painting council – Solvent Cleaning.

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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PIPELINE FOR HDD CROSSING
EDITION : 1

2.2 In case of conflict between the requirements of this specification and that of above
referred documents/ codes, the requirements of this specifications shall govern.

3.0 SPECIFICATION FOR FIELD JOINT COATING MATERIAL

3.1 General

This scope covers the minimum requirement of materials, equipment required for
installation of field joint coating by wraparound fibre-reinforcement heat-shrinkable
sleeve used for corrosion protection and sealing of field joints in pipelines that are
forced through the soil by Horizontal Directional Drilling technique. The sleeves shall
be suitable for 3LPE/FBE coated pipes operating up to 60°C continuously.

3.1.1 Each Joint Coating System shall consist of :

a) For HDD Joint Coating fiber glass reinforced heat shrinkable sleeve certified
to Stress class C60 type CANUSA-TBK or COVALENCE / DlRAX shall be
used. Directional drilling kit, multilayer sleeve system or equivalent to be
approved by Owner / Engineer.

b) Only coating material C-60 Class as per EN 12068 and DVGW certified
(wrapping tape and heat shrinkable material) will be accepted for all material
to be coated.

c) A solvent-free, two component liquid epoxy primer

d) A specifically designed wear cone

e) A clamping belt

3.1.2 Sleeve Backing

The heat shrinkable sleeves shall be manufactured from minimum 1.0 mm thick
radiation cross linked, thermally stabilized, UV -resistant heat-shrinkable fabric,
composed of a fibre glass reinforcement and polyolefin fibres, embedded in a
polyolefin matrix.

3.1.3 Sleeve Adhesive

The inner surface of the sleeves shall be coated with a controlled thickness of
minimum 1mm of adhesive which in combination with the modified epoxy primer, will
bond to and seal to the steel pipe and common yard applied medium temperature
yard coatings.

3.1.4 Epoxy Primer

The Epoxy primer shall be a solvent free, modified two components liquid epoxy type
primer, which is applied to cleaned and dry steel surface. When the sleeve coatings,
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
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834002 OIL & GAS SBU, DELHI

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PIPELINE FOR HDD CROSSING
EDITION : 1

comes in contact with the liquid primer during installation, a strong bond is formed
upon full curing of the system.

3.2 Properties of Field Joint Coating Material

The pipe sleeves furnished under this specification shall be tested and shall meet the
requirements specified in the table below:-

3.2.1 Heat-Shrinkable Sleeve Material

Property Test Condition Requirement

Method
Cold Crack ISO 4675 Below 40°C
Chemical ISO 175 168 hrs. immersion on either
resistance 0.1 N

NaCl @ 23°C, 0.1N H2 SO4

@
23°C, 0.1 N NaOH @ 23°C,
Fuel oil @ 23°C. Petroleum
jelly @ 70°C
Followed by test ISO 3303 23°C 1100 N Min.
for bursting
strength
Thermal ageing ISO 188 150°C 168 hrs. 1700 N Min.

Followed by test ISO 3303 23°C

for bursting
strength

3.2.2 Adhesive material

Property Test Condition Requirement

Method
Softening point ASTM 85°C minimum
E28
Peel Strength DIN 23°C. CHS* 200 N/cm minimum
30672 100 mm/ min.
60°C 60 N/ cm
Peel Strength DIN 23°C. CHS* 200 N/cm minimum
After immersion for 4 30672 100 mm/ min.
weeks
at 23°C~NaOH pH12
H2SO4
pH2 ground water
solution:-
1.2% H3PO4
1.6% KOH
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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PIPELINE FOR HDD CROSSING
EDITION : 1

Property Test Condition Requirement

Method
1.2NaCl
1.0% Fe2O3

Peel Strength after DIN 23°C. CHS* 60 N/cm minimum

conditioning for 30 30672 100 mm/ min.
cycles from -30°C to 60°C
Shear strength ISO 4587 23°C. CHS* 200 N/cm2
50 mm/ min. minimum

Corrosive effect ASTM D 120°C. No corrosion

2671 16 hrs.

3.2.3 Primer Material

Property Test Method Condition Requirement

Density ASTM 23 +/- 0.50 C Part A: 60+/- 30 Pas

D1084 Part A: 2 rpm, spindle Part B: 1.55+/-0.55
#6 Pas
Part B: 20rpm, spindle
#3
Mixing ratio By weight 23°C 100:40
By volume 100:60
Shear ISO 4587 23°C. CHS* 1000 N/cm2 minimum
strength 50 mm/ min.

* CHS = Cross Head Speed

3.2.4 Functional Properties

Sl. Property Test Method Condition Requirement

No.
a) Impact DIN 30672 23°C. No holidays when
resistance Class C tested at 20 KV
b) Penetration DIN 30672 60°C. Minimum 70% of
resistance Class C original resistance
thickness left; no
holidays when tested at
20 KV
c) Specific DIN 30672 23°C. 108 Ohm sq. m
coating minimum; no oxidation
resistance on pipe surface
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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PIPELINE FOR HDD CROSSING
EDITION : 1

Sl. Property Test Method Condition Requirement

No.
d) Cathodic ASTM G42 60°C. 15 mm increase in
disbondment 30 days radius of disbondment
resistance max.
e) Resistance to TEST No cut propagation
*
split METHOD-1
propagation
f) Resistance to TEST 50 KN minimum
*
circumferentia METHOD-2
l edge loading
g) Resistance to TEST 6 KN minimum
*
local edge METHOD-3
loading
(chisel test)

*Test Methods

3.3 Test Methods

3.3.1 Resistance to split propagation (Test Method -1)

A rectangular piece of 50mm width by 150 mm length shall be cut from the material
as delivered. A 5mm long, clean cut shall be made mid-way in the piece along once
of the long edges perpendicular to this edge. The sample shall be mounted on a
clamp that holds it securely and avoids any shrinking during testing.
0
The assembly shall be placed in an air-circulating oven present at 170 C.

After 15 minutes, the sample shall be removed from the oven, allowed to cool down
to room temperature and examined for cut propagation.

This test simulates the unlikely event when the sleeve gets cut during the installation
phase. Sleeves based upon extruded polyelfin show a distinct tendency to propagate
the cut along the total width of the sleeve. Sleeves suitable for HDD works shall not
exhibit this behaviour.

3.3.2 Resistance to circumferential edge loading (Test method -2)

The sleeve shall be installed on a DN 200 three -layer PE coated steel pipe piece. A
thick wall steel ring that fits a DN 200 three-layer PE coated steel pipe with a
tolerance of 0.2+-0.2 mm shall be positioned against the front edge of the wear cone
sleeve and then pushed towards the sleeve system at a constant speed of 5 mm/
min over a distance of 50 mm. The forces necessary shall continuously be
registered. The minimum required force shall be less than 50 KN.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
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PIPELINE FOR HDD CROSSING
EDITION : 1

During the pushing or pulling operation, any obstacle protruding from the smooth
pipe surface is loaded by the surrounding soil that passes by. This test simulates the
shear forces that are exerted on to the sleeve by rigid soil type.

3.3.3 Resistance to local edge loading (Chisel test: Test Method -3)

The sleeve shall be installed on a DN 200 three-layer-PE coated steel pipe piece.

A chisel as depicted in Figure -1 shall be positioned against the front edge of the
wear cone sleeve and, pushed parallel to the pipe surface towards the sleeve
system at a constant speed of 5mm/ min over a distance of 50 mm. The forces
necessary shall continuously be registered. The minimum required force should not
be less than 6 KN.

During the pushing or pulling operation, the pipe may traverse soil area containing
solid particles, such as stones, pebbles or crushed rock. These particles tend to rip
away the pipe coating locally. Any obstacle protruding from the smooth pipe surface
is lifted, leading to soil undercutting. This test determines the resistance of sleeve
against this type of abuse.

35mm I5mm

View AA

Figure- 1 Chisel
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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PIPELINE FOR HDD CROSSING
EDITION : 1

3.4 Qualification for Contractor’s supplied Materials and their Manufacturer

3.4.1 Prior to procurement of coating materials, Contractor shall furnish the following
information for qualification of the Manufacturer and material:

a. Complete descriptive technical catalogs describing the materials offered

along with samples of corrosion coating materials, its properties and
application instruction as applicable specifically to the project.

b. Reference list of previous supplies, in last 5 years, of the similar material or

manufacturer shall be notified to Company, whose approval in writing of all
charges shall be obtained before the materials are manufactured.

3.4.2 Contractor shall ensure that the coating materials supplied by him are properly
packed and clearly marked with the following :-

- Manufacturer’s name

- Material Qualification Certificate Number

- Batch Number

- Date of Manufacturing and date of expiry

3.4.3 Prior to shipment of materials from the Manufacturer’s Works. Contractor shall
furnish the following documents:

a. Test certificate/results as per Manufacturer’s Quality Control Procedure for

each batch of materials complying with the requirements of relevant sub-
clauses of clause no. 3.2 of the this specification.
b. Specific application instructions with pictorial illustrations.
c. Specific storage and handling instructions.

3.4.4 All documents shall be in English language only.

3.5 Storage of Materials

Material shall be stored in sheltered storage by the Contractor in the manufacturer’s

original packing and away from direct sunlight and in accordance with
manufacturer’s instructions.

4.0 APPLICATION PROCEDURE

4.1 General

a) The application procedure shall be in accordance with manufacturer’s

instruction and the minimum requirements required below whichever are the
most stringent and shall be demonstrated to and approved by the Owner.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
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EDITION : 1

b) Contractor shall provide and maintain mobile facilities which contains all
necessary tools, propane torches, epoxy primer pumps, silicon rollers, testing
instruments, equipment, and spares for cleaning, coating, repairs, inspection
and testing.

c) Contractor shall furnish sufficient number of the following equipment and the
required spares as a minimum for inspection and testing purpose for each
crew :

- Fully automatic full circle adjustable holiday detector with audio and
visual output signal for inspection of coating.
- Portable Tensile Strength Tester
- Digital Thermometer
- Solid state digital thickness gauge for measuring thickness of joint
coating.

4.2 Pipe Surface Preparation

a) The Contractor shall thoroughly clean and dry the joint surface by power tool
cleaning in accordance with SSPC-SP1. The complete procedure and details
of equipment used shall be prepared by the Contractor for Owner’s approval
prior to commencement of joint coating work.

b) Prior to cleaning operation, Contractor shall visually examine the joint surface
area and shall ensure that all defects, flats and other damages have been
repaired or removed.

c) Where oil, grease or other materials detrimental to the finished coating is

present, it shall be removed with a continuous removal solvents cleaning
system to remove completely all such materials in accordance with SSPC-
SP1.

d) The standard of finish for cleaned pipe surface shall conform to SA 2½ of

Swedish Standard SIS-055900 latest edition. The degree of preparation
required to obtain an end product that fulfil the requirements of this
specification may not be sufficiently covered and is not limited by SIS-
055900. Surface of pipe after shot blasting shall be have an anchor pattern of
50 to 70 microns. This shall be measured by a suitable instrument such as
Elecometer.

e) Piper temperature immediately prior to blasting shall be minimum 20°C. At

no time shall be blast cleaning be performed when the relative humidity
exceeds 85%. Surface temperature must be at least 3°C above the dew
point temperature.

f) The abrasive blast material shall be free of impurities and inclusions, water
and oil. All abrasives shall be removed after blast by brush or vacuum type
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PIPELINE FOR HDD CROSSING
EDITION : 1

cleaner prior to applying joint coating. The abrasive shall be stored in a dry
condition and maintained dry during use.

g) The compressed air for blasting shall be free of water and oil. Contractor to
verify air cleanliness at the start of the work and every four hours thereafter.
Separators and the traps shall be provided at the compressor and blasting
station. Separators and traps shall be checked daily for effective moisture
and oil removal during coating operations.

h) The ends of existing line pipe protective coating shall be inspected and
chamfered. Unbonded portions of the coating shall be removed and then
suitably trimmed. Portions where parent coating is removed shall be
thoroughly cleaned as specified.

i) Pipe shall be visually inspected by Contractor immediately after blast cleaning

for surface defects such as slivers, laminations, leafing, scores, indentation
slugs or any other defects considered injurious to the coating integrity. Such
defects shall be reported to Owner and on permission from Owner, such
defects shall be removed by filling or grinding in such a way as not to “blue”
the steel.

4.3 Procedure

a) The application procedure shall be in accordance with manufacturers

instruction and the minimum requirements specified below whichever are the
most stringent and shall be demonstrated to and approved by the owner.

b) Applicators for coating application shall be given necessary instructions and

training before start of work by the CONTRACTOR. To verify and qualify the
application procedures, all coating applied during the qualification test, shall
be removed for destructive testing until the requirements stated in sections
‘Inspection’ and ‘testing’ of this specification are met.

c) Prior to surface cleaning, the surface shall be completely dry. An effective

heating equipment which shall not give rise to deposits shall be used. Care
shall be taken to avoid damage to existing coating.

d) All pipe joint surfaces shall be thoroughly examined before the application of
the coating in order to ensure that the surfaces are free of oil, grease, rust,
mud, earth or any other foreign matter.

e) Liquid epoxy primer shall be applied on the joints immediately after the
completion of heating operation.

f) The heat shrink sleeve is then wraparound the joint while the primer is still
wet and shall overlap the existing pipe coating by minimum 100 mm on each
side.
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834002 OIL & GAS SBU, DELHI

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PIPELINE FOR HDD CROSSING
EDITION : 1

g) The wraparound sleeve is shrunk on pipe joint with a propane torch moved
back and forth over the surface when heated above 125°C, the sleeve shall
shrink tightly around the substrate on to the wet-primer. At the time of
application of the primer, th pipe surface temperature shall be at least 60°C at
every point. To check this, approved temperature indicators shall be used .
temperature indicating crayons shall not be used.

h) The wraparound sleeve shall be entirely wrapped around the pipe positioning
the closure patch off to one side of the pipe in 10m or 2 O’clock position, with
edge of the undergoing layer facing upward and an overlap of min. 100 mm.

i) Heat shrinking shall be procedure shall be applied to shrink the sleeve in

such a manner that all entrapped air is removed using gloved hands and
hand rollers. The complete shrinking of entire sleeves shall be obtained
without undue heating of existing pipe coating and providing due bonding
between pipe, sleeve and pipe coating. A thermochrome paint shall be
applied a an closure patch to indicate that sufficient heat/ temperature has
been obtained. The joint coating shall have wear cone applied over the
leading edge of the sleeve and the clamping belt tightened over it.

j) Application of Wear Cone - The leading edge will be given an extra wear
0
cone. Start by heating the leading edge area of the main sleeve to 70 C.
Wrap the leading edge sleeve over the transition Mill coating. Ensure that the
closure is placed away from the main sleeve closure Shrink the leading edge
sleeve.

k) Application of Metal Belt - The metal belt shall be applied over the wear cone
sleeve. The metal belt will be tightened using the strapper tool supplied by
the manufacturer.

l) Sufficient manpower working on opposite sides of each pipe joint are

required for installation of the sleeve.

m) The installed sleeve shall not be disturbed until the adhesive has solidified.

5.0 INSPECTION

5.1 For wraparound coating, a visual inspection shall be carried out for the following :

- Mastic extrusion on either ends of the sleeves shall be examined

- There shall be no sign of punctures or pinholes or bond failure. The external
appearance of the sleeves shall be smooth, free of dimples, air entrapment or
void formation.
- Weld bead profile shall be visible over the sleeves.
- The entire closure patch shall have changed colour uniformly.
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PIPELINE FOR HDD CROSSING
EDITION : 1

5.2 Holiday Inspection

5.2.1 The Holiday Detector used shall be checked and calibrated daily with an accurate
D.C. voltmeter. The detector electrode shall be in direct contact with the surface of
coating to be inspected.

5.2.2 The entire surface of the joint section shall be inspected by means of a full circle
Holiday Detector approved by OWNER set to DC Voltage of at least 25 kV for
wraparound sleeves. Inspection of the heat shrink sleeve coating shall be conducted
only after the joint has cooled below + 50°C.

5.2.3 All the coated joints shall be subjected to Holiday Detection test.

5.2.4 An installed sleeve with more than two holiday shall be stripped and a new one be
installed.

6.0 TESTING

a) OWNER reserves the right to test one out of every 30 joint coating subject to
a minimum of 2 joints. CONTRACTOR shall provide all assistance in
removing and testing of field joint coatings. From each test sleeve, one or
more strips of size 25 mm x 200 mm shall be cut one perpendicular to the
pipe axis and slowly peeled off. This test shall be conducted between either
sleeve and metal or sleeve and mill coating as per direction of Owner/
Engineer-in-charge.

b) The required peel strength shall be 60 N/cm (min.) at 23°C. The system shall
fail only in the adhesive layer. No failure either in adhesion to steel or
adhesion to backing shall be permitted. The adhesive layer that remains on
the pipe surface shall be free of voids resulting from air or gas inclusion.

c) If the sleeve taken away for test does not meet the requirement of clause 6.0
(b), the adjacent two sleeves do not meet the requirements of clause 6.0 (b)
the field joint coating shall be stopped until OWNER is satisfied with
application methods.

d) For the test tensile strength, two parallel incisions spaced 1 CM. Apart are
made right down to the surface of the steel. A further incision shall then be at
right angles to the first angles to the first two incisions. With the aid of a 1 cm.
Wide knife the coating is lifted over a length of about 2 cm. And clamped into
the tensile tester, where upon a uniform pull is exerted at an angle of 90
degree. The tensile strength shall be more than a 2500psi.

e) Coating thickness shall be checked by non destructive method for each field
joint.
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834002 OIL & GAS SBU, DELHI

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PIPELINE FOR HDD CROSSING
EDITION : 1

7.0 REPAIR OF FIELD JOINT COATING

7.1 If a field joint is detected to be unacceptable after inspection and testing as per
clause no. 6.0 of this specification. The CONTRACTOR shall , at his own cost :

- determine the cause of the faulty results of the coatings.

- mobilise the services of expert of manufactures, if required.

- test to the complete satisfaction of the OWNER, already completed field joint
coatings.

- stop joint coating until remedial measures are taken against the causes of
such failures, to the complete satisfaction of the OWNER.

7.2 CONTRACTOR shall replace all the joints coating found or expected to be
unacceptable as per clause no. 6.0 of this specification.

7.3 CONTRACTOR shall, at his own cost repair all areas where the coating has been
removed for testing by the OWNER or by the CONTRACTOR to the complete
satisfaction of the OWNER.

7.4 The upright edges of the damaged areas shall be chamfered, in addition to the steel
shall be free from rust, dirt, oil and grease. The coating around the damaged area
shall be roughened. After thorough mixing (in accordance with the recommendations
of the manufacturer) the filler shall be applied, to sufficient Thickness with the aid of
stooping knife, whilst observing ample overlap hardening. The material will require
the approval of OWNER.

7.5 After the coating work on welded joints and repairs to the coating have been
completed, The coating area as a whole shall be tested with spark-tester before pull
back/ lowering/jacking the pipeline.

7.6 Company shall be entitled to check the coating on buried pipelines or parts of
pipelines with equipment such as the “Pearson meter” and the resistance meter. If
the coating defects are established, the Contractor shall be responsible for
excavation at such points, repairing the coating, spark testing and backfilling the
excavations without extra charge.

8.0 REPAIR OF PIPE COATING DEFECTS

8.1 Any defect or damage in pipe coating observed till incorporation on permanent works
shall be rectified by the Contractor at his risk and cost. However, for repair of
damaged coating observed during taking over of Owner supplied pipe, if any, shall
be paid extra in accordance with the relevant items of Schedule of Rates.

8.2 Field repair of coated pipes shall be carried out by using same type of wraparound
sleeves used for joint coating.
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PIPELINE FOR HDD CROSSING
EDITION : 1

8.3 The repair procedure shall be same as specified herein above for application of anti-
corrosion field joint coating on welded pipe.

9.0 DOCUMENTATION

9.1 Prior to start the coating works at site Contractor shall furnish following Owner/
Consultant’s approved documents in addition to that mentioned in clause no. 3.4 of
this specification.

- Procedure for field joint coating & their repair

- Procedure for repair of pipe line coating defects
- Procedure qualification record
- Inspection test plan
- Inspection format

9.2 Final submission of all documents after finish the work shall be as per relevant
specification & SCC enclosed with the tender or as per direction of Engineer-in-
charge.
 Rev. : 0
Edition : 1

SPECIFICATION
FOR
PIPELINE CROSSINGS USING HORIZONTAL
DIRECTIONAL DRILLING METHOD

SPECIFICATION NO.: MEC/S/05/21/75

(OIL & GAS SBU)

MECON LIMITED
DELHI 110 092
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
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834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 1

TITLE PIPELINE CROSSINGS USING MEC/S/05/21/75 REVISION : 0

HORIZONTAL DIRECTIONAL
DRILLING METHOD EDITION : 1

CONTENTS

SL.NO. DESCRIPTION

1.0 SCOPE

2.0 REFERENCE DOCUMENTS

3.0 DESIGN AND ENGINEERING

4.0 CONSTRUCTION

5.0 DOCUMENTATION

PREPARED BY: CHECKED BY: APPROVED BY: ISSUE DATE :

(Shalini Singh) (Sunil Kumar) (A.K. Johri) Jan. 2009

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
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834002 OIL & GAS SBU, DELHI

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HORIZONTAL DIRECTIONAL
DRILLING METHOD EDITION : 1

1.0 SCOPE

1.1 This specification covers th e m inimum re quirements f or va rious a ctivities to be

carried out by the Co ntractor fo r t he eng ineering and co nstruction o f p ipeline
crossing using directional drilling method.

1.2 This specification shall be re ad in conjunction with the requirements of specification

and other documents included in the CONTRACT between owner and Contractor.

1.3 Contractor shall, execute the work in co mpliance with laws, by laws, ordinanc e and
regulations. Contractor shall provide all services, labour , inclusive of supervision
thereof, supply of all materials (ex cluding “Owne r supplie d Mate rial), e quipment ,
appliances etc..

1.4 Contractor shall take full responsibility for the stability and safety of all operation and
methods involved in the work.

1.5 Contractor shall b e d eemed t o hav e insp ected and ex amined the work area and its
surroundings and t o hav e sat isfied himself as far as pract icable wit h t he surface
conditions, hy drological and climatic conditions, the ex tent and nat ure of t he work
and materials necessary for the completion of the work, and the means of access to
the work area.

1.6 Contractor shall b e d eemed t o hav e o btained all necessary information with regard
to risks, contingencies and all other circumstances, which may influence the work.

1.7 Contractor shall, in connection with the work, provide and maintain at his own costs
all lights, guards, fencing, as necessary or directed by Owner or their representative.

1.8 For the purpose of this specification, the following definitions shall hold.

- The words `Shall’ and `Must’ are mandatory.

- The words `Should, May and Will’ ar e non mandatory, advisory, or

recommendatory.

1.9 Contractor shall provide free of charge reas onable facilities to Owner’s personnel to
witness all stages of construction.

2.0 REFERENCE DOCUMENTS

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

a. ASME B 31.4 : Pipeline Transportation Systems for Liquid

Hydrocarbons and Other Liquids.

b. ASME B 31.8 : Gas Transmission and Distribution Piping Systems.

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834002 OIL & GAS SBU, DELHI

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HORIZONTAL DIRECTIONAL
DRILLING METHOD EDITION : 1

c. OISD 226 : Natural Gas T ransmission Pipeline and City Gas

Distribution Network.

d. MECON’s Standards : Navigable Waterway Pipeline Crossing Warning Sign

ME C/S/05/21/10

e. MECON’s Standards : Standard Specification for Pipeline Construction

ME C/S/05/21/01

In case o f co nflict b etween t he req uirements of this specification and the above
referred documents, the requirements of this specification shall govern.

3.0 DESIGN AND ENGINEERING

3.1 The limits of each crossing shall be de termined by the Contractor on the basis of
crossing profile based on survey drawings, design, equipment, installation technique
and sit e condit ion. Cont ractor shall furnish all engineer ing de sign c alculation and
crossing drawings etc. to owner for their approval prior to execution of the work.

3.2 Within the entire limits of crossing, the minimum cover to top of coated pipe shall be
as specified in the Special Conditions of Contract (SCC).

However, wherever the drilled length for a crossing includes the crossings of
obstacles such as roads, railroads, cannals, st reams, et c. T he following minimum
requirements of c over to the pipe shall be satisfied unless specif ied otherwise in the
scope of work in SCC.

For Road Crossing : 1.4 m from top of road to top of pipe.

For railroad crossing : 1.7 m from base of Rail to top of pipe.

For canal crossing : 1.5 m from lowest bed level to top of pipe.

In case the pipeline crosses other utilities, viz., other pi pelines, sewers, drain pipes,
water mains, telephone conduits and other underground structures, the pipeline shall
be installed with at least 500 mm free clearance from the obstacle or as specified in
the drawing or suc h gre ater minimum distan ce as may be re quired by authoritie s
having jurisdict ion. Also in all cases, t he minimum cove rs specified above shall be
maintained within the entire limits of crossing.

3.3 The ent ry and ex it p oints o f t he p ipeline at ground level shall not c ome w ithin the
limits of crossing as defined in the crossing drawings.

3.4 Contractor shall carry out calculations for de termining the maximum pe rmissible
overburden o n p ipe, t o check t hat t he em pty pipeline is safe from collapse at any
point along the drilled crossing section. Cont ractor shall submit these calculations to
Owner for approval.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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HORIZONTAL DIRECTIONAL
DRILLING METHOD EDITION : 1

3.5 Pipeline Axis

The plane containing the pipeline route axis shall b e perpendicular to the horizontal
plane. The re shall be no be nding of the pipeline route ax is at depths shall lower
than 2 meters below ground level.

3.6 Back-reamed hole and Pipeline Interface

3.6.1 Contractor shall derive combination of:

- Back-reamed hole diameter

- Bentonite density
- Pipeline submerged weight in bentonite (and means to achieve that weight)

to optimise the crossing design in terms of pipeline stresses and power requirement

3.6.2 Contractor shall indicated what max imum shear stress in the pipeline coating will
result from his choice of above parameters and other characteristics described in this
section.

3.6.3 Contractor shall furnish all calc ulations for Owner’s approv al. If shear stress in pipe
coating is, in the opinion of Owner, beyond the permissible limits, Contractor shall
revise his choice of paramete rs to reduce shear stress on pipe coating to permissible
value.

3.7 Contractor shall determine in the mi nimum allowable e lastic be nd radius for pipe
from the following consideration:

3.7.1 Maximum Longitudinal Stress During Installation

Total maximum longitudinal stress in the pi peline due to tension and bending at any
location shall not exceed 90% of the SMYS of the pipe material.

Contractor sh all, in orde r to c heck th is re quirement, e valuate th e maximum tensile

forces to which the pipeline is subjected to at any phase of its installation during the
pulling operation.

3.7.2. Maximum Equivalent Stress During Final Hydrostatic Test

After in stallation, th e pipe line sh all be h ydrostatically tested to a minimum test

pressure e qual to 1.4 time s the design pressure or at a pressure stipulated in the
Special Conditions of Contra ct whichever is higher. Howev er, during hy drostatic
testing, t he co mbined eq uivalent stress in the pipe line due to be nding and te st
pressure shall not exceed 90% of the SMYS of pipe material.
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HORIZONTAL DIRECTIONAL
DRILLING METHOD EDITION : 1

3.7.3 Maximum Equivalent Stress During Service

Permissible values of max imum equivalent stress during services shall be gove rned
by the requirements of ANSI B 31.8/B 31. 4 as applicable. T he details of pipe line
operating parameters are provided in the Special Conditions of Contract.

3.7.4 The minimum allowable radius of curvature for the pipeline shall be the highest value
of the minimum pipeline elast ic radius as computed from the considerations outlined
in clause 2.7.1 to 2.7.3 above afte r correction for drilling inaccuracies or
multiplication by the factor 1.85. whichever results in th e hig hest p ermissible v alue
of minimum elastic bend radius.

3.7.5 Contractor shall submit all calculations for Company’s approval alongwith procedure.

3.8 Pipeline Configuration along the Support String Before Entry Point

3.8.1 Contractor shall determine the required pipeline configuration in order to allow
smooth pull in the crossing entry point and admissible stress in the supported
pipeline string. Pipeline combined st ress shall no t ex ceed 95% o f t he sp ecified
minimum yield strength for line pipe material.

3.8.2 Contractor shall furnish all calculation an d specify the number of re quired supports,
description of the supports, their co-ordinates and capacity in metric tons.

3.8.3 Contractor shall also furnish a drawing of the launching ramp indicat ing the pipeline
configuration.

3.8.4 The distance between each roller shall also be specified and justified.

3.9 Contractor shall, based on result of de sign and e ngineering carried o ut b y him,
prepare c onstruction drawings for the c rossing and shall submit the same for
Owner’s approval. Construction drawings shall indicate the pipeline profile with levels
furnished at sufficient intervals for proper control during construction. Other relevant
details viz., e ntry and e xit angle s, radius of be nds, e tc. shall also be indic ated.
Contractor shall also calculat ed th e tota l le ngth of pipe line required as well as the
maximum tension required on the pull head of the rig.

3.10 All c onstruction w orks sh all be c arried ou t in accordance with the construction
drawings approved by Owner.

3.11 Before co mmencement o f any field wo rk, Contractor shall furnish for Owner’s
approval all design calculations and construction drawings as stipulated in the above
clauses.

4.0 CONSTRUCTION

Contractor shall comply with all the conditions and requirements issued by
Authorities having jurisdiction in the area where the work is to be performed.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
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HORIZONTAL DIRECTIONAL
DRILLING METHOD EDITION : 1

If no public road ex ists, Contractor sh all arrange on his own for access t o his work
area at no extra cost to owner.

4.1.0 Installation Procedure

4.1.1 Contractor shall, before commencing any work at site, submit for Owner’s approval a
detailed installation procedure.

4.1.2 The installation procedure as a minimum shall include the following:

a) Project Organisation Chart:

This shall indicate Contractor’s organi sational set-up at site and manpower
deployment.

b) Details of fabrication yard and launching areas.

c) Details of Equipment :

Contractor shall furnish the complete list of all e quipment to be deployed for
preparation of pipe string and installation of c rossing. Te chnical
characteristics and cap acity o f each equipment including instrumentation,
monitoring and control equipment shall be furnished in details.

d) Pipeline string preparation details (hauling, stringing, welding etc.)

e) Hydrostatic test procedure (pre and post installation)

f) Disposal methodology of bentonite slurry.

g) Method of installation c overing all st eps of const ruction, v iz. Rig up, P ilot
hole, Back-Reaming, Pulling Down, Backfilling etc.

h) Calculation for max imum pulling fo rce on the rig and recommended
maximum pulling velocity.

i) Time schedule for construction.

4.1.3 The time schedule shall be in accordance with overall time schedule for the project.

4.1.4 Approval by Owne r of the methods used by Contractor shall in no way relieve
Contractor from the sole resp onsibility for safe and satisf actory installation, working
and operational use of the pipeline crossing.

4.2 Pipe String Preparation

Complete pipe string shall be prepared as a single string for pulling. Welding,
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
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834002 OIL & GAS SBU, DELHI

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HORIZONTAL DIRECTIONAL
DRILLING METHOD EDITION : 1

radiographic inspection of joints and joint coating of the string shall be performed in
accordance w ith th e respective applicable specifications includ ed in t he Co ntract
document.

4.3 Pre-testing

4.3.1 Contractor shall hydrostatically pre-test the c omplete pipe strin g of e ach c rossing
before installation as per approved procedure for a minimum period of 24 hours.

4.3.2 After pre -testing, join t c oating of th e w elds shall be done as per specification for
specific field joint coating of p ipeline fo r HDD cro ssing includ ed in t he co ntract
document

4.3.3 The section of the pipeline corresponding to the crossing shall, before installation, be
subjected to h ydrostatic te st pre ssure a s stipu lated in th e S pecial C onditions of
Contract. During the test, Contractor shall check all welds for leakage. Failure, if any,
during the test shall be rectified by the Contractor.

4.4 Gauging

4.4.1 Before pre and post installation hydros tatic te sting, C ontractor sh all prove the
diameter of the pipeline by passing a gaug ing pig through the pipeline. The gauging
pig shall have a diameter equal to 95% of the nominal internal diameter of the pipe.
Contractor shall supply and install all temporary scrape r launchers/ receivers and
other equipment, piping and materials and consumables required for the purpose.

4.5 Installation

4.7.1 Installation shall be done in accordance with approval installation procedure.

4.7.2 The lat eral o ffset o f t he act ual ex it p oint of the pilot h ole from the calculated and
theoretical e xit poin t sh all n ot e xceed h alf pe r cent (0.5%) of the length of the
crossing.

4.7.3 The length tolerance shall not exceed one per cent of the crossing length, subject to
the condition th at th e a ctual e xit poin t sh all not be within the limits of crossing as
defined in the approved drawings.

4.7.4 Back reaming shall be done separately from the pipeline pulling operation. The size
of the b ack-reamed ho le shall b e ad equate (ap proximately 1. 5 t imes t he p ipeline
diameter) to allow enough clearance for a smooth pull-back of the pipeline.

4.7.5 Contractor shall be responsible for mainta ining the drilled hole till such time the
pipeline is pulled in.

4.7.6 During pulling operation, the buoyancy of th e pipeline shall be co ntrolled by suitable
approved methods so as to m aintain th e bu oyancy a s c lose a s possible to ze ro
during pull-back in order to reduce friction forces of the pipeline in the hole.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

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HORIZONTAL DIRECTIONAL
DRILLING METHOD EDITION : 1

4.7.7 Bentonite slurry of specified viscosity shall b e pumped into the hole, preventing the
wall from collapsing and protecting the pipeline coating.

4.6 Contractor shall be responsible for the integrity of the corrosion coating.

4.6.1 Before pull- back ope ration, me gger te st shall be done for the entire pipeline
(externally corrosion coated) string made for crossing by HDD method.

4.6.2 After pull-back ope ration to e nsure th e integrity of pipe line c oating, again me gger
test shall be done for the bore d string before t ied-in t o t he mainline pipe. The
megger value before & after pu lling operation of the pipelin e string shall be nearly
same and acceptable to Owner.

4.6.3 However, if, in Owner’ s opinion, the integrity of ex ternal corrosion coating of bored
pipeline string is not established by above (Clause No. 3.6.1 & 3.6. 2), then further in
order to e nsure the integrity of coating of the bored pipeline string, me gger test of
the coating shall be carried out in accordance with the following steps:

a) The test must be carried out before the bored pipe is t ied-in to the mainline
pipe

b) Measure the natural potential of the bored pipe at both ends.

c) Set u p th e te mporary im pressed c urrent syste m w ith a digital multimeter

connected to measure t he o utput current . P osition t he t est elect rode ano de
as far from the bored pipe as interco nnecting cable will allow and no closer
than 10 meters.

d) Place the reference electrode at t he remo te end (o pposite t o imp ressed

current system) to monitor the bored pipe potential

e) Impress a current into the bored pipe start at Zero amp. and increase slowly
until the bore d pipe pote ntial is de pressed to 1.5 V with re spect to the
reference electrode.

f) Note the current fro m t he d igital mult imeter and calculat e t he current
density.

g) The desirable value of calculated current density should be less than 70 micro
ampere per square meter of drilled pipe surface in contact with the soil.

4.6.4 If Cont ractor again fails t o establish the integrity of coating of the bore d pipe line
string and the same is n ot a cceptable to Ow ner, th e a bove w orks sh all n ot be
continued further unt il t he cause analy sed and rect ified by t he Cont ractor t o t he
entire satisfaction of Owner.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 8 of 11

TITLE PIPELINE CROSSINGS USING MEC/S/05/21/75 REVISION : 0

HORIZONTAL DIRECTIONAL
DRILLING METHOD EDITION : 1

4.7 Final Hydrostatic Test

4.7.1 The co mplete cro ssing sect ion shall be tested after inst allation. Th e te st pressure
shall be as stipulated in the Special Co nditions of Cont ract. Aft er t emperature
stabilisation, pressure shall be retained in the pipeline fo r a period of 6 hours and
recorded b y mano thermograph. T he hy drostatic te sting sh all be c arried out in
accordance wit h ap proved p rocedures and sp ecification detailed elsewhere in the
document.

4.7.2 Test Procedure

Contractor shall prepare for Company's approval a hydrostatic test procedure manual
for p re-testing and p ost-installation t esting o f p ipeline. T he t est p rocedure manual
shall include, but shall not be limited to, the following items:

a. For the pipe se ction to be te sted, 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.

b. Estimated a mount of te st w ater, wate r sourc e, inc luding required

concentration of corrosion inhibit ors and additive s, proc edure for inhibitor
injection and control of concentration.

c. Filling and flushing procedures, incl uding a complete description of all

proposed eq uipment and inst ruments (includ ing spares), their location and
set-up.

d. The type and se quence of pigs and the pig tracking system for cleaning and
removal of air poc kets, pig inspe ction procedures, including procedure to be
followed in case the gauging pig indicates damage.

e. Procedures for levelling and stabilizat ion after filling and for pressurization
and to allow for temperature stabilization.

f. Pressure testing proced ure including a complete de scription of all propose d

equipment and inst ruments (including sp ares), their location and se t-up, and
proposed syste m for obse rvation and re cording of data during the pre ssure
test.

g. All calculations including air-volume ca lculations and pre ssure change due to
temperature change calculations.

h. Procedure for detection and location of leaks.

i. Procedure for safe dewat ering t he pi peline section after testing, including a
complete de scription of all propose d e quipment and instrume nts (inc luding
spares), their location and set-up, the type and sequence of pigs and the pig
tracking system along with the pig specifications.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 9 of 11

TITLE PIPELINE CROSSINGS USING MEC/S/05/21/75 REVISION : 0

HORIZONTAL DIRECTIONAL
DRILLING METHOD EDITION : 1

j. Forms for recording the testing data.

4.7.3 Contractor shall furnish all necessary equipment & inst rumentation for performing
the work inc luding all temporary piping, hydro t est header and scraper launcher /
receiver etc.

4.7.4 The test medium shall be fresh water to be arranged by the Contractor. The water to
be use d shall be filte red, shall not be cont aminated, an d free from sand of silt .
Contractor shall submit labora tory test reports of water used for t esting. Contractor
shall provide Company approve d corrosion inhibitors, oxyge n sc avengers and
bactericides to be a dded to th e te st w ater. Contractor shall furnish and install all
temporary piping, whic h may be ne cessary to co nnect fro m so urce o f wat er t o it s
pumps and manifolds / tankage.

4.7.5 Before filling operation, Contractor shall clean the pipeline by air driven pigs provided
with spring loaded brushes and cups to re move all mill scale, rust / sand from the
internal of pipe sections.

4.7.6 The hydrostatic test shall be considered as positive if pressure has k ept a constant
value t hroughout t he t est d uration, ex cept fo r chang es d ue t o t emperature effects,
and there is no abrupt pressure drop throughout the test duration.

If test section fails to mainta in the specified test pressure after isolation, Contractor
shall determine by search the loc ation of le akage or fa ilure. All leaks and failures
within the pipe wall or longitudinal seam sh all be repaired by re placement of e ntire
joint or joints in which leak age or failure occurs. In those cases where leaks occur in
circumferential welds the me thod of repair shall be determined by Company.
Contractor shall comply wi th in structions of th e C ompany w hether to re place a
section of the line pipe that includes the line leak or whet her t o rep air t he
circumferential weld. This re pair should, however, meet the requirements of welding
specification cont ained here in. Where failures oc cur in pipe line fie ld be nds, be nds
shall be re placed with same degree of bends. Af ter c ompletion of re pairs, th e
hydrostatic test shall be repeated in full, as per the approved procedures.

All work of reinstating line pipe, to replace failures, shall be done in accordance with
the specifications contained herein.

Contractor shall haul and stockpile all damaged and de fective pipe s to storage
locations de signated by the Company. All cracks and splits re sulting nom failures
shall be coat ed wit h an applicat ion of gr ease t o p reserve t he charact eristics of
failures nom corrosion. Joints of failed pipes shall be marked with paint, with a tag
indicating failure de tails, date and loc ation of failure and pre ssure at which failure
occurred.

4.7.7 After c ompletion of suc cessful hydrote st of t he ab ove p ortion, t he p ipeline shall be
capped and burie d. Pipe line e nd position on t he b anks shall b e mark ed o n t he
ground by installing location markers on both banks approved by Company.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 10 of 11

TITLE PIPELINE CROSSINGS USING MEC/S/05/21/75 REVISION : 0

HORIZONTAL DIRECTIONAL
DRILLING METHOD EDITION : 1

4.8 Permanent Pipeline Markers

On both banks of e ach river crossing, Contractor shall install a Navigable Waterway
Pipeline Crossing Warning Sign in a ccordance with Std. No. ME C/S/05/21/05.
Contractor shall supply all materials and fabricat e and inst all t he mark ers as per
reference drawing. Wherever feasible, the pipeline markers shall be installed on the
embankments, however, exact location shall be decided based on site conditions and
as directed by Company.

4.9 Fencing

Wherever sp ecified, Co ntractor shall supply all materials and install G.I. Wire Chain
link security fencing of size 10 m x 10 m x 25 m high with lockable steel gate around
the pipe e nds and te st stations for te mporary C.P. on both side s of e ach rive r
crossing.

4.10 Idle Time Preservation of Pipeline

When so stated in the Contract, Contractor shall supply all materials and consumable
including wate r and inhibitor and shall install all piping connections, valves,
instrumentation, etc., and pe rform all works for pre servation of pipe line by
pressurization with inhibited water. Contractor shall use approved inhibitors and shall
determine the required dosages of inhibitors and pressure for idle time preservation
of the pipeline for a pe riod of maximum si x months nom t he date of complet ion of
construction. Corrosion inhibit ors and dosages shall be su bject to C ompany's
approval prior to use.

4.11 Final Clean up

4.11.1 After completion of construction, Contractor shall clear the site of all balance material
and debris and bentonite slurry. All balance pipe lengths shall be returned to Owner’s
designated stock yard(s). Site/ ROW sh all be cleared to th e complete satisfaction of
the land owner’s and aut horities having jurisdiction. All such work s shall be done at
no extra cost t o Owner. T he Owner shall be indemnified agains t any / all claims
arising as a result thereof.

4.11.2 Contractor shall arrange for safe disposal of all surp lus soil and bentonite slurry &
corrosion inhibited test w ater so a s to a void a ny h arm to th e e nvironment /
occupants at locations duly approve d by authorities and pollution control boards
having jurisdiction and/or as instructed by Company without any extra cost.

5.0 DOCUMENTATION

5.1 In additional to the doc uments spe cified elsewhere in t his sp ecification. Contractor
shall submit to the Owner the following documents/ records.

• Copies of the permits obtained from authorities having jurisdiction.

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 11 of 11

TITLE PIPELINE CROSSINGS USING MEC/S/05/21/75 REVISION : 0

HORIZONTAL DIRECTIONAL
DRILLING METHOD EDITION : 1

• Records of pre and post installation hydrostatic testing.

• Record of non-destructive testing of welds.
• Detailed drilling log and downhole data, including, but not limited to, the
following :
i) Torque and pulling/pushing force
ii) Data on drilling fluid.
- Density
- Type of mud and additive employed.
- Mixing, pumping and cleaning.

• Wash and drill pipe data, viz.,

i) Dimension and material properties.
ii) Data on API classification.
iii) Age of and type of inspection previously carried out on these pipes.

• Permits obtained from authorities having jurisdiction for the various works.
• Plan & profile of the drilled hole along with the water level variations.
• Records of hydrostatic pre-testing and final testing.
• Record of Non Destructive Testing of welds.
• Clearance cert ificates fo rm t he land owners and Authorities having ju risdiction
regarding satisfactory clean-up and restoration of pipeline RoU and work areas.

• Clearance cert ificate fro m t he land o wners and aut horities having ju risdiction
regarding satisfactory clea n-up and re storation of the pipe line ROW and work
sites.

5.2 After completion of c onstruction, C ontractor sh all pre pare a nd f urnish six se ts of
copies and two se ts of reproducible of `As-built’ for the crossings. As built drawings
shall , as a minimum include the following information

• True profile of the crossing along the pipeline.

• True profile of the pipeline as installed and the depth of cover to top of pipe at
regular intervals.
• Location of e ntry and e xit point and angle s of e ntry and ex it alongwith lateral
offset of exit point from the original pipeline alignment.
• Location and angle of field bends
• Location of pipeline markers.
• All As-Built drawings shall be prepared using software AutoCAD Release 2000 or
above. Manually drafte d drawings are not acceptable to Company. I n addition,
to the hard c opies, as-built drawings shall also be submitted in electronic media
i.e. CD / DVD.

5.3 All documents shall be in English language.

 PROCESS & PIPING DESIGN SECTION
MECON LIMITED
DELHI - 110 092

TECHNICAL SPECIFICATION
FOR
LONG RADIUS BENDS

SPECIFICATION NO. : MEC/TS/05/62/015, Rev-1

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 MECON LIMITED PROCESS & PIPING STANDARD SPECIFICATION
DELHI DESIGN SECTION

TITLE LONG RADIUS BENDS SPECIFICATION NO. PAGE 1 OF 8

MEC/TS/05/62/015 REVISION 1

CONTENTS

1.0 SCOPE

2.0 REFERENCE DOCUMENTS

3.0 MATERIAL

4.0 MANUFACTURE

5.0 INSPECTION AND TESTS

6.0 MARKING, PACKING AND SHIPMENT

7.0 WARRANTY

8.0 DOCUMENTATION

Revision No. Date Revised by Checked by Approved by

PREPARED BY : CHECKED BY : APPROVED BY :

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 MECON LIMITED PROCESS & PIPING STANDARD SPECIFICATION
DELHI DESIGN SECTION

TITLE LONG RADIUS BENDS SPECIFICATION NO. PAGE 2 OF 8

MEC/TS/05/62/015 REVISION 1

1.0 SCOPE

This specification cove rs lon g radiu s s teel pipe be nds to be man ufactured in
accordance w ith t he req uirements o f MSS-SP ( Manufacturers St andardisation
Society – St andard Practice) – 75, latest edition, to be used in pipeline syst em
handling Natural Gas. The selection of options permitted by MSS-SP-75 shall be
as described be low. All applicable re quirements con tained in th e MS S-SP-75
shall be fu lly valid u nless can celled, re placed or ame nded by more
requirements a s st ated in t his specific ation. In cas e of con flict be tween th e
requirements of t his specifica tion a nd MSS- SP-75, t he req uirements o f t his
specification shall govern.

2.0 REFERENCE DOCUMENTS

Reference has also been made in this specification to the latest edition of t he
following codes, standards and specifications.

a) ANSI B31.8 : Gas Transmission a nd Dist ribution Pip ing

System.

b) ASME – Sec. VIII : Boiler and Pressure Vessel Code

Div. 1

c) ASME – Sec IX : Boiler & Pressure Vessel Code

Welding and Brazing Qualifications

d) API Spec. 5L : Line Pipe

e) ASTM Part-I : Steel – Piping, Tubing, Fittings

In ca se o f co nflict b etween t he a bove reference d ocuments a nd t his

specification, the requirements of the specification shall prevail.

3.0 MATERIALS

3.1 Bends shall be fabricated from bare steel line pipe (to be issued as free issue
item by Pu rchaser). Th e de tails of fre e is sue lin e pipe mate rial is given
separately in LR Bend Data Sheet & Purchase Requisition.

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 MECON LIMITED PROCESS & PIPING STANDARD SPECIFICATION
DELHI DESIGN SECTION

TITLE LONG RADIUS BENDS SPECIFICATION NO. PAGE 3 OF 8

MEC/TS/05/62/015 REVISION 1

3.2 All mecha nical p roperties o f t he b ends after finishing shall be s ame as pipe
specification as referred in section 3.1. The following tests shall be conducted
on fin ished be nds an d te st proce dures s hall be as per pipe specification as
referred in para 3.1.

3.2.1 One t ransverse t ensile t est will be conducted t o est ablish t he yield st rength,
ultimate tensile strength and elongation of :

a) Base material at inside radius of the bend.

b) Base material at outside radius of the bend.

3.2.2 One a ll weld t ensile t est will be conduc ted (wherever a pplicable) t o est ablish
yield strength, u ltimate te nsile s trength an d e longation of we ld mate rial on
bend.

3.2.3 Three transverse Charpy-V-notch impact tests shall be conducted on full sized
specimen of the same heat in a ccordance with ASTM A370 a t 0°C fo r each of
the following :

a) Base material at outside radius of the bend.

b) Weld material of bend

3.2.4 Guided Bend Tests

One face and one root guided bend weld test shall be performed on samples
cut from one bend per heat of s teel. The dimensions `A’ in guided bend test
shall not exceed 4.0 times the nominal wall thickness and dimension `B’ sha ll
be equal to A + 2t + 3.2mm.

4.0 MANUFACTURE

4.1 Bends shall be manufactured by hot bending of pipe applying induction heating
only.

The adopted proce dure s hall be compl eted by s uitable h eat tre atment to
achieve the required mechanical and chemical properties of the finished bends
and is acce pted on ly afte r writte n appr oval of th e Pu rchaser. The procedure
shall ensure unifo rm bending without any defects other than those allowed in
this specification and pipe specification as referred in para 3.1.

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 MECON LIMITED PROCESS & PIPING STANDARD SPECIFICATION
DELHI DESIGN SECTION

TITLE LONG RADIUS BENDS SPECIFICATION NO. PAGE 4 OF 8

MEC/TS/05/62/015 REVISION 1
4.2 When bending, the weld wherever applicable shall be located at approx. 10° from
the neutral zone, measured at outside of the bend as indicated in figure below.
10°

W E LD H ER E B E N D IN G P L A N E
OR
HERE

BEND

10°

4.3 Bevels at the ends shall be as specified in MS S-SP-75 unless o therwise sp ecified
differently in the material/ purchase requisition.

4.4 Bends shall not have any circumferential joint.

4.5 No repair by welding is allowed on any part of the bends.

4.6 The cooling o f t he b end immed iately a fter b ending sha ll b e a n int erval c ooling,
alternatively with water and air at a minimum pressure of 2 atmospheres.

4.7 The p rocedure sha ll b e suc h w hich sha ll no t req uire a ny a dditional hea t –
treatment after bending. If such a heat treatment is required, it is permitted only
after the written approval of purchaser and shall be carried out at Manufacturer’s
expense.

4.8 Bulges, dents and flat areas shall not appear within 100mm from end of the bend.

For the remaining part of the bend these deviations from the original contour of
the pipe are permitted but the same shall be repaired, provided these deviations
shall not exceed 6.5% o f no minal w all t hickness in heig ht/ d epth a nd t he sa me
shall not extend (in a ny direction) over a distance of more than 25% of nominal
diameter.

4.9 The excess weld material wherever applicable at the inside of the bend shall be
removed over a distance of 100mm at both ends.

4.10 Tolerances
The d imensions o f b ends sha ll b e c ontrolled t o ma ke sure t hat t hey a re
manufactured a ccording t o t he t olerances ind icated b elow over and above the
requirements of MSS-SP-75

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 MECON LIMITED PROCESS & PIPING STANDARD SPECIFICATION
DELHI DESIGN SECTION

TITLE LONG RADIUS BENDS SPECIFICATION NO. PAGE 5 OF 8

MEC/TS/05/62/015 REVISION 1
4.10.1 Minimum Inside Diameter : -2.5% of inside nominal
diameter except 200mm from ends

Bend Angle : ±1°

Bend Radius : ± 1% of bending nominal

Diameter

4.10.2 The manufacturer s hall ch eck th e wal l th ickness of th e pi pe be fore an d af ter

bending alon g th e ou tside radiu s e ither at distances approximately equal to
pipe diameter or 3 00mm whichever is less. The measured wall thickness shall
be atleast equal to :

tmin = 0.95 (tnom. - t)

tnom = nominal wa ll t hickness a s specified in the

material/ purchase requisition.

t = 0.35mm for a wall thickness smaller than

10mm.
t = 0.50mm for a wall thickness 10mm or more.

4.10.3 Ovality may be defined as :

OD max. – OD min
OD nom.

The above value shall be < 1% w ithin 100mm fro m each end and < 6% fo r
remaining part of th e be nd. Th e me asurement s hall be made over the
circumference of the b end eit her a t d istance a pproximately eq ual t o p ipe
diameter or 300mm whichever is less.

4.10.4 Wrinkles

Measurements of the outside diameter shall be taken in the plane of the bend
at lo cations w here w rinkles a re p resent ( OD ma x.) and at locations where
wrinkles a re no t p resent ( OD min, ). T he acceptance limit shall be as defined
below.
OD max. – OD min
------------------------- < 1%
OD nom.

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 MECON LIMITED PROCESS & PIPING STANDARD SPECIFICATION
DELHI DESIGN SECTION

TITLE LONG RADIUS BENDS SPECIFICATION NO. PAGE 6 OF 8

MEC/TS/05/62/015 REVISION 1

5.0 INSPECTION AND TESTS

5.1 The ma nufacturer sha ll perform a ll inspect ion a nd tests as per the
requirements of t his specifica tion a nd MSS- SP-75 p rior t o ship ment at his
works. Such inspection and tests shall be, but not limited to, the following :

a) Verify that the unfinished product arriving at manufacturer’s shop is in

full compliance with the pipe specification as referred in para 3.1.
b) Visual Inspection.
c) Dimensional an d tole rances ch eck as pe r MS S-SP-75 an d re quirements
of section 4.0 of this specification.
d) Check hea t t reatment, if ca rried o ut, a s req uired a nd ma intain its
records.
e) Temperature against time recorder charts for each induction heating.
f) Material properties shall be checked to meet the requirements of section
3.0 of this specification.
g) The non-destructive inspection on the finished bend shall be carried out
as given below :

• All longit udinal sea m welds sh all be fully radiographed and

acceptance limit s sha ll be a s per pipe specifica tion a s referred in
para 3.1.
• The full circumference of bot h ends of ea ch bend a fter bevelling
shall be ult rasonically tested for la minations over a length of 25mm
and acceptance limits shall be as per pipe specification as referred in
para 3.1.

5.2 Purchaser’s Representative reserves t he right to perform stagewise inspection

and witness te sts on all be nds as in dicated in para 5 .1 at Man ufacturer’s
works, prior to shipment.

Manufacturer s hall gi ve re asonable n otice of ti me and shall provide without

charge rea sonable a ccess and facilities required for inspect ion, t o t he
Purchaser’s Rep resentative. I nspection and test pe rformed or witn essed by
Purchaser’s Rep resentative sha ll in no way relieve the Manufacturer’s
obligation t o perform t he required inspection and t ests. Und er no
circumstances any action of t he Purc haser’s Rep resentative sha ll relieve t he
Manufacturer of his responsibility for t he ma terial, design, qua lity a nd
operation of the equipment.

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 MECON LIMITED PROCESS & PIPING STANDARD SPECIFICATION
DELHI DESIGN SECTION

TITLE LONG RADIUS BENDS SPECIFICATION NO. PAGE 7 OF 8

MEC/TS/05/62/015 REVISION 1

5.3 Test Certificates

The Manufacturer shall p roduce t he Cert ificates (in origina l) for a ll, but not
limited to, the following :

a) Certificates of ch emical an alysis an d m echanical te sts carri ed ou t on

pipe and bends separately.

b) Certificates of required non-destructive test inspection.

c) Certificates of heat treatments, if any.

d) Certificates of all other tests as required in this specification.

In case any of t he a bove sa id cert ificates a re no t a vailable d uring t he fina l

inspection, the supply shall be considered incomplete.

6.0 MARKING, PACKING AND SHIPMENT

6.1 All bends shall be marked as per MSS-SP-75.

6.2 All loos e an d fore ign mate rial i.e . ru st, gre ase, e tc. shall be removed from
inside and outside of the bends.

6.3 All bends except bevelled ends shall be coated internally and externally with a
thin f ilm of zi nc ch romate re d ox ide pai nt f or prote ction agai nst corrosion
during transit and storage. The coating shall be easily removable in the field.
Manufacturer shall furnish the details for the same.

6.4 Both ends of all bends shall be suitably protected to avoid an y damage during
transit by means of metallic bevel protectors.

6.5 Package s hall be marke d le gibly with suit able ma rking t o indica te t he
following:

a) Order Number
b) Package Number
c) Manufacturer’s Name
d) Size (Inches) and wall thickness (mm)

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 MECON LIMITED PROCESS & PIPING STANDARD SPECIFICATION
DELHI DESIGN SECTION

TITLE LONG RADIUS BENDS SPECIFICATION NO. PAGE 8 OF 8

MEC/TS/05/62/015 REVISION 1

7.0 WARRANTY

Purchaser will be reimbursed by Ma nufacturer for a ny bend furnished on t his

order that fails under field hydrostatic test if such fa ilure is caused by a defect
in t he bend which is out side the acceptance limit s of t his specifica tion. T he
reimbursement cost shall include bend cost, labour cost and equipment rental
for searching, excavation, cu tting ou t an d in stallation of re placed be nd in
position. T he field hydrost atic t est pre ssure will not exceed t hat va lue which
will cause a calculated hoop stress equivalent to 100% o f specified minimum
yield strength of the attached pipe.

8.0 DOCUMENTATION

8.1 All documents shall be in English language.

8.2 At the time of bidding, bidder shall submit the following documents :

a) Reference list of previous supplies of bends of similar specifications.

b) Clause-wise list of deviation from this specification, if any.

c) Brief description of manufacturing a nd qua lity cont rol fa cilities of t he

Manufacturer’s works.

8.3 Within o ne w eek o f p lacement o f o rder t he Ma nufacturer shall submit four

copies, of th e manufacturing process and quality assurance plan for pipe and
bends.

Once th e approv al h as be en gi ven by Pu rchaser any change in material and

method of manufacture and q uality co ntrol sha ll b e no tified t o Purcha ser
whose approval in writ ing of a ll such changes s hall be obtain ed be fore th e
bends are manufactured.

8.4 Within f our we eks f rom th e approv al date Manufacturer shall submit one
reproducible and s ix copie s of th e docu ments as s tated in para 8 .3 of th is
specification.

8.5 Prior to s hipment, th e Man ufacturer s hall submit one reproducible and six
copies of test certificates as listed in para 5.3 of this specification.

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 Rev. : 0
Edition : 1

SPECIFICATION
FOR
SEAMLESS FITTINGS & FLANGES
[SIZE UPTO DN 400 mm (16”) NB]

SPECIFICATION NO.: MEC/TS/05/21/025

(OIL & GAS SBU)

MECON LIMITED
DELHI 110 092
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 1

TITLE SEAMLESS FITTINGS & MEC/TS/05/21/025 REVISION : 0

FLANGES [SIZE UPTO DN 400
mm (16”) NB] EDITION : 1

CONTENTS

SL.NO. DESCRIPTION

1.0 SCOPE

2.0 REFERENCE DOCUMENTS

3.0 MANUFACTURER’S QUALIFICATION

4.0 MATERIALS

5.0 DESIGN AND MANUFACTURE

6.0 INSPECTION AND TESTS

7.0 TEST CERTIFICATES

8.0 PAINTING, MARKING AND SHIPMENT

9.0 DOCUMENTATION

PREPARED BY: CHECKED BY: APPROVED BY: ISSUE DATE :

(Shalini Singh) (Sunil Kumar) (A.K. Johri) Dec. 2008

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 5

TITLE SEAMLESS FITTINGS & MEC/TS/05/21/025 REVISION : 0

FLANGES [SIZE UPTO DN 400
mm (16”) NB] EDITION : 1

1.0 SCOPE

This specification covers the minimum requirements for the design, manufacture and
supply of following carbon steel flanges and fittings of size upto DN 400 mm (16") to
be installed in onshore pipeline systems handling non-sour hydrocarbons in liquid or
gaseous phase including Liquefied Petroleum Gas (LPG) :

- Flanges such as welding neck flanges, blind flanges, spectacle blinds,

spacers and blinds etc.

- Seamless fittings such as tees, elbows, reducers, caps, outlets etc.

2.0 REFERENCE DOCUMENTS

2.1 Reference has been made in this specification to the latest edition (edition enforce at
the time of issue of enquiry) of the following Codes, Standards and Specifications :

ASME B31.4 - Pipeline Transportation Systems for Liquid

Hydrocarbons and Other Liquids

ASME B31.8 - Gas Transmission and Distribution Piping Systems

ASME B16.5 - Pipe Flanges and Flanged Fittings

ASME B16.9 - Factory Made Wrought Steel Butt Welding Fittings

ASME B 16.11 - Forged Steel Fittings, Socket Welding and Threaded

ASME B 16.48 - Steel Line Blanks

ASME Sec VIII - Boiler and Pressure Vessel Code - Rules for
Construction of Pressure Vessels

ASME Sec IX - Boiler and Pressure Vessel Code - Welding and

Brazing Qualifications

ASTM A 370 - Standard Test Methods and Definitions for Mechanical

Testing of Steel Products.

MSS-SP-25 - Standard Marking System for Valves, Fittings, Flanges

and Unions
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 2 of 5

TITLE SEAMLESS FITTINGS & MEC/TS/05/21/025 REVISION : 0

FLANGES [SIZE UPTO DN 400
mm (16”) NB] EDITION : 1

MSS-SP-97 - Forged Carbon Steel Branch Outlet Fittings - Socket

Welding, Threaded and Butt welding Ends.

2.2 In case of conflict between the requirements of this specification and the
requirements of above referred Codes and Standards, the requirements of this
specification shall govern.

3.0 MANUFACTURER'S QUALIFICATION

Manufacturer who intends bidding for fittings must possess the records of a
successful proof test, in accordance with the provisions of ASME B16.9 / MSS-SP-75
as applicable.

4.0 MATERIAL

4.1 The Carbon Steel used in the manufacture of flanges and fittings shall be fully killed.
Material for flanges and fittings shall comply with the material standard indicated in
the Purchase Requisition. In addition, the material shall also meet the requirements
specified hereinafter.

4.2 Each heat of steel used for the manufacture of flanges and fittings shall have Carbon
Equivalent (CE) not greater than 0.45 calculated from check analysis in accordance
with the following formula:

Mn Cr + Mo + V Ni + Cu
CE = C + ------- + --------------------- + ---------------
6 5 15

Carbon contents on check analysis shall not exceed 0.22%.

4.3 For flanges and fittings specified to be used for Gas service or LPG service, Charpy
V-notch test shall be conducted on each heat of steel. Unless specified otherwise,
the Charpy V-notch test shall be conducted at 0°C in accordance with the impact test
provisions of ASTM A 370 for flanges and fittings.

The average absorbed impact energy values of three full-sized specimens shall be
27 joules. The minimum impact energy value of any one specimen of the three
specimens analysed as above, shall not be less than 22 Joules.

When Low Temperature Carbon Steel (LTCS) materials are specified for flanges and
fittings in Purchase Requisition, the Charpy V-notch test requirements of applicable
material standard shall be complied with.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 3 of 5

TITLE SEAMLESS FITTINGS & MEC/TS/05/21/025 REVISION : 0

FLANGES [SIZE UPTO DN 400
mm (16”) NB] EDITION : 1

4.4 For flanges and fittings specified to be used for Gas service or LPG service,
Hardness test shall be carried out in accordance with ASTM A 370. Hardness testing
shall cover at least 10% per item, per size, per heat, per manufacturing method. A
full thickness cross section shall be taken for this purpose and the maximum
hardness shall not exceed 248 HV10.

4.5 In case of RTJ (Ring Type Joint) flanges, the groove hardness shall be minimum 140
BHN. Ring Joint flanges shall have octagonal section of Ring Joint.

5.0 DESIGN AND MANUFACTURE

5.1 Flanges such as weld neck flanges and blind flanges shall conform to the
requirements of ASME B16.5.

5.2 Spectacle blind and spacer & blind shall conform to the requirements of ASME B
16.48.

5.3 Fittings such as tees, elbows, reducers, etc. shall be seamless type and shall
conform to ASME B16.9 for sizes DN 50 mm (2") to DN 400 mm (16") (both sizes
included) and ASME B 16.11 for sizes below ON 50 mm (2").

5.4 Fittings such as weldolets, sockolets, nippolets, etc. shall be manufactured in

accordance with MSS-SP-97.

5.5 Type, face and face finish of flanges shall be as specified in Purchase Requisition.

5.6 Flanges and fittings manufactured from bar stock are not acceptable.

5.7 All butt weld ends shall be bevelled as per ASME B 16.5 / ASME B 16.9 / MSS-SP-
97 as applicable.

5.8 Repair by welding on flanges and fittings is not permitted.

5.9 Stub-in or pipe to pipe connection shall not be used in the manufacture of tees.
Tees shall be manufactured by forging or extrusion methods. The longitudinal weld
seam shall be kept at 90° from the extrusion. Fittings shall not have any
circumferential joint .
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 4 of 5

TITLE SEAMLESS FITTINGS & MEC/TS/05/21/025 REVISION : 0

FLANGES [SIZE UPTO DN 400
mm (16”) NB] EDITION : 1

6.0 INSPECTION AND TESTS

6.1 The Manufacturer shall perform all inspections and tests as per the requirement of
this specification and the relevant codes, prior to shipment at his works. Such
inspections and tests shall be, not but limited to the following :

a) All flanges and fittings shall be visually inspected. The internal and external surfaces
of the flanges and fittings shall be free from any strikes, gauges and other
detrimental defects.

b) Dimensional checks shall be carried out on finished products as per ASME B16.5 for
flanges, ASME B16.48 for spacers and blinds and ASME B16.9 / MSS-SP-97 as
applicable for fittings and as per this specification.

c) Chemical composition and mechanical properties shall be checked as per relevant

material standards and this specification, for each heat of steel used.

d) All finished wrought weld ends subject to welding in field, shall be 100% tested for
lamination type defects by ultrasonic test. Any lamination larger then 6.35 mm shall
not be acceptable.

6.2 Purchaser's Inspector reserves the right to perform stage wise inspection and
witness tests, as indicated in clause 6.1 of this specification at Manufacturer's Works
prior to shipment. Manufacturer shall give reasonable notice' of time and shall
provide, without charge, reasonable access and facilities required for inspection, to
the Purchaser's Inspector.

Inspection and tests performed / witnessed by Purchaser's Inspector shall in no way

relieve the Manufacturer's obligation to perform the required inspection and tests.

7.0 TEST CERTIFICATES

Manufacturer shall furnish the following certificates:

a) Test certificates relevant to the chemical analysis and mechanical properties

of the materials used for manufacture of flanges and fittings as per relevant
standards and this specification.

b) Test Reports on non destructive testing.

c) Certificates for each fitting stating that it is capable of withstanding without

leakage a test pressure, which results in a hoop stress equivalent to 100 % of
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI

DOCUMENT NO. Page 5 of 5

TITLE SEAMLESS FITTINGS & MEC/TS/05/21/025 REVISION : 0

FLANGES [SIZE UPTO DN 400
mm (16”) NB] EDITION : 1

the specified minimum yield strength for the pipe with which the fitting is to be
attached without impairment of serviceability.

8.0 PAINTING, MARKING AND SHIPMENT

8.1 After all inspection and tests required have been carried out; all external surfaces
shall be thoroughly cleaned to remove grease, dust and rust and shall be applied
with standard mill coating for protection against corrosion during transit and storage.
The coating shall be easily removable in the field.

8.2 Ends of all fittings and weld neck flanges shall be suitably protected to avoid any
damage during transit. Metallic or high impact plastic bevel protectors shall be
provided for fittings and flanges. Flange face shall be suitably protected to avoid any
damage during transit.

8.3 All flanges and fittings shall be marked as per applicable dimension / manufacturing
standard.

9.0 DOCUMENTATION

Documentation to be submitted by Manufacturer to Company is summarized below.

Number of Copies (Hard copies / soft copies etc.) shall be as indicated in
CONTRACT document / Material Requisition.

9.1 At the time of bidding, Manufacturer shall submit the following documents:

a) Reference list of previous supplies of similar fittings of similar specification.

b) Clausewise list of deviations from this specification, if any.
c) Brief description of the manufacturing and quality control facilities at
Manufacturer's works.
d) Manufacturer's qualification requirement as per clause 3.0 of this specification.
e) Quality Assurance Plan (QAP) enclosed with this tender duly signed, stamped
and accepted.

9.2 Prior to shipment, the Manufacturer shall submit test certificates as listed in clause
7.0 of this specification.

9.3 All documents shall be in English Language only.

 PROCESS & PIPING DESIGN SECTION
MECON LIMITED
DELHI 110 092

TECHNICAL SPECIFICATION
FOR
ASSORTED PIPES

SPECIFICATION NO. : MEC/TS/05/62/59A, R-0

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 MECON LIMITED PROCESS & PIPING TECHNICAL SPECIFICATION
Delhi DESIGN SECTION FOR
ASSORTED PIPES

TECHNICAL SPECIFICATION NO. : MEC/TS/05/62/59A REV-0 PAGE 1 OF 9

CONTENTS

Sl.No. Description Page No.

1.0 GENERAL 2

2.0 IBR PIPES 4

3.0 HYDROSTATIC TEST 5

4.0 MARKING & DESPATCH 5

ANNEXURE-I : HYDROSTATIC TEST 7

Prepared By : Checked By : Approved By :

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 MECON LIMITED PROCESS & PIPING TECHNICAL SPECIFICATION
Delhi DESIGN SECTION FOR
ASSORTED PIPES

TECHNICAL SPECIFICATION NO. : MEC/TS/05/62/59A REV-0 PAGE 2 OF 9

1.0 GENERAL

1.1 All pipes and their dimensions, tolerances, chemical composition, physical
properties, h eat treatment, h ydrotest and o ther te sting and marking
requirements shall conform t o the latest codes and standards specified in
the Material Requisition (MR) . Devia tion(s), if a ny, sha ll be clea rly
highlighted in the offer.

1.2 Testing

1.2.1 Test reports shall be supplied for all mandatory tests as per the applicable
material sp ecifications. T est rep orts sha ll a lso be furnished for any
supplementary tests as specified in the MR & Clauses 1.10 & 1.11.

1.2.2 Material test cert ificates ( physical propert y, chemica l com position &
treatment report) shall also be furnished for the pipes supplied.

1.3 Manufacturing Processes

1.3.1 Steel made by Acid Bessemer Process shall not be acceptable.

1.3.2 All lo ngitudinally w elded p ipes o ther t han I S:3589 should employ
automatic welding.

1.4 Pipe shall be supplied in single or double random length of 4 to 7 and 7 to

14 meters, respectively.

1.5 a) Seamless and E.R.W. pipes shall not have any circumferential seam
joint in a r andom length. However, in case of E.FS .W. pipe, in one
random length one welded circumferent ial seam of same quality as
longitudinal weld is permit ted. T his weld sha ll be at lea st 2.5 m
from eit her end . T he lo ngitudinal sea ms o f the two portions shall
be staggered by 90°. Single random length in such cases shall be 5
to 7m.

b) Unless otherwise mentioned in t he re spective ma terial code,

E.FS.W. pipes < 3 6” s hall n ot h ave more t han one longitudinal
seam joint and E.FS.W. pipes ≥ 36” sha ll not have more than two
longitudinal seam joints.

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Delhi DESIGN SECTION FOR
ASSORTED PIPES

TECHNICAL SPECIFICATION NO. : MEC/TS/05/62/59A REV-0 PAGE 3 OF 9

1.6 Pipe with s crewed e nds s hall h ave N PT e xternal taper pipe threads
conforming to ASME/ ANSI B1.20.1 upto 1.5” NB & IS:554 for 2” to 6” NB.

1.7 Pipe with be velled e nds s hall be in accordan ce wi th ASME B16.25. Weld
contours shall be as follows:

Material Wall Thickness Weld Contour

Carbon St eel ( Except Low Upto 22mm Figure 2 Type A
Temp. Carbon Steel) > 22mm Figure 3 Type A
Alloy Steel St ainless St eel & Upto 10 mm Figure 4
Low Temp. Carbon Steel >10 mm & Upto 25 mm Figure 5 Type A
> 25 mm Figure 6 Type A

1.8 Gavanished pipes shall be coated with zinc by hot dip process conforming
to IS:4736/ ASTM A 153.

1.9 All austenitic stainless steel p ipes shall b e sup plied in so lution a nnealed
condition.

1.10 I.G.C. Test for Stainless Steels

1.10.1 For a ll austenitic st ainless st eel p ipes, int ergranular corrosion test shall
have to be conducted as per following:

ASTM A262 practice “ B “ with acceptance c riteria of “ 60 mils/ yea r

(max.)”

OR

ASTM 262 p ractice “ E ’’ with acceptance c riteria of “ No cracks as

observed from 20X magnification” & “Microscopic structure to be observed
from 250X magnification”.

1.10.2 When specifica lly a sked for in MR for high t emperature application o f
some grades of austenitic stainless steel (eg.SS 309, 310, 316, 316H etc.),
ASTM A262 practice “C” with acceptance criteria of “15 mils/ year (max.)”
shall have to be conducted.

1.10.3 For the IGC test as described in 1.10.1 & 1.10.2, two sets of samples shall
be drawn from e ach s olution annealing lot; one s et corresponding to
highest carbon content an d the oth er co rresponding to th e h ighest pi pe

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Delhi DESIGN SECTION FOR
ASSORTED PIPES

TECHNICAL SPECIFICATION NO. : MEC/TS/05/62/59A REV-0 PAGE 4 OF 9

thickness. When testing in is conducted as per Practice “E”, photograph of

microscopic structure shall be submitted for record.

1.11 All welded pipes indicated a s ‘CRYO’ & ‘LT ’ in MR sha ll be imp act tested
per requirement and acceptance criteria of ASME B31.3. The impact test
temperature shall b e –196° C & - 45° C fo r sta inless st eel a nd c arbon
steel, respectively, unless specifically mentioned otherwise in MR.

1.12 Pipes under ‘NACE’ category sha ll meet the req uirements g iven in
MR-01-75.

1.13 Specified hea t t reatment fo r ca rbon st eel & alloy steel and solution
annealing for stainless steel pipes shall be carried out after weld repairs.
Number of weld repairs at the same spot shall be restricted to maximum
two by approved repair procedure.

1.14 For black o r ga lvanised p ipes t o IS:1239, t he minimum p ercentage o f

elongation shall be 20%.

2.0 IBR PIPES

2.1 IBR Documentation

2.1.1 Pipes u nder pu rview of IBR s hall be a ccompanied wi th IBR certificate

original in Form IIIA, duly approved and countersigned by IBR a uthority/
local authority empowered by the Central Boiler Board of India. Photocopy
of the original certificate duly at tested by the local boiler inspector where
the supplier is located is the minimum requirement for acceptance.

2.1.2 For materials 1 ¼ Cr- ½ Mo (ASTM A335 Gr. P11/ A691 Gr. 1 ¼ Cr) & 2
¼ Cr-1Mo (ASTM A335 Gr.P22/ A691 Gr. 2 ¼ Cr. ), fro m III-A ap proved
by IBR sha ll include t he t abulation of Et , S c & Sr va lues fo r t he ent ire
temperature ra nge g iven b elow. E t , Sc & S r va lues sha ll be such t hat
throughout the temperature range

Et / 1.5 ≥
Sr / 1.5 ≥ Sa
Sc ≥
where,
SA : Allowable stress at the working metal temperature.
Et : Yield point (0.2% proof stress at the working metal
temperature).

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Delhi DESIGN SECTION FOR
ASSORTED PIPES

TECHNICAL SPECIFICATION NO. : MEC/TS/05/62/59A REV-0 PAGE 5 OF 9

Sc : The average stress to produce elongation of 1% (creep) in

1,00,000 hrs at the working metal temperature.
Sr : The average stress to produce rupture in 1,00,000 hrs. at
the working metal temperature and in no case more than
1.33 times the lowest stress to produce rupture at this
temperature.

SA (psi) Temperature (°F)

Material 500 600 650 700 750 800 850 900 950 1000 1050 1100
A335 Gr. P11 17200 16700 16200 15600 15200 15000 14500 12800 9300 6300 4200 2800
A 691 Gr. 1½ Cr 18900 18300 18000 17600 17300 16800 16300 15000 9900 6300 4200 2800
A335 Gr. P2/ 17900 17900 17900 17900 17900 17800 14500 12800 10800 7800 5100 3200
A691 Gr. 2 ¼ Cr

Note: SA values given above are as per ASME B31.3-1999. Values shall be as per
the latest edition prevailing.

2.2 For carbon steel pipes under IBR, the chemical composition shall conform
to the following;

Carbon (max.) : 0.25%

Others (S, P, Mn) : As prescribed in IBR regulation.

The chemical composition as indicated in this clause is not applicable for

pipes other than IBR services.

3.0 HYDROSTATIC TEST

Refer Annexure – I.

4.0 MARKING AND DESPATCH

4.1 All pipes sha ll be ma rked in a ccordance wit h t he a pplicable co des,

standards and specifications. In addition, the purchase order number, the
item code & special conditions like “IBR”, “ CRYO”, “NACE”, etc., shall also
be marked.

4.2 Pipes under “IBR”, “CRYO”, & “NACE” shall be painted in red stripes, light
purple brown s tripes & canary ye llow stripes, respect ively, longit udinally
throughout the length for easy identification.

4.3 Paint or ink for marking sha ll no t conta in a ny ha rmful meta l or meta llic
salts such as zinc, lead or copper which cause corrosive attack on heating.

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Delhi DESIGN SECTION FOR
ASSORTED PIPES

TECHNICAL SPECIFICATION NO. : MEC/TS/05/62/59A REV-0 PAGE 6 OF 9

4.4 Pipes s hall be dry, cle n an d fre e from from mois ture, dirt and loose
foreign materials of any kind.

4.5 Pipes s hall be prote cted from ru st, c orrosion and mechanical damage
during transportation, shipment and storage.

4.6 Rust p reventive us ed o n ma chined surfa ces t o b e w elded sha ll b e ea sily

removable with a petroleum solvent and the same shall not be harmful to
welding.

4.7 Both ends of the pipe shall be protected with the following material:

Plain end : Plastic cap

Bevel end : Wood, Metal or Plastic cover
Threaded end : Metal or Plastic threaded cap

4.8 End prote ctors t o be u sed on be velled e nds s hall be s ecurely and tightly
attached with belt or wire.

4.9 Steel end protectors to be used on galvanised pipes shall be galvanised.

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TECHNICAL SPECIFICATION NO. : MEC/TS/05/62/59A REV-0 PAGE 7 OF 9

ANNEXURE–I

3.0 HYDROSTATIC TEST

3.1 All pipes shall be hydrostatically tested.

3.2 The mill test pressure shall be as follows:

3.2.1 Seamless, E.R.W. & Spiral Welded

a) Carbon Steel

Material Standard Test Pressure Standard

ASTM A 106 Gr. B ASTM A 530
API 5L Gr. B, Seamless API 5L
API 5L, E.R.W. API 5L
API 5L, Spiral API 5L
ASTM A333 Gr.3 & 6, Seamless ASTM A 530
ASTM A 333 Gr. 3 & 6, E.R.W. ASTM A 530

b) Seamless Alloy Steel

Material Standard Test Pressure Standard

ASTM A335 GR. P1, P 12, P11, P22, P5, ASTM A 530
P9
ASTM A268 TP 405, TP410 ASTM A530

c) Seamless Stainless Steel

Material Standard Test Pressure Standard

ASTM A312 Gr.TP304, 304L, 304H, 316, ASTM A 530
316L, 316H, 321, 347

d) Seamless Nickel Alloy

Material Standard Test Pressure Standard

ASTM B161 UNS No.2200 ASTM B161
ASTM B165 UNS No.4400 ASTM B165
ASTM B167 UNS No.6600 ASTM B167
ASTM B407 UNS No.8800 ASTM B407

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TECHNICAL SPECIFICATION NO. : MEC/TS/05/62/59A REV-0 PAGE 8 OF 9

e) Welded Nickel Alloy

Material Standard Test Pressure Standard

ASTM B725 UNS No.2200, 4400 ASTM B725

ASTM B517 UNS No.6600 ASTM B517

ASTM B514 UNS No.8800 ASTM B514

3.2.2 Electric Fusion Welded

a) Carbon Steel & Alloy Steel E.FS.W. (16” & above)

Material Standard Test Pressure Standard

API 5L Gr.B P=2ST/ D

ASTM A 671 Gr.CC65, 70 (Cl.32) S= 90% of S MYS (ex cept for A PI 5L
ASTM A 672 Gr.C60, 65, 70 (Cl.12,22) Gr.B)
ASTM A 671 Gr.CF60, 65, 66, 70 (Cl.32) S=85% of SMYS for API 5L Gr.B
ASTM A 691 Gr. ½ Cr, 1Cr, 1 ¼Cr, 2 T=Nominal Wall Thickness
¼Cr, 5Cr, 9Cr (Cl.42) D=O.D. of Pipe

b) Stainless Steel E.FS.W. (2” to 6”)

The hydrostatic test pressure in kg/ cm2 for the following m aterials
shall be as given below:

Material Gr.1: ASTM A312 TP304/ 304H/ 316/ 316H/ 321/

347 welded

Material Gr.2: ASTM A312 TP 304L/ 316L welded

Pipe Schedule: S10 Pipe Schedule : S40 Pipe Schedule : S80

Size Material Material Material Material Material Material
Gr.1 Gr.2 Gr.1 Gr.2 Gr.1 Gr.2
2” 100 80 155 130 230 190
3” 80 60 155 130 230 190
4” 80 50 155 130 230 190
6” 65 35 90 75 155 130

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TECHNICAL SPECIFICATION NO. : MEC/TS/05/62/59A REV-0 PAGE 9 OF 9

c) Stainless Steel E.FS.W. (8” and above).

Material Standard Test Pressure Standard

ASTM A358 T P 304L, 304, 304H, P = 2ST/D
316L, 316, 31 6H, 3 21, 34 7 S = 85% of SMYS
(Classes 1, 3 & 4) T = Nominal Wall Thickness
D = O.D. of Pipe
ASTM A358 T P 304L, 304, 304H, P = 2ST/D
316L, 316, 31 6H, 3 21, 34 7 S = 72% of SMYS
(Classes 2 & 5) T = Nominal Wall Thickness
D = O.D. of Pipe

3.2.3 Carbon Steel Pipes to IS Standards

Material Standard Test Pressure Standard

IS :1239 IS :1239
IS :3589 IS :3589

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MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF:
RANCHI 834002
OIL & GAS SBU, DELHI

DOCUMENT NO. Page 1 of 20

TITLE BALL VALVE MEC/TS/05/21/002 REVISION : 1

EDITION : 1

STANDARD TECHNICAL
SPECIFICATION
FOR
BALL VALVES

SPECIFICATION NO.: MEC/TS/05/21/002

(OIL & GAS SBU)

MECON LIMITED
DELHI 110 092
PREPARED BY: CHECKED BY: APPROVED BY: ISSUE DATE :
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF:
RANCHI 834002
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DOCUMENT NO. Page 2 of 20

TITLE BALL VALVE MEC/TS/05/21/002 REVISION : 1

EDITION : 1

AMENDMENT STATUS

Clause / Paragraph / By Verified

Sl. Page
Annexure / Exhibit / Rev. Date
No. No.
Drawing Amended Name Sig. Name Sig.

1. Cl. No. 4.6 4 1 April 09 Gurdeep Singh K.K. De

2. Overall Revision All 1 July 20 K.P. Singh A.K. Tyagi

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
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DOCUMENT NO. Page 3 of 20

TITLE BALL VALVE MEC/TS/05/21/002 REVISION : 1

EDITION : 1

Abbreviations :

ASME : American Society of Mechanical Engineers

ASTM : American Society for Testing and Materials
API : American Petroleum Institute
BHN : Brinell hardness number
DN : Nominal Size
HAZ : Heat Affected Zone
LC : Lock Close (valve locked in full close position)
LO : Lock Open (valve locked in full open position)
MSS-SP : Manufacturers Standardization Society – Standard Practice
NDT : Non Destructive Testing
NPS : Nominal Pipe Size
RTJ : Ring Type Joint
SSPC : Steel Structures Painting Council
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
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TITLE BALL VALVE MEC/TS/05/21/002 REVISION : 1

EDITION : 1

CONTENTS

Sl.No. Description

1.0 SCOPE

2.0 REFERENCE DOCUMENTS

3.0 MATERIALS

4.0 DESIGN AND CONSTRUCTION

5.0 INSPECTION AND TESTS

6.0 EXTENT OF INSPECTION & TESTING

7.0 TEST CERTIFICATES

8.0 PAINTING, MARKING AND SHIPMENT

9.0 SPARES AND ACCESSORIES

10.0 DOCUMENTATION

11.0 GUARANTEE

FIGURE-1 VENT, DRAIN & SEALANT INJECTION DETAILS

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1.0 SCOPE

This specification covers the minimum requirements for design, manufacture, testing
and supply of carbon steel ball valves of size DN 50 mm (2”) and above and ANSI
pressure rating class 150 to 900 to be used in on-shore pipeline systems handling
non-sour hydrocarbons in liquid or gaseous phase, including Liquefied Petroleum
Gas (LPG).

This specification does not cover ball valves for sour hydrocarbon (liquid / gas)
service as defined in NACE standard MR-01-75.

2.0 REFERENCE DOCUMENTS

2.1 All valves shall be manufactured and supplied in accordance with the latest edition of
American Petroleum Institute (API) Specification 6D / ISO 14313, with additions and
modifications as indicated in the following sections of this specification.

2.2 Reference has also been made in this specification to the latest edition of the
following Codes, Standards and Specifications:

ASME B 16.5 : Pipe flanges and flanged fittings

ASMEB 16.10 : Face-to-face and end-to-end dimensions of valves

ASME B 16.25 : Butt welding ends

ASME B 16.34 : Valves – flanged, threaded and welding ends

ASME B16.47 : Large diameter steel flanges

ASME B 31.3 : Process piping

ASME B 31.4 : Pipeline transportation systems for liquid

hydrocarbons and other liquids

ASME B 31.8 : Gas transmission and distribution piping systems

ASME Sec VIII : Boiler and pressure vessel code - Rules for
construction of pressure vessels

ASME Sec IX : Boiler and pressure vessel code - Welding and brazing
qualifications

ASTM A 370 : Standard test methods and definitions for mechanical

testing of steel products

ASTM B 733 : Autocatalytic nickel phosphorous coating on metals

API 6FA : Fire test for valves

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API 607 : Fire test for soft-seated quarter-turn valves

API 1104 : Welding of pipelines and related facilities

BS EN ISO 10497 : Testing of valves – Fire type-testing requirements

MSS-SP-6 : Standard finishes for contact faces of pipe flanges and

connecting-end flanges of valves and fittings

MSS-SP-44 : Steel pipeline flanges

SSPC-VIS-1 : Steel structures painting council-visual standard

2.3 In case of conflict between the requirements of this specification, API 6D and the
Codes, Standards and Specifications referred in clause 2.2 above, the requirements
of this specification shall govern. Order of precedence shall be as follows :

 Valve Data Sheets

 Material Requisition
 This Specification
 API 6D Specification
 Other Referred Codes & Standards
 Manufacturer’s Standard

3.0 MATERIALS

3.1 Material for major components of the valves shall be as indicated in Valve Data
Sheet. Other components shall be as per Manufacturer’s standard (suitable for the
service conditions indicated in Data Sheet) and shall be subject to approval by
Purchaser. In addition, the material shall also meet the requirements specified
hereinafter.

3.2 Carbon steel used for the manufacture of valves shall be fully killed.

3.3 The Carbon Equivalent (CE) of valve end connections which are subject to further
field welding by Purchaser, shall not exceed 0.43% (as calculated by the following
formula) on check analysis for each heat of steel used:

%Mn %Cr + %Mo + %V %Ni + %Cu

CE = %C + -------- + ------------------------- + -------------------
6 5 15

3.4 For Valves specified to be used for Gas service or LPG service, Charpy V-notch test,
on each heat of base material shall be conducted as per API 6D Clause 8.5, for all
pressure containing parts such as body, end flanges and welding ends as well as
bolting material for pressure containing parts. Unless stated otherwise, the Charpy V-
notch test shall be conducted at 0 °C. Test procedure shall conform to ASTM A370.
The average absorbed energy value of three full sized specimens shall be 27 J. The
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minimum impact energy value for any one specimen of the three specimens
analysed as above, shall not be less than 22 J.

When Low Temperature Carbon Steel (LTCS) materials are specified in Valve Data
Sheet or offered by Manufacturer, the Charpy V-notch test requirements of
applicable material standard shall be complied with.

3.5 For all such valves where carbon steel is used as ball material, the ball shall have 75
micrometer (0.003 inch) thick Electroless Nickel Plating (ENP) as per ASTM B733
with following classification : SC2, Type II, Class 2. The hardness of plating shall be
minimum 50 RC.

3.6 For valves specified to be used for Gas service or LPG service, hardness test shall
be carried out as per ASTM A370 for each method of manufacture and each heat of
steel used in the manufacture of valves. A full thickness cross-section shall be taken
for this purpose and the maximum hardness of the materials of valve components
shall not exceed 248 HV10 .

3.7 All process-wetted parts, metallic and non-metallic, shall be suitable for the fluids and
service specified by the Purchaser. The service gas composition shall be as given
elsewhere in the Material Requisition. In addition, Manufacturer shall confirm that all
wetted parts are suitable for treated water / seawater environment, which may be used
during field testing.

3.8 Non-metallic parts of the valves (including O-rings, soft seal etc.) intended for
hydrocarbon gas service at pressures of PN 100 (600 #) and above shall be resistant
to explosive decompression.

4.0 DESIGN AND CONSTRUCTION

4.1 Valve design shall meet the requirements of API 6D and other referred codes and
shall be suitable for the service conditions indicated in Valve Data Sheet. The ASME
Boiler & Pressure Vessel Code, Section VIII, Division 1, may be used to design the
valve body. Allowable stress requirements shall comply with the provisions of ASME
B31.3. In addition, corrosion allowance indicated in Valve Data Sheet shall be
considered in valve design. However, the minimum wall thickness shall not be less
than the minimum requirement of ASME B16.34. The Manufacturer shall have a valid
license to use API 6D monogram for manufacture of ball valves.

4.2 For above ground valves, valve body design shall be either fully welded or bolted
type, as indicated in Valve Data Sheet. Valve body joints with threads are not
permitted.

For buried valves, valve body design shall be fully welded type only. Valve body
joints with bolts or threads are not permitted.

4.3 Ball shall be of single piece, solid type construction.

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4.4 Valves shall be Full Opening (FO) or Reduced Opening (RO) as indicated in Valve
Data Sheet. FO valves shall be suitable for the passage of all types of pipeline
scraper and inspection pigs on regular basis without causing damage to either the
valve component or the pig. The FO valve shall provide an unobstructed profile for
pigging operations in either direction. FO valves shall be designed to minimize
accumulation of debris in the seat ring region to ensure that valve movement is not
impeded.

The opening size of RO valves shall be corresponding to that of a FO valve of smaller

nominal diameter as indicated in table below. For sizes of a particular rating not
covered in API 6D, the opening sizes of the RO valve shall be as per Manufacturer’s
standard.

Nominal Valve Nominal Valve

Nominal Valve Nominal Valve
Size for Reduced Size for Reduced
Size Size
Opening Opening

DN mm (NPS inches) DN mm (NPS inches) DN mm (NPS inches) DN mm (NPS inches)

50 (2) 50 (2) 600 (24) 500 (20)
80 (3) 50 (2) 650 (26) 550 (22)
100 (4) 80 (3) 700 (28) 600 (24)
150 (6) 100 (4) 750 (30) 600 (24)
200 (8) 150 (6) 800 (32) 650 (26)
250 (10) 200 (8) 850 (34) 700 (28)
300 (12) 250 (10) 900 (36) 750 (30)
350 (14) 250 (10) 950 (38) 800 (32)
400 (16) 300 (12) 1000 (40) 850 (34)
450 (18) 350 (14) 1050 (42) 900 (36)
500 (20) 400 (16) 1200 (48) 1050 (42)
550 (22) 450 (18)

4.5 Ball mounting shall be trunnion / pivot type or as indicated in Valve Data Sheet. Ball
mounting, either trunnion or floating, unless otherwise specified, shall be as follows.

Sl. Nominal Valve Size (NPS inches)

ANSI Pressure Rating
No. Floating Ball Trunnion Mounted
1. 150# < 8” > 8”
2. 300# < 4” > 4”
3. 600# Nil > 2”
Valve design shall minimize the possibility of debris ingress into the trunnion as far
as practicable.
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4.6 Valve seats shall have metal to metal contact. O-rings or other seals, if used for drip
tight sealing, shall be encased in a suitable groove in such a manner that it can not
be removed from seat ring and there is no extrusion during opening or closing
operation of valve at maximum differential pressure corresponding to valve class
rating. The seat rings shall be so designed as to ensure sealing at low as well as
high differential pressures.

4.7 Valves shall have double block and bleed feature to facilitate complete flushing,
draining and venting of the valve body cavity.

4.8 For valves to be used in liquid service, the body cavity over-pressure shall be
prevented by self relieving seat rings / assemblies. A pressure relief hole in the ball
is not permitted. Self relieving seat rings shall relieve at a body cavity differential
pressure not exceeding 50% of the valve class rating pressure.

4.9 Valves shall be designed to withstand a sustained internal vacuum of at least 1 (one)
milli-bar in both open and closed positions.

4.10 FO valves of nominal size DN 200 mm (8”) & above and RO valves of nominal size
DN 250 mm (10”) & above shall have provision for secondary sealant injection under
full line pressure for seat and stem seals. All sealant injection connections shall be
provided with a needle valve, a grease fitting and non-return valve. Valve design
shall have a provision to replace the sealant injection fitting under full line pressure.
Location and arrangement of sealant points shall be as per Figure-1.

4.11 Valves shall be provided with vent and drain connections. Location and arrangement
of vents and drains shall be as per Figure-1. Body vent and drain shall be provided
with valves (ball or plug type). Number and size shall be as per Figure-1.

4.12 Valve design shall ensure repair of stem seals / packing under full line pressure.

4.13 a) Valve ends shall be either flanged or butt welded or one end flanged and one end
butt welded as indicated in Valve Data Sheet. Flanges of the flanged end cast/
forged body valves shall be integrally cast / forged with the body of valve. Face-to-
face/ end-to-end dimensions shall conform to API 6D. Face-to-face and end-to-end
dimensions for valve sizes not specified in API 6D shall be in accordance with ASME
B 16.10. Face-to-face and end-to-end dimensions not shown in API 6D or in ASME B
16.10 shall be as per Manufacturer Standard and shall be subject to approval by
Purchaser.

b) Flanged ends shall have flanges as per ASME B16.5 for valve sizes up to DN 600
mm (24 inches) excluding DN 550 mm (22 inches) and as per MSS-SP-44 / ASME B
16.47 series A for valve sizes DN 550 mm (22 inches) & for DN 650 mm (26 inches)
and above. Flange face shall be either raised face or ring joint type (RTJ) as
indicated in Valve Data Sheet. Flange face finish shall be serrated or smooth as
indicated in Valve Data Sheet. Smooth finish when specified shall be 125 to 200
microinches AARH. In case of RTJ flanges, the groove hardness shall be minimum
140 BHN.
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c) Butt weld end preparation shall be as per ASME B16.25. The thickness of the pipe
to which the valve has to be welded shall be as indicated in Valve Data Sheet.
Valves shall be without transition pups, unless otherwise specified in Valve Data
sheet. In case significant difference exists between thickness of welding ends of
valve and connecting pipe, the welding ends of valve shall have bevel preparation as
per ASME B31.4 or ASME B31.8, as applicable.

4.14 Design of weld end valves shall be such that during field welding operations, the soft
seals or plastic components of the valve (where ever used) are not liable to be
damaged. The Manufacturer shall furnish necessary field welding instructions and
post-weld test procedure to demonstrate integrity and leak-tightness of valves after
field welding operations.

4.15 Valves shall be provided with ball position indicator and stops of rugged construction
at the fully open and fully closed positions.

4.16 FO valves of nominal size  DN 200 mm (8”) and RO valves of nominal size  DN
250 mm (10”) shall be equipped with support foot and lifting lugs. Tapped holes and
eye bolts shall not be used for lifting lugs. Height of support foot shall be kept a
minimum. The location and size of support foot / lifting lugs shall ensure unrestrictive
operation of vent / drain valves.

4.17 Valve design shall be such as to avoid bimetallic corrosion between carbon steel and
high alloy steel components. Suitable insulation shall be provided as required.

4.18 Valves shall be of fire resistant design as per API 607/BS EN ISO 10497/API 6FA,
as indicated in Valve Data Sheet.

4.19 Valves shall be provided with anti-static devices to ensure electrical continuity
between stem / ball and valve body.

4.20 Valves shall be suitable for either buried or above ground installation as indicated in
Valve Data Sheet.

4.21 When stem extension requirement is indicated in Valve Data Sheet, the valves shall
have the following provisions :

a) Valves provided with stem extension shall have water proof outer casing.
Length of stem extension shall be as indicated in Valve Data Sheet. The
length indicated corresponds to the distance between centerline of the valve
opening and the top of mounting flange for valve operating device (gear
operator / power actuator as applicable).

b) Vent and drain connections and sealant injection lines shall be terminated
adjacent to the valve operator by means of suitable piping anchored to the
valve body. Pipe used shall be API 5L Gr. B / ASTM A 106 Gr. B, with Sch.
80. Fittings shall be ASTM A 105 / ASTM 234 Gr. WPB, Socket Welded,
ANSI class 6000.
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c) Stem extension and stem housing design shall be such that the complete
assembly will form a rigid unit giving a positive drive under all conditions with
no possibility of free movement between valve body, stem extension or its
operator.

d) Outer casing of stem extension shall have 3/8” or ½” NPT plugs at the top
and bottom, for draining and filling with oil to prevent internal corrosion.

4.22 Operating Devices

a) Valves shall have a power actuator or manual operator as indicated in Valve Data
Sheet. In case of manual operator, valve sizes < DN 100 mm (4 inches) shall be
wrench operated and valve sizes  DN 150 mm (6 inches) shall be gear operated.
Each wrench – operated valve shall be supplied with wrench. Valve design shall be
such that damage due to malfunctioning of the operator or its controls will only occur
in the operator gear train or power cylinder and that damaged parts can be replaced
without the valve cover being removed.

b) The power actuator shall be in accordance with the Purchaser specification issued
for the purpose and as indicated in Valve and Actuator Data Sheet. Operating time
shall be as indicated in Valve Data Sheet. Valve operating time shall correspond to
full close to full open/full open to full close under maximum differential pressure
corresponding to the valve rating. For actuated valves, the actuator torque output
shall be 1.25 times the break torque required to operate the ball valve under the
maximum differential pressure corresponding to the valve class rating.

c) For manual operator of all valves, the diameter of the hand wheel or the length of
operating wrench shall conform to API 6D requirements and be such that under
maximum differential pressure, the total force required to operate the valve does not
exceed 350 N. Manufacturer shall also indicate the number of turns of hand wheel
(in case of gear operators) required for operating the valve from full open to full close
position.

d) Direction of operation of hand wheel or wrench shall be in clock-wise direction while

closing the valve. Hand wheels shall not have protruding spokes.

e) Gear operators, when provided, shall have a self locking provision and shall be fully
encased, in water proof/ splash proof/ dust proof/ weather proof enclosure and shall
be filled with suitable grease.

f) Operating devices shall be designed for easy operation of the valve under maximum
differential pressure corresponding to the valve rating.

4.23 All welds shall be made by welders and welding procedures qualified in accordance
with the provisions of ASME Section IX. The procedure qualification shall include
impact test and hardness test and shall meet the requirements of clauses 3.4 and
3.6 of this specification, respectively.

4.24 All welds shall be stress relieved in accordance with ASME Section VIII.
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4.25 Repair by welding is not permitted for fabricated and forged body valves. However,
repair by welding as per ASME B16.34 is permitted for cast body valves. Such
repairs shall be carried out at casting supplier’s care only. Repair shall be carried out
before any heat treatment of casting is done. Repair welding procedure qualification
shall also include impact test and hardness test and shall meet the requirements of
clauses 3.4 & 3.6 of this specification, respectively.

4.26 The tolerance on internal diameter and out of roundness at the ends for welded end
valves shall be as per applicable connected pipe specification as indicated in Valve
Data Sheet.

4.27 When indicated in Material Requisition, valves shall have locking device to lock the
valve either in full open (LO) or full close (LC) positions. Locking devices shall be
permanently attached to the valve operator and shall not interfere with operation of
the valve.

4.28 Valve stem shall be capable of withstanding the maximum operating torque required
to operate the valve against the maximum differential pressure corresponding to
applicable class rating. The combined stress shall not exceed the maximum
allowable stresses specified in ASME Section VIII, Division I. In case of power
actuated valves, the valve stem shall be designed for maximum output torque of the
selected power actuator (including gear box, if any) at valve stem.

5.0 INSPECTION AND TESTS

5.1 The Manufacturer shall perform all inspection and tests as per the requirements of
this specification and the relevant codes, prior to shipment, at his works. Such
inspection and tests shall be, but not limited to, the following:

5.1.1 All valves shall be visually inspected. The internal and external surfaces of the valves
shall be free from any strikes, gouges and other detrimental defects. The surfaces
shall be thoroughly cleaned and free from dirt, rust and scales.

5.1.2 Dimensional check on all valves shall be carried out as per the Purchaser approved
drawings.

5.1.3 Chemical composition and mechanical properties shall be checked as per relevant
material standards and this specification, for each heat of steel used.

5.1.4 Non-destructive examination of individual valve material and components consisting

of, but not limited to castings, forgings, plate and assembly welds shall be carried out
by the Manufacturer.

a) Body castings of all valves shall be radiographically examined on 100% of the

surface of critical areas as per ASME B16.34. Procedure and acceptance criteria
shall be as per ASME B16.34. The extent of radiography shall be as follows:
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ANSI Pressure Rating Valve Size Extent of Radiography

150 # All sizes Nil
< DN 400mm (16”) Nil
300 #
> DN 450mm (18”) 100%
> 600 # All sizes 100%

All castings shall be wet magnetic particle inspected 100% of the internal surfaces.
Method and acceptance shall comply with ASME B.16.34.

b) All valves, with body fabricated from plates or made by forgings, shall be
ultrasonically examined in accordance with the procedure and acceptance standard
of Annexure E of ASME B16.34.

All forgings shall be wet magnetic particle inspected 100% of the internal surfaces.
Method and acceptance shall comply with ASME B 16.34

c) Bodies and bonnets made by welded assembly of segments of castings, forgings,

plates or combinations thereof shall be examined, as applicable, by methods of
clause 5.1.4 a) for cast components or clause 5.1.4 b) for forged components and
plates.

5.1.5 Full inspection by radiography shall be carried out on all welds of pressure containing
parts. Acceptance criteria shall be as per ASME B 31.4 or ASME B31.8, as
applicable, and API 1104.

5.1.6 Welds, which in Purchaser’s opinion cannot be inspected by radiographic methods,

shall be checked by ultrasonic or magnetic particle methods and acceptance criteria
shall be as per ASME Section VIII, Division 1, Appendix 12 and Appendix 6,
respectively.

5.1.7 a) All finished wrought weld ends subject to welding in field shall be 100% ultrasonically
tested for lamination type defects for a distance of 50mm from the end. Laminations
shall not be acceptable.

b) Weld ends of all cast valves subject to welding in field shall be 100% radiographically
examined and acceptance criteria shall be as per ASME B16.34.

c) After final machining, all bevel surfaces shall be inspected by dye penetrant or wet
magnetic particle methods. All defects longer than 6.35 mm are rejected, as are
defects between 6.35 mm and 1.59mm that are separated by a distance less than 50
times their greatest length. Rejectable defects must be removed. Weld repair of
bevel surface is not permitted.

5.1.8 All valves shall be tested in compliance with the requirements of API 6D. During
pressure testing, valves shall not have sealant lines and other cavities filled with
sealant, grease or other foreign material. The drain, vent and sealant lines shall be
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either included in the hydrostatic shell test or tested independently. Test pressure
shall be held for at least 30 minutes. No leakage is permissible during hydrostatic
testing. The body cavity self-relieving feature meeting the requirements of clause 4.8
of this specification shall also be checked.

5.1.9 A supplementary air seat test as per API 6D (Annex B, Clause B.3.3, Type II) shall
be carried out for all valves. A bubble tight seal is required without the use of any
sealant. No leakage is allowed. Test pressure shall be held for at least 15 minutes.

5.1.10 Manufacturer who intends bidding, must submit at bid stage, certificate and report for
successful fire type-tests for valves in accordance with API-607/ BS EN ISO 10497 /
API 6FA, as applicable in Valve Data Sheet.

Failure to comply with this requirement shall be a cause of rejection of the

Bidder’s offer.

5.1.11 Valves shall be subjected to Operational Torque Test as per API 6D (Annex B,
Clause B.6) under hydraulic pressure equal to maximum differential pressure
corresponding to the valve pressure class rating.

For manual operator of all valves, it shall be established that the force required to
operate the valve does not exceed the requirements stated in clause 4.22(c) of this
specification.

5.1.12 Power actuated valves shall be tested after assembly of the valve and actuator at the
valve Manufacturer’s works. At least five Open-Close-Open cycles without internal
pressure and five Open-Close-Open cycles with maximum differential pressure shall
be performed on the valve actuator assembly. The time for Full Open to Full close
shall be recorded during testing. If required, the actuator shall be adjusted to ensure
that the opening and closing times are within the limits stated in Actuator Data Sheet
issued for the purpose.

Hand operator provided on the actuator shall also be checked after above testing, for
satisfactory manual over-ride performance.

These tests shall be conducted on minimum one valve out of a lot of five (5) valves
of the same size, rating and the actuator model / type. In case the tests do not meet
the requirements, retesting / rejection of the lot shall be decided by Purchaser’s
Inspector.

5.1.13 Subsequent to successful testing as specified in clause 5.1.11 and 5.1.12 above,
one (1) valve out of the total ordered quantity shall be randomly selected by the
Purchaser’s Representative for cyclic testing as mentioned below :

a) The valve shall be subjected to at least 100 Open-Close-Open cycles with

maximum differential pressure corresponding to the valve rating.

b) Subsequent to the above, the valve shall be subjected to hydrostatic test and
supplementary air seat test in accordance with clause 5.1.8 and 5.1.9.
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In case this valve fails to pass these tests, the valve shall be rejected and two more
valves shall be selected randomly and subjected to testing as indicated above. If
both valves pass these tests, all valves manufactured for the order (except the valve
that failed) shall be deemed acceptable. If either of the two valves fails to pass these
tests, all valves shall be rejected or each valve shall be tested at the option of
Manufacturer.

Previously carried out test of similar nature shall be considered acceptable if the
same has been carried out by Manufacturer in last two years. Valves of two sizes
below and two sizes above the size of valve previously tested, and rating similar or
one rating lower of valve tested previously, shall be qualified.

5.1.14 Checks shall be carried out to demonstrate that the dissimilar metal used in the
valves are successfully insulated as per the requirement of clause 4.17 of this
specification.

5.1.15 When indicated in Valve Data Sheet, valves shall be subjected to anti-static testing
as per supplementary test requirement of API 6D (Annex B, Clause B.5).

5.2 Purchaser reserves the right to perform stage-wise inspection and witness tests as
indicated in clause 5.1 above at Manufacturer’s works prior to shipment.
Manufacturer shall give reasonable access and facilities required for inspection to
the Purchaser’s Inspector.

Purchaser reserves the right to require additional testing at any time to confirm or
further investigate a suspected fault. The cost incurred shall be to Manufacturer’s
account.

In no case shall any action of Purchaser or his Inspector relieve the Manufacturer of
his responsibility for material, design, quality or operation of valves.

Inspection and tests performed/ witnessed by the Purchaser’s Inspector shall in no

way relieve the Manufacturer’s obligation to perform the required inspection and
tests.

6.0 EXTENT OF INSPECTION & TESTING

6.1 Purchaser’s Inspector shall perform inspection and witness tests on all valves or as
indicated in the Quality Assurance Plan (QAP) attached with this specification.

6.2 The hydrostatic testing and cyclic opening and closing of the valves with the operator
shall be witnessed by Purchaser’s Inspector.
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7.0 TEST CERTIFICATES

7.1 Manufacturer shall submit the following certificates:

a) Mill test certificates relevant to the chemical analysis and mechanical

properties of the materials used for valve construction as per the relevant
standards.

b) Test certificates of hydrostatic and pneumatic tests complete with records of

timing and pressure of each test.

c) Test reports on radiograph and ultrasonic inspection.

d) Test report on operation of valves conforming to clause 5.1.11, 5.1.12 and

5.1.13 of this specification.

e) All other test reports and certificates as required by API 6D and this
specification.

The certificates shall be valid only when signed by Purchaser’s Inspector. Only those
valves which have been certified by Purchaser’s Inspector shall be despatched from
Manufacturer’s works.

8.0 PAINTING, MARKING & SHIPMENT

8.1 Valve surface shall be thoroughly cleaned, freed from rust and grease and applied
with sufficient coats of corrosion resistant paint. Surface preparation shall be carried
out by shot blasting to SP-6 in accordance with “Steel Structures Painting Council –
Visual Standard SSPC-VIS-1”. For valves to be installed underground, when
indicated in Valve Data Sheet, the external surfaces of the buried portion of valves
shall be painted with three coats of suitable coal tar epoxy resin with a minimum dry
film thickness of 300 microns.

8.2 Manufacturer shall indicate the type of corrosion resistant paint used, in the drawings
submitted for approval.

8.3 All valves shall be marked as per API 6D. The units of marking shall be metric
except Nominal Diameter which shall be in inches. Marking shall be done by die-
stamping on the bonnet or on the housing. However, for buried valves, the marking
shall be done on the above ground portion of the stem housing only.

8.4 Valve ends shall be suitably protected to avoid any damage during transit. All
threaded and machined surfaces subject to corrosion shall be well protected by a
coat of grease or other suitable material. All valves shall be provided with suitable
protectors, for flange faces, securely attached to the valves. Bevel ends shall be
protected with metallic or high impact plastic bevel protectors.

8.5 All sealant lines and other cavities of the valve shall be filled with sealant before
shipment.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF:
RANCHI 834002
OIL & GAS SBU, DELHI

DOCUMENT NO. Page 17 of 20

TITLE BALL VALVE MEC/TS/05/21/002 REVISION : 1

EDITION : 1

8.6 Packaging and shipping instructions shall be as per API 6D.

8.7 On packages, following shall be marked legibly with suitable marking ink :

a) Order Number
b) Manufacturer’s Name
c) Valve Size and Rating
d) Tag Number
e) Serial Number

9.0 SPARES & ACCESSORIES

9.1 Manufacturer shall furnish list of recommended spares and accessories for valves
required during start-up and commissioning and supply of such spares shall be
included in the price quoted by Manufacturer.

9.2 Manufacturer shall furnish list of recommended spares and accessories required for
two years of normal operation and maintenance of valves and price for such spares
shall be quoted separately.

9.3 Manufacturer shall quote for spares & accessories as per Material Requisition.

10.0 DOCUMENTATION

10.1 At the time of bidding, Manufacturer shall submit the following documents:

a) General arrangement / assembly drawings showing all features and relative

positions and sizes of vents, drains, gear operator / actuator, painting, coating
and other external parts together with overall dimensions as well as weights
of valve & actuator.

b) Sectional drawing showing major parts with reference numbers and material
specification. In particular, a blow-up drawing of ball-seat assembly shall be
furnished complying the requirement of clause 4.6 of this specification.

c) Reference list of similar ball valves manufactured and supplied in last five
years indicating all relevant details including project, year, client, location,
size, rating, service, etc.

d) Torque curves for the power actuated valves along with the break torque and
maximum allowable stem torque. In addition, sizing criteria and torque
calculations shall also be submitted for power actuated valves.

e) Descriptive technical catalogues of the Manufacturer.

f) Copy of valid API 6D certificate.

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF:
RANCHI 834002
OIL & GAS SBU, DELHI

DOCUMENT NO. Page 18 of 20

TITLE BALL VALVE MEC/TS/05/21/002 REVISION : 1

EDITION : 1

g) Details of support foot, including dimensions and distance from valve centre
line to bottom of support foot.

h) Quality Assurance Plan enclosed with this tender duly signed, stamped and
accepted.

i) List of recommended spares required during start-up and commissioning.

j) List of recommended spares required for 2 years of normal operation and

maintenance.

k) Other documents / drawings / data as per Material Requisition.

10.2 Within two weeks of placement of order, the Manufacturer shall submit six copies of,
but not limited to, the following drawings, documents and specifications for
Purchaser’s final approval :

a) Detailed sectional arrangement drawings showing all parts with reference

numbers and material specifications as referred to in clause 10.1 above.

b) Assembly drawings with overall dimensions and features. Drawing shall also
indicate the number of turns of hand wheel (in case of gear operators)
required for operating the valve from full open to full close position and the
painting scheme. Complete dimensional details of support foot (where
applicable) shall be indicated in these drawings as referred to in clause 10.1
above.

c) Welding, heat treatment and testing procedures.

d) Procedure for cyclic testing.

e) Details of corrosion resistant paint to be applied on the valves.

f) Design calculation for pressure containing parts.

g) Other documents / drawings / data as per Material Requisition.

Manufacture of valves shall commence only after approval of the documents

indicated in clause 10.2a) to 10.2c) above. Once approval has been given by
Purchaser, any changes in design, material and method of manufacture shall
be notified to Purchaser whose approval in writing of all changes shall be
obtained before the valve is manufactured.

10.3 Within 2 weeks from the approval date, Manufacturer shall submit to Purchaser six
copies of the approved drawings, documents and specifications as listed in clause
10.2 above.
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF:
RANCHI 834002
OIL & GAS SBU, DELHI

DOCUMENT NO. Page 19 of 20

TITLE BALL VALVE MEC/TS/05/21/002 REVISION : 1

EDITION : 1

10.4 Prior to shipment, Manufacturer shall submit six hard copies and six soft copies (on
CD-ROMs) of the following:

a) Test certificates as per clause 7.0 of this specification.

b) Manual for installation, erection, maintenance and operation instructions,

including a list of recommended spares for the valves.

c) Other documents / drawings / data as per Material Requisition.

10.5 All documents shall be in English language.

10.6 The above documents & data requirements shall also be supplemented by all
requirements of clause 2.0 of the Material Requisition.

11.0 GUARANTEE

11.1 Manufacturer shall guarantee that the materials and machining of valves and fittings
comply with the requirements in this specification and in the Purchase Order.

11.2 Manufacturer is bound to replace or repair all valve parts which should result
defective due to inadequate engineering or to the quality of materials and machining.

11.3 If valve defect or malfunctioning cannot be eliminated, Manufacturer shall replace the
valve without delay,

11.4 Any defect occurring during the period of Guarantee shall be attended to by making
all necessary modifications and repair of defective parts free of charge to the
Purchaser as per the relevant clause of the bid document.

11.5 All expenses shall be to Manufacturer’s account.

MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF:
RANCHI 834002
OIL & GAS SBU, DELHI

DOCUMENT NO. Page 20 of 20

TITLE BALL VALVE MEC/TS/05/21/002 REVISION : 1

EDITION : 1

VENT, DRAIN & SEALANT INJECTION DETAILS

TECHNICAL NOTES FOR GATE & GLOBE
VALVES
 TECHNICAL NOTES FOR GATE & GLOBE VALVES

1.0 General

1.1 Valves shall be designed, manufactured, tested, inspected, marked and supplied as per
the specifications, applicable design standards & codes and manufacturing standards
(latest editions) as specified.

1.2 Material test certificates (Physical property, Chemical composition & Heat treatment
report) of the pressure containing parts shall be furnished for the valves supplied.
Material test certificates of other parts shall also be furnished for verification during
inspection.

1.3 For heavy valves, provision for lifting shall be made by way of lugs, eyebolts, or
similar standard devices.

1.4 Unless otherwise stated, all flanged valves shall have end flanges integral with valve
body. Weld on flanges are not acceptable. Flange finish shall be serrated finish 250
AARH (250 AARH to 500 AARH) or 125 AARH (125
AARH to 250 AARH) or 63 MRH (32 AARH to 63 AARH) as per valve
specification sheet.

1.5 For all weld end valves, with bevel end as per ANSI B 16.25, the bevel
contour shall be as follows:

Wall Thickness Weld Contour

Material
Carbon Steel (Except Low Upto 22 mm Figure 2 Type A
Temp. Carbon Steel) > 22 mm Figure 3 Type A
Alloy Steel Upto 10 mm Figure 4
Stainless Steel & > 10 mm & upto 25 mm Figure 5 Type A
Low Temp Carbon Steel > 25mm Figure 6 Type A

1.6 If an overlay weld-deposit is used for the body seat ring, seating surface, the seat ring
base material shall be at least equal to the corrosion resistance of the materials of the
shell.

1.7 For valve body/ bonnet, forging is acceptable where castings are specified but not
vice versa.

1.8 Material of construction of yoke shall be as a minimum equivalent to body/ bonnet

material.

1.9 Stem shall be forged or machined from a forged bar. Castings are not
permitted except integral stem.

1.10 Stelliting/ hard facing by deposition shall have minimum 1.6mm thickness.
Renewable seat rings shall be seal welded.

1.11 Face to face dimension of flanged valves shall conform to ANSI B 16.10 to the extent
covered. For valves not covered in the ANSI specification, Contractor shall furnish
certified dimensional drawings.
1.12 Flange dimensions of steel, alloy steel and stainless steel flanged valves shall
conform to ANSI B 16.5 for sizes up to 24” and API 605 for size 26‟‟ and above.

1.13 Flange dimensions for cast iron flanged valves shall conform to ANSI B 16.1 for
size up to 24” class 125 and API 605 with flat face for sizes greater than 24”.

1.14 Unless otherwise mentioned, various valves should conform to following

standards / codes.

SW gate valves (1 1/2‟‟ and below) : API 602

SW Globe valves (1 1/2” and below) : BS 5352
Flanged gate valves API 600 & API-6D
Flanged Globe valves : BS 1873

1.15 Wherever stellite is specified, it means facing of seat and disc are welded by Cr-Co-
W alloy. Stellite facing shall maintain minimum hardness of 375 BHN at high
temperature.

1.16 All weld end valves shall have bevel ends as per ANSI B 16.25.

1.17 If an overlay weld deposit is used for the body seat ring or seating surface, the seat
ring base material shall be at least equal to corrosion resistance of the material of the
shell.

1.18 By Pass

- Unless otherwise noted, by-pass requirement for gate valves shall be under -

150 Class : on sizes 26” and above

300 Class : on sizes 16” and above
600 Class : on sizes 6” and above
900 Class : on sizes 4” and above
1500 Class : on sizes 4‟ and above
2500 Class : on sizes 3” and above

- By-pass valve shall be a globe valve.

- Contractor shall supply the by-pass valve duly tested and fitted to the main
valve. By-pass attachment to the main valve body shall not be screwed. All
fillet welds for by-pass installation shall be 100% examined by DP / MP test.

1.19 Spiral wound bonnet gasket is to be provided with inner / outer ring except when
encapsulated gaskets type body bonnet joints are employed. Outer ring may be
avoided in case of non-circular spiral wound gasket used in 150# valve provided the
outermost layer of spiral touches the bolts ascertaining the centering.

1.20 Pressure Test

- Valves covered under API codes shall be tested as per API 598 unless
otherwise specified in the applicable valve code.

- Valves covered under BS code shall be tested as per BS 6755 unless

otherwise specified in the applicable valve codes.

1.21 For all austenitic stainless valves, inter-granular corrosion test shall have to be
 conducted as per following: -

- ASTM A 262 Practice „E‟ with acceptance criteria of “60 mils / year (max.)”.
OR

- ASTM A 262 practice „E‟ with acceptance criteria of “No cracks as observed
from 20X magnification U & Microscopic structure to be observed from
250X magnification”.

1.22 When specifically asked for high temperature application of some grades of austenitic
stainless steel (like SS 309, 310, 316, 316H etc.) ASTM A 262 practice „C‟ with
acceptance criteria “15 MILS/YEAR” shall have to be conducted. When testing is
conducted as per practice „E‟ photograph of microscopic structure shall be submitted
for record.

1.23 For the IGC test as described in 1.16.1 & 1.16.2 two sets of samples shall be drawn
from each solution treatment lot, one set corresponding to highest carbon content and
other set corresponding to the highest rating/ thickness.

2.0 OPERATION

2.1 Valves shall be supplied with gear operations based on the following requirements:

Class Size Requiring Gear

Valve Types Operation
Gate & Diaphragm Valves 150 14” and larger
300 14” and larger
600 12” and larger
900 6” and larger
1500 3” and larger
2500 3” and larger
Globe Valves 900 6” and larger
1500 3” and larger
2500 3” and larger

2.2 Gear operator shall be as under with position indicators for open / close positions,
with limit stops.

For Gate / Globe / Diaphragm Valves Totally enclosed bevel gear in grease
case with grease nipples/ CHECK

2.3 Gear operators shall be so designed to operate effectively with the differential
pressure across the closed valve equal to the cold non-shock pressure rating.

2.4 Hand wheel diameter shall not exceed 750 mm and effort to operate shall not exceed
35 kg at hand wheel periphery. In case these limits cannot be satisfied for any valve, a
gear operation shall be provided.

3.0 INSPECTION AND TESTING

3.1 All the mandatory shop tests and inspection required by the respective data
sheet and applicable standards & codes etc. shall be carried out.

3.2 The extent of inspection by shall be as under. However the exact extent with hold
 points shall be decided during review of the inspection plan to be submitted to
Company as part of the post-order documentation.

3.3 Valves under NACE should follow the requirements of MR-01-75

FORGED VALVES
- Visual and dimensional inspection
- Review of material test certificates
- Any mandatory or supplementary test
- Hydrostatic test of all valves
- Strip check on 1% of total ordered quantity of valves at random to verify
compliance with specification requirements.

CAST STEEL VALVES

- Visual and dimensional inspection
- Review of material test certificates
- Review of radiographs / radiographic reports and reports of any other NDT
tests, wherever applicable as per data sheets
- Any mandatory or supplementary tests
- Hydrostatic test 100% for body
- Strip check on 1% of total ordered quantity of valves at random to verify
compliance with specification requirements.

3.4 For motor /actuator operated valves, functional / operational checks as per the
requirements of the specifications shall be made on each valve.

4.0 RADIOGRAPHY OF CAST VALVES

4.1 When specifically not mentioned in individual data sheets, valves castings shall
undergo radiographic examination as specified hereunder:

RATING SIZE RANGE RADIOGRAPHY

MATERIAL
All 150# 24” and below Nil
150# 26” and above 100%
300# 16” and below Nil
300# 18” and above 100%
600# and above All sizes 100%

4.2 Radiography procedure areas of casting to be radiographed shall be as per ANSI B

16.34 and acceptance criteria shall be as per ANSI B 16.34 Annexure — B. However
for areas of casting to be radiographed for types of valve not covered in ANSI B
16.34, Contractor shall enclose details of areas to be radiographed in line with ANSI
B 16.34.

5.0 IBR VALVES

5.1 All valves described as “IBR Valves” shall be in accordance with the latest IBR
(Indian Boiler Regulations) as well as the other requirements specified in the
specification.

5.2 For BW / SW end carbon steel valves under “IBR”, the chemical composition shall
conform to the following:
 Carbon (Max.) : 0.25%

Others (S, B, Mn) : As per IBR

Above composition is not applicable for non-IBR valves.

5.3 For all “IBR Valves”, test certificate in form III-C shall be furnished duly signed by
IBR inspection authority or an IBR approved representative.

5.4 All valves shall be painted red.

6.0 MARKING

6.1 Valves markings, symbols, abbreviations, etc. shall be in accordance with MSS-SP-
25 or the standard referred to in the specifications as applicable Manufacturer‟s name,
valve size and rating, material designation, nominal size, direction of flow (if any)
etc. shall be integral on the body.

6.2 Each valve shall have a corrosion resistant tag giving size and valve tag/code no.
securely attached on the valve body.

6.3 Paint or ink used for marking shall not contain any harmful metal or metal salts such
as zinc, lead or copper which may result in corrosive attack on heating.

6.4 Carbon steel valves shall be painted with two coats of red oxide zinc chromate
primer.

6.5 All alloy steel high temp valves shall be painted with heat resistant silicone paint
suitable for intended temperature.

7.0 DESPATCH

7.1 Valves shall be dry, clean and free from moisture, dirt and loose foreign
material of any kind.

7.2 Valves shall be protected from rust, corrosion and any mechanical damage
during transportation, shipment, and storage.

7.3 Rust preventative applied on machined surfaces to be welded shall be easily

removable with a petroleum solvent or shall not be harmful to welding.

7.4 Each end of valves shall be protected as follows:

Flange Face : Wood, plastic or metal cover

Beveled End : Wood, plastic or metal cover
SW / Screwed End : Plastics cap

7.5 End protectors to be used on flange faces shall be attached by at least three
bolts or wires through bolt holes and shall not be smaller than the outside
diameter of the flange. Plastic caps for SW / Screwed and valves shall be press
fit type.

7.6 End protectors to be used on beveled ends shall be securely attached.

MECHANICAL DRAWINGS
DEEPAK FERTILISERS AND PETROCHEMICALS
CORPORATION LIMITED

NAME OF WORK

Detailed Geotechnical Investigation for DFPCL gas pipe

line near Panvel railway yard and other associated works

DETAILED ROUTE SURVEY REPORT

[Inclusive of Corrosion Survey & PDI
Survey Reports]

MNEC Consultants Pvt. Ltd.

(An ISO 9001:2008 & ISO 27001:2005 Certified Company)
First Floor, ‘Pratibha Sankul’, 1, Bhagwaghar Layout, Besides Alankar Cinema, Dharampeth, Nagpur-10
Ph. : +91-712-2542261 Fax : +91-712-2542291
E-mail : [email protected]
 INDEX

Sr. Page Nos

Particulars
No. From To
1. At a Glance A1 A3
2. Chapter-1 : Scope of Work 1-1 1-4
3. Chapter-2 : Approach & Methodology 2-1 2-7
4. Chapter-3 : Description of Route 3-1 3-3
5. Chapter-4 : General Information and Annexures 4-1 4-9
6. Chapter-5 : Corrossion Survey 5-1 5-30
7. Chapter-6 : Population Density Index Survey 6-1 6-7
8. Alignment Drawing I I
Detailed Route Survey for DFPCL Gas pipeline near Panvel Railway Yard and other
associated works.
Deepak Fertilizers & Petrochemicals Corporation Ltd.

ALIGNMENT AT A GLANCE

1. Details of Pipeline Sections:

Sr. Chainage (Km) Length

Description of Section Remark
No. From To (Km)

1 Realignment Section 0.00 0.812 0.812

Total 0.812

2. Details of Forest across pipeline.

There are no notified forest patches encountered during the detailed engineering
survey.

3. Details of Wild Sanctuary across pipeline

Sr. Name of Chainage (Km) Length Toposheet

District (State)
No. Sanctuary Starting Ending (Km) No.

1. NIL

4. Details of Rocky Stretches across pipeline

Sr. Chainage (Km)

Description Length (km)
No. From To
1 The route alignment runs through the barren land for major portion.

5. Details of Crossing

Sr.
Type of Crossing Total No. of Crossings
No.
1 Rivers 001
2 Railway lines 000
3 National Highways 000
4 State Highways 000
5 Other Metalled roads 000

Document Name- Detailed Route Survey Report MNEC Consultants Pvt. Ltd.

A-1
Detailed Route Survey for DFPCL Gas pipeline near Panvel Railway Yard and other
associated works.
Deepak Fertilizers & Petrochemicals Corporation Ltd.

Sr.
Type of Crossing Total No. of Crossings
No.
6 Unmetalled roads 000
7 Cart tracks 000
8 Canals 000
9 Nalas 000
10 Pond 000
11 Drains 000
12 Other Pipeline 001
13 HT/LT/Telephone Lines 001
Total 003

6. States and districts involved with chainages and lengths

Sr. Chainage (Km) Length

Name of District State
No. Starting Ending (Km)
Maharashtr
1 Raigarh 0.000 0.812 0.812
a
Total 0.812

7. Total number of Turning Points (TP’s) :

Sr. Nos. of
Description of Section Remark
No. TP’s

1 Realignment Section 7

TOTAL 7

8. Length of the longest section: 0.235 km between

10. Type of terrain: Corridor selected for the proposed pipeline passes within
western railway ROU.

11. Accessibility with road network: 100% of alignment is approachable with the
help of roads, whereas western railway is running parallel to
the route alignment all the time.

14. Hydrological Data

Document Name- Detailed Route Survey Report MNEC Consultants Pvt. Ltd.

A-2
Detailed Route Survey for DFPCL Gas pipeline near Panvel Railway Yard and other
associated works.
Deepak Fertilizers & Petrochemicals Corporation Ltd.

The proposed pipeline crosses the Kalundre River near Railway Bridge
constructed on right side at a distance 46.0mts.
Kalundre River is as under,
3
Maximum discharge = 650.312 m /sec
(Observed at River gauge station situated at Village-Gadhi, Tq.-Panvel, Dist:
Raigarh which is located 2.2 km (Approx.) upstream of Railway Bridge on
26.07.2005, source Water Resources Dept., Hydrology Project (SW), State Data
Storage Center, Nashik)
Salient features of Kalundre River is as under,
3
 Maximum Discharge = 650.312 m /sec
 Average Velocity = 1.50 m/sec
 HFL = 8.965 m
 Bed width = 56.04 m
 Bank to Bank width = 78.79 m
 Lowest bed level = 2.298 m

14. Metrological data

The metrological data based on the information contained in “Climatological Tables
of Observatories in India (1961-1990)” as published by India Meteorological
Department as per observatory along pipeline route is given below.

Temperature Relative Mean wind

District / (°C) Humidity (%) speed (km/hr)
Observatory Name
Max. Min. Max. Min. Max. Min.
Raigarh 40.0 9.4 89 64 26.0 4.0

16. Survey of India’s topographic sheets involved with length of alignment

covered in each:

SR.NO. SECTION TOPOSHEET NO. LENGTH IN (M)

Panvel Railway
1 47-F-01 0.812
Yard

Document Name- Detailed Route Survey Report MNEC Consultants Pvt. Ltd.

A-3
Detailed Route Survey for DFPCL Gas pipeline near Panvel Railway Yard and other
associated works.
Deepak Fertilizers & Petrochemicals Corporation Ltd.

CHAPTER – 1

SCOPE OF WORK

1.0 There is an existing natural gas pipeline of Deepak Fertilizers & Petrochemicals
Corporation Ltd. (DFPCL) from Uran to Taloja near Panvel Railway Yard. Since
the Western Railway intends to lay a new railway track and have expanded the
corridor of railway’s. Hence, DFPCL needs to realign the route of the natural gas
pipeline within the corridor of railways. To realign the natural gas pipeline a
reconnaissance survey is to be carried out followed by a detailed route survey.

In this Detailed Route Survey Report, the shifting of existing natural gas pipeline
within the corridor of Western Railway is discussed in detail. The proposed
pipeline traverses through only one district & state i.e. District Raigarh & state of
Maharashtra.

1.1. The work of reconnaissance survey, detailed engineering survey, soil resistivity,
soil corrosion survey, geotechnical investigation, hydrological survey etc. is
awarded to MNEC Consultants Pvt. Ltd., Nagpur vide LAO No. 4100002837 dt.
31.05.2013.

1.2 The scope of the work includes the following pre-construction activities viz.

The location of starting points and termination points of survey of pipeline shall
be decided/fixed by DFPCL/MECON and shall be informed to the Surveyor during
detailed pipeline route survey.

The width of corridor to be surveyed shall be 60 metres and shall be between the
extents of the outermost Railway track on the South-Western side (Near the AC
traction Sub Station Side) towards the ROW limit of railways on the North-Eastern
Side. The proposed pipeline shall be aligned approximately 5 metres inside the
ROW limit of the Railways. The corridor to be surveyed shall however also
include the nearby Permanent / Semi-permanent structures outside the ROW
limit of Railways, within the 60 metres corridor showing the features on both sides
of the proposed pipeline route.

Document Name- Detailed Route Survey Report MNEC Consultants Pvt. Ltd.

1-1
Detailed Route Survey for DFPCL Gas pipeline near Panvel Railway Yard and other
associated works.
Deepak Fertilizers & Petrochemicals Corporation Ltd.

1.2.1 Route survey work along the entire route of the proposed pipeline and other
proposed installations including intervening shallow water bodies to be carried
out in accordance with technical specification.

1.2.2 Carrying out soil investigation along the proposed pipeline route and proposed
installations including water body crossing in accordance with enclosed technical
specification.

1.2.3 Carrying out Hydrographic survey of canals and water bodies as per enclosed
technical specification.

1.2.4 Pipeline alignment shall be surveyed and marked taking into account all existing
and planned/proposed future development along the proposed route. The
existing pipeline already laid inside the corridor has to be located and marked on
the corridor surveyed.

1.2.5 Supply and installation of the survey markers as per instruction of

DFPCL/MECON.

1.2.6 Tie-in of the starting and termination point of the proposed pipeline survey to the
grid-control system being used for end facilities. A global geo-refrencing system
to be used for complete integration of the survey database.

1.2.7 Locating all buried/ above ground pipelines, cablesand other utilites within the
corridor of 60 metres with the help of pipelines/ cable locators or other suitable
instruments.[In case of the city portions and otherrestrictive locations this may
be limited to the extent feasible and approved by Engineer-in-charge on the
merit of each case.] All detailed interference survey work to be carried out as per
technical specification.

1.2.8 Carrying out population density survey and locationclass along the pipeline route
as per enclosed technical specification.

1.2.9 The Surveyor shall digitise all details and mark the pipeline route on maps with

Document Name- Detailed Route Survey Report MNEC Consultants Pvt. Ltd.

1-2
Detailed Route Survey for DFPCL Gas pipeline near Panvel Railway Yard and other
associated works.
Deepak Fertilizers & Petrochemicals Corporation Ltd.

the following details.

- Major features/land marks including:

All built-up areas such as-
Religious place, school, hospital, multi storyed buildings, etc.
District/village and panchayat roads.
Water bodies
Overhead and underground utility crossings
Marshy land/ waste land
These informations shall be adequate in all respect for ROU acquisition.

1.2.10 Pipeline Alignment must be selected in a manner that the entire width of ROU
corridor proposed to be acquired lies in firm ground and with minimum
interferences.

1.2.11 Presentation of route survey data in the form as defined in the document.

1.2.12 Carrying out corrosion survey including measurement of soil resistivity, chemical
analysis of soil/water and collection of Cathodic Protection related data including
powerlines along ROU of the proposed pipeline and of data as per Standard
Specification of Corrosion Survey.

1.2.13 Resurvey can be ordered in case of doubt; discrepancy; change in route; and
better option.

The discretion to pay compensation and allotment of additional time shall be by

DFPCL/MECON on case-to-case basis.

1.2.14 The detailed survey to ensure:

- Connectivity with adjoining surveys.
- Geocoding/ geo-referencing be done and closing of surveys at both
the ends.
- Preparation and compliance to an approved Quality Assurance
Plan.
- All deliverables to be submitted in the format, scale and quantities

Document Name- Detailed Route Survey Report MNEC Consultants Pvt. Ltd.

1-3
Detailed Route Survey for DFPCL Gas pipeline near Panvel Railway Yard and other
associated works.
Deepak Fertilizers & Petrochemicals Corporation Ltd.

as per specification.

1.2.15 The scope of work shall also include any other item/work required to complete
the work in all respects as per specifications, drawings and instructions of
DFPCL/MECON whether specifically mentioned herein or not, but is required to
fulfill the intended purpose of this tender document.

1.3. About the Agency :

The consultancy MNEC Consultants Pvt. Ltd. is the agency fixed for execution
of work mentioned in paras above. The head office of the company is at First
Floor, ‘Pratibha Sankul’, 1 Bhagawaghar Layout, Beside Alankar Cinema,
Dharmpeth, Nagpur-10. The company is having experienced and expert staff
members and state of the art equipments and machineries for smooth execution
of such type of Engineering Survey work. MNEC Consultants Pvt. Ltd., is certified
with ISO 9001 : 2008 (QMS) and ISO 27001 : 2005 (ISMS) and follow all the
quality, management and security norms as per the international standards.
-x-x-x-x-

Document Name- Detailed Route Survey Report MNEC Consultants Pvt. Ltd.

1-4
Detailed Route Survey for DFPCL Gas pipeline near Panvel Railway Yard and other
associated works.
Deepak Fertilizers & Petrochemicals Corporation Ltd.

CHAPTER – 2

APPROACH AND METHODOLOGY

A preliminary survey for locating the centre-line of pipeline alignment on the ground has
been be carried out as follows:

3.1.1 Surveyor made a preliminary survey along the route of the Proposed Pipe line to
establish and flag control point. Based on the preliminary survey drawings and
the Reconnaissance Survey Report- a geocoded mapping be developed as
preliminary plan, particularly the start and end point and other major TP'S/IP's.
Surveyor shall study and suggest better alignment based on site visit and shall
make suitable alteration in the proposed route after consultation with
MECON/DFPCL.

3.1.2 Surveyor located and identified the existing features or obstructions along the
route that are not shown in available maps or drawings.
Environmentally sensitive areas, marshy lands, and built-up areas were avoided.

3.1.3 Where it became apparent that a better route could be followed, the Surveyor
consulted DFPCL/MECON for authorisation to make a change.

3.1.4 Turning Points (TPs) were located in consultation with DFPCL/MECON

considering the following:

 Detailed survey was carried out using Differential Geographical Positioning

system and/or Geographical Positioning system and Total Stations. Use of high
precision theodolite and/ or total stations is also made in suitable conjunction with
GPS to establish the markers.
 To avoid obstruction along the line, by ranging on ground and shifting the Turning
Points wherever needed.
 Checked for terrain gradient by using hand clinometer/ total stations.
 Ensured proper angle of crossing by keeping as nearly right angle (to
road/rail/rivers etc.) as possible. Unless mentioned otherwise all minor/ major
crossings were surveyed by total stations.
 Checked the route for ease of construction and avoid objects like, trees,
dwellings, poles (power, telephone and telegraph), walls, tubewells or such other
structures falling in the strip of land, 30M on either side of pipeline alignment
unless directed otherwise.

3.2 Staking of pipeline route

3.2.1 The pipeline defining trench centre line was staked by placing suitably painted
marker stakes at Turning Points (TPs) and at Intermediate Points (IPs) between
consecutive TPs. All Turning Points (TPs) and intermediate points are referred as
Intersection Points. All such points were georeferenced on an approved global
system.

The pipeline centre line was staked on the ground as follows:

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First, the Turning Points (TPs) were staked on the ground. After locating and
marking the TPs, the intermediate points were staked while measuring slack
distance. The staking was normally done at intervals of 500 M along the centre
line of the pipeline. These points were electronically marked in the drawings with
a geo-referencing procedure.

3.2.2 The Intersection Points were serially numbered from the starting point.
The serial number of each Intersection Point was boldly inscribed on the marker
stake. In addition, the Turning Point (TP) marker stake will identify the Turning
Point reference number from the starting point.

3.2.3 For Intermediate Points (IPs) letter ""P" is preceding the serial number of the
intersection point marker. For Turning Points, the ""TP" is preceding the Turning
Point reference number.

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

3.2.5 Change in direction of line is marked on the TP marker stakes. In

addition, direction markers near TPs and other locations were placed wherever
necessary.

3.3 Stakes and Markers

3.3.1 All marker stakes were of size and type as given in tender drawings.
The exposed surface of the blocks had a smooth finish and were painted with
Post Office' red paint. All letters and figures were paint marked on the surface of
the blocks in white.

3.3.2 On the top surface of the reinforced concrete blocks, a cross inside a circle
is engraved at the centre or a nail is put centrally inside an engraved circle, to
indicate the exact position of the Intersection Point. The circle is of approximately
50mm diameter.

3.3.3 Surveyor can, however, propose DFPCL/MECON other types stakes/markers

which are better suited to site conditions and the work will carried out using such
markers on approval.

3.3.4 Where it is apprehended that the marker may get lost, damaged, flooded or
Vandalised some adjoining markers and landmark locations were also be
included.

4.0 CROSSING

4.1 General

As far as possible, crossing is made at right angles. The Surveyor will record the
angles of crossing for all fences, property lines, utilities, roads, railways, canals,
streams, etc. that are crossed. In addition, the true bearings of the centreline of
the road, railway, canal, as well as that of the pipe centre-line is recorded.
Turning Points (TPs) provided near crossings were located, at least 50m from the

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crossing's boundaries, in stable and firm ground. All forthcoming expansion,

broadening, diversion and development plans were recorded.

4.2 Railway Crossings

The angles for all railway crossing were as close to 90 degrees as possible, but in
no case less than 85 degrees to the center line of the railway, unless approved
otherwise.

4.3 Primary Road Crossings

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

4.4 Secondary Road Crossings

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

4. 5 River/Stream crossings
These crossings were established as close as possible to the locations shown on
the route map. Crossings were located in a comparatively straight reach of the
river where the banks are stable and there is sufficient area for construction.
Angle of crossing were as close to 90 degrees as possible, unless approved
otherwise. Crossings was proposed on firm ground and banks and where there is
no presence of authorised/ unauthorised borrow area for gravel/sand etc. The
classification of river/ water body and its major data be obtained from official
sources and recorded w.r.t. nearest recording station/ irrigation works (who geo-
referencing is recorded).

5.6 Canals/Drainage Ditch Crossings

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

5.7 Utility Crossings

Utilities crossings were located at their centre-lines with stakes containing station
numbers in the survey. The angle of crossings is measured and locations
established relative to their above-ground facilities. The names and sizes of all
utility lines were included in the survey notes. In the cases of overhead power
and telephone lines, the distance to the poles and towers on each side of the
survey line were measured, and the numbers of poles or towers noted. Line
voltage were also recorded. Where possible, the survey was established so that
there is a minimum distance of 50 metres from the survey line to the nearest High
Tension pole or tower except at crossings.
Underground utilities were located as far as possible and staked for a minimum
distance of 25 metres on either side of the Survey Line.

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In city area this distance can be suitably adjusted as per requirement on approval
by Engineer-in-charge.

6.0 PROFILE

6.1 The continuous profile of the proposed pipeline route is established from the
reduced levels taken.
i) at the starting point,
ii) at all Turning Points (TPs)
iii) at all Intermediate Points staked on the ground
iv) at all points on the pipeline route where there is a changes in scope

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

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

6.4 For road and railway crossings, the reduced levels were recorded at all points
along the pipeline alignment wherever there is a change in slope with the entire
width of the Right-of-Use of the road/railway. SURVEYOR prepared a detailed
drawing for the crossing in scale 1:100 (in both horizontal and vertical directions)
which is truly representative of the crossing profile.

6.5 For river/stream/nala/canal crossings, levels were taken at intervals of 5M to 30M

beyond the highest banks of both sides. Levels were taken at closer intervals, if
there is a change in slope. SURVEYOR prepared a detailed drawing for the
crossing in scale 1:100 (in both Horizontal and Vertical directions) which is truly
representative of the crossing profile.

6.6 In right-of-use having slope across the pipeline alignment, as encountered in hilly
areas, Ghat regions, ravines and other similar areas as directed by
DFPCL/MECON, cross-sections at 50M interval and for a length of 25M on either
side of the pipeline alignment were observed and recorded.

6.7 For major water crossing sites, cross section as above were observed at both
banks.

6.8 Method of RISE and FALL was used to compute reduced levels of various points.

6.9 Maximum misclosure not exceeded 24 K~ MM where'K' is the distance in KMs

Maximum length of the sight not exceeded 100 M

6.10 All levels were with respect of Mean Sea Level (MSL).

6.11 A DTM (Digital Terrain Model) of both types viz TIN/ Triangulated Irregular
Network) and Grid Model were developed as a part of GIS development.

7. BUILT-UP AREA

7.1 Monuments and Properties

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The pipeline alignment runs clear of the existing monuments, properties and
structures etc., as indicated in Pipeline Route Survey Data Sheet Annexure-IV.
For congested areas, closer distance is adopted, however, location is approved
by DFPCL/MECON on case-to-case basis.

7.2 Parallel Alignment

The pipeline alignment wherever runs parallel to an existing or planned
under/over ground facility will be treated as parallel alignment. For underground
facilities surveyor identified and located them with suitable special ground laths.
The following clearances were observed in case of parallel alignment defined
above.

Between existing/planned electrical power cables/lines and the proposed line —

50.0 metres. Between existing/planned communication cables/lines and the
proposed line — 25.0 metres.
Between existing/ planned steel pipelines carrying water and gas/ petroleum
product and the proposed line -

7.3 Parallel encroachment

When the pipeline alignment runs generally parallel to a road or railway unless
otherwise stated, it was kept sufficiently clear of the Right of Way limits of the
facility.

8.0 SURVEY NOTES, OBSERVATIONS AND COMPUTATIONS

8.1 The procedures followed both for field and office calculations are such that the
results obtained are readily understood and retraceable.

8.2 All up-to-date notes and observations related to the basis for determination of
boundary lines and corners are maintained by surveyor.

8.3 Survey records contains schematic diagrams of all horizontal controls pertinent to
the project showing all existing and established control points, bench marks, any
triangulation station and boundary lines. Wherever required photographic and
vides records are also included in GIS reports.

8.4 Geo-graphical and UTM co-ordinates of all Turning Points and starting/end points
of the pipeline are computed and furnished to DFPCL/MECON.

8.5 All intermediate and final records/ data are organized in a systematic and
preformatted manner as per approved Quality Assurance Plan. All the
intermediate data computations and records are open for inspection and review
by DFPCL/ MECON.

9.0 MAPS AND DRAWINGS

9.1 All maps and drawings are made on standard format furnished by the
DFPCL/MECON. Surveyor performed mapping and drawing work so as to
contain all relevant data consistent with the survey notes and observations. The

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drawings also contain details of roads, streets, highways, structures, all types of
crossings, terrain, surface vegetation and all other details which will be required
for the purpose of engineering design. All maps and drawings also incorporate
the update and ground truth brought out by Satellite Imageries and conform to
the laid Quality Assurance requirement including those of GIS.

9.2 Following types of detailed survey drawings are made (in hard and soft copies)
- Right of Use Planimetry in UTM grid : 1:2500 along the line
1:2500 across the line
- Ground Profile : 1:2500 Horizantal
1:500 Vertical
- Crossing Details (Road and Railway Crossing) 1:100 Horizontal
1: 100 Vertical
- Detailed Route Map : 1:50000
- Cross Section for sloping Right-of-Use : 1:100 Horizontal
1:100 Vertical

10.0 PRESENTATION OF FIELD SURVEY DATA

Survey drawings contain the following data.

10.1 Pipeline Route Map

Pipeline route map are prepared on approved GIS package. Pipeline route map
shows all features including, but not limited to roads and railroads, canals,
streams, residences that are located within a distance of 500m from the pipeline
centre-line on either sides of it. For the entire region, contours are plotted on the
route map at 5M contour interval. Additional information like cultivated areas,
barren land, areas prone to flooding, rocky areas and forests including access
path/roads to Right-of-Use are also shown on the route maps.

11.2 Right-of-Use Planimetry shows all objects within 50 metres on either side of the
Pipeline in Plan. For city portion this width will generally by 30m from centre of
the road unless required otherwise.

11.3 In case of all rail, road, river, stream, canal and utility crossings, the angle of
crossing is mentioned.

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

11.5 For all river, stream and nala crossings, the level of water at the time of survey
and the approximate surface velocity of the flowing stream are observed and
recorded and reported in the survey drawings. Also, the general nature of the
surface soil (soft/hard, normal soild or rock/boulders) at the banks of the
river/stream/nala are observed and mentioned in the drawings.

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12. DOCUMENTS/DATA SUBMISSION

All drawings are prepared on approved AutoCAD and GIS based package
including but not limited to the Pipeline Route map, alignment sheets and
Crossing details. All other document reports are also prepared on computer
package approved by DFPCL/MECON. The documents are generally prepared
on latest version of MS Office. All output are in colony and in conformity with
approved QAP. In addition, hard copies of documents will also be submitted.

-x-x-

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CHAPTER - 3

DESCRIPTION OF THE ROUTE

3.1 Topography and Physiography

3.1.1 The route alignment of realigned pipeline covers a length of 0.812km at

Panvel Railway Yard, Tah. Panvel, Dist. Raigarh in the State of Maharashtra.

Spherical coordinates of the extremities of this zone on the system being followed
by Survey of India are as follows:

Sr. Section Start Point End Point

No. Name Longitude Latitude Longitude Latitude
Realigned
1. 7307’31.23” 18059’16.45” 7307’50.22” 18058’57.62”
Pipeline

SOI ‘s Toposheet no. 47-F1 on 1:50,000 scale, cover the corridor of entire realigned
pipeline route.

3.1.3 The entire length of this realigned pipeline falls in the following districts of
Maharashtra. Length of the alignment covered is given below;

Sr. Chainage (Km) Length

Name of District State
No. Starting Ending (Km)

1 Raigarh 0.000 0.812 0.812 Maharashtra

Total 0.812

3.1.4 The entire area is surrounded by barren land. Western Railway runs parallel
on the left side of the route alignment all the time.

The terrain is flat with elevation ranging between 7.07m and 10.64m above MSL
except at river and road crossing locations. At these locations, it attains a low of
2.28m at Kalundri river crossing.

3.1.5 There are no such remarkable scores of water bodies. Entire length of the
alignment is accessible by a network of National Highways, State Highways, major

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Detailed Route Survey for DFPCL Gas pipeline near Panvel Railway Yard and other associated
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and other district roads, which in turn, connects various villages enroute through a
series of metal roads.

3.1.6 This area experiences a fluctuating temperature varying between as high as

40.0C and attains as low as 9.4C. Monsoon period is between June to November
with peak season during August-October. Most of annual rain occurs during
Southwest monsoon.

3.1.7 A set of new benchmarks have been established close to the permanent
structures by double tertiary method.

3.1.8 Entire length of the realigned pipeline is easily approachable with the help of
cart track, unmetalled roads and metalled roads emanating from National Highways
and State Highways.

3.2 Route Description

This being a realignment survey of existing natural gas pipeline, the route
length is very small and the entire pipeline is near Panvel Railway Yard. The
realigned pipeline runs from north-west to south-east direction and crosses Kalundri
river enroute.

3.5 Terrain Features and Classification:-

3.5.1 Soil Strata:-

General sub soil along the pipeline route is observed major portion with silty
clay with sand. The terrain is flat and plain all along the route.

3.5.2 Land Use

The pipeline is existing in the corridor of railway’s, hence, does not pass
through any barren, cultivated etc. lands.

3.5.4 Cost of Building Material and Labour

Information regarding cost of building material and its availability and the cost
of skilled labors have been collected by local contact and statement of
information attached with this report.

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Detailed Route Survey for DFPCL Gas pipeline near Panvel Railway Yard and other associated
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Sl.
Description Unit Rate (Rs.)
No.

Raigarh

1. Bricks Per 1000 Nos. 6000.00

2. Sand Per Cum 2000.00
3. Cement Per 50Kg Bag. 300.00
4. Stone Aggregate Per Cum 1800.00
5. Class Teak Wood Per Cum 100000.00
6. Local Wood Per Cum 8000.00
7. Tor Steel. Per MT 48000.00
8. Labour- Male Per Day 300.00
9. Labour – Female Per Day 220.00
10. Labour – Semi Skilled Per Day 350.00

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CHAPTER – 4

GENERAL INFORMATION

4.1.0 GENERAL INFORMATION

MAJOR DEVELOPMENT:-
District Raigarh :

Raigarh district is located in Maharashtra state in Konkan region of India. The

district got its name from Raigad fort which was formerly the ruled by Maratha
leader Shivaji. Enveloped by dense forests and Western Ghats of Sahyadri
ranges; Raigad district is bounded by Mumbai Harbour, Thane, Pune, Ratnagiri
districts. It is bounded by the Arabian Sea in the west. Raigad district is very
popular for its beaches, forts and other travel destinations. There are several
tribes that inhabit in Raigad. Some of them are- Mahadev Koli, Katkari and
Thakur.

Transport in Raigad – The district is well connected with all the major highways.
Sion-Panvel Highway, Mumbai-Pune expressway and NH17 are all linked. The
konkan railway is another option for transport to Raigad. Major attractions near
Raigad are Raigad Fort, Murud Janjira Fort, Ballaleshwar Ganpati-Pali, Varad
Vinayak Ganapati – Mahad, Birla Ganesh Temple, Kanakeshwar- Alibag,
Elephanta Caves, Mandaw and Kihim Beach, Hari Harihareshwar Beach,
Matheran etc.

There is no major development along the pipeline route and care has been taken
to avoid any such major development encountered while finalizing the route
alignment.

4.2.0 INDENTIFICATION OF SUITABLE SITE FOR CONSTRUCTION CAMP &

STOCK YARD

Details of locations and other facilities are furnished as below.

Sr.
Site Remarks
No.
1 Panvel Panvel Railway Yard.

4.3.0 Power and Water resources:-

Power supply in Maharashtra State is moderately satisfactory. Here in Panvel the
power supply is regular and good network of transmission line.
Many big rivers are flowing across Maharashtra State including Godavari, Tapi
etc. and all are flooded with water however, there is problem of water in some
remote locations in Maharashtra.

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Detailed Route Survey for DFPCL Gas pipeline near Panvel Railway Yard and other
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4.4.0 Metrological data

The metrological data based on the information contained in “Climatological
Tables of Observatories in India (1961-1990)” as published by India
Meteorological Department as per observatory along pipeline route is given
below.

Temperature Relative Mean wind

District / (°C) Humidity (%) speed (km/hr)
Observatory Name Min.
Max. Max. Min. Max. Min.
Raigad 40.0 9.4 89 64 26.0 4.0

4.5.0 Rail Head and Communication Network:-

Communication system in pipeline route is satisfactory. Therefore accessibility
during construction and maintenance will not pose much problem.

In general, all the length of the pipeline route is parallel to Western Railway.

4.6.0 District wise Pipeline Length:-

The pipeline route passes through only one district of Maharashtra. The details of
district wise length of pipeline is as per the table below.

State Wise And District Wise Length :

Sr. Chainage (Km) Length

Name of District State
No. Starting Ending (Km)

1 Raigad 0.000 0.812 0.812 Maharashtra

Total 0.812
4.8.0 General Facility:-

Well furnished hotel accommodation and medical facilities are available at

Raigad, Panvel, Alibag.

4-7-1 Drawings:-
Following drawing have been prepared and enclosed along with this report.

Sr.
Particulars Scale Drawings
No.
1. Alignment Sheet 1:50,000 MNECC/DFPCL/ALN/01
Water Pipeline Crossing 1:500 MNECC/DFPCL/CS/WPL/01
2.
Drawing
Kalundri River Crossing 1:500 MNECC/DFPCL/CS/RIV/01
3.
Drawing

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4.8.0 Acknowledgement:-
We record our sincere thanks to the officers of Deepak Fertilizers &
Petrochemicals Corporation Ltd. & MECON Ltd. for their continuous guidance’s
and sincere co-operations extended to us from time to time during the field as
well as office work of above mentioned work.

We also record our thanks to all state govt. and semi govt. officers for providing
valuable information and kind co-operation extended to us during the preparation
of this report.

-x-x-x-x-x-x-

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Details of TPs & Ips

SR. PARTIAL REDUCED

T.P./ I.P. No. CHAINAGE(KM)
NO. DISTANCE ( M ) LEVEL

1 TP 0 0.00 000+000.000 10.644

2 TP 1 34.05 000+034.051 10.489

3 TP 2 29.20 000+063.248 9.738

4 TP 3 124.19 000+187.439 8.802

5 TP 4 218.18 000+405.615 8.652

6 TP 5 12.09 000+417.707 8.987

7 IP 5/1 232.67 000+650.382 7.360

8 TP 6 147.68 000+798.057 7.524

9 TP 7 14.65 000+812.705 7.665

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DETAIL LIST OF CROSSING OF PROPOSED PIPELINE ROUTE

Description of Crossing
Sr. Crossing Location of Chainage Height
Crossing and Length
No. Code Occurance (m) (m) (m)
Details
1 CS/WPL/001 WATER PIPELINE TP 02 TO TP 03 000+176.162 5.050
2 66KV LINE TP 02 TO TP 03 000+199.461 8.400
KALUNDRE
3 CS/RIV/001 TP 03 TO TP 04 000+257.439 80.210
RIVER
4 66KV LINE TP 03 TO TP 04 000+297.222 8.000
5 66KV LINE TP 04 TO TP 05 000+413.207 8.200

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STATEMENT OF ANGULAR DEVIATIONS

SR.No. TP. NO. Angular Deviation
Deg - Min - Sec
1 TP 00 0°0'0"
2 TP 01 197°37'56.8"
3 TP 02 186°12'1.2"
4 TP 03 180°40'27.2"
5 TP 04 212°48'38.7"
6 TP 05 212°55'59.4"
7 TP 06 229°59’41.5"
8 TP 07 0°0'0"

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Detailed Route Survey for DFPCL Gas pipeline near Panvel Railway Yard and other
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STATEMENT OF TRUE BEARING

SR.No. Description of the Line Fore Bearing
Deg - Min - Sec

1 TP 00 - TP 01 338°36'28.4"
2 TP 01 - TP 02 320°58'31.6"
3 TP 02 - TP 03 314°46'30.4"
4 TP 03 - TP 04 315°26'8.0"
5 TP 04 - TP 05 282°38'39.4"
6 TP 05 - TP 06 315°34'28.8"
7 TP 06 - TP 07 0°0'0.0"

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Detailed Route Survey for DFPCL Gas pipeline near Panvel Railway Yard and other
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STATEMENT OF TP REFERENCE
True Bearing of
Distance of
TP Reference Point
Details of Renferences Reference Point
NO. From TP
From TP ( m )
Deg Min Sec
REF 1 HOUSE 291°53'19" 3.176
TP 0 REF 2 HOUSE 192°23'41" 4.817
REF 3 TEMPLE 311°1'5" 5.743
REF 1 HOUSE 204°22'44" 5.827
TP 1 REF 2 TEMPLE 271°27'42" 18.495
REF 3 WELL 261°55'14" 21.580
REF 1 DFC STONE 278°45'36" 7.329
TP 2 REF 2 HOUSE 44°37'13" 27.132
REF 3 WELL 23°34'27" 17.815
REF 1 LT POLE 81°45'54" 10.547
TP 3 REF 2 66KV POLE 138°51'46" 11.798
REF 3 66KV POLE 102°11'1" 22.642
REF 1 TREE 337°44'42.9" 23.777
TP 4 REF 2 HOUSE 351°59'37.5" 18.606
REF 3 BUILDING 99°51'52.2" 29.764
REF 1 TREE 198°37'51.0" 12.599
TP 5 REF 2 HUT 164°0'10.7" 17.338
REF 3 BUILDING 97°17'48.9" 15.481
REF 1 DFC STONE 30°16'19" 40.961
TP 6
REF 2 66KV POLE 99°7'41" 3.200
TP 7 REF 1 CULVERT 191°32'55" 21.562

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LIST OF BENCH MARK

REDUCED
Sr. LEVEL DESCRIPTION AND LOCATON OF
TBM NO.
No. ABOVE MSL BENCH MARK
(M)
TBM is located on right side of allingment near
1 TBM 1 12.127
railway track in between TP1 and TP2
TBM is located on RIGHT side of allingment in
2 TBM 2 12.71
between railway track near AP 3
TBM is located on RIGHT side of allingment near
3 TBM 3 11.100
railway track and near TP 7.

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CHAPTER – 5

CORROSSION SURVEY

The oil companies are more sensitive to the menace of corrosion in pipeline.
Since the degree of corrosion directly depends upon the state through which the
pipeline passes. Deepak Fertilizers & Petrochemicals Corporation Ltd. have
included soil testing work for the realignment work of existing natural gas pipeline.
This includes testing resistivity of soil on field at every 500 m interval at 100 cm,
150 cm and 250 cm depths and stratification of soil and chemical analysis of soil
sample. The field resistivity results measured by Wenner 4-pin method.

1.1.0 The soil resitivity measured by Wenner 4-pin method at 500 m interval along
the entire route of pipeline is classified in to five groups as per standard given
below.

Soil Resistivity Classification

Less than 1000 ohm-cm Very high Corrosive
1000 – 2500 ohm-cm Highly Corrosive
2500 – 5000 ohm-cm Medium Corrosive
5000 – 10000 ohm-cm Low Corrosive
More than 10000 ohm-cm Very low Corrosive

On the basis of above norms the classification of soil is below. The total No. of
readings taken for the route are 4.

Nature of Soil Chainage (Km)

Very High Corrosive 0.012 To 0.146

High Corrosive 0.146 & 0.804.

Medium Corrosive NIL
Low Corrosive NIL
Very Low Corrosive NIL

1.1.1 Soil Resistivity Along The Route of Pipeline:-

The very high corrosive condition is observed for 0.134 km (16.50 %) of entire
realigned pipeline length.
The high corrosive condition is observed at Ch. 0.146km & 0.804Km of entire
route.

1.2.0 Soil Stratification :

As per specification the auger bore hole are taken at 250 m interval and upto
3.0m depth for entire realigned length. There is no rock observed up to 3.0m
depth for entire route. At Start Point location silty clay with sand is observed up
to 3.0m depth. The details are discussed in the next chapter.

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1.3.0 Soil Chemical Analysis:

The chemical analysis for soil sample collected at every 250m interval has done.
The procedure adopted for this analysis is an approved procedure. The detail of
chemical analysis was discussed in later chapter. Some of the important findings
are given below.

Out of 4 samples collected all samples are found to be medium corrosive.

The moisture content of soil was found around 20% throughout the route. The
highest moisture content is 22 % at BH-3. Most of the route passes through the
flat terrain of barren land.

Highest pH observed is 8.46 at BH-02 and lowest pH observed is7.36 at BH-1.

Lowest redox potential observed is 444.6mV at BH-1

The highest chloride percentage observed is 0.004 % at BH-4

Highest sulphate observed is 0.020 % at BH-2.

All the Observation data obtained are further treated for evaluating and
discussion in the following paragraphs.

1.3.1 Equipments:-

The equipments used for soil resistivity measurement and laboratory equipments
used for chemical analysis are most advanced, having maximum accuracy and
precision. The detail list is given below.

List of Equipments used for Soil Chemical Analysis:

Sr. No.of
Name of Equipments Make/Model
No Equipments
1 Digital Flame Photometer Aimil/048000
1
(Including Na & K Filter)
2 Ca Filter Aimil 1
3 Digital UV Spectrophotometer Systronics 1
4 Electronic Single Pan Balance Topson-200I 2
5 pH Meter (Lab) Equiptronics 1
6 pH Meter (Pocket)) Equiptronics 3
7 Oven (Alu) 2500C Labline 1
8 Distilled Water Plant Labline 1
9 Hot Plate 1000 w Labline 4
10 Magnetic Stirrer with 2 needle Equiptronics
3
& heater
11 Heating Mentle 2-3 Lits Cap. Labline 5
12 Muffle Furnace 8000C Labline 1
13 Auto Clave 12x12 Labline 2
14 Bacteriological Incubator (Alu) Labline
2
450x450x450
15 Colony Counter Aimil 2
16 Dry Air Oven Labline 2
17 Refrigerator Godrej 1

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Sr. No.of
Name of Equipments Make/Model
No Equipments
18 TDS Meter Equiptronics 2
19 DO Meter Equiptronics 1
20 Dessicator Labline 6
21 Centrifuge Machine Labline 1
22 Test Sieves 10

List of Equipments used for Soil Resistivity and Stratification Survey

Sr. No.of
Name of Equipments Make/Model
No Equipments
1 Digital Resistivity Meter with IGIS, Hydrabad/DDR- 2
Accessories 3
2 Manuals Augers Locally fabricated 6

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GRAPHICAL AND TABULAR PRESENTATION OF SOIL SURVEY

2.0.0 The data collected from soil resistivity survey, soil stratification survey
and soil chemical analysis have been presented in form of graphs,
tables and histograms. This will facilitate the analysis of data.

2.1.0 Resistivity Survey Results

2.1.1 The resistivity data is classified in to five categories as specified in the
scope of work.

2.1.2 The average resistivity measured at depth 100cm, 150cm and 250cm
is divided in to lengthwise group and presented in Table 1.1.

2.1.3 The resistivity data plotted at depth 100cm in magenta colour, 150cm
in green colour and 250cm in blue colour on y-axis and chainage on x-
axis in the semi log graph 1.1 to 1.1.

2.1.4 The percentage occurrence of soil resistivity presented in the

histogram 1.1 to 1.1.

The soil resistivity data collected and its graphs for entire route
presented in the table below.

Resistivity
Depth Earth
Sr. Location Multiplier ohm-cm
No. (Km.)
'D' Resistance
(2PiD) (Multiplier Remarks
in cms 'R' in ohms
x R)
100 2.32 628.319 1457.699 High Aggressive
1 0.012 150 1.16 942.478 1093.274 High Aggressive
Very High
250 0.26 1570.796 408.407 Aggressive
Very High
100 0.93 628.319 584.336 Aggressive
Very High
2 0.146 150 0.77 942.478 725.708 Aggressive
Very High
250 0.38 1570.796 596.903 Aggressive
Very High
100 0.10 628.319 62.832 Aggressive
Very High
3 0.615 150 0.09 942.478 84.823 Aggressive
Very High
250 0.03 1570.796 47.124 Aggressive
100 3.54 628.319 2224.248 High Aggressive
4 0.804 150 1.31 942.478 1234.646 High Aggressive
250 0.87 1570.796 1366.593 High Aggressive

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2.2.0 Soil Stratification Survey:

2.2.1 The data recorded during soil stratification survey by auger boring is
presented below;

Sr. B.H. Weathered

Clay Sand Rock Type of Strata Remarks
No. No. Rock
1 BH-01 0.0-3.0 - - - Silty Clay with Sand
2 BH-02 0.0-2.0 - - - Silty Clay with Sand
Highly Weathered
- - 2.0-3.0 -
Rock
3 BH-03 0.0-2.0 - - - Silty Clay with Sand
Highly Weathered
- - 2.0-3.0 -
Rock
4 BH-04 0.0-2.0 - - - Silty Clay with Sand
Highly Weathered
- - 2.0-3.0 -
Rock

2.2.2 The following Graph shows stratification along entire route of pipeline.

2.2.3 The Graph presents stratification data at each borehole taken at an

interval of 250m for entire length of pipeline.

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3.0 METHODOLOGY

Introduction

Resistivity has historically been used as a broad indicator of soil

corrosivity. Resistivity was measure of ionic current which developed
across ground surface. Since ionic current flow is associated with soil
corrosion reaction, high soil resistivity will arguable slow down corrosion
reaction. Soil resistivity generally decreases with increasing water content
and the concentration of ionic species, soil resistivity is by no means the
only parameter affecting the risk of corrosion damage. A high soil resistivity
alone will not guarantee the absence of serious corrosion.

3.1.0 Principal & Methodology of Resistivity Survey:

The electrical resistivity method is the process to investigate the nature
of soil surface formations by studying the variation in electrical properties.
The resistivity is defined as the resistance offered by a unit cube
substance, to the flow of electric current when the voltage is applied at the
apposite faces of the cube.
Resistivity of soil is determined by the entrapped water and the ions
dissolved in it, soil resistivity generally decreases with an increase in the
moisture content. Thus soil with good drainage properties exhibit relatively
large resistivity. Similarly high ionic contents in the soil water decrease
resistivity, form different studies & experience it has been found that soil
resistivity can be serve as a useful indicator to the corrosivity of the soil.
Therefore soil resistivity survey often conducts to get estimate of the soil
corrosivity.
The most widely used method for measuring soil resistivity is the 4-Pin
Wenner’s Method. In this method four stainless pins are fixed in to the
ground at an equal spacing. The current I is applied to the outer electrode
C1, C2 which called as current electrode and the voltage drop V developed
between inner electrode P1, P2 which called as potential electrode is
measured.

The resistivity rho(C), at a soil depth approximately equal to the pin

spacing is given by
C = 2a  V/I

Measurement conducted at different spacing would give an indication of

soil resistivity variations with depth from the ground surface.

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On the basis of resistivity observation of soil at various depths, soil is

classified in the general five groups indicating the corrosive nature of soil.
This is specified in the scope of work of PRRPL.

Resistivity Classification
Less than 1000 Very High Corrosive
1000-2500 High Corrosive
2500-5000 Medium Corrosive
5000-10000 Low Corrosive
More than 10000 Very low Corrosive

3.1.1 Procedure for Measurement of Resistivity:

As specified in the scope of work, for the measurement of resistivity 4-

Pin Wenner’s Method is used. This method commonly adopted and is very
convenient & reliable. The resistivity survey has carried out during month
of June. This is period when moisture content of the soil is medium. The
resistivity was measured by advance electronic microprocessor based
single stacking resistivity meter DDR3 manufactured by IGIS Pvt. Ltd.,
Hydrabad.
The scope of work in brief is as follow:
a. Along ROW:
1. Soil resistivity all along the route shall be measured at 500m interval
with following Pin spacing equal to depth at 100 cm, 150 cm, 250 cm.
2. The reading at two successive intervals is differing by ratio 2:1 then the
intermediate reading shall be taken. However, since the length is very
small and next reading is at very close interval hence, intermediate
reading is not taken.
3. The lower reading is greater than 10000  cm then the condition 2 of
the ratio 2:1 is not applicable.

The data collected through resistivity survey is tabulated and carried over
for further evaluation and study.

3.2.0 Soil Stratification Survey:

The stratification survey for the entire stretch of pipeline was carried
out by simple manual auger boring method up to 3.0 m depth or rock
encounter. This is very cheaper way to know stratification at a lower depth.
The screw auger is used for this work, which is locally fabricated from good
quality steel. Thus soil sample collected at depth 2.0 m for chemical
analysis. If water is encountered, it also collected for the measurement of
pH and chemical analysis.
After boring the soil is visually observed at different depths and
classified as per specified in the scope of work. i.e. Clay soil, Sand,
Murrum /Soft rock, Hard Rock etc.
The data collected in stratification survey is tabulated and carried over
for the further evaluation. The soil sample collected at 2.0m were well
packed in sample bags and transported to laboratory for chemical analysis.

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3.3.0 Soil Chemical Analysis:

The corrosivity of soil depends on several variables. Therefore the

chemical analysis of the soil is essential. The scope of work specified the
necessary tests which are comprehensive to assign corrosivity of soil.
The chemical tests are divided into the 4 categories as follows.

1) General Test - Moisture percentage.

- pH Value.
- Redox Potential.
- Oxygen Activity.
- Total Dissolved Solids.
2) Cations - Calcium
- Magnesium
- Sodium
- Potassium.
3)Anions - Chloride.
- Sulfate.
- Sulfide.
- Carbonate.
- Bicarbonate.
- Nitrate.
- Nitrite.

3.3.1 Principle And Methodology:

I)The following methods are prepared using the standard literature as

listed below:-
1)Standard Methods of American Public Health Association (APHA),
Washington.
2)Manual on Water & Waste Water Analysis, NEERI, Nagpur.
3)Analytical Agricultural Chemistry by S L Chopra, J S Kanwar.
4)Vogel’s Textbook of Quantitative Chemical Analysis, ELBS, England

II)Processing Of Soil Samples:-

1)Air-dry the sample by spreading it over filter/news paper under fan with
proper labeling. Soil not to be dried under direct sun light.
2)Grind about 70 g sample to a fine powder and sieve it.
3)Take 50 g sample in 250 ml plastic beaker & add 100 ml distilled water to
it. Shake it for 10 min. and allow it to stand for 1 hour. After measuring pH
and mV of this solution, add 150 ml water to it, shake well. Take 10 ml of
this fresh solution add 40 ml water mix well and measure its TDS by TDS
meter, then allow it to stand. Use the CLEAR SUPERNATANT LIQUID for
other cat ions & anions.

III)Parameter To Be Tested:-

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1)pH 2) Redox Potential 3) Moisture 4) Organic matter 5)Oxygen activity

6)Total dissolved solids (TDS) 7)Ca 8)Mg 9) Na 10) K11) Chlorides 12)
Sulphates 13) Sulphides 14) Phosphate 15) Nitrite 16) Nitrate 17)
Carbonate 18) Bicarbonate 19) Aerobic bacteria 20) Anaerobic bacteria

1 Determination of pH &:-
a) Principle:
The pH is determined by measurement of the electromotive force of a cell
comprising an indicator electrode (an electrode responsive to hydrogen
ions such as glass electrode) immersed in the test solution and a reference
electrode (usually a calomel electrode). The contact between the test
solution and the reference electrode is usually achieved by means of a
liquid junction, which forms a part of the reference electrode. PH meter
measures the E.M.F. of this cell.
b) Reagents:
i)Buffer solution of pH 4 : Dissolve 1.02 gm anhydrous potassium
biphthalate, KHC8H4 in boiled and cooled distilled water. Dilute to 100 ml.
Or use buffer tablet.
ii)Buffer solution of pH 9.2 : Dissolve 0.953 gm borax (Na2B4O7.10H2O) in
boiled & cooled distilled water. Dilute to 250 ml. Or use buffer tablet.
c) Equipment: pH Meter
d) Procedure:
a)Clean the pH electrode before and after each measurement.
b)Calibrate the pH meter using buffer solution.
c)Take solution of soil (1:2 dilution as prepared in processing of soil
samples) in 100ml beaker so that the electrode is properly inside the
solution.
d)Put the select switch of pH meter to read pH and note the pH of solution.

2.Determination of Redox Potential:-

The sample which is prepared for pH measurement, is used for the

measurement of oxygen activity. Platinum electrode and the Calomel
reference electrode are introduced into the soil suspension as per
specifications. The Oxygen activity (Ep) value is recorded directly from the
display after it stablises. The Redox Potential (Eh), at pH 7, of the soil
suspension is calculated as shown below.

Calculation :-
Redox Potential (mV), Eh=Ep + Eη + 60 (pH-7)
Where,
Eh = Standard redox potential of soil sample, in mV
Ep = oxygen activity measured with reference calomel reference
electrode having a potential of Eη in mV
Eη = + 250 mV for Calomel reference electrode.

pH = pH of the soil sample (1:2.5 dilution ratio).

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3. Determination of moisture:-
a) Principle:
The soil sample when air - dried for several days the most of its water
content is evaporated. Even after such air-drying of soil for a long period,
some amount of water remains inside the sample. This remaining water
content, which is removed when the sample is dried in oven at 105oC for
several hours, is the moisture of the soil.
b) Equipment:
Petri dishes, oven, desiccator, Analytical balance
c) Procedure:
1)Take the weight of dry empty petri dish.
2)Take about 10g air dry sieved soil sample in petri dish and note the
weight.
3)Dry in oven at 105 oC for 12 hours.
4)Cool in a desiccator and weigh. = 100 x% Moisture weight loss / Weight
of soil taken

4) Determination of Organic matter:-

a) Principle:
The organic component of the soil sample is determined by this method.
The air dry sieved sample is ignited under controlled condition at 550-
600oC for half an hour in side the Temperature controlled Muffle Furnace.
The loss in weight is expressed as organic matter of the soil. The
temperature of the furnace should be maintained at 550-600oC. If it rises
beyond this, the inorganic materials of soil are likely to be decomposed.
b) Equipment:
Crucible, Muffle Furnace (700oC), desiccator.

c) Procedure:
a)Take the weight of dry empty crucible.
b)Take about 5g air dry soil sample in the crucible and note the weight.
c)Keep it in a Muffle Furnace & maintain the temperature at 550+50oC for
30 minutes.
d)Cool the crucible partially in air and then in desiccator.
e)Take the weight of crucible with residue.
%Organic matter=100 x weight loss/Weight of soil taken

5) Determination of Dissolved Oxygen/Oxygen Activity:-

Principal & Theory: Ref. Standard Method of APHA, Washington Page
474.
The solubility of atmospheric oxygen in fresh water ranges from 14.6
mg/L at 0oC to about 7.0 mg/L at 35 oC 1 atmospheric pressure. Since it is
purely soluble gas its solubility directly varies with the atmospheric
pressure at any given temperature. Oxygen is an important factor in
corrosion.
The Winklar Method with azide modification:

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Oxygen present in sample rapidly oxidizes the dispersed divalent

manganous hydroxide to its higher valancy, which precipitates as a brown
hydrated oxide after addition of NaOH & KI. Upon acidification, manganese
revert to divalent state and liberates iodine from KI equivalent to the
original DO content. The liberated iodine is titrated against Na2S2O3 using
starch as a indicator.

Apparatus and Reagents:

a) BOD bottles 300 ml capacity
b) Sampling device for collection of samples.
c) Manganese Sulphate : Dissolve 480 gm MnSO4.4H2O or 400gm
MnSO4.2H2O or 360gm MnSO4. H2O and dilute to 1000ml. Filter if
necessary. This solution should not give colour with starch when added to
an acidified solution of KI.
d) Alkali Iodide Azide reagent : Dissolved 500gm NaoH (or 700 KOH) and
150gm KI dilute to 1000ml. Add 10gm Sodium azide (NaN3) dissolved in
40ml distilled water. This should give no colour with starch solution when
diluted and acidified.
e) Starch indicator; prepare solution of 2gm soluble starch powder and
0.2 gm salicylic acid as preservative in distilled water. Pour this solution in
100ml boiling water. Allow to boil for few minutes, cool and then use.
f) Stock sodium thiosulphate solution 01 N: dissolve 24.82gm
Na2S2O3.5H2Oin boiled distilled water., preserve by adding 0.4gm solid
NaOH or 1.5ml 6N NaOH and dilute to 1000ml.
g) Standard sodium thiosulphate 0.025N: Dilute 250ml stock Na2S2O3
solution to 1000ml with freshly boiled and cooled distilled water. Add
NaOH as preservative before making up the volume. This solution will
have to standarised against standard potassium dichromate solution.
h) Standarization of sodium thiosulphate using potassium dichromate
0.025N: Using oven dried potassium dichromate prepare 0.025N solution.
Dissolved about 2gm KI in 100ml distilled water in an Erlenmeyer flask.
Add 10ml of 10% H2SO4 and 20ml standard potassium dichromate. Place
the container in dark for about 5 minutes. Titrate with 0.025N sodium
thiosulphate using starch as an indicator.

Procedure:
1. Take 10/20ml. Sample and remaining amount of distilled water in BOD
bottole.
2. Add 2ml MnSO4 followed by 2ml of alkali iodide azide reagent. The tip
of pipette should be below the liquid level adding these reagents. Stopper
immediately.
3. Mix well by inverting the bottle 2-3 times and allow the precipitate to
settled.
4. Add 2ml conc. H2SO4 Na2S2O3. Mix well till the precipitate goes in to
solution.
5. Take 100ml in conical flask and titrate against Na2S2O3 solution using
starch as an indicator.
Calculations:

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1ml of 0.025N Na2S2O3 solutin = 0.2mg of oxygen

Rideal Stewart Modification:

This modification is used when sample contain ferrous ions. Add 0.7ml
conc. H2SO4 followed by 1.0ml 0.63% KMnO4 immediately after sample
collection in the BOD bottle itself. If ferric ions present in large
concentration add 1 ml of 40% KF solution. Remove excess KMnO4 using
potassium oxalate just sufficient to neutralized KMnO4 as excess oxalate
give negative error.
Alum flocculation Modification:
Sample containing high suspended matter, consume appreciable
amount of iodine in acid condition. Therefore, the samples are treated as
follows:
Add 10ml of 10% alum solution followed by 1-2 ml of conc.NH4OH to
1000ml of the sample. Allow to settle for 10 minutes and siphon the clear
supernatant for DO estimation.

6) Determination of Total dissolved solids (TDS):-

a) Principle:
All the dissolved inorganic, organic substances in the water together are
called as total dissolved solids (TDS). These dissolved ionic substances
impart conductivity to the solution. From the conductivity of the solution, the
TDS is measured using TDS meter. Or alternately evaporate 50 ml of the
solution to dryness and report the dried residue as TDS.
b) Equipment:
Beakers 100ml cap, Oven, TDS meter
c) Procedure:
i) By Using TDS Meter:
1 Take 10ml of 1:5 soil solution of step 3 under processing of samples.
2 Add 40 ml distilled water to this solution & using TDS meter, measure the
TDS.
ii) By evaporation technique:
a)Take 50 ml of aqueous soil extract in a tarred dish & evaporate on the
water bath.
b)When the volume is reduced to about 5 ml add 2 ml 20% H2O to oxidize
the organic matter.
c)Evaporate to dryness in an air oven at 105oC for 1 hour.
d)Cool in desiccator and weigh
e)Calculate the TDS from the weight of dry residue and the amount of soil
taken for solution.

7) Determination of Ca &:-
8) Determination of Mg:(or by AAS)
i) Hardness of Water:
a) Principle:
Water hardness is the traditional measure of the capacity of water to react
with soap, hard water required a considerable amount of soap to produce

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lather. Scaling of hot water pipes, boilers and other household appliances
is due to hard water. Hardness of water is a variable and complex mixture
of captions and anions. It is caused by dissolved polyvalent metallic ions.
In fresh water, the main hardness causing ions are calcium & magnesium.
However, the Iron, Strontium, Barium, Manganese also contribute to
hardness. The degree of hardness of drinking water has been classified in
terms of the equivalent Ca CO3 concentration as follows:
Soft: 0 – 60 mg/L Hard:,120 – 180 mg/L,
Medium: 60 – 120 mg/L Very hard > 180 mg/L
Although hardness is caused by cation, it may also be discussed in terms
of carbonate (temporary) and non-carbonate (permanent) hardness.
Carbonate hardness refers to the amount of carbonate & bicarbonates in
solution that can be removed or precipitated by boiling. This type of
hardness is responsible for the deposition of scale in hot water pipes,
boilers and kettles. Non–carbonate hardness is caused by the association
of the hardness causing cation with sulphate, chloride or nitrate and is
called as ‘permanent hardness’ as it can not be removed by boiling.
In alkaline condition, EDTA reacts with Ca & Mg to form a soluble chelated
complex. Ca & Mg ions develop wine red colour with Eriochrome black T.
When EDTA is added as a titrant, Ca & Mg divalent ions get complexed
resulting in a sharp change from wine red to blue, which indicates end
point of the titration. The pH for the titration has to be maintained at 10.0 +
0.1. At higher pH i.e. at about 12.0 Mg++ ion precipitates and only Ca++ ion
remains in solution. At this pH Murexide indicator forms a pink colour with
Ca++ ion. When EDTA is added Ca++ ion gets complexed resulting in a
change from pink to purple, which indicates end point of the reaction.
Interferences: Interference of metal ions can be overcome by addition of
inhibitors.
a) Reagents:
1) Buffer solution 2) Inhibitor 3) Eriochrome black T indicator 4) Murexide
indicator, 5) Sodium hydroxide 2N 6) Standard EDTA solution 0.01 N 7)
Standard Calcium solution
1. Buffer solution:- Dissolve 16.9g NH4Cl in 143ml NH4OH. Add 1.25g
magnesium salt of EDTA to obtain sharp change in colour of indicator and
dilute to 250ml. If Mg salt of EDTA is unavailable, dissolve 1.179g di-
sodium salt of EDTA (AR grade) & 780mg MgSO4.7H2O or 644mg
MgCl2.6H2O in 50ml distilled water. Add to above solution of NH4Cl in
NH4OH and dilute to 250ml.
2. Inhibitor: Dissolve 4.5g hydroxyl amine hydrochloride in 100ml 95% ethyl/
isopropyl alcohol.
3. Eriochrome black T indicator: Mix 0.5g dye with 100 ml NaCl to prepare
dry powder.
4. Murexide indicator: Prepare a ground mixture of 200mg of murexide with
100g of NaCl.
5. Sodium hydroxide 2N: Dissolve 80g NaOH and dilute to 1000ml.
6. Standard EDTA solution 0.01 N: Dissolve 3.723 g EDTA sodium salt and
dilute to 1000ml. Standardize against standard Ca solution, 1ml = 1mg
CaCO3.

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7. Standard Calcium solution: Take accurately 1g AR grade CaCO3 in a

250ml conical flask. Add 1:1 HCl till CaCO3 dissolves completely. Add
200ml distilled water and boil for 30 minutes to expel CO2.Cool & add
few drops of methyl red indicator. Add 3N NH4OH till intermediate orange
colour develops. Dilute to 1L to obtain 1ml=1mg CaCO3.

II) Total Hardness(Ca+Mg):

a) Procedure:
1. Take 10 to 50 ml sample in a conical flask.
2. Add 1-2 ml buffer solution followed by 1ml inhibitor.
3. Add a pinch of Eriochrome black T and titrate with standard
EDTA(0.01M) till wine red colour changes to blue. Note the volume
of EDTA required (A ml).
4. Run a reagent blank. Note the volume of EDTA (B ml).
5. Calculate volume of EDTA required by sample,
C = (A - B)
Total hardness as CaCO3 (mg/L) = CxDx1000/ volume of sample\D = mg
CaCO3 equivalent to 1.0 ml EDTA titrant.
III) Calcium Hardness:
1. Take 10 to 50 ml sample in a conical flask.
2. Add 1 ml NaOH to raise pH to 12.0 and a pinch of murexide indicator
3. Titrate immediately with EDTA till pink colour changes to purple. Note
volume of EDTA (A’).
4. Run a reagent blank. Note the volume of EDTA & keep it aside for
comparison.
5. Standardise the EDTA (0.1M) solution following the procedure of
Calcium hardness from 1 to 4 using standard Calcium solution.
Calcium hardness as CaCO3 (mg/L) = A’xDx1000/ volume of sample D
is mg of CaCO3 equivalent to 1.0 ml EDTA titrant

IV) Magnesium Hardness:

Magnesium Hardness=Total Hardness–Calcium hardness

9) Determination of Na &
10) Determination of K(Flame Photometry / AAS)
11) Determination of Chlorides:-
a) Principle:
Chloride in the water extract of soil can be determined by titrating the
extract against AgNO3 solution using potassium chromate as indicator.
Silver chloride is first quantitatively precipitated before red silver chromate
is formed.
If the solution is too coloured or turbid to allow the end point to be readily
detected, this interference may be reduced by the following treatment with
a suspension of aluminium hydroxide. Add 3 ml aluminium hydroxide
suspension to the measured quantity of sample. Stir thoroughly, set aside
for a few minutes and filter. Wash the ppt with distilled water and collect
the washings with the filtrate.

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NaCl + AgNO3 = AgCl (white ppt) +

NaNO3
K2CrO4 + 2AgNO3 = Ag2CrO4 (red ppt) + 2KNO3
b) Reagents:
Potassium chromate indicator, Silver nitrate 0.015N, Sodium chloride 0.015
N,
1. Potassium chromate indicator:- Dissolve 5g K2CrO4 in 50ml distilled water.
Add small amounts of AgNO3 till definite red precipitate is formed. Allow to
stand for 12 hrs. Filter and dilute to 100ml.
2. Silver nitrate 0.015N:- Dissolve 1.2g AgNO3 in distilled water and make up
the volume to 500ml. Standardize against 0.03 N NaCl.
3. Sodium chloride 0.03 N:- Dissolve 1.5g NaCl (dried at 140oC) & make up
the volume to 1000ml by distilled water.
4. Aluminum Hydroxide Suspension: Special reagent to remove colour
and turbidity: Dissolve 125g AlK(SO4)2.12H2O or AlNH4(SO4)2.12H2O &
dilute to 1000ml. Warm to 60oC & add 55-60ml conc. NH4OH slowly. Allow
to stand for 1 hour. Transfer to a large bottle and wash precipitate by
successive addition of distilled water with through mixing & decanting until
free from chloride when freshly prepared. Finally after settling, decant off
as much clean liquid as possible, leaving only the concentrated
suspension.
c) Procedure:
1. Take 5 – 20ml well mixed sample adjusted to pH 7.0–8.0 and add1.0ml
K2CrO4.
2. Titrate with standard AgNO3 solution till Red Ag2CrO4 starts
precipitating.
3. Standardize AgNO3 against standard NaCl.
4. For better accuracy titrate distilled water in the same way to establish
reagent
blank.
5. Calculate as follows:
Chloride mg/L = (A – B) x N x 35.45 x 1000 / ml of sample
Where, A – ml of AgNO3 required for sample
B - ml of AgNO3 required for blank
N – Normality of AgNO3

12) Determination of Sulphates:-

a) Principle:
Sulphate ion (SO42-) is precipitated in an acidic medium with Barium
Chloride so as to form Barium Sulphate crystals of uniform size. Light
absorbance of the BaSO4 suspension is measured at 420 nm by a
spectrophotometer or the scattering of light by Nephelometer.
Interferences: Colour, turbidity and silica in the concentration of 500 ppm
interfere in this estimation. Filtration is adopted to remove turbidity. In
presence of organic matter, precipitation of barium sulfate may not be
satisfactory. Colour is removed using Aluminium Hydroxide Suspension as
done for chloride above.
b) Reagents:

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1. Conditioning Reagent: Mix 50 ml glycerol with a solution containing 30

ml conc. HCl, 300 ml distilled water, 100 ml 95% ethyl or isopropyl alcohol
and 75 g sodium chloride
2 Barium Chloride : Crystals 20 – 30 mesh
3 Standard Sulphate solution: Dissolve 0.074 g anhydrous
sodium sulphate (Na2SO4) in distilled water and dilute to 500 ml.
1 ml = 100gm of SO4
c) Procedure:
1) For calibration graph, prepare the following system in 11 volumetric
flask of 100 ml capacity each. After addition of BaCl2 make up the volume
to 100ml.

No. 1 2 3 4 5 6 7 8 9 10 blank
Ml of 1 2 3 4 5 6 7 8 9 10 @
SO4
H2O ml 50 50 50 50 50 50 50 50 50 50 50
Reagen 5 5 5 5 5 5 5 5 5 5 5
t
BaCl2 2-3 2-3 2-3 2-3 2-3 2-3 2-3 2-3 2- 2-3 Nil
gm 3
@–To correct for sample colour and turbidity, add that volume of sample in
blank which is added for analysis of sample. If sample solution is
colourless, distilled water may be used.
a)After stirring for 5 minutes measure the O.D. of each container at 420
nm. Keep a period of 5 minutes between addition of BaCl2 and
measurement of O.D. for stirring each container.
b)Plot a graph of concentration against O.D.
c)Take about 2-10 ml of sample (taking equal amount for blank without
BaCl2 in 100ml volumetric flask. Add about 50 ml water and 5 ml
conditioning reagent. Add 2-3 gm of BaCl2 shake it for 5 minutes and
measure O.D.
d)Calculate the SO4 concentration in sample using calibration graph.

13) Determination of Sulphides:

a) Principle:
Iodometric Method:
In acidic condition sulphide gets oxidized by standard iodine solution added
in excess. Residual iodine is back titrated with Sodium thiosulphate using
starch as an indicator.
b)Reagents:
Hydrochloric Acid: 6N
Standard Iodine Solution 0.025N: Dissolve 12-13 gm KI in about 40-
50ml water taken in 500ml volumetric flask. Add 1.6 gm Iodine to it. After
iodine has dissolved completely, make up the volume to 500ml and
standardize against 0.025N Sodium thiosulphate using starch as indicator.
Sodium Thiosulphate solution 0.025N: Dissolve 3.1025g Sodium
Thiosulphate 500ml water.

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i) Standardisation of Sodium thiosulphate by Potassium dichromate :

(Vogel)
Potassium dichromate is reduced by an acid solution of potassium iodide,
& iodine is set free:
Cr2O72- + 6I- + 14 H+  2Cr3+ + 3I2 + 7H2O
The errors in this reaction are a) the hydriodic acid(from excess of iodide
and acid) is readily oxidised by air, especially in the presence of
chromium(III) salts & b) it is not instantaneous.
Following method utilizes a trace of CuSO4 as a catalyst to increase the
speed of the reaction & a weaker acid is employed to reduce the extent of
atmospheric oxidation of hydriodic acid.
Take 25ml of 0.02N potassium dichromate in a 250ml conical flask, add
5ml glacial acetic acid, 5ml 0.001N copper sulphate, and wash the sides of
the flask with distilled water. Add 30 ml of 10% KI solution & titrate the
liberated iodine with 0.025N sodium thiosulphate solution using starch as
an indicator near the end point. At the end point blue colour of the solution
disappears. Subtract 0.05 ml to allow for the iodine liberated by the copper
sulphate.
Potassium dichromate 0.02N: (Mol. Wt= 294.184, Eq. Wt.= 49.031)
Make a fine powder & dry at 140 – 150oC for about 40 –60 minutes. After
cooling in a desiccator, dissolve 0.245g of dry potassium dichromate and
make up the volume to 250ml. Calculate the exact strength from the actual
weight of the sample taken.
a) Procedure:
1. Take 10ml Iodine solution in to 250ml flask, add about20ml water and
2ml 6N HCl to it.
2. Add 2-10 ml sample (discharging sample under solution surface in the
flask). If Iodine colour disappears, add more iodine so that colour remains.
3. Back titrate the excess iodine with Sodium thiosulphate solution. Add
few drops of freshly prepared starch near the end point and continue
the titration till blue colour disappears.
1ml 0.025N Iodine = 0.4 mg Sulphide (S2-)
Sulphide in gm/kg of soil = [ (AxN1) – (BxN2)]x400/ wt of soil per 250ml
Where: A – ml of iodine solution,N1 – Normality of Iodine solution
B – ml of Sodium thiosulphate, N2 – Normality of Sodium
thiosulphate

14) Determination of Total Phosphate:

a) Principle:
Organically combined phosphorus & all phosphate including
polyphosphate are first converted to orthophosphate by digestion and then
it is determined by spectrophotometer.
b) Equipment: Spectrophotometer 690 nm. & glass wares
c) Reagents:
1. Stock phosphate solution: Dissolve 0.7111g anhydrous KH2PO4 and
dilute to
1000ml. 1ml = 0.5 mg PO4 = 500 ppm PO4

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2. Phosphate working solution: Dilute 20ml stock solution to 500ml using

distilled
water. 1ml = 20 ppm PO4
3. Ammonium Molybdate solution:
Dissolve 31.4 g in about 200ml distilled water. Add carefully 250 ml
conc. H2SO4 to 400ml distilled water. Cool and add 3 – 4ml conc.
HNO3 to this solution add molybdate solution and dilute to 1000 ml.
4. Strong Acid Reagent: Add 300ml conc. H2SO4 to 600ml distilled water.
Add 4ml
conc. HNO3 cool, dilute to 1000 ml.
5. Sodium Hydroxide: (3N) Dissolve 12 g NaOH and dilute to 100ml.
6 Phenolphthalein Indicator: Dissolve 0.05 g in 50 ml 95% ethanol. Add
50 ml
distilled water. Add dropwise 0.02N NaOH till faint pink colour appears.
7 Ansa Reagent (1-Amino 2-Napthol 4-Sulphonic Acid): Take separately
0.75g
ANSA, 42g Na2SO3, and 70g Na2S2O5. Grind ANSA with small portion
of Na2S2O5 in mortor. Prepare solution of remaining salts in a small
quantity of water. Dissolve the above mixture in this solution. Dilute
to 1000 ml & filter through whatman filter paper no.42.
a) Procedure:
Preparation of Calibration Curve:
1. Take 1, 2, 5, 8, 10, 12, 15, 18 & 20ml working PO4 solution in 100ml
volumetric flask.
2. Add 2ml ammonium molybdate solution to each flask & mix properly.
3. Add 2ml ANSA solution to each flask & make up the volume to 100ml
each.
4. Prepare blank using distilled water in the same way.
5. Measure the OD of blue coloured complex at 690 nm between 10-12
minutes after the development of the colour.
6. Prepare a calibration graph.
Preparation of Sample:
1. Take 10 ml sample, add 1 drop of phenolphthalein indicator.
2. If red colour develops, add dropwise H2SO4 solution till colour
disappears.
3. Add 1ml H2SO4 solution in excess & boil gently for 100 min.
maintaining volume to ~ 25ml.
4. Cool, add 1 drop phenolphthalein & neutralise by NaOH to faint pink
colour.Filter if required.
5. Then taking this entire sample, follow the steps 2 – 5 of the Preparation
of Calibration Curve.
6. Comparing with calibration curve, calculate the PO4 concentration of
sample.

15) Determination of Nitrite:-

a) Principle:
Nitrite (NO2 --) is determined through formation of a reddish purple azodye
produced at pH 2.0 – 2.5 by reacting diazotized sulphanilic acid with N-(1-

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Naphthyl) ethylenediamine dihydrochloride (NED- dihydrochloride). The

method is suitable for determination of nitrite down to 10g/L at 543 nm.
Chloride in the sample or nitrogen trichloride which normally coexist with
nitrite produce a false colour. This can be minimised by addition of the
NED dihydrochloride reagent first and then the sulfanilic acid reagent.
b) Reagents:
1 Sulfanilamide reagent: Dissolve 5g sulfanilamide in a mixture of 50ml
conc. HCl and about 300ml water. Dilute to 500ml with water. The solution
is stable for many months.
2 NED- dihydrochloride solution: Dissolve 500mg N-(1-naphthyl)-
ethylenediamine dihydrochloride in 500ml water. Store in a dark bottle.
Replace monthly or immediately when it develops a strong brown colour
3 Stock nitrite solution: Dissolve 1.232g sodium nitrite in distilled water and
dilute to 1000ml using distilled water.
1ml = 821.5 g of nitrite.
Standardisation of stock nitrite solution: Take 50ml 0.05N KMnO4 add 5ml
conc. H2SO4 and 50ml stock nitrite solution well below surface by pipette.
Warm to 70 – 80 oC. Titrate excess KMnO4 using 0.05N sodium oxalate.
Calculate nitrite by the following equation:
A = [ B.C - D.E ] x 7/ F
Where - A– mg of nitrite per ml B – Total ml of KMnO4 used
C – Normality of KMnO4 D – standard sodium oxalate added.
E – Normality of sodium oxalate F – ml of stock nitrite used
1725mg of sodium nitrite consumes 1ml of 0.05N KMnO4
4 Standard nitrite solution: Dilute the above standardised nitirte solution
suitably to get about 5 – 10 ppm solution.
d) Procedure:
1. If sample contains suspended solids, filter through filter paper and take
10 ml
clear sample.
2. Add 1 ml sulfanilamide solution. Let reagent react for 2-8 min.
3. Add 1ml NED dihydro chloride solution and mix immediately.
4. Measure absorbance after 10min. but before 2 hours at 543nm.
5. Prepare blank in the same way substituting water for the sample.
6. Prepare calibration curve by taking 3, 5, 8, 10, 12, 15, 20, 25, 30ml
standard nitrite solution and following the steps 2 – 5.
7. Calculate the nitrite concentration in the sample by comparing with
calibration curve.

16) Determination of Nitrate:

a) Principle:
In general Nitrate is the product of the aerobic decomposition of the
organic nitrogeneous matter. Significant sources of nitrate are chemical
fertilizers, decayed vegetable and animal matter, domestic effluents,
sewage sludge disposal to land, industrial discharge, leachates from
refuse dumps and atmospheric washout.
Phenol Disulphonic Acid (PDA) Method: Nitrate reacts with PDA and
produces a nitroderivative which in alkaline solution develops yellow colour

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due to rearrangement of its structure. The colour produced follows Beer’s

law and is proportional to the concentration of NO3 present in the sample.
Chloride and nitrite are the two main sources of interference.
Pretreatment of sample is necessary when the interfering radicals are
present.

b)Equipment: Spectrophotometer410nm., glasswares, Waterbath

c)Reagents:
1. Standard Silver Sulphate: Dissolve 2.2g Ag2SO4 in distilled water and
dilute to 500ml using distilled water.
2. Phenol Disulphonic Acid: (PDA) : Dissolve 25g white phenol in 150ml
conc. H2SO4. Add 75ml fuming H2SO4 (15% free SO3) stir well and heat
for 2 hours on water bath. If fuming H2SO4 is not available add
additional 85ml conc. H2SO4 to the 150 ml H2SO4 stir well and heat for
2 hours on water bath.
3. Ammonium Hydroxide: Concentrated
4. Potassium Hydroxide 12N: Dissolve 336.5g KOH in distilled water and
make up the volume to 500ml using distilled water.
5. Stock Nitrate Solution: Dissolve 721.8mg anhydrous potassium nitrate
and dilute to 1000ml with distilled water. 1ml = 100 μg N
6. Standard Nitrate Solution: Evaporate 50ml stock nitrate solution to
dryness on water bath. Dissolve residue in 2ml PDA reagent and dilute
to 500ml. 1ml = 10 μg N
7. EDTA reagent: Rub 50g EDTA with 20ml distilled water to form a
paste. Add 60ml ammonium hydroxide and mix well.
8. Aluminum Hydroxide Suspension: Special reagent to remove colour
and turbidity: Dissolve 125g AlK(SO4)2.12H2O or AlNH4(SO4)2.12H2O &
dilute to 1000ml. Warm to 60 oC & add 55-60ml conc. NH4OH slowly.
Allow to stand for 1 hour. Transfer to a large bottle and wash
precipitate by successive addition of distilled water with through mixing
& decanting until free from chloride when freshly prepared. Finally after
settling, decant off as much clean liquid as possible, leaving only the
concentrated suspension.
d) Procedure:
a) Pretreatment of sample:
1) Colour removal: If the sample has an intense colour, add 3-4 drops of
aluminium hydroxide suspension to 20ml sample. Stirr well and allow to
settle for a few min. Filter and use the filtrate for analysis.
1. Nitrite removal: Add sulfamic acid to the sample to suppress nitrite
interference.
2. Chloride removal: Determine the Cl contents of the sample and precipitate
out as AgCl by adding appropriate amount of Ag2SO4 solution. Excess
Ag2SO4 should be avoided.
b) Colour development:
1)Neutralize the clarified sample to pH 7.0.
1)Take 10 ml of the sample in a beaker and evaporate to dryness on
waterbath.

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2)Dissolve the residue with 2ml PDA reagent using glass rod. Transfer to
100ml volumetric flask using distilled water.
3)Add 5ml ammonium hydroxide or KOH. If turbidity is developed add the
EDTA reagent dropwise till it dissolves. Filter and make up to 100ml. To
avoid turbidity add ammonium hydroxide only.
1)Prepare blank in the same way using distilled water instead of sample.
2)Measure the OD at 410nm .
3)Prepare calibration curve using 3, 5, 8, 10, 12, 15, 20, 25, 30ml of treated
(following above steps 2-6) standard nitrate solution (50ppm).

17) Determination of Carbonate & 18) Determination of Bicarbonate:

a) Principle: The alkalinity of water is a measure of its capacity to neutralize
acids.
The alkalinity of natural water is due to the dissolved salts of carbonates,
bicarbonates, borates, silicates and phosphates along with the hydroxyl
ions in the free state. However, the major portion of the alkalinity in natural
water is caused by hydroxide, carbonate and bicarbonate. Alkalinity values
provide guidance in applying proper doses of chemicals in water and waste
water treatment processes, particularly in coagulation, softening and
operational control of anaerobic digestion.
Alkalinity of sample can be estimated by titrating with standard sulfuric acid.
Titration to pH 8.3 or decolourization of phenolphthalein indicator will
indicate complete neutralization of OH and ½ of CO3 while to pH 4.5 or
sharp change from yellow to orange of methyl orange indicator will indicate
total alkalinity, (complete neutralization of OH, CO3, HCO3).
c)Reagents: Standard H2SO4, 0.02 N, Phenolphthalein indicator, Methyl
orange indicator
1. Standard Oxalic Acid:- Take about 0.315 gm of AR/GR grade oxalic acid
in 250 ml volumetric flask, dissolve it in water. Make up the volume to 250
ml.
2. NaOH Solution 0.02N:- Take about 0.4 gm of NaOH in 500 ml
volumetric flask, dissolve it in water. Make up the volume to 500ml.
Standardize this NaOH solution against oxalic acid using Phenolphthalein
indicator. At the end point, excess of NaOH will give pink colour.
3. H2SO4 Solution 0.02N:- Dilute 0.5ml of concentrated H2SO4 to 1000ml
by distilled water and standardize against standard 0.02N NaOH using
phenolphthalein indicator. By addition of NaOH to H2SO4 containing
Phenolphthalein indicator, the colour at the end point will change to pink.
d) Procedure:
1 Take 10 ml sample in a conical flask & add 2 – 3 drops of phenolphthalein
indicator.
2 If pink colour develops titrate with 0.02 N H2SO4 till it disappears or attains a
pH of 8.3.If not, then go to step 3.
3 Add 2-3 drops of methyl orange to the same flask, & continue titration till pH
comes down to 4.5 or yellow colour changes to orange.
4 Calculate total (T), phenolphthalein (P), and methyl orange (M) alkalinity as
follows & express in mg/l of CaCO3.

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P – Alkalinity, mg/l of CaCO3. Ax1000/ volume of sample

T – Alkalinity, mg/l of CaCO3. = Bx1000/ volume of sample
In case H2SO4 is not 0.02 N apply the following formula:
Alkalinity, mg/l of CaCO3. = AxBxNx50000/ volume of sample
Where, A = volume of H2SO4 required to bring the pH to 8.3
B = volume of H2SO4 required to bring the pH to 4.5
N is normality of H2SO4
Once, the phenolphthalein and total alkalinity are determined, then three
types of alkalinities i.e. hydroxide, carbonate and bicarbonate are easily
calculated from the table given below:
Values of P & T OH CO3 HCO3
P=0 0 0 T
P<½<T 0 2P T – 2P
P=½T 0 2P 0
P>½T 2P-T 2(T-P) 0
P= T T 0 0
Once carbonate & bicarbonate alkalinities are known then their conversions
to miligrams per litre of CO3-- or HCO3- are possible.
mg/l of CO3-- = mg/l carbonate alkalinity x 0.6
mg/l of HCO3- = mg/l bicarbonate alkalinity x 1.22

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OBSERVATIONS AND DISCUSSIONS

4.1.0 General :-
In this, the observations and finding from soil survey are discussed in
details. The data collected during the field work through resistivity survey,
stratification survey and laboratory chemical analysis incorporated. The
scope of work specified by DFPCL is comprehensive to define the
character of soil corrosion, it covers various parameters which is related
with the corrosivity soil.

4.1.1 Soil Corrosivity:-

Corrosion is an electrochemical reaction based on universal law of
nature. All metallic structures are corrode. It is just a question of how
quickly. Steel for example, is man made substance produced from iron
oxide. The energy added in the refining process is unstable. Given a
suitable environment, steel will release this energy and return to it natural
state of iron ore. When immersed in an electrolyte, such as soil, water or
concrete, metal produce a current which causes iron to leave their surface.
The rate of current flow determine the life of structure. One ampere of
current consume approximately 20 pounds of iron per year. Thus, to stop
this process of corrosion, it is must to know the exact cause of corrosion.
Corrosion of pipeline wall can occur either internally or externally. The
external corrosion is cause due to various factor present in soil as well as
other outside factor. The corrosivity of soil mainly depends on texture of
soil, moisture content, acid, alkalies and salts present in soil,
electrochemical potential and microorganisms present in soil.
The resistivity survey and chemical analysis specified and
recommended by DFPCL are comprehensive tools to measure corrosivity
often by soil which is discussed in details as follows.

4.2.2 Observations On A Soil Resistivity:-

The study and analysis of resistivity of soil done by using graphs and
histogram. The following observations are made as follows.

Summary Distribution of Soil Resistivity Along ROU

Chainage (Km) Total

Sr. No. Nature of Soil Length Avg. Resistivity (Ohm Cm)
From To (Km)
1 2 3 4 5 6
1 Very High Aggressive 0.146 0.615 0.469 358.59
Total 0.469
2 High Aggressive 0.00 0.146 0.146 1275.49
3 0.615 0.804 0.189 1608.50
Total 0.335
4 Medium Aggressive - - Nil
5 Low Aggressive Nil
6 Very Low Aggressive - - Nil

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4.3.0 Observation Of Soil Stratification Survey:-

Observation of Soil Stratification Survey and Subsoil Profile along the
route based on visual examination of soil samples from borehole taken
at 250m interval at depth 3.0m or rock encountered the observation of
subsoil profile is presented below

Sr.No
Location Subsoil Classification
.
1. BH-01 Silty Clay with Sand
2. BH-02 Silty Clay with Sand
3. BH-03 Silty Clay with Sand
4. BH-04 Silty Clay with Sand

4.4.0 Corrosion Factor Method of Assessment of Corrosivity of Soil:-

The corrosion is an electrochemical reaction. Hence soil acts as an
electrolyte for pipe made from steel. The important factor affecting steel
pipe are discussed below.
1) Moisture : Water represents the essential electrolyte requirement for
electrochemical corrosion and also acts as a solvent for soluble salts
present in soil. The corrosivity of soil is very low at dry regions.
2) pH : Soil usually have a pH range of 5-8. In this range pH is generally
not considered to be the dominant variable affecting corrosion rate. More
acidic soils obviously represent a serious corrosion risk to common
construction material such as steel, cast iron and zinc coatings. Soil acidity
is produced by mineral leaching, decomposition of acidic plants, industrial
waste, acidic rain and certain form of microbiological activities. Alkaline
tend to have high sodium, potassium, magnesium and calcium content.
The latter two elements tend to form calcareous deposits on buried
structure with protective properties against corrosion. The pH level can
affect the solubility of corrosion products and also the nature of
microbiological activity.
3) Redox Potential : The redox potential essentially is a measure of the
degree of aeration in a soil. As high redox potential indicates high oxygen
level. Low redox value may provide an indication that, conditions are
conductive to anaerobic microbiological activity. Soils which are low in
oxygen are subject to sulphate reducing bacteria corrosion.

4) Chloride Level : Chloride ions are generally harmful, as they

participate directly in anodic dissolution reaction of metals and their
presence tends to decrease the soil resistivity. They may be found
naturally in soils as a result of brackish ground water and historical
geological sea beds or from external sources such as de-icing salts
applied to roadways. The chloride ions concentration in the corrosive
aqueous soil electrolyte will vary, as soil conditions alternate between wet
and dry.

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5) Sulphate Level : Compared to the corrosive effect of chloride ions

levels, sulphates are generally considered to be more benign in their
corrosive action towards metallic materials. However concrete may be
attacked as a result of high sulphate levels. Presence of sulphate does
pose a major risk for metallic material in the sense that sulphate can be
converted in to highly corrosive sulphide by anaerobic silphate reducing
bacteria.

6) Sulphide : Sulphate reducing bacteria converts sulphate in to

hydrogen sulphide which is at high concentration are high corrosive.

7) Soluble Soil Salts : Sub surface water acts as solvent for salts derived
from the soil. In areas of average rain fall the solution is relatively dilute.
The total salt contents in the dry areas salt content is generally high since
ions are transported from deeper region to the surface because of water
evaporation. The main ions founds includes, Na+, K+, Ca++, Mg++, Cl -, So4-
-
. The type of ionic species and their content of found in a soil could also
be attend by the use of fertilizers or the dumping of industrial waste.

8) Microbiologically Influenced Conditions (MIC) :

Microbiologically influenced condition (MIC) refer to corrosion that is
influenced by the presence and activities of micro organisms and their
metabolic. Bacteria, fungi and other microorganism can play a major part
in soil corrosion. Spectacularly rapid corrosion failures have been
observed in soil due to microbial action and it is becoming increasingly
apparent that most metallic alloys are susceptible to some form of MIC.

9) Soil Resistivity : Soil resistivity was a measure of conductivity of

soil, which play an important role for scope of corrosivity. Low resistivity
means high corrosive soil and some time it is work as a single tool to
decide soil corrosivity.

10) Assessment of Corrosion Factor :The point system for predicting soil
corrosivity, which is most commonly used is adopted here to assign
corrosion factor of soil. The most of the part of PHCPL passes through flat
area and cultivated land the moisture content is high and thus redox
potential is towards higher side. The point system used for redox potential
is based on AWWA C-105 standard (American Water Works Association).

Sr. Parameter Range C.F.

No.
1. Soil Type Most of the pipeline passes through
hilly and barren land, thus the soil 0
type does not have major impact on
corrosiveness.
2. Moisture Content Less than 20.000% 0
(%) More than 20.000% -1

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3. PH Greater than 5 0
Less than 5 -1
4. Redox Potential >400 2
(mV) 400 – 300 0
300 – 200 -1
< 200 -2
5. Calcium, > 5.0 – 1 % +2
Magnesuium and 1.0 to 5.0 % +1
Carbonate < 1.0% 0
content (%)
6. Chloride level (%) < 0.010 % 0
> 0.010 % -1
7. Sulphate (%) < 0.020 % 0
0.020 to 0.050 % -1
> 0.050 % -2
8. Sulphide (%) Absent 0
Traces -2
9. Soil Resistivity > 10000 Ohm cm -2
1000 to 10000 Ohm cm -4
< 1000 Ohm cm -6
On the basis of above factor, all soil survey data tabulated for each
sample. The sum of all assign corrosion factor gives clear idea about
corrosivity of soil and following norms are used to decide corrosivity of soil.

Sr. No. Sum of Corrosion Factor Category

1. >0 Low to very low Corrosive
2. 0 to –5 Medium corrosive
3. -6 to –9 Highly corrosive
4. < -9 Very high corrosive

4.5.0 Classification Of Corrosivity Of Soil Based On Corrosion Factor :-

On the basis of above combine corrosion factor the soil classified in to
different categories to assign corrosivity. With this analysis also graphical
representation is given for better understanding of relation between various
parameters. Generally moisture content, pH, redox potential, chloride,
sulphate and resistivity are dominant character. The table given below
briefs the classification on the basis of corrosion factor.

Distribution of soil sample based on Total

No.
CF
Sr. Soil
Section in Km Medium Highly Very
No Sampl
Corrosive Corrosive Corrosive
e
No. % No. % No. %
1 0 – 0.812 4 4 100 0 0 0 0

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CHEMICAL ANALYSIS OF SOIL SAMPLES

Oxygen Activity
Sample

Bicarbonate
Magnesium
Percentage

Carbonate

Potassium
Moisture

Calcium
Details

Sodium
Sr. Total
pH Redox Potential TDS Chloride
No. 13=(10+11+12)
Loc. Depth

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
m % CF CF mV CF mV % % % % CF % % % % CF %
BH-1 1.0 16.0 0 0 444.6 2 173 0.0000 0.0016 0.0055 0 0.0018 0.0008 0.000004 0
1 7.36 0.0039 0.002 0.002
BH-2 1.0 19.0 0 0 513.6 2 176 0.0000 0.0096 0.0145 0 0.0032 0.0022 0.000008 0
2 8.46 0.0049 0.003 0.004

3 BH-3 1.0 22.0 -1 7.61 0 470.6 2 184 0.0000 0.0030 0.0039 0.0069 0 0.0016 0.0009 0.000006 0.003 0 0.002
BH-4 1.0 17.0 0 0 469.6 2 162 0.0000 0.0083 0.0153 0 0.0020 0.0016 0.000011 0
4 7.96 Phospha 0.007 0.004 0.003

Corrosio
n Factor
Sample Remark

Total
Sr. Details
te

Sulphate Sulphide Nitrate Nitrite Soil Resistivity Based on

No.
Loc. Depth Total CF
1 2 3 22 23 24 25 26 27 28 29 30 31 32
Ohm
m % CF % CF % % % cm CF CF
1 BH-1 1.0 0.002 0 Absent 0 0.0003 0 0.00003 1457.7 -4 -2
2 BH-2 1.0 0.020 -1 Absent -2 0.0006 0 0.00014 584.3 -4 -5 Medium
3 BH-3 1.0 0.010 0 Absent -2 0.0002 0 0.00008 62.8 -4 -5 Corrossive

4 BH-4 1.0 0.015 0 Absent -2 0.0004 0 0.00001 2224.0 -4 -4

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CHAPTER-V
FINDINGS & RECOMMENDATIONS

5.0.0 The finding from resistivity shows the medium corrosivity observed, for
the entire route.

5.1.0 There is no hard rock observed for entire route during auger drilling
upto 3.0m whereas in the river bed the hard rock is observed at shallow
depths of about 5m.

5.1.1 Ground water table is observed and is reported in the borelogs of

respective boreholes.

5.2.0 The chemical analysis of soil indicates that the dominant chemical
contents of soil are ph, redox, chloride, sulphate & sulphide. The other
parameters moisture calcium, carbonate, and magnesium are not favorable
for Corrosivity of soil in this region.

5.2.1 Low moisture content is observed because of the sandy & non-cohesive
nature of soil.

5.2.2 Additional care should be taken for HT line, which is running parallel
across the line.

Acknowledgement:-
5.3.0 We record our sincere thanks to the officers of Deepak Fertilizers &
Petrochemicals Corporation Ltd. / MECON Ltd. for their continuous
guidance’s and sincere co-operations extended to us from time to time
during the field as well as office work.

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CHAPTER – 6

POPULATION DENSITY INDEX SURVEY

Scope :

Scope of work for this project includes carrying out Population Density Index survey adhering to the technical
specifications of tender documents and OISD STD 226 & ASME B-31.8. Following activities were covered
under the scope of work;

i) To identify the route of the existing pipeline.

ii) Establish the class location for Population Density Index.
iii) Prepare the Population Density Index Survey report.

Procedure Adopted for Determination of Population Density & Class Location :

A zone of 400m wide keeping center line of pipeline at the center of this zone is to be demarcated. The entire
length of the pipeline is divided in to the 1600 m (One mile) zone of each such that the individual length of
1600m will include the maximum number of dwellings made for residential or commercial purposes. The total
numbers of such dwellings intended for human occupancy shall be counted and reported accordingly.

Classification of Location based on number of dwellings :

The location is classified on the basis of total number of dwellings the pipeline route (400 m wide with pipeline
at the center) covers. It is categorized in the four classes viz. Class I, Class II, Class III & Class IV which is
explained as follows;

Class Location : The zone of 1600m (One Mile) length containing at the most 10 or less dwellings
intended for human occupancy.

Class II Location : The zone of 1600m (One Mile) length containing the number of dwellings
in the range of 11 to 45 intended for human occupancy.

Class III Location : The zone of 1600m (One Mile) length containing the number of dwellings
more than 45 (i.e. 46 onwards). Further, the zones where there are places like schools, colleges, hospitals,
temples etc, where the gathering of peoples takes place are also classified as Class III.

Class IV Location : This is the last Class Location of length 1600 m (One Mile) that covers the
area where there are multi storied buildings, traffic is heavy or dense, or there are numerous under ground
utilities.

Apart from above criteria, additional consideration is given to possibilities of increase in concentration of
population along the pipeline route such as may be caused by the presence of schools, hospitals, recreational
areas of an organized character, places of assembly, places of worship etc. If one or more of these facilities are
present, the area shall be classified as a class 3 Location.

Nevertheless, while determining class location of an area due consideration has been given to the possibility of
future development of the area during the design life of the pipeline. In case it is observed that future
development may cause a change in the location class, the same was taken into consideration while determining
its class location.

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When cluster of building intended for human occupancy indicates that a basic 1.6km is identified as a location
class 2 or 3, the location class 2 or location class 3 is terminated at 220 mtr. from the nearest building in the
cluster.

Number of dwellings intended for human occupancy of 1600m zone is counted and presented in a tabular
column as shown below

Perpendicular distance of Direction Total no. Whether

Sr. Village Pipeline dwelling from pipeline Right of Left Type of of >20 people Remark
No. Name Chaiange centre line in Mtrs. Dwelling dwelling assemble
in (Km) Right Left (building/ units in during
15- facilities) case of normal
0-15 >100
100 PDM course
Mtrs Mtrs
Mtrs (yes/no)
(pp)

Note :

Type of dwelling facility shall be identified as

TH - Temporary Hutments
PD - Permanent dwelling having 03 or less storeys
PDM - Permanent dwelling 04 or more storeys.
PP - Public place like school, Hospital, Play Ground, Market Place,
Temple, Place for Public Gathering/ Annual Fare etc.

The Population Density Index Survey report in tabulated form along with relevant annexures for comparison is
given in the following paragraph.

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POPULATION DENSITY INDEX SURVEY

DISTANCE FROM WHETHER >20

Direction TYPE OF PEOPLE
CENTERLINE (m) NO. OF
DWELLING ASEMBLE
SR. CHAINAGE DWELLINGS
NAME OF VILLAGE (Building DURING REMARK
No. (m) 100- IN CASE OF
0-15 15-100 Right Left Facility) NORMAL
200 PDM
(Note-1) COURSE
(YES/NO)

1 Panvel (Podi) 6851    TH No Tin House

   TH No Tin Temple

  PD No House

   PP Yes Temple

    PP Yes Cavel House

   TH No Tin House

   PD No RCC Tin House

   No Cavel House
PD

   No Cavel House
PD

   No Cavel House
PD

   PD No Cavel House

   TH Yes Tin House

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DISTANCE FROM WHETHER >20

Direction TYPE OF PEOPLE
CENTERLINE (m) NO. OF
DWELLING ASEMBLE
SR. CHAINAGE DWELLINGS
NAME OF VILLAGE (Building DURING REMARK
No. (m) 100- IN CASE OF
0-15 15-100 Right Left Facility) NORMAL
200 PDM
(Note-1) COURSE
(YES/NO)

  PP No RCC slab animal Hospital



  PP No RCC Apartment

   PD No RCC Apartment House

   PD No RCC V/C Building

   PD Yes RCC Apartment

   PD Yes RCC Apartment

   PD Yes RCC House

   PD Yes RCC Apartment

   TH No Cement Sheet House

   No Cement Sheet House

TH
   PD Yes Apartment

   PD Yes Apartment

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DISTANCE FROM WHETHER >20

Direction TYPE OF PEOPLE
CENTERLINE (m) NO. OF
DWELLING ASEMBLE
SR. CHAINAGE DWELLINGS
NAME OF VILLAGE (Building DURING REMARK
No. (m) 100- IN CASE OF
0-15 15-100 Right Left Facility) NORMAL
200 PDM
(Note-1) COURSE
(YES/NO)

   PP Yes Colony Flats Start Point

   PP Yes Colony Mid Point

   PP Yes Colony Flats End Point

   TH No Chicken Shop

   PD Yes Apartment

   PD Yes RCC Apartment

   TH Yes Cement Sheet House

  PP No Temple RCC

   TH No House Cement Sheet

  PD No RCC Building House U/C

  PD No RCC Building House

   PD No RCC Building

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DISTANCE FROM WHETHER >20

Direction TYPE OF PEOPLE
CENTERLINE (m) NO. OF
DWELLING ASEMBLE
SR. CHAINAGE DWELLINGS
NAME OF VILLAGE (Building DURING REMARK
No. (m) 100- IN CASE OF
0-15 15-100 Right Left Facility) NORMAL
200 PDM
(Note-1) COURSE
(YES/NO)

RCC Building U/C

  PD Yes
Apartment

   TH No Hut Tin

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POPULATION DENSITY INDEX AT A GLANCE

CLASS LENGTH (KM)

I 0.00
II 0.00
III 0.00
IV 0.812
TOTAL 0.812

BROAD POPULATION DENSITY INDEX

Chainage (km)
Class
From To
0.00 0.812 IV

OBSERVATION :

The pipeline route is classified as per the above four classes and additional criteria.

The route of the pipeline is classified as Class IV covers the area of about 0.0kms to 0.812kms as the
there underground utilities whereas for the entire route length railway is running along side the pipeline
and every time there are number of people gathering along the pipeline route. Hence, it is classified as
Class IV.

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DEEPAK FERTILISERS AND PETROCHEMICALS
CORPORATION LIMITED

NAME OF WORK

Detailed Geotechnical Investigation for DFPCL gas pipe

line near Panvel railway yard and other associated works

GEOTECHNICAL INVESTIGATION REPORT

OF BORE HOLE NO. 1 to 4

MNEC Consultants Pvt. Ltd.

(An ISO 9001:2008 & ISO 27001:2005 Certified Company)
First Floor, ‘Pratibha Sankul’, 1, Bhagwaghar Layout, Besides Alankar Cinema, Dharampeth, Nagpur-10
Ph. : +91-712-2542261 Fax : +91-712-2542291
E-mail : [email protected]
 INDEX

Page No.
Sr.
Particulars Remark
No.
From To

1. Geotechnical Investigation Report 01 19

2. Borelogs 20 23

3. Laboratory Test Sheet 24 25

4. Graphs 26 27

Letter from Water Resources Dept.

5 28 28
Nashik

6 Sub – Soil Profile Drawing 29 29

7 Hydrological Survey Drawing 30 30

8 L-Section Drawing of Kalundri River 31 31

DFPCL, Mumbai MNEC Consultants Pvt. Ltd.

Geo-Technical Investigation Report

1.0.0 Introduction
Extensive soil investigation is carried out at proposed locations of DFPCL gas
pipe line near Panvel railway yard and other associated works for M/s DFPCL
Mumbai to study the stratification and making classification of physical
properties of the soils. On the basis of this study, foundation can be classified.
The laboratory testing carried out by us, and deals with the aspects
relating to classification of soils and stratification.

2.0.0 General Discussion.

MNEC Consultants Pvt. Ltd. has carried out the entire scope of work of Geo-
technical investigations based on the investigation plan, specifications and data
requirements of M/s DFPCL Mumbai.

3.0.0 SCOPE OF GEO-TECHNICAL INVESTIGATION :

The geo-technical investigation programmed drawn by M/s DFPCL Mumbai for
this project envisages obtaining sufficient data regarding the engineering
properties of soil for different soil strata. The relevant data regarding sub-soil
profile is to be generated for all kinds of strata at investigation location by
drilling boreholes up to relevant depths.

3.1.0 Scope of work as covered M/s DFPCL Mumbai includes the following;
 To identify the soil stratification up to recommended depth by sinking
150mm dia borehole at each location. All boreholes locations were
approved by the Engineer-in-Charge.
 To conduct standard penetration tests (SPT) at various depths in boreholes,
generally at 1.5m intervals up to terminated depth and to collect
representative samples.
 Collect disturbed samples from boreholes generally at 1.5m intervals or at
every change of stratum in cohesive and semi-cohesive soils.

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 Extract undisturbed samples from boreholes generally at 1.5m intervals or

at every change of stratum in cohesive and semi-cohesive soils.
 To record standing ground water levels in boreholes.
 To conduct laboratory tests on undisturbed, disturbed and SPT soil samples
to obtain strength, classification and other parameters as per Technical
Specifications.
 To collect rock sample, record core recovery percentage and RQD if rock
encountered.
 To carryout following tests on the DS & UDS samples at Laboratory.
i) Natural moisture content Bulk and Dry Density
ii) Void ratio
iii) Liquid limit, plastic limit and plasticity index.
iv) Specific gravity
v) Bulk and Dry Density
vi) Direct shear test
vii) Sieve and hydrometer analysis
viii) Test on core samples
ix) Chemical analysis of the soil & sub-soil water

4.0.0 METHODOLOGY OF INVESTIGATION AND FIELD WORK

4.1.0 BORING AND DRILLING:
All exploratory boreholes of 150 mm nominal diameter were sunk by deploying
boring rigs using the conventional rotary drilling Methodology followed for
boring conformed to IS: 1892. Boring was effected by the cutting action of
rotating bit with casing in the top layer to stabilize the side of the bore and to
prevent soil from absorbing water during drilling process.
* - Bore logs are attached with this report separately.

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4.1.1 SAMPLING :
UDS samples were collected from the cohesive stratum wherever possible.
The recovered samples from SPT tests have also been collected wherever
possible.

4.2.0 STANDARD PENETRATION TEST:

Standard Penetration Test (SPT) to determine penetration resistance was
conducted in the boreholes at various depths following the procedure
described in IS: 2131. In this method, driving bit is replaced by split spoon
sampler (50.8mm OD and 35.0mm ID) and the sampler is driven by dropping
65 kg hammer on top of the driving collar with free fall of 75 cm. The length of
the sampler is 60 cm. The sampler is first driven through 15 cm as “Seating
Drive”. It is further driven through 30 cm. The number of blows required to
drive the sampler for 30 cm beyond seating drive is termed as “Penetration
resistance’, ‘N’. Test is terminated on recording a blow count of 100 blows for
30 cm or less penetration for consecutive two tests.

4.3.0 GROUND WATER LEVEL:

The standing ground water level in the borehole after stabilization of the water
level it was recorded wherever water table has been met.

4.4.0 Laboratory Testing

Brief procedure for conducting laboratory tests is described below;

4.5.0 Particle size analysis

Testing procedure generally conforms to IS : 2720 (Part 4)- 1985.
Both sieve analysis and hydrometer analysis has been carried out.

4.5.1 Sieve Analysis

Sieve analysis for coarser fractions has been done by dry sieving, while wet
sieving method has been followed for soil fractions with appreciable amount of

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DFPCL, Mumbai MNEC Consultants Pvt. Ltd.

clay. Sieving has been done using a sieve shaker by passing through the
following IS sieves.
4.75 mm, 2.36 mm, 1.70 mm, 1.40 mm, 1.00 mm, 600 microns, 425 microns,
100 microns and 75 microns.

4.5.2 Hydrometer Analysis

Soil suspension prepared by adding sodium hexa metaphosphate and sodium
carbonate is transferred to 75 micron IS sieve placed on a receiver and the soil
washed on the sieve without any loss. The suspension that has passed through
the sieve is transferred to 1000 ml measuring cylinder and made upto exactly
1000 ml with distilled water and then shaken thoroughly. Hydrometer is
immersed to a depth slightly below its floating position and then allowed to flat
freely. Hydrometer readings are taken at 10, 20, 30, and 45 seconds and then
at 1, 2 ,4, 8, 15 and 30 minutes and 1, 2, 4, 8 and 24 hours.
The diameter of the particle in suspension at any sampling time ‘t’ is calculated
using “Stokes” formula as shown below and the percentage finer is calculated.
D=(30)/[980(G-Gl)] x [(HR)/( t)]
Where, D= diameter of particle in suspension, in mm.
U= Coefficient of viscosity of water at the temperature of suspension
at the time of taking the hydrometer reading, in poise.
G= Specific gravity of the soil friction used in the sedimentation analysis
G1= Specific gravity of water.
HR= Effective depth corresponding to Rh.
t= time elapsed between the beginning of sedimentation
and taking of hydrometer reading, in minutes.
Rh = hydrometer reading corrected for meniscus = R’h +
Cm
R’h= hydrometer reading at the upper rim of the
meniscus.
Cm= Meniscus correction.
Semi log graph is then plotted with grain size (mm) in ‘x’ axis and percentage
passing in ‘y’ axis in the standard graph sheet. The graph represents respective

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DFPCL, Mumbai MNEC Consultants Pvt. Ltd.

percentage of coarse and fine fractions and is useful as a tool for visual
presentation.

4.6.0 Atterberg’s Limits

Liquid limit and plastic limit tests on clayey samples were done as per
procedure in IS : 2720 (Part 5)- 1985.

4.6.1 Liquid Limit

Testing is done as per IS : 2720 (Part 5) 1985. About 200 gm of soil sample
passing through 425 micron IS sieve is mixed thoroughly with distilled water
on the flat glass to form a uniform paste. The paste generally has a
consistency that will require 30 to 35 drops of the cup to cause the required
closure of standard groove. The ready mix soil is placed in the Casagrande cup
in such a way to form a depth of 1 cm at the centre of the cup, and then
central groove of 12 mm is made using standard grooving tool. The cup is
fitted and dropped by turning the crank at the rate of 2 revolutions per second
until the two halves of the soil close. The number of drops required to make
the groove close for the length of 12 mm is recorded.
A portion of the sample is then taken out for water content determination and
the water content corresponding to 25 blows represents the liquid limit.

4.6.2 Plastic Limit

About 15 gms of oven dried soil passing through 425 microns sieve is mixed
with sufficient quantity of water such that the soil mass becomes plastic
enough to be easily shaped into a ball. A portion of this ball is rolled on a glass
plate with the palm of the hand into a thread of uniform dia of 3 mm. The
water content represents the plastic limit.

4.6.3 Plasticity Index

It is the difference between liquid limit and plastic limit.

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4.7.0 Natural Moisture Content (NMC)

A moisture cup is loosely filled with soil and weighed with lid. It is then kept in
oven with lid removed and maintained at temperature of the oven at 110 0 C
for 24 hours. The lid of the container is replaced and the dry weight found out.
The percentage of water content is calculated using the formula.
W= W2-W3 x 100
W3-W1
Where W2= weight of container with wet soil, in g.
W3= weight of container with dry soil, in g
W1= weight of container with lid, in g
W= moisture content (%)

4.8.0 Bulk and Dry Density

Test procedure shall be as per IS: 2720 (Part-7) – 1987.
The unit weight of soil in g/cc is its weight per unit volume. Soil is filled in
container and its weight determined. Knowing the volume of container, the
ratio of weight to volume represents bulk density.
The soil is then oven dried and weighed and dry density d(g/cc) is computed
using formula.
d = b /(1+W)
Where, b = bulk density in g/cc
W= natural moisture content in %

4.9.0 Specific Gravity

Test procedure shall be as per IS: 2720 (Part 3/ Section 1) – 1987 for fine-
grained soils. Specific gravity of soil solids can be defined as the weight of
given volume of soil particles to the weight of equal volume of distilled water.
This term is used in relating weight of soil to its volume.
Specific gravity is found out using standard specific gravity bottle of 50 ml
capacity by weighing empty bottle (w1), bottle+ dry soil (w2), bottle + dry soil
+ water (w3), bottle + water (w4)
Specific gravity of soil = (w2-w1) / ((w2-w1) – (w3 – w4))

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4.10.0 Direct Shear Test

Test procedure shall be as per IS : 2720 (Part 13). In this test the soil
specimen is confined in a square metal box split into two halves horizontally.
Perforated metal plates and porous stones are placed above and below the
specimen to allow free drainage. After applying vertical load the soil is
gradually sheared by applying horizontal force, which makes the two halves of
the box move relative to each other. The shear is applied at a constant strain
rate and measured in a proving ring. Vertical deformation is measured with dial
gauge. Minimum of three specimens are tested and the graph drawn with
normal stress in ‘X’ axis and shear stress in ‘Y’ axis. From the straight line plot,
values of C and  are measured.

4.11.0 Chemical Test on Soil Sample

Procedure for pH, Chloride and Sulphate is as below.
Preparation of Aqueous extract
Calculated quantity of field soil sample is mixed with distilled water in the
ration of 1:1
The suspension is mixed thoroughly and allowed to stand for 24 hours and the
extract is obtained by filtering with the help of a vacuum pump.
Final extract is filtered again and used for chemical tests.

4.11.1 Measurements of pH
20 g of soil sample is mixed with 50ml of distilled water. The suspension is
stirred for few seconds and is allowed to stand for 1 hour with occasional
stirring. It is stirred again, immediately before testing.
The pH meter is calibrated with standard buffers and the pH of the soil
suspension is measured.

4.11.2 Chloride
5 to 6 drops of Potassium chromate indicator is added to 10 ml of filtrate to
get yellow colour and then titrated against Silver nitrate solution (0.02N)
End point : Yellow Brick Red colour.

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Chloride content, % = 0.071 x V1 x V

S Wd
Where,
V1 = Volume of Silver nitrate used during titration (ml)
S = Volume of filtrate taken for the test (ml)
Wd = Weight of dry soil taken for filtration (g)
V = Volume of filtrate obtained from Wd (ml)

4.11.1 Sulphate
10ml of Sodium Chloride- Hydrochloric acid mixture, 10ml of Glycerol-Ethanol
mixture and 0.15 g of Barium Chloride is added to 50 ml of soil filtrate.
This is stirred for about an hour and the absorbance is measured against
distilled water blank using a colorimeter.
The Sulphate content of the sample is deduced from the standard curve.

5.0.0 Scour Depth Calculations

When the velocity of flow exceeds the limiting velocity, which the erodable
particles of bed material can stand, the scour occurs. The normal scour depth
is the depth of water in the middle of the stream when it is carrying the peak
flood discharge. Alluvial streams bed and bank are composed of loose granular
material that has been deposited by stream and can be picked up and
transported again by the current during flood. These streams tend to scour or
silt up till it has acquired such a cross section and more particularly such a
slope that the resulting velocity is ‘non-silting’ and ‘non-scouring’. When such a
stage occurs the stream become stable and tends to maintain the acquired
shape and size of its cross-section and the acquired slope. For a safe and
sound design of a structure it is important to estimate the correct scour depth.

5.1.0 Factors affecting scour depths are-

i) Water quality
The quality of water is one important factor which governs the magnitude of
scouring action. The flowing water is either clear water or carrying sediments.

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It is theoretically proved that scouring capacity of clear water flowing river is

more than that of sediments carrying rivers. The principal behind theory is that
the sediment transported flows; the equilibrium condition will be achieved with
a shortest span.
ii) Bed material characteristics
As per the theoretical investigation, actual physical reasoning and detailed
analysis of experimental data, many investigation reports have arrived at the
basic flow parameters for which the scour depth is related. The moment of bed
material at average shear stress varies according the size of sediment
particles; i.e. the scour depth is directly related to the size of river bed
material. It is generally observed that for a specific flow condition larger the
sediment size, scouring action is less.
iii) Sub-soil stratification
Sub soil stratification is very much useful to determine the magnitude of
scouring action. In general if a river bed having relatively thin course grain
layer below a thick fine grained layer is considered as critical condition. Once
the top layer is scoured away, scour depth increases rapidly.

5.2.0 Calculation of scour depth

This is very important to assess scour depth in the river bed. For the
calculation of scour depth Lacey Inglish method is used.
Mean scour depth (dsm) = 1.34 x (qb)2 1/3

ksf
Where,
qb = Discharge per meter width (m3/sec)
ksf = Silt factor

Discharge per meter width (qb) = Design discharge . (m3/sec)

Bed width or effective water way
Where,
Design discharge = 1.1x Maximum Discharge (m3/sec)

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5.2.1 Evaluation of Silt Factor

The silt factor is calculated from mean grain size analysis (dm). The mean grain
size is determined by using Lacey’s formula,

 = 1.76  dm

Where,
= Silt Factor
dm = mean diameter of particle in mm.

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6.0.0 Location: Kalundre River

Sr. Terminated G.W.T. Below G.L.
BH-NO.
No. Depth (m) (m)
1. BH-01 (A1) 15.00 1.50
2. BH-02 (A2) 15.00 2.00
3. BH-03 7.00 Standing Water
4. BH-04 16.00 1.50

6.1.0 Scope of work

Above mentioned boreholes have been executed for the proposed construction
of DFPCL gas pipeline near Panvel railway yard. The terminated depth and
ground water table at all the boreholes is as mentioned above. The borehole
locations are shown in Sub-soil Profile drawing attached with this report.

6.2.0 Sub-soil Profile

Layer I – Filling Materials
The occurrence of this layer, depth and ‘N’ is tabulated below:

BH-No. Depth (m) Thickness (m) ‘N’ values

BH-01 (A1) 0.00 – 1.50 1.50 -

BH-02 (A2) 0.00 – 1.50 1.50 -

BH – 04 0.00 – 1.50 1.50 -

This formation is observed at above mentioned locations. No laboratory test is
possible in this type of sample.

Layer II – Silty Sand with Gravels

The occurrence of this layer, depth and ‘N’ is tabulated below:

BH-No. Depth (m) Thickness (m) ‘N’ values

BH-01 (A1) 1.50 - 3.45 1.95 08, 20

BH – 04 1.50 - 3.00 1.50 26

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This formation is encountered at above mentioned locations. The

representative samples are collected and tested for the determination of index
properties in laboratory.
Layer III – Soil with Boulders
The occurrence of this layer, depth and ‘N’ is tabulated below:

BH-No. Depth (m) Thickness (m) ‘N’ values

BH-02 (A2) 1.50 - 3.00 1.50 >100

This formation is encountered at above mentioned locations. No Laboratory
test is possible in this type of sample.

Layer IV – Highly Weathered Rock

The occurrence of this layer, depth and ‘N’ is tabulated below:

BH-No. Depth (m) Thickness (m) ‘N’ values

BH-01 (A1) 3.45 – 4.95 1.50 80

BH-02 (A2) 3.00 – 3.27 0.27 >100

BH - 04 3.00 – 3.28 0.28 >100

The highly weathered rock formation is observed at above mentioned
locations. No laboratory test is possible in this type of sample.

Layer-VI: Fine Grained Hard Rock

The fine grained hard rock (Basalt) formation is encountered at following
mentioned locations. The representative samples are collected. The occurrence
of fine grained hard rock is tabulated below:
Run (m) Thickness Core Recovery
BH-No. RQD (%)
From To (m) (%)

BH-01 (A1) 4.95 6.00 1.05 30 Nil

6.00 6.40 0.40 62 35
6.40 7.60 1.20 96 80
7.60 9.10 1.50 96 89
9.10 10.20 1.10 83 20
10.20 11.50 1.30 90 81

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Run (m) Thickness Core Recovery

BH-No. RQD (%)
From To (m) (%)

11.50 13.00 1.50 93 85

13.00 14.00 1.00 96 90
14.00 15.00 1.00 96 92
BH-02 (A2) 3.27 4.00 0.73 70 Nil
4.00 5.00 1.00 82 55
5.00 6.50 1.50 94 94
6.50 7.50 1.00 94 94
7.50 8.90 1.40 96 96
8.90 10.00 1.10 94 89
10.00 11.00 1.00 90 82
11.00 12.00 1.00 96 85
12.00 13.50 1.50 98 92
13.50 15.00 1.50 97 94
BH-03 0.00 1.00 1.00 89 45
1.00 2.50 1.50 90 80
2.50 4.00 1.50 97 88
4.00 5.50 1.50 96 92
5.50 7.00 1.50 98 94
BH-04 3.28 4.50 1.22 34 11
4.50 6.00 1.50 94 94
6.00 7.50 1.50 96 96
7.50 8.70 1.20 94 94
8.70 10.00 1.30 93 93
10.00 11.00 1.00 97 97
11.00 12.00 1.00 95 95
12.00 13.00 1.00 98 98
13.00 14.00 1.00 97 94
14.00 15.00 1.00 99 99
15.00 16.00 1.00 97 97

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The fine grained hard rock formation is perceived at above mentioned

locations. The core recovery percentages and RQD (Rock Quality Designation)
observed in this layer indicates that strength of rock is moderate to very good.

6.3.0 Laboratory Test Results:

6.3.1 Index Properties of Soil Samples.
Depth NMC Gravels Sand Silt Clay L.L. P.I.
BH-No.
(m) (%) (%) (%) (%) (%) (%) (%)
BH-01 (A1) 1.95 14 06 32 60 02 NL NP
BH-04 1.95 12 09 40 49 02 NL NP

6.3.2 Physical Test on Rock Samples.

Water Compressive
Depth Bulk Density
BH-No. Absorption Strength
(m) (g/cc)
(%) (Kg/cm2)

BH-01 (A1) 6.00 2.89 0.39 510

7.60 2.90 0.34 615

11.50 2.93 0.29 790

14.00 2.91 0.31 810

BH-02 (A2) 4.00 2.86 0.56 340

6.50 2.90 0.41 465

8.90 2.92 0.23 590

12.00 2.95 0.21 720

BH-03 1.00 2.84 0.51 305

2.50 2.87 0.46 450

5.50 2.91 0.31 525

BH-04 4.50 2.84 0.49 360

6.00 2.86 0.52 485

10.00 2.91 0.35 615

12.00 2.94 0.31 810

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6.4.0 Engineering Analysis

At BH-01 (A1) location silty sand with gravels is observed at upper layer and is
followed by highly weathered rock and fine grained hard rock. The SPT value
shows low dense condition for upper layer. Below these hard strata is observed.

6.5.0 Safe Bearing Capacity Calculations

6.5.1 Permissible Bearing value: Settlement Criteria
Net allowable bearing capacity is calculated by settlement criteria for 40mm
allowable settlement as per IS: 8009 (Part-I) 1976. For 3.0m wide footing.

i) Size of Footing: 3.0m x 3.0m

At BH-02 (A2) at 1.50 m depth the observed SPT Value is 100.
Hence,
B = 3.00m, N = 100
Corrected ‘N’ value for dialency = 57.5
Settlement at a load of 1 kg/cm2 = 4.5 mm
4.5
Water table correction for the settlement =
0.5
= 9.0 mm

40 x 10
Load at 40mm settlement = = 44.44 t/m2 ≈ 44.00 t/m2
9.0

6.5.2 Calculation of Permissible Bearing Pressure

Wherever foundation is rested on rocky strata, safe bearing pressure is
evaluated from unconfined compressive strength of rock and nature of
discontinuities observed in rock.
Permissible bearing pressure can be estimated from
qa = Ksp x qu
Where,
qa – Permissible Bearing Pressure
qu – Average Unconfined Compressive Strength of Rock
Ksp – Empirical coefficient, depending on spacing of discontinuities and
including factor of safety 3.
Ksp = 0.10 for Moderately closed spacing of discontinuities

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= 0.25 for wide spacing of discontinuities

= 0.40 for very wide spacing of discontinuities
By considering nature of rock, value of Ksp is taken as 0.10 for calculations.

At BH-02 (A2), Foundation below 4.0 m depth,

Unconfined Compressive Strength of Rock = 340 Kg/cm2
= 3400 t/m2
qa = 3400 x 0.10
Permissible or safe Bearing Pressure = 340 t/m2

As per IRC 78-1983, the factor of safety for foundation rock is 8 (In above
calculations factor of safety 3 is already taken.)
Permissible or safe Bearing Pressure = 125.00 t/m2
6.5.3 Recommendation for SBC
Depth of Safe Bearing
Size of
Location Foundation Pressure
Footing (m)
(m) (t/m2)

BH-01(A1) 3.00 3.0 x 3.0 11.00

4.50 3.0 x 3.0 35.50
6.00 - 190.00
BH-02 (A2) 1.50 3.0 x 3.0 44.00
3.00 3.0 x 3.0 44.00
4.50 - 125.00
BH-03 1.50 - 110.00
3.00 - 165.00
4.50 - 195.00
BH-04 1.50 3.0 x 3.0 12.50
3.00 3.0 x 3.0 44.00

6.6.0 Silt Factor

To estimate the scour depth silt factors need to be evaluated. Silt factor
evaluated on the basis of grain size analysis are presented as under.

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BH. No. DEPTH (m)

BH-01 (A1) 1.54

BH-04 2.10
Average 1.82

6.7.0 Hydrological Data

The proposed pipeline crosses the Kalundre River near Railway Bridge
constructed on right side at a distance 46.0mts.
Kalundre River is as under,
Maximum discharge = 650.312 m3 /sec
(Observed at River gauge station situated at Village-Gadhi, Tq.-Panvel, Dist:
Raigarh which is located 2.2 km (Approx.) upstream of Railway Bridge on
26.07.2005, source Water Resources Dept., Hydrology Project (SW), State
Data Storage Center, Nashik)
Salient features of Kalundre River is as under,
 Maximum Discharge = 650.312 m3/sec
 Average Velocity = 1.50 m/sec
 HFL = 8.965 m
 Bed width = 56.04 m
 Bank to Bank width = 78.79 m
 Lowest bed level = 2.298 m

6.8.0 Scour Depth Calculation

Bed width or effective water way = 67.415 m
Design discharge = 1.1 x 650.312 = 715.3432 m3/sec
Discharge per meter width (qb) = 715.3432 (m3/sec)
67.415

= 10.61 m3/sec

Mean scour depth (dsm) = 1.34 x (qb)2 1/3

ksf

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= 1.34 x (10.61)2 1/3

1.82

= 5.23 m

1.27 times of the scour depth = 1.27 x 5.23 m

= 6.64 m
The corresponding R.L. below HFL of 8.965 m = RL 8.965 m – 6.64 m
= RL 2.33 m
1.5 times of the scour depth = 1.5 X 5.23 m
= 7.84 m
The corresponding R.L. below HFL of RL 8.965 m = RL 8.965 m – 7.84 m
= RL 1.12 m
Two times of the scour depth = 2 X 5.23 m
= 10.45 m
The corresponding R.L. below HFL of RL 8.965 m = RL 8.965 m – 10.45 m
= RL -1.49 m
From above calculation of scour depth, it is revealed that 2 times score depth
is 3.79m below lowest bed level (loose bed).

6.9.0 Stability of bank slope

The both riverbank are stabilised by various constructions at crossing location,

thus question of stability of bank slop does not arise.

6.10.0 Consolidation Settlement

The consolidation settlements that may occur due to loads likely to be imposed
by the structure on the strata below foundation. At this location, on bank silty
sand with gravels is observed at upper layer and is followed by highly
weathered rock and fine grained hard rock and in the river bed open hard rock
is observed. In such type of strata settlement may not be observed for low
load structures.

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6.11.0 Proposed Methodology for Pipeline Crossing

At this crossing location pipeline should be laid through cut and fill type of
trench. The open cut trench type of crossing will be more economical than HDD
method. The cushioning at bottom should be provided and trench should be
filled with concrete. The river course was defined by protection wall and open
rock observed at bed, in such rivers, scouring does not occur, the pipeline
should be kept below lowest firm bed level with sufficient depth.
During construction, river flow should be diverted by constructing required
shaped earth cofferdam for suitable portion of river width and after construction
of pipeline same method should be applied for remaining portion. The type of
casing should be decided by considering overall factors.

6.12.0 Chemical Analysis of soil and water samples

Soil and water samples tested for pH, chloride and Sulphate as SO4 and SO3
indicate that the result of water samples is within the permissible limits as per
IS:456-2000, Table No.1, Clause 5.4. The chemical test result is presented in
tabular format with this report.
Location Depth Ph Sulphate (%) Chloride (%)
BH-1 (A1) 1.95 7.23 0.0088 0.0036

BH-4 1.95 7.41 0.0124 0.0046

Water - 8.26 0.0098 0.0312

6.13.0 Conclusions
 Hard rock with sufficient compressive strength was found at lower depths.
 From test results of core, for such loads the open foundation will be more
suitable.
 Designer may decide type of foundation depending on overall
considerations.
 The pipeline should be kept below lowest bed level with sufficient depth.
 The necessity of casing the pipeline shall be considered at the engineering
design stage.

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BORE LOG

PROJECT: GEO-TECHNICAL INVESTIGATION FOR THE PROPOSED CONSTRUCTION TYPE OF BORING : Rotary Drilling
OF DFPCL GAS PIPE LINE NEAR PANVEL RAILWAY YARD AND OTHER
ASSOCIATED WORKS..
CLIENT: DFPCL, Mumbai BORE HOLE DIA. : 150 mm

BORE HOLE NO : BH-01 (A1) WATER TABLE 1.50 m

(Below GL) :
LOCATION :- Bank (Kalundre River)

STANDARD PENETRATION TEST

ROCK DRILLING
NO. OF BLOWS FOR

LEGEND
DEPTH BELOW GL (m)
ENGINEERING TYPE OF
REMARKS
CLASSIFICATION SAMPLING FIRST NEXT NEXT 'N'- CORE
15 cm 15 cm 15 cm VALUE RECOVERY RQD (%)
(N1) (N2) (N3) (N2 + N3) (%)
From To Run

0.00 1.50 1.50 Filling Materials DS

0000
1.50 1.95 0.45 0000 SPT-01 03 04 04 08
0000
0000
1.95 3.00 1.05 Silty Sand with Gravels 0000 DS
0000
0000
3.00 3.45 0.45 0000
SPT-02 03 04 16 20
0000
3.45 4.50 1.05 DS
Highly Weathered Rock
4.50 4.95 0.45 SPT-03 13 28 52 80
+ + + +
4.95 6.00 1.05 CORE 30 Nil
+ + + +
6.00 6.40 0.40 + + + + CORE 62 35
+ + + +
6.40 7.60 1.20 + + + + CORE 96 80
+ + + +
7.60 9.10 1.50 + + + + CORE 96 89
Fine Grained Hard Rock + + + +
9.10 10.20 1.10 + + + + CORE 83 20
(Basalt)
+ + + +
10.20 11.50 1.30 + + + + CORE 90 81
+ + + +
11.50 13.00 1.50 + + + +
CORE 93 85
+ + + +
13.00 14.00 1.00 CORE 96 90
+ + + +
14.00 15.00 1.00 + + + + CORE 96 92
+ + + +

BH Terminated at 15.00 m
SPT = STANDARD PENETRATION TEST
DS = DISTURBED SAMPLE
UDS = UNDISTURBED SAMPLE

Surveyor
Date: 13.06.2013

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BORE LOG

PROJECT: GEO-TECHNICAL INVESTIGATION FOR THE PROPOSED CONSTRUCTION TYPE OF BORING : Rotary Drilling
OF DFPCL GAS PIPE LINE NEAR PANVEL RAILWAY YARD AND OTHER
ASSOCIATED WORKS..
CLIENT: DFPCL, Mumbai BORE HOLE DIA. : 150 mm

BORE HOLE NO : BH-02 (A2) WATER TABLE 2.00 m

(Below GL) :
LOCATION :- Bank (Kalundre River)

STANDARD PENETRATION TEST

ROCK DRILLING
NO. OF BLOWS FOR

LEGEND
DEPTH BELOW GL (m)
ENGINEERING TYPE OF
REMARKS
CLASSIFICATION SAMPLING FIRST NEXT NEXT 'N'- CORE
15 cm 15 cm 15 cm VALUE RECOVERY RQD (%)
(N1) (N2) (N3) (N2 + N3) (%)
From To Run

0.00 1.50 1.50 Filling Materials DS

0000
1.50 1.76 0.26 0000 SPT-01 >100
Soil Mix Boulders 0000
1.76 3.00 1.24 0000 DS
0000
3.00 3.27 0.27 Highly Weathered Rock SPT-02 >100

3.27 4.00 0.73 + + + + CORE 70 Nil

+ + + +
4.00 5.00 1.00 + + + + CORE 82 55
+ + + +
5.00 6.50 1.50 + + + + CORE 94 94
+ + + +
6.50 7.50 1.00 + + + + CORE 94 94
+ + + +
7.50 8.90 1.40 Fine Grained Hard Rock + + + + CORE 96 96
(Basalt) + + + +
8.90 10.00 1.10 + + + +
CORE 94 89
+ + + +
10.00 11.00 1.00 CORE 90 82
+ + + +
11.00 12.00 1.00 + + + + CORE 96 85
+ + + +
12.00 13.50 1.50 + + + + CORE 98 92
+ + + +
13.50 15.00 1.50 + + + + CORE 97 94

BH Terminated at 15.00 m
SPT = STANDARD PENETRATION TEST
DS = DISTURBED SAMPLE
UDS = UNDISTURBED SAMPLE

Surveyor
Date: 15.06.2013

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BORE LOG

PROJECT: GEO-TECHNICAL INVESTIGATION FOR THE PROPOSED CONSTRUCTION TYPE OF BORING : Rotary Drilling
OF DFPCL GAS PIPE LINE NEAR PANVEL RAILWAY YARD AND OTHER
ASSOCIATED WORKS..
CLIENT: DFPCL, Mumbai BORE HOLE DIA. : 150 mm

BORE HOLE NO : BH-03 WATER TABLE At Ground Level

(Below GL) :
LOCATION :- Bed (Kalundre River)

STANDARD PENETRATION TEST

ROCK DRILLING
NO. OF BLOWS FOR

LEGEND
DEPTH BELOW GL (m)
ENGINEERING TYPE OF
REMARKS
CLASSIFICATION SAMPLING FIRST NEXT NEXT 'N'- CORE
15 cm 15 cm 15 cm VALUE RECOVERY RQD (%)
(N1) (N2) (N3) (N2 + N3) (%)
From To Run
+ + + +
0.00 1.00 1.00 CORE 89 45
+ + + +
1.00 2.50 1.50 + + + + CORE 90 80
+ + + +
Fine Grained Hard Rock + + + +
2.50 4.00 1.50 CORE 97 88
(Basalt) + + + +
4.00 5.50 1.50 + + + + CORE 96 92
+ + + +
5.50 7.00 1.50 + + + + CORE 98 94
+ + + +

BH Terminated at 7.00 m
SPT = STANDARD PENETRATION TEST
DS = DISTURBED SAMPLE
UDS = UNDISTURBED SAMPLE

Surveyor
Date: 16.06.2013

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BORE LOG

PROJECT: GEO-TECHNICAL INVESTIGATION FOR THE PROPOSED CONSTRUCTION TYPE OF BORING : Rotary Drilling
OF DFPCL GAS PIPE LINE NEAR PANVEL RAILWAY YARD AND OTHER
ASSOCIATED WORKS..
CLIENT: DFPCL, Mumbai BORE HOLE DIA. : 150 mm

BORE HOLE NO : BH-04 WATER TABLE 1.50 m

(Below GL) :
LOCATION :- Bank (Kalundre River)

STANDARD PENETRATION TEST

ROCK DRILLING
NO. OF BLOWS FOR

LEGEND
DEPTH BELOW GL (m)
ENGINEERING TYPE OF
REMARKS
CLASSIFICATION SAMPLING FIRST NEXT NEXT 'N'- CORE
15 cm 15 cm 15 cm VALUE RECOVERY RQD (%)
(N1) (N2) (N3) (N2 + N3) (%)
From To Run

0.00 1.50 1.50 Filling Materials DS

0000
1.50 1.95 0.45 0000 SPT-01 14 21 26
Silty Sand with Gravels 0000
1.95 3.00 1.05 0000 DS
0000
3.00 3.28 0.28 Highly Weathered Rock SPT-02 >100
+ + + +
3.28 4.50 1.22 CORE 34 11
+ + + +
+ + + +
4.50 6.00 1.50 CORE 94 94
+ + + +
6.00 7.50 1.50 + + + + CORE 96 96
+ + + +
7.50 8.70 1.20 + + + + CORE 94 94
+ + + +
8.70 10.00 1.30 + + + + CORE 93 93
Fine Grained Hard Rock + + + +
10.00 11.00 1.00 + + + + CORE 97 97
(Basalt)
+ + + +
11.00 12.00 1.00 + + + + CORE 95 95
+ + + +
12.00 13.00 1.00 CORE 98 98
+ + + +
+ + + +
13.00 14.00 1.00 CORE 97 94
+ + + +
14.00 15.00 1.00 + + + + CORE 99 99
+ + + +
15.00 16.00 1.00 + + + + CORE 97 97
+ + + +

BH Terminated at 16.00 m
SPT = STANDARD PENETRATION TEST
DS = DISTURBED SAMPLE
UDS = UNDISTURBED SAMPLE

Surveyor
Date: 18.06.2013

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DFPCL, Mumbai MNEC Consultants Pvt. Ltd.

LAB TEST RESULTS

BORE DEPTH SAMP- GRAIN SIZE ANALYSIS LIQUID PLASTIC SHRI- PLASTI- NMC BULK DRY FREE DIRECT

IS CLASSIFICATION

STRENGTH (Kg/cm )
SPECIFIC GRAVITY

2
Point Load Strength

ABSORPTION (%)
HOLE NO. (m) LING GRAVEL SAND SILT CLAY LIMIT LIMIT NKAGE CITY (%) DEN- DEN- SWELL SHEAR TEST

COMPRESSIVE
SILT FACTOR

VOID RATIO

Index(Mpa)
(%) (%) (%) (%) (%) (%) LIMIT INDEX SITY SITY INDEX

WATER
COHESION
(%) (%) (g/cc) (g/cc) (%)

ANGLE f
(kg/cm )
2
BH-01 (A1) 1.95 DS 06 32 60 02 NL NP - NP CL 14 - - 04 2.640 1.54 - - - - - -

6.00 CORE - - - - - - - - - - 2.89 2.88 - 2.950 - - 2.318 - - 0.39 510

7.60 CORE - - - - - - - - - - 2.90 2.89 - 2.970 - - 2.795 - - 0.34 615
11.50 CORE - - - - - - - - - - 2.93 2.92 - 3.010 - - 3.591 - - 0.29 790

14.00 CORE - - - - - - - - - - 2.91 2.90 - 2.980 - - 3.682 - - 0.31 810

BH-02 (A2) 4.00 CORE - - - - - - - - - - 2.86 2.84 - 2.940 - - 1.545 - - 0.56 340

6.50 CORE - - - - - - - - - - 2.90 2.89 - 2.960 - - 2.114 - - 0.41 465

8.90 CORE - - - - - - - - - - 2.92 2.91 - 2.970 - - 2.682 - - 0.23 590
12.00 CORE - - - - - - - - - - 2.95 2.94 - 3.000 - - 3.273 - - 0.21 720

BH-03 1.00 CORE - - - - - - - - - - 2.84 2.83 - 2.920 - - 1.386 - - 0.51 305

2.50 CORE - - - - - - - - - - 2.87 2.86 - 2.900 - - 2.045 - - 0.46 450

5.50 CORE - - - - - - - - - - 2.91 2.90 - 2.960 - - 2.386 - - 0.31 525

BH-04 1.95 DS 09 40 49 02 NL NP - NP CL 12 - - 02 2.639 2.10 - - - - - -
4.50 CORE - - - - - - - - - - 2.84 2.83 - 2.960 - - 1.636 - - 0.49 360

6.00 CORE - - - - - - - - - - 2.86 2.85 - 2.980 - - 2.205 - - 0.52 485

10.00 CORE - - - - - - - - - - 2.91 2.90 - 2.970 - - 2.795 - - 0.35 615
12.00 CORE - - - - - - - - - 2.94 2.93 - 3.000 - - 3.682 - - 0.31 810

Document Name: Geo-Technical Investigation Report Page-24

DFPCL, Mumbai MNEC Consultants Pvt. Ltd

CHEMICAL TEST RESULTS OF SOIL SAMPLES:-

Borehole Depth Organic Matter Chloride Sulphate Nitrate Total Alkalinity Magnesium
Sr. NO. pH
No. (m) % % mg/l % mg/l % mg/l % mg/l % mg/l
1 BH-01 (A1) 1.95 7.23 0.75 0.0036 35.7 0.0088 88 0.0005 5.0 0.0018 18 0.0030 30.1
2 BH-04 1.95 7.41 0.94 0.0046 45.7 0.0124 124 0.0008 7.7 0.0024 24 0.0031 31.1

Document Name: Geo Technical Investigation Report Page-25

 Government of Maharashtra
Water Resources Department 91-253-2533408
Hydrology Project (SW) eMail: [email protected]
State Data Storage Center
Nashik - 422 004

No. SDSC/NSK/DFL/ 1128 / 2013 Date: 19-June-2013

To,
MNEC Consultants Pvt Ltd.,
First Floor, Pratibha Sankul,
Besides Alankar Cinema,
Dharmapeth, Nagpur

Sub: Hydrological / Meteorological Data

Ref: 1) Proforma Invoice No. SDSC/NSK/PP/ 1128 Dated 18/06/2013
2) 11/06/2013

In connection with the letters under reference, the requested data, listed as below, is sent here with.
SNo. Station Name Parameter Period Missing/Not served Data
1 Gadhi HQC 01/01/2002-31/12/2012
2 Gadhi HZS 01/01/2002-31/12/2012

Please treat the data value -999.99, in the database as null data. i.e. Data is not measured.

Applicable Terms and Conditions:

1. The supplied data should be used strictly for the purpose of Design of Water Resource Structures only,
for which the data has been requested.
2. Publicity of the data in any form without the prior permission of the SDSC Manager, Nashik is strictly
prohibited.
3. The data shall not be re-sold or shall not be transferred for any commercial purpose.
4. Any inference drawn based on these data will be the sole responsibility of the users and SDSC Nashik
will not be responsible for any kind of loss or damage in any form occurring due to the use of this data.
5. Data supplied to HDU shall not be used in the Court / Judicial Veridict as an evidence.
Note Data of year 2011 & 12 is under the process of validatio and hence is currently treated as raw data.

SDSC Manager &

Encl: As Above Superintending Engineer,
Data Analysis Circle, Nashik
CIVIL DRAWINGS
CATHODIC PROTECTION DRAWINGS
8 mm dia (M8) Cd Coated
Brass Nut Bolt washer
8 mm dia (M8) Cd Coated
Brass Nut Bolt washer